Starter Motor: Service and Repair

NOTE: Some Toyota models have an access plate in the fender well to facilitate starter service. Check for such an access point before beginning starter service.





REMOVAL OF STARTER





1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY.
2. DISCONNECT TWO WIRES FROM STARTER
(a) Remove the nut and disconnect the battery cable from the magnetic switch on the starter motor.
(b) Disconnect the other wire from terminal 50.

3. REMOVE STARTER MOTOR

(22R and 22R-E Engines)
Remove the nut and bolt, and remove the starter motor from the flywheel bellhousing.









DISASSEMBLY OF STARTER
1. REMOVE FIELD FRAME WITH ARMATURE FROM MAGNETIC SWITCH ASSEMBLY.





(a) Remove the nut and disconnect the lead wire from the magnetic switch terminal.





(b) Remove the two through bolts. Pull out the field frame with the armature from the magnetic switch assembly.
(c) (1.4, 1.6kW) Remove the 0-ring.

2. REMOVE STARTER HOUSING FROM MAGNETIC SWITCH ASSEMBLY





(a) Remove the two screws.





(b) Remove the starter housing with the pinion gear (1.4, 1.6 kw), idler gear, bearing and clutch assembly.

3. REMOVE CLUTCH ASSEMBLY AND GEARS FROM STARTER HOUSING.





4. REMOVE STEEL BALL AND SPRING.
Using a magnetic finger, remove the spring and steel ball from the clutch shaft hole.
5. REMOVE BRUSHES AND BRUSH HOLDER
(a) Remove the two screws and pull the end cover with 0-ring (1.4, 1.6 kw) off the field frame.





(b) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the four brushes and remove the brush holder.
6. REMOVE ARMATURE FROM FIELD FRAME





INSPECTION OF STARTER

Armature Coil





1. INSPECT THAT COMMUTATOR IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature.





2. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature.
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES
If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe.
2. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V-blocks.





(b) Using a dial indicator, measure the circle runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
3. INSPECT COMMUTATOR DIAMETER





Using calipers, measure the commutator diameter.
Standard diameter:
30 mm (1.18 in.)
Minimum diameter:
29 mm (1.14 in.)
If the diameter is less than minimum, replace the armature.
4. INSPECT UNDERCUT DEPTH OF SEGMENT





Check that the undercut depth is clean and free of foreign material. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a hacksaw blade.
Field Frame (Field Coil)
1. INSPECT FIELD COIL FOR OPEN CIRCUIT





Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame.
2. INSPECT THAT FIELD COIL IS NOT GROUNDED





Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame.

Brushes INSPECT BRUSH LENGTH





Using calipers, measure the brush length.
Standard length:
1.0 kw 13.5 mm (0.531 in.)
1.4 kw 15.5 mm (0.610 in.)
1.6 kw 15.5 mm (0.610 in.)
Minimum length:
1.0 kw 8.5 mm (0.335 in.)
1.4 kw 10.0 mm (0.394 in.)
1.6 kw 10.0 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and field frame.

Brush Springs
INSPECT BRUSH SPRING LOAD





Take the pull scale reading the instant the brush spring separates from the brush.
Standard installed load:
1.785 2.415 kg (3.9 - 5.3 lb 18 - 24 N)
Minimum installed load
1.2 kg (2.6 lb, 12 N)
If the installed load is less than minimum, replace the brush springs.

HINT: Take the pull scale reading the instant the brush spring separates from the brush.

Brush Holder
INSPECT INSULATION OF BRUSH HOLDER





Using an ohmmeter, check that there is no continuity between the positive (+ and negative (-) brush holders. If there is continuity, repair or replace the brush holder.

Clutch and Gears
1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. If damaged,replace the gear or clutch assembly. If damaged, also check the flywheel ring gear for wear or damage.

2. INSPECT CLUTCH





Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion counterclockwise and check that it locks. If necessary, replace the clutch assembly.

Bearings
1. INSPECT BEARINGS





Turn each bearing by hand while applying inward force. If resistance is felt or if the bearing sticks, replace the bearing.

2. IF NECESSARY, REPLACE BEARINGS





(a) Using SST, remove the bearing.
SST 09286-46011





(b) Using SST and a press, press in a new bearing.
SST 1.0 kw 09285-76010,
1.4 kw, 1.6 kw 09201-41020.

Magnetic Switch
1. PERFORM PULL-IN COIL OPEN CIRCUIT TEST





Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the magnetic switch assembly.

2. PERFORM HOLD-IN COIL CIRCUIT TEST





Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch assembly.





ASSEMBLY OF STARTER

HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.

1. PLACE ARMATURE INTO FIELD FRAME
Apply grease to the armature bearings and insert the armature into the field frame.

2. INSTALL BRUSH HOLDER





(a) Place the brush holder over the frame.
(b) Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the four brushes.

HINT: Check that the positive (+) lead wires are not grounded.
(c) (1.4, 1.6 kw) Place the 0-ring on the field frame.

(d) Install the end cover to the field frame with the two screws.





3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
(a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole





4. INSTALL GEARS AND CLUTCH ASSEMBLY
(a) Apply grease to the gears and clutch assembly.
(b) Place the clutch assembly, idler gear, bearing and pinion gear (1.4, 1.6 kw) in the starter housing.





5. INSTALL STARTER HOUSING
(a) Apply grease to the return spring.
(b) Insert the return spring into the magnetic hole.
(c) Place the starter housing on the magnetic switch and install the two screws.

6. INSTALL FIELD FRAME WITH ARMATURE TO MAGNETIC SWITCH ASSEMBLY
(a) (1.4, 1.6 kw)
Place the 0-ring on the field frame.





(b) Align the protrusion of the field frame with the cutout of the magnetic switch.





(c) Install the two through bolts.
(d) Connect the lead wire to the magnetic switch terminal C, and install the nut.

PERFORMANCE TEST OF STARTER

NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

1. PERFORM PULL-IN TEST





(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the magnetic switch assembly.

2. PERFORM HOLD-IN TEST





While connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out. If the clutch pinion gear returns inward, replace the magnetic switch assembly.

3. INSPECT CLUTCH PINION GEAR RETURN





Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. If the clutch pinion gear does not return, replace the magnetic switch assembly.

4. PERFORM NO-LOAD PERFORMANCE TEST





(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter reads the specified current. Specified current: 90 A or less at 11.5 V

INSTALLATION OF STARTER
1. INSTALL STARTER MOTOR ON TRANSAXLE





(22R and 22R-E Engines)
Place the starter motor in the flywheel bellhousing install and torque the bolt and nut.

(3VZ-E Engine)
Place the starter motor in the flywheel bellhousing install and torque the starter mounting bolts. Torque: 400 kg-cm (29 ft-lb, 39 N.m)

2. CONNECT TWO WIRES TO STARTER





Connect the connector to the terminal on the magnetic switch. Connect the cable from the battery to the terminal on the switch, and install the nut.

3. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
Check that the engine starts.