Starting System: Starter: Disassembly

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: 9.3 N.m (95 kgf.cm, 82 in..lbf) 

   Fig 1: Locating Nut

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3. Pull out the field frame together with the armature from the magnetic switch assembly.
   NOTE: At the time of assembly, align the protrusion of the field frame with the groove of the magnetic switch.
4. Remove the O-ring from the field frame.

   HINT:

   At the time of assembly, use a new O-ring.

Fig 2: Pulling Out Field Frame

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1. Remove the 2 screws.

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

   Fig 3: Locating Screws

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2. Remove these parts from the magnetic switch assembly:
   1. Starter housing
   2. Return spring
   3. Idler gear
   4. Bearing
   5. Starter clutch assembly

   HINT:

   At the time of assembly, please refer to the following items. Apply grease to the return spring and insert the return spring into the clutch shaft hole.

Fig 4: Idemtifying Parts From Magnetic Switch Assembly

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Using a magnetic finger, remove the steel ball from the clutch shaft hole.

HINT:

At the time of assembly, apply grease to the steel ball and insert the steel ball into the clutch shaft hole.

Fig 5: Removing Steel Ball From Clutch Shaft Hole

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1. Remove the 2 screws w/ O-ring and the end cover from the field frame.

   Torque: 3.8 N.m (39 kgf.cm, 34 in..lbf) 

2. Remove the O-ring from the field frame.

   HINT:

   At the time of assembly, use a new O-ring.

   Fig 6: Locating Screws

   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.