Starter ASSY: Overhaul

WARNING: This page is about a different car, the 2005 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE REPAIR SERVICE STARTER KIT
1. Remove the nut and disconnect the lead wire from the repair service starter kit.
  
  Fig 1: Disconnecting Lead Wire From Repair Service Starter Kit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 screws which are used to secure the repair service starter kit to the repair service starter kit.
3. Remove the repair service starter kit.
4. Remove the return spring and the plunger from the repair service starter kit.
Fig 2: Removing 2 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER YOKE ASSY
1. Remove the 2 through bolts and pull out the starter yoke together with the starter commutator end frame.
  
  Fig 3: Removing 2 Through Bolts & Pulling Out Starter Yoke Together With Starter Commutator End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the starter yoke from the starter commutator end frame.
Fig 4: Removing Starter Yoke From Starter Commutator End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ARMATURE PLATE
1. Remove the starter armature plate from the starter yoke.
Fig 5: Removing Starter Armature Plate From Starter Yoke
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRIVE HOUSING STARTER BEARING COVER
1. Using a screwdriver, remove the drive housing starter bearing cover.
Fig 6: Removing Drive Housing Starter Bearing Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ARMATURE ASSY
1. Using snap ring pliers, remove the snap ring and the plate washer.
2. Remove the starter armature from the commutator end frame.
Fig 7: Removing Snap Ring & Plate Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PLANET GEAR
1. Remove the 3 planet gears from the repair service starter kit.
Fig 8: Removing 3 Planet Gears From Repair Service Starter Kit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REPAIR SERVICE STARTER KIT
1. Check the plunger.
  1. Push in the plunger and check that it returns quickly to its original position.
  If necessary, replace the repair service starter kit.
  
  Fig 9: Checking Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the pull-in coil for open circuit.
  1. Using an ohmmeter, check that there is continuity between terminals 50 and C.
  If there is no continuity, replace the repair service starter kit.
  
  Fig 10: Checking Continuity Between Terminals 50 & C
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check whether or not the hold-in coil has an open circuit.
  1. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
  If there is no continuity, replace the repair service starter kit.
Fig 11: Checking Continuity Between Terminal 50 & Switch Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER ARMATURE ASSY
1. Check the commutator for open circuit.
  1. Using an ohmmeter, check that there is continuity between the segments of the commutator.
  If there is no continuity between any segments, replace the starter armature.
  
  Fig 12: Checking Continuity Between Segments Of Commutator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the commutator for ground.
  1. Using an ohmmeter, check that there is no continuity between the commutator and the armature coil core.
  If there is continuity, replace the starter armature.
3. Check the commutator for dirty and burned surface.
  If the surface is dirty or burned, correct it with sandpaper (No. 400) or lathe.
  
  Fig 13: Checking Continuity Between Commutator & Armature Coil Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the commutator depth.
  1. Using vernier calipers, measure the commutator depth.
  Standard length: 3.3 mm (0.1299 in.)
  
  Maximum length: 4.0 mm (0.1575 in.)
  
  If the depth is greater than maximum, replace the starter armature.
Fig 14: Identifying Commutator Depth
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER COMMUTATOR END FRAME ASSY
1. Check the brush holder length.
  1. Using vernier calipers, measure the brush holder length.
  Standard length: 9.0 mm (0.354 in.)
  
  Minimum length: 4.0 mm (0.158 in.)
  
  If the length is less than minimum, replace the starter commutator end frame.
  
  Fig 15: Identifying Brush Holder Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the brush holder.
  1. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders.
  If there is continuity, repair or replace the starter commutator end frame.
Fig 16: Checking Continuity Between Positive (+) & Negative (-) Brush Holders
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REPAIR SERVICE STARTER KIT
1. Check the starter clutch.
  1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.
  If necessary, replace the repair service starter kit.
Fig 17: Rotating Clutch Pinion Gear Counterclockwise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PLANET GEAR
1. Apply grease to the planet gears and pin parts of the planetary shaft.
2. Install the 3 planet gears to the repair service starter kit.
Fig 18: Installing 3 Planet Gears To Repair Service Starter Kit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSY
1. Apply grease to the plate washer and the armature shaft.
2. Install the starter armature to the starter commutator end frame.
3. Using snap ring pliers, install the plate washer and a new snap ring.
  
  Fig 19: Installing Plate Washer & New Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using vernier calipers, measure the snap ring.
  Maximum length: 5.0 mm (0.197 in.)
If the length is greater than maximum, replace it with a new snap ring.

Fig 20: Identifying Snap Ring Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE HOUSING STARTER BEARING COVER
1. Install the drive housing starter bearing cover to the starter commutator end frame.
Fig 21: Installing Drive Housing Starter Bearing Cover To Starter Commutator End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE
1. Insert the starter armature plate to the starter yoke.
2. Align the keyway of the starter plate with the key inside the starter yoke, and install the starter plate.
Fig 22: Aligning Keyway Of Starter Plate With Key Inside Starter Yoke
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSY
1. Align the rubber with the convex cutout of starter yoke.
2. Install starter commutator end frame to the starter yoke.
Fig 23: Installing Starter Commutator End Frame To Starter Yoke
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSY
1. Align the key of the starter yoke with the keyway of repair service starter kit.
  
  Fig 24: Aligning Key Of Starter Yoke With Keyway Of Repair Service Starter Kit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter yoke with the 2 through bolts.
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
Fig 25: Installing Starter Yoke With 2 Through Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REPAIR SERVICE STARTER KIT
1. Apply grease to the plunger and the hook.
2. Hang the plunger hook of the repair service starter kit to the drive lever.
3. Install the plunger and the return spring.
  
  Fig 26: Installing Plunger & Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install repair service starter kit with the 2 screws.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
  
  Fig 27: Installing 2 Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the lead wire to the repair service starter kit with the nut.
  Torque: 6.5 N.m (66 kgf.cm, 58 in.lbf)
Fig 28: Connecting Lead Wire To Repair Service Starter Kit With Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002