Starter ASSY: Overhaul

HINT:

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

1. REMOVE STARTER YOKE ASSY 
   1. Remove the dust protector.
   2. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
   3. Remove the 2 bolts, and pull out the starter yoke (with armature) from the magnetic switch.
   4. Remove the O-ring from the starter yoke.
      Fig 1: Removing Starter Yoke Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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 steel ball, 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
3. REMOVE END COVER 
   1. Remove the 2 screws and end cover.
      Fig 3: Removing End Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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.
      Fig 4: Removing Starter Brush Holder Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE STARTER ARMATURE ASSY 
6. INSPECT STARTER ARMATURE ASSY 
   1. Check the commutator surface for contamination and burns.

      If the surface is dirty or burnt, correct it with sandpaper (#400) or a lathe.

   2. Check that the commutator does not have 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: Checking Commutator Does Not Have An Open Circuit

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Check that the commutator is not 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: Checking Commutator Is Not Grounded

         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 assy.

         Fig 7: Checking Commutator Circle Runout

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using a vernier caliper, measure the commutator diameter.

      Diameter: 

      COMMUTATOR DIAMETER SPECIFICATION
      
      

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

      Fig 8: Measuring Commutator Diameter Using Vernier Caliper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   6. Measure the undercut depth of the commutator.

      Depth: 

      COMMUTATOR DEPTH SPECIFICATION
      
      

      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.

   7. Check that the bearings rotate smoothly.

      OK: Rotates smoothly 

      If necessary, replace the armature assy.

7. 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 1 Ω 

         If the result is not as specified, replace the starter yoke assy.

         Fig 10: Checking Field Coil Resistance

         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 result is not as specified, replace the starter yoke assy.

         Fig 11: Inspecting Shunt Coil Resistance

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSPECT BRUSH 
   1. Using a vernier caliper, measure the length of the brushes.

      Brush length: 

      BRUSH LENGTH SPECIFICATION
      
      

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

      Fig 12: Inspecting Brush

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

9. 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 13: Checking Brush Insulation

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a pull scale, measure the brush spring load.

      Spring load: 

      SPRING LOAD SPECIFICATION
      
      

      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 Using Pull Scale

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

10. INSPECT STARTER CLUTCH SUB-ASSY 
    1. Check that the starter clutch can rotate clockwise, but cannot rotate counterclockwise.

       If the starter clutch is does not operate as specified, replace it.

       Fig 15: Inspecting Starter Clutch Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSPECT MAGNET STARTER SWITCH ASSY 
    1. Check that the pull-in coil does not have 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 16: Checking Pull-In Coil Does Not Have An Open Circuit

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the hold-in coil dose not have 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 17: Checking Hold-In Coil Dose Not Have An Open Circuit

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. INSTALL STARTER ARMATURE ASSY 
    1. Apply grease to the armature bearings.
    2. Insert the armature into the yoke.
13. 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 all 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.

       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
14. 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 O-ring (1), the starter clutch (2), idler gear (3), and bearing (4) on the starter housing.
       Fig 22: Installing New O-Ring, Starter Clutch, Idler Gear & Bearing On Starter Housing

       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
15. 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 with the 2 bolts.

       Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf) 

       Fig 25: Installing Starter Yoke & Armature

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the lead wire to terminal C with the nut.

       Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) 

    5. Install a new dust protector.