Toyota 28100-0D080 Starter Assembly

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Before diagnosing problems with the starter, ensure that the battery is fully charged. If there is a malfunction in the starting circuit, do not assume that it is the starter right away. In case of a fault in the starter's operation one should check the following parts:Make sure that battery cable clamps are clean and fastened securely to the battery posts.Check if battery cables are broken anywhere and replace them if necessary.Test battery's condition and change it if it fails any tests.Inspect starter solenoid wiring and connections.Ensure that starter mounting bolts are tight.Examine the fusible links close to positive battery terminal for any burnt ones as well as check operation of ignition switch circuit.For correct operation make sure transmission range sensor (automatic transaxle) or clutch start switch (manual transaxle) returns path through shift lever position. If, when you turn ignition switch to START, engine does not engage with starter, then check at solenoid positive terminal voltage from ignition switch compatible with this system. If there is no current, examine each fuse and relay of the circuit within starting system. In case there is voltage but no movement by motor inside starter assembly you should take it out and test on a test bench. When cranked slowly enough, analyze starting cranking voltage drop across solenoid contacts and current pulled from battery-they must match specified ranges; otherwise substitute faulty unit for new one. In other words to have a good power source matched to engine load; also keep all terminals and cables clean between starts. Also remember about preheating block of ice-cold engine by heating up a car accumulator, for instance, before testing its performance. Finally if you have applied voltage across solenoid windings with no motion at all, then take off whole starter/solenoid assembly to bench-test it and to replace as required on basis of the bench test. If engine is seized attempt to turn crankshaft pulley first. To start with, provide battery voltage to solenoid S terminal during its check and possible starter assessment in a separate operational mode.

After disconnecting the starter solenoid, you should remove the starter motor mounting bolts and then remove the starter from the vehicle.

Remove and check the starter/solenoid assembly on the bench. The solenoid is likely defective. Before proceeding, try to rotate the crankshaft pulley to ensure the engine is not seized. With the starter/solenoid assembly mounted in a vise, connect jumper cables from the negative battery terminal to the body of the solenoid and from the positive battery terminal to the B+ terminal on the solenoid. Apply battery voltage to the solenoid S terminal for 10 seconds or less. If the solenoid plunger extends and rotates the pinion drive, the assembly is working properly. If the pinion drive extends but does not rotate, the starter motor is defective. If there is no movement but the solenoid clicks, either the solenoid or the starter motor is defective.

The electrical connector from the starter solenoid can be disconnected by unplugging it.