Starter ASSY: Overhaul

HINT:

Use 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 Starter Yoke Assy
  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 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: Removing Starter Brush Holder Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ARMATURE ASSY

INSPECT STARTER ARMATURE ASSY

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.
Check if the commutator has an open circuit.
1. Measure the resistance between the segments of the commutator.
Standard: Below 1 Ω.
1. If the result is not as specified, replace the armature assy.
Fig 5: Checking Commutator Has An Open Circuit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check if the commutator is grounded.
1. Measure the resistance between the commutator and armature coil core.
1. Standard: 10 kΩ or higher
If the result is not as specified, replace the armature assy.

Fig 6: Checking Commutator Is Grounded
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the commutator circle runout.
1. Place the armature on the V-blocks.
2. Using a dial gauge, measure the circle runout.
1. 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: Checking Commutator Circle Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a vernier caliper, measure the commutator diameter.

Standard:

MEASURING COMMUTATOR DIAMETER TABLE

Standard	35.0 mm (1.378 in.)
Minimum	34.0 mm (1.339 in.)

Fig 8: Measuring Commutator Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the diameter is less than the minimum, replace the armature.

Measure the undercut depth of the commutator.

Standard:

MEASURING UNDERCUT DEPTH OF COMMUTATOR TABLE

Standard	0.7 mm (0.028 in.)
Minimum	0.2 mm (0.008 in.)

Fig 9: Measuring Undercut Depth Of Commutator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the undercut depth is less than the minimum, correct it with a hacksaw blade.

Inspect the bearings.
1. OK: Rotate 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.
  1. Standard: Below 1 Ω
  If the result is not as specified, replace the starter yoke assy.
2. Inspect the shunt coil resistance.
  1. Using an ohmmeter, measure the resistance between the shunt coil terminals.
  1. Standard: 1.5 to 1.9 Ω at 20°C (68°F)
  Fig 11: Inspecting Shunt Coil Resistance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the result is not as specified, replace the starter yoke assy.

INSPECT BRUSH

Using a vernier caliper, measure the length of the brushes.

Standard:

BRUSH LENGTH REFERENCE TABLE

Standard	15.0 mm (0.591 in.)
Minimum	9.0 mm (0.354 in.)

Fig 12: Inspecting Brush

If the length is less than the minimum, replace the brush holder assy and starter yoke assy.

INSPECT STARTER BRUSH HOLDER ASSY

Check the brush insulation.
1. Check the resistance between the positive (+) and negative (-) brush holders.
1. Standard: 10 kΩ or higher
Fig 13: Checking Brush Insulation
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the result is not as specified, repair or replace the end frame assy.

Using a pull scale, measure the brush spring load.

Specified spring load:

SPECIFIED SPRING LOAD TABLE

Standard	21.5 to 27.5 N (2.2 to 2.8 kgf, 4.9 to 6.2 lbf)
Minimum	12.7 N (1.3 kgf, 2.9 lbf)

Fig 14: Measuring Brush Spring Load

If the spring load is less than the minimum, replace the brush springs.

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 15: Inspecting Starter Clutch Sub-Assy
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.
  1. Standard: Below 1 Ω.
  If the result is not as specified, replace the magnetic switch assy.
  
  Fig 16: Checking Pull-In Has An Open Circuit
  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.
  1. Standard: Below 2 Ω.
  If the result is not as specified, replace the magnetic switch assy.
  
  Fig 17: Checking Hold-In Coil Has An Open Circuit
  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.
  
  Fig 18: Holding Brush Spring Back & Connecting Brush Into Brush Holder Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new O-ring to the groove of the starter yoke.
4. Install the end cover to the starter yoke with the 2 screws.
  1. Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)
  Fig 19: 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.
  
  Fig 20: Inserting Steel Ball Into Clutch Shaft Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply grease to the return spring.
4. Insert the return spring into the magnetic switch hole.
  
  Fig 21: Inserting Return Spring Into Magnetic Switch Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Place a new gasket (1), the starter clutch (2), idler gear (3) and bearing (4) on starter housing.
  
  Fig 22: Identifying Gasket (1), Starter Clutch (2), Idler Gear (3) And Bearing (4)
  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 23: 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 24: Aligning Protrusion Of Starter Yoke With Groove Of Magnetic Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the starter yoke and armature assy with the 2 bolts.
  1. Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
  Fig 25: Installing Starter Yoke & Armature Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the lead wire to terminal C with the nut.
  1. Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)