Starter ASSY: Overhaul

HINT:

These high-temperature grease to lubricate the bearings and gears when assembling the starter.

REMOVE STARTER YOKE ASSY
1. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
2. Remove the 2 bolts and pull out the starter yoke together with the armature from the magnetic switch.
3. Remove the O-ring from the starter yoke.
  
  Fig 1: Removing Nut And Disconnecting Lead Wire From Magnetic Switch Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MAGNET STARTER SWITCH ASSY
1. Remove the 2 screws, and separate the starter switch and starter housing.
2. Remove the O-ring, starter clutch, return spring, idler gear and bearing.
3. Using a magnetic finger, remove the steel ball from the clutch shaft hole.
  
  Fig 2: Removing Magnet Starter Switch Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE END COVER
1. Remove the 2 screws and end cover.
  
  Fig 3: Removing Screws And End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER BRUSH HOLDER ASSY
1. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.
2. Disconnect the brushes, and remove the brush holder.
  
  Fig 4: Holding Spring Back And Disconnecting Brush From Brush Holder Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ARMATURE ASSY
INSPECT STARTER ARMATURE ASSY
1. Check the commutator for contamination and burns on its surface.
  If the surface is dirty or burnt, correct it with sandpaper (#400) or a lathe.
2. Check if the commutator has an open circuit.
  1. Measure the resistance between the segments of the commutator.
  Standard: Below 1 Ω
  
  If the result is not as specified, replace the armature assy.
  
  Fig 5: Measuring Resistance Between Segments Of Commutator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check if the commutator is grounded.
  1. Measure the resistance between the commutator and armature coil core.
  Standard: 10 kΩ or higher
  
  If the result is not as specified, replace the armature assy.
  
  Fig 6: Measuring Resistance Between Commutator And Armature Coil Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the commutator circle runout.
  1. Place the armature on the V-blocks.
  2. Using a dial gauge, measure the circle runout.
  Maximum circle runout: 0.05 mm (0.0020 in.)
  
  If the circle runout is greater than the maximum, correct it with sandpaper (#400) or replace the armature.
  
  Fig 7: Measuring Circle Runout Using Dial Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using vernier calipers, measure the commutator diameter.
  Specified diameter:
  
  Fig 8: Specified Diameter Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the diameter is less than the minimum, replace the armature.
  
  Fig 9: Measuring Commutator Diameter Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Measure the undercut depth of the commutator.
  Specified depth:
  
  Fig 10: Specified Depth Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the undercut depth is less than the minimum, correct it with a hacksaw blade.
  
  Fig 11: Measuring Undercut Depth Of Commutator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Inspect the bearings.
  OK:
  
  Rotates Smoothly
  
  If necessary, replace the armature assy.
INSPECT STARTER YOKE ASSY
1. Check the field coil resistance.
  1. Using an ohmmeter, measure the resistance between the lead wire and both brushes.
  Standard: Below 1Ω
  
  If the result is not as specified, replace the starter yoke assy.
  
  Fig 12: Measuring Resistance Between Lead Wire And Both Brushes Using Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the shunt coil resistance.
  1. Using an ohmmeter, measure the resistance between the shunt coil terminals.
  Standard: 1.5 to 1.9 Ω at 20°C (68°F)
  
  If the resistance is not as specified, replace the starter yoke assy.
  
  Fig 13: Measuring Resistance Between Shunt Coil Terminals Using Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRUSH
1. Using a vernier caliper, measure the length of the brushes.
  Specified brush length:
  
  Fig 14: Specified Brush Length Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the length is less than the minimum, replace the brush holder assy and starter yoke assy.
  
  Fig 15: Measuring Length Of Brushes Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER BRUSH HOLDER ASSY
1. Check the brush insulation.
  1. Check the resistance between the positive (+) and negative (-) brush holders.
  Standard: 10 KΩ or higher
  
  If the result is not as specified, repair or replace the end frame assy.
  
  Fig 16: Checking Resistance Between Positive And Negative Brush Holders
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pull scale, measure the brush spring load.
  Specified spring load:
  
  Fig 17: Specified Spring Load Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the spring load is less than the minimum, replace the brush springs.
  
  Fig 18: Measuring Brush Spring Load Using Pull Scale
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER CLUTCH SUB-ASSY
1. Check that the starter clutch operates as show in the illustration.
  If the starter clutch is does not operate, replace it.
  
  Fig 19: Checking Starter Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MAGNET STARTER SWITCH ASSY
1. Check if the pull-in coil has an open circuit.
  1. Using an ohmmeter, measure the resistance between terminals 50 and C.
  Standard: Below 1 Ω
  
  If the result is not as specified, replace the magnetic switch assy.
  
  Fig 20: Measuring Resistance Between Terminals 50 And C Using Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check if the hold-in coil has an open circuit.
  1. Using an ohmmeter, measure the resistance between terminal 50 and the switch body.
  Standard: Below 2 Ω
  
  If the result is not as specified, replace the magnetic switch assy.
  
  Fig 21: Measuring Resistance Between Terminal 50 And Switch Body Using Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSY
1. Apply grease to the armature bearings.
2. Insert the armature into the yoke.
INSTALL STARTER BRUSH HOLDER ASSY
1. Place the brush holder on the starter yoke.
2. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder. Connect the 4 brushes.
  NOTE: Check that the positive lead wires are not grounded.
3. Install a new O-ring to the groove of the starter yoke.
  
  Fig 22: Holding Brush Spring Back Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the end cover to the starter yoke with the 2 screws.
  Torque: 3.8 N.m (39 kgf.cm, 34 in. lbf)
  
  Fig 23: Installing End Cover To Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MAGNET STARTER SWITCH ASSY
1. Apply grease to the steel ball.
2. Insert the steel ball into the clutch shaft hole.
3. Apply grease to the return spring.
  
  Fig 24: Inserting Steel Ball Into Clutch Shaft Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert the return spring into the magnetic switch hole.
  
  Fig 25: Inserting Return Spring Into Magnetic Switch Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Place these parts on the starter hosing:
  1. A new O-ring.
  2. The starter clutch.
  3. The idler gear.
  4. The bearing.
    
    Fig 26: Placing Parts On Starter Hosing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the starter housing to the magnetic switch with the 2 screws.
  Torque: 9.3 N.m (95 kgf.cm, 82 in. lbf)
  
  Fig 27: Installing Starter Housing To Magnetic Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSY
1. Install a new O-ring to the groove of the starter yoke.
2. Align the protrusion of the starter yoke with the groove of the magnetic switch, and install the starter yoke and armature.
  
  Fig 28: Installing O-Ring To Groove Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the starter yoke and armature assy with the 2 bolts.
  Torque: 9.3 N.m (95 kgf.cm, 82 in. lbf)
4. Connect the lead wire to terminal C with the nut.
  Torque: 5.9 N.m (60 kgf.cm, 52 in. lbf)
  
  Fig 29: Locating Bolt Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002