Section 24 (Starting System): Starter: Disassembly

WARNING: This page is about a different car, the 2005 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE DUST PROTECTOR
REMOVE FIELD FRAME AND ARMATURE
1. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
  Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2. Remove the 2 through bolts.
  Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
  
  Fig 1: Removing Field Frame And Armature
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull out the field frame together with the armature.
  HINT:
  
  At the time of reassembly, align the protrusion of the field frame with the indentation of the magnetic switch.
  
  Fig 2: Identifying Protrusion & Indentation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring from the yoke.
  HINT:
  
  At the time of reassembly, use a new O-ring.
REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
1. Remove the 2 screws.
  Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
  
  Fig 3: Removing Starter Housing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the starter housing and clutch assembly (1), return spring (2), idler gear (3) and bearing from the magnetic switch.
  
  Fig 4: Removing Starter Housing And Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.

Fig 5: Removing Steel Ball From Clutch Shaft Hole
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRUSH HOLDER
1. Remove the 2 screws and end cover from the field frame.
  Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
2. Remove the O-ring from the field frame.
  
  Fig 6: Removing End Cover From Field Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.
  NOTE: At the time of reassembly, check that the positive (+) lead wires are not grounded.