Starting Sys PDF
Starting Sys PDF
Fig. 4-01
TL623f401c
Starting System
Overview
4-1
Section 4
Magnetic switch
Overrunning clutch
Ignition switch contacts
Park/neutral position (A/T) or clutch start (M/T) switch
Clutch start cancel switch (on some models)
Starter relay
Starting System
Components Automatic
Transmission
These components make
up a typical starting
system (automatic
transmission).
Fig. 4-02
TL623f402
4-2
Starting System
Components Manual
Transmission
These components make
up a typical starting
system (manual
transmission).
Fig. 4-03
L623f403
4-3
Section 4
Starter Motor Toyota vehicles are fitted with one of two types of starter motors:
Gear reduction
Planetary Reduction Segment (PS)
Starter Motor
The Gear Reduction starter is a compact
lightweight unit with high torque capacity.
Fig. 4-04
TL623f404c
Gear-Reduction The gearreduction starter motor contains the components shown. This
Starter Motor type of starter has a compact, highspeed motor and a set of reduction gears.
While the motor is smaller and weighs less than conventional starting
motors, it operates at higher speed. The reduction gears transfer this torque
to the pinion gear at 1/4 to 1/3 the motor speed. The pinion gear still rotate
faster than the gear on a conventional starter and with much greater torque
(cranking power).
4-4
The reduction gear is mounted on the same shaft as the pinion gear.
Unlike the conventional starter, the magnetic switch plunger acts
directly on the pinion gear (not through a drive lever) to push the gear
into mesh with the ring gear.
This type of starter was first used on the 1973 Corona MKII with the
4M, six cylinder engine. It is now used on most 1975 and newer
Toyotas. Ratings range from 0.8 KW on most Tercels and some older
models to as high as 2.5 KW on the diesel Corolla, Camry and Truck.
The coldweather package calls for a 1.4 KW or 1.6 KW starter, while a
1.0 KW starter is common on other models.
The gearreduction starter is the replacement starter for most
conventional starters.
4-5
Section 4
NOTE
Older Toyota models use conventional type starters. This type of starter
drives the pinion gear directly. The pinion gear turns at the same speed
as the motor shaft. These starters are heavier and draw more current
than gear reduction and PS type starters.
Fig. 4-05
TL623f405c
4-6
Over-running Both conventional and gear reduction starter motors are fitted with a
Clutch oneway, overrunning clutch. The clutch prevents damage to the
starter when the engine starts.
Clutch Operation:
1. During engine start, the starter pinion gear drives the engines
flywheel ring gear.
2. Once the engine fires, the ring gear almost instantly begins to turn
faster than the starter pinion gear. Overspeeding would damage
the starter motor if it were not immediately disengaged from the
pinion gear.
3. The clutch uses its wedged rollers and springs to disengage the
pinion shaft from the clutch housing (which turns with the motor
armature). This happens any time the pinion shaft tries to turn
faster than the clutch housing.
Engine Starting
The clutch housing,
armature, and pinion gear
turn together.
Fig. 4-06
TL623f406c
4-7
Section 4
Engine Started
The clutch housing and the armature turn
together. The ring gear drives the pinion
gear. The pinion shaft is disengaged
from the clutch housing.
Fig. 4-07
TL623f407c
4-8
Ignition Switch The ignition switch incorporates contacts to provide B+ to the starter.
The relay energizes the starter magnetic switch when the driver turns
the ignition key to the START position.
Ignition Switch
With key to START
position, B+ is applied to
the starter motor.
Fig. 4-08
TL623f408c
4-9
Section 4
Fig. 4-09
TL623f409c
4-10
Clutch Start For manual transmissions the clutch start switch performs the same
Switch (Manual function as the park/neutral position switch. The clutch start switch
Transmission) opens the starter control circuit unless the clutch is engaged.
Clutch Start
Switch
The switch closes when
the clutch pedal is
depressed.
Fig. 4-10
L623f410c
4-11
Section 4
Clutch Start
Cancel Switch
This switch lets the
driver bypass the clutch
start switch for off-road
operations.
Fig. 4-11
T623f411c
4-12
Ignition Switch to ST
The plunger pulls the drive lever, which
moves the pinion gear into engagement
with the ring gear.
Fig. 4-12
TL623f412
4-13
Section 4
Fig. 4-13
TL623f413c
4-14
Ignition Switch ON
Current through the starter relay stops.
The pinion gear disengages from the ring
gear, and the magnetic switch opens.
Fig. 4-14
TL623f414c
4-15
Section 4
PS Starter Motors All current Toyota models are fitted with Planetary Reduction Segment
- Overview Conductor (PS) starters.
Planetary reduction allows the starter motor to operate at a higher
speed than a conventional starter.
The reduction gear set reduces the pinion gear speed compared to
motor shaft speed.
Higher motor speed yields greater torque.
Segment conductor type starters incorporate several design
improvements:
More compact
Lighter weight
Greater output torque
PS Starter
- Overview
All current Toyota models
are fitted with PS starters.
Fig. 4-15
TL623f415
4-16
PS Starter
- Construction
Coil wires in PS type
starters are square in
cross-section for more
compact winding and
greater output torque.
Fig. 4-16
TL623f416
4-17
Section 4
PS Starter Motors Armature coil wires The coil wires in a PS starter armature are
- Construction square in crosssection.
More compact winding than round crosssection wires
Greater output torque
Surface commutator The square shape of the armature conductors
allow the surface of the armature to act as a commutator.
Field coils Conventional starters use field coils. PS type starters use
two types of permanent magnets instead:
Main magnets
Interpolar magnets
The two types of magnets are arranged alternately inside the yoke.
Work together to increase magnetic flux
Allows shorter yoke
PS Starter - Construction
PS type starters use two types of
permanent magnets instead of
field coils.
Fig. 4-17
TL623f415
4-18
1. Current travels from the battery through the closed ST1 contacts of
the Ignition Switch and the Park/Neutral Switch, through the coil
of the ST Relay to ground.
2. The ST Relay contacts close.
Ignition Switch
to START
Current from Ignition
Switch ST1 contacts
energizes the ST
Relay coil.
Fig. 4-18
TL623f418c
4-19
Section 4
ST Relay
Energized
With the ST Relay
contacts closed, voltage
is applied to the pull-in
and hold-in coils.
Fig. 4-19
TL623f419c
4-20
Starter Motor
Turns at Slow
Speed
Current is present
through the hold-in coil to
ground and through the
pull-in coil and the motor
windings to ground.
Fig. 4-20
TL623f420c
4-21
Section 4
5. With the pullin coil energized, the solenoid plunger moves the
drive lever to mesh the pinion gear with the ring gear.
6. As the pinion gear engages the ring gear, the magnetic switch closes.
7. With the magnetic switch closed, voltage is applied directly from
the battery, through the magnetic switch, to the pullin coil. With
voltage applied to both sides of the pullin coil, no current is present
through the coil. The magnetic switch is now held closed by the
magnetic force of the still energized holdin coil.
Current Through
Pull-in Coil Stops
With battery voltage
applied to both sides of
the pull-in coil, no current
is present in the coil.
Fig. 4-21
TL623f421c
4-22
Pinion Gear
Engaged with
Ring Gear
With the magnetic switch
closed, there is a large
current directly from the
battery through the
motor windings.
Fig. 4-22
TL623f422c
4-23
Section 4
With the engine started and the ignition switch released to the ON or
IG position:
9. Voltage is removed from the Ignition Switch ST contacts and
applied to the IG contacts. Current is present through the IG2
contacts to the ignition coils.
10. Current through the holdin coil stops. Current through the pullin
coil reverses direction and flows from the battery through the
magnetic switch, the pullin coil, and the holdin coil to ground.
With current through the pullin coil reversed, the magnetic fields
of the pullin and holdin coils cancel each other out.
11. A return spring pulls the solenoid plunger and the drive lever back.
The pinion gear disengages from the ring gear. The magnetic switch
opens. Current through the starter motor stops.
Ignition Switch
Released to ON
Current is no longer
present and the pinion
gear releases from the
ring gear.
Fig. 4-23
TL623f423c
4-24
Diagnosis The starting system requires little maintenance. The battery should be
and Testing fully charged and connections kept clean and tight.
Diagnosis of starting system problems is usually straightforward.
Problems may be electrical or mechanical.
The Starting System Troubleshooting chart lists the most common
starting system problems, the possible causes, and recommended
actions to resolve the problem.
Begin with a thorough visual inspection. If this fails to turn up the
possible cause, several tests are available to help you find the problem:
Starter motor current draw test
Voltage drop tests
Operational and continuity tests
Starter motor bench tests
4-25
Section 4
Starting System
Troubleshooting Chart
Symptoms
Possible Cause
Action Needed
Dead battery
Loose connections
Check engine
Weak battery
Test starter
Mechanical problems
roblems with
engine or starter
Fig. 4-24
4-26
Visual Inspection A visual inspection of the starting system can save you time and effort
by uncovering obvious or simple and easytofix problems.
CAUTION
Visual Inspection
BATTERY
Inspect the battery for external damage
to the case or the cables, corroded
terminals, and loose connections.
Check the batterys state of charge
(with a battery analyzer). Charge if
needed.
Check the electrolyte level and top up
with distilled water if needed.
STARTER
Inspect the starter motor for external
damage to the case or wiring (including
the magnetic switch circuit), corroded
terminals, and loose connections.
Check for loose mounting hardware.
Tighten as needed.
IGNITION SWITCH
Inspect the ignition switch for loose
connections and damaged wiring.
Confirm that the battery voltage is available
at the magnetic switch with the ignition
switch set to ON and the clutch switch or
neutral start switch closed.
If you suspect the ignition switch is faulty,
use a remote starter switch and jumper
wire to confirm starter operation.
PARK/NEUTRAL/CLUTCH START SWITCHES
Conduct a voltage drop test to verify
proper operation (max. 0.1 V drop).
Fig. 4-25
4-27
Section 4
Current Draw Test The starter current draw test effectively checks the entire starting
system. A special purpose tester connects to the battery to measure
starting current and cranking voltage.
The procedure shown here applies to the VAT40 and (with some minor
differences) the VAT60:
1. Make a visual inspection of the battery, electrolyte, and battery
cables.
2. Turn off all electrical accessories and lights in the vehicle; set
ignition switch to OFF.
3. Disable the fuel or ignition system so the engine will not start while
cranking.
4. Connect the tester in this sequence:
Red lead to positive battery terminal
Black lead to negative battery terminal
Current probe on negative battery cable
Fig. 4-26
TL623f426c
4-28
NOTE
For most Toyota vehicles, you can pull the Electronic Fuel Injection
(EFI) fuse or relay to prevent engine start.
You can connect the current probe to either battery cable. Just be sure
to orient the arrow on the probe correctly. The arrow should point down
(away from the battery) for the positive cable; the arrow should point
up (toward the battery) for the negative cable.
Do not crank the engine longer than 10 seconds at a time.
4-29
Section 4
Voltage Drop Tests Voltage drop tests can find excessive resistance in the starting system.
- Starter Motor High resistance in the starter motor circuit can
Circuit
Reduce starter motor current.
Cause slow cranking.
Preparation Prepare the tester and the vehicle with these steps:
1. Disable the fuel or ignition system so engine will not start while
cranking.
NOTE
For most Toyota vehicles, you can pull the Electronic Fuel Injection
(EFI) fuse or relay to prevent engine start.
2. Set the VAT40 volt selector to EXT 3 (volts). If youre using a
DMM, select a low voltage scale.
3. Connect the VAT40 or DMM leads to measure voltage drop for the
following:
Battery + post to + cable
Battery + cable to starter
Starter relay to starter (PS type)
Starter case to cable cable to battery post
Terminal C to terminal 30 (gear reduction type)
Battery to terminal 50 (gear reduction type)
Normal voltage drops in the starting system are in the range of 0.2
volts to 0.5 volts.
4-30
Battery Positive This test measures the voltage drop across the positive battery post to
Cable the cable and the connections at the battery and the starter.
NOTE
Battery Positive
Cable
Meter connected to
measure voltage drop.
Fig. 4-27
TL623f427c
4-31
Section 4
Battery Negative This test measures the voltage drop across the negative battery cable,
Cable the connections at the battery and the starter, and the connection to
ground through the starter motor case:
1. Connect the tester or meter leads:
Red lead to the starter motor housing
Black lead to negative terminal of the battery
NOTE
4-32
Battery
Negative Cable
Meter connected to
measure voltage drop.
Fig. 4-28
TL623f428c
4-33
Section 4
Magnetic Switch This test measures the voltage drop across the magnetic switch:
NOTE
NOTE
Magnetic Switch
Meter connected to
measure voltage drop.
Fig. 4-29
TL623f429c
4-34
Voltage Drop Tests Excessive resistance in the starter control circuit can reduce the
- Starter Control voltage available to the magnetic switch. Symptoms of excessive
Circuit voltage include the following:
Pinion gear does not engage
Pinion gear engages only partially
There are several areas where excessive resistance can occur:
ST contacts of the ignition switch
Neutral start switch /clutch start switch
Circuit wiring and connections
Starter
Control Circuit
Voltage drop testing can
find excessive resistance.
Fig. 4-30
TL623f430c
4-35
Section 4
Test for excessive resistance in the starter control circuit with these steps:
1. Connect tester or meter leads
Red lead to the positive battery terminal
Black lead to terminal 50 on the starter motor
2. On a vehicle with an automatic transmission, put the shift selector
in Park or Neutral. For a vehicle with a manual transmission,
depress the clutch pedal.
NOTE
4-36
NOTE
Starter Relay
Tests
Relays must be tested
for continuity in both
states: energized and
de-energized.
Fig. 4-31
TL623f431c
4-37
Section 4
Ignition Switch Check the ignition switch both mechanically and electrically.
and Key
Mechanically Switch should turn smoothly without binding. Binding
may mean problems with the lock cylinder or the electrical contacts.
Check the ignition key for excessive wear or rough surfaces.
Electrically Disconnect the battery ground cable and check for
continuity through the ST contacts. Refer to the appropriate service
manual for wiring details.
Ignition Switch
Switch must operate
smoothly and provide the
correct current path.
Fig. 4-32
TL623f432c
4-38
Park/Neutral Adjust the park/neutral position switch if you can operate the starter
Position Switch with the gear selector in any position other than Park or Neutral.
Adjust the switch as follows:
1. Loosen the switch retaining bolt.
2. Disconnect the switch electrical connector.
3. Set the gear selector to the Neutral position.
4. Connect an ohmmeter across the switch contacts (refer to the
appropriate service manual for wiring details).
5. Adjust the switch to the point where the ohmmeter shows continuity.
6. Set the gear selector to Park; confirm that there is still continuity
through the switch.
7. Set the gear selector to any position other than Park or Neutral.
Confirm that there is no continuity through the switch.
Fig. 4-33
TL623f433
4-39
Section 4
Clutch Start Switch Adjust the Clutch Start Switch using the appropriate service manual.
The procedure involves checking clutch pedal height and freeplay in
the switch.
Use a digital multimeter to check continuity through a properly
adjusted switch:
Pedal depressed There should be continuity through the switch
with the clutch pedal depressed.
Pedal released There should be no continuity through the switch
with the clutch pedal released.
Fig. 4-34
TL623f434c
4-40
Clutch Start Troubleshoot the Clutch Start Cancel Switch with these continuity and
Cancel Switch operational checks.
Continuity Use a digital multimeter to confirm that there is no
continuity between these terminals:
1 and 2
1 and 3
2 and 3
Replace the switch if you find continuity between any of these pairs of
pins.
Operational Connect a battery across pins 1 and 3. Use a digital
multimeter to check for continuity as follows:
no continuity between pins 1 and 2 with switch OFF
continuity between pins 1 and 2 with switch ON
Replace the switch if either of these tests gives a continuity result
different from the specification.
4-41
Section 4
Clutch Start
Cancel Switch
Switch must be tested
with continuity checks
and operational checks.
Fig. 4-35
T623f435c
4-42