ST-1

STARTING SYSTEM

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ST-2
STARTING SYSTEM - SYSTEM CIRCUIT

SYSTEM CIRCUIT
 ST-3
STARTING SYSTEM - VEHICLE INSPECTION

PREPARATION
SST (SPECIAL SERVICE TOOLS)
09286-4601 1 Injection Pump Spline Shaft Armature bearing
Puller for reduction type

09820-00030 Alternator Rear Bearing Replacer Armature rear bearing

for reduction type

RECOMMENDED TOOLS
09082-00050 TOYOTA Electrical Tester Set

09200-00010 Engine Adjust Kit

EQUIPMENT
Dial indicator Commutator

Magnetic finger

Oil stone Armature shaft

for conventional type
Pull scale Brush spring

Sandpaper Commutator

Steel wire

Torque wrench

V-block

Vernier calipers Commutator

Brush

ON-VEHICLE INSPECTION
NOTICE: Before changing the starter, check the following items again:
• Connector connection
• Accessory installation, e.g.: theft deterrent system
ST-4
STARTING SYSTEM - STARTER (Conventional Type)

STARTER (Conventional Type)

STARTER REMOVAL
1. DISCONNECT NEGATIVE TERMINAL CABLE FROM
BATTERY
CAUTION (w/ SRS): Work must be started after 90 sec-
onds from the time the ignition switch is turned to the ’
LOCK’ position and the negative (-) terminal cable is
disconnected from the battery.

2. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
(c) Remove the 2 bolts and starter.
 ST-5
STARTING SYSTEM - STARTER(Conventional Type)

COMPONENTS FOR DISASSEMBLY AND

ASSEMBLY

STARTER DISASSEMBLY
(See Components for Disassembly and Assembly)
1. REMOVE MAGNETIC SWITCH
(a) Remove the nut, and disconnect the lead wire from
the magnetic switch terminal.
(b) Loosen the 2 nuts holding the magnetic switch to the
drive housing.
(c) Lift the magnetic switch up and out to unhook the
plunger from the drive lever.
2. REMOVE END COVER
(a) Remove the 2 screws and bearing cover.
(b) Using a feeler gauge, check the armature shaft thrust
clearance between the lock plate and end frame.
Thrust clearance:
0.05 - 0.80 mm (0.0020 - 0.0236 in.)
ST-6
STARTING SYSTEM - STARTER(Conventional Type)

(c) Remove the lock plate, spring and rubber.

(d) Remove the 2 through bolts and end cover.

3. REMOVE BRUSH HOLDER

Using a piece of steel wire, hold the spring back and
disconnect the brush from the brush holder. Discon-
nect the 4 brushes, and remove the brush holder.

4. REMOVE FIELD FRAME FROM STARTER HOUSING

Pull apart by hand.
5. REMOVE ARMATURE
(a) Remove the drive lever from the starter housing.
(b) Pull the armature from the starter housing.

6. REMOVE STARTER CLUTCH

(a) Using a screwdriver, tap down the stop collar.
(b) Using a small screwdriver, pry out the snap ring.
(c) Remove the stop collar from the shaft.

(d) If the pinion was difficult to pull out, smooth the shaft
with an oil stone.
(e) Remove the starter clutch.
 ST-7
STARTING SYSTEM - STARTING SYSTEM-STARTER(Conventional Type)

STARTER INSPECTION
Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segment, replace
the armature.

2. INSPECT COMMUTATOR FOR GROUND

Using an ohmmeter, check that there is no continuity
between the commutator and armature coil core.
If there is continuity, replace the armature.

Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, correct with sandpaper
(No.400) or a lathe.

2. INSPECT COMMUTATOR CIRCLE RUNOUT

(a) Place the commutator on V-blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout:
0.4 mm (0.016 in.)
If the circle runout is greater than maximum, correct it
on a lathe.

3. INSPECT COMMUTATOR DIAMETER

Using vernier calipers, measure the commutator diam-
eter.
Standard diameter:
28.0 mm (1.102 in.)
Minimum diameter:
27.0 mm (1.083 in.)
If the diameter is less than minimum, replace the
armature.
ST-8
STARTING SYSTEM - STARTER(Conventional Type)

4. INSPECT UNDERCUT DEPTH

Check that the undercut depth is clean and free of
foreign materials. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it
with a hacksaw blade.

Field Frame (Field Coil)

1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity
between the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.

2. INSPECT FIELD COIL GROUND

Using an ohmmeter, check that there is no continuity
between the field coil end and field frame.
If there is continuity, repair or replace the field frame.

Brushes
1. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length:
16.0 mm (0.630 in.)
Minimum length:
10.0 mm (0.394 in.)
If the length is less than minimum, replace the brush
(field frame side) or brush holder, and dress with an
emery cloth.
 ST-9
STARTING SYSTEM - STARTER(Conventional Type)

Brush Springs
INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush
spring separates from the brush.
Spring installed load: .
10- 16 N (1.0- 1.6 kgf, 2.2-3.5 lbf)
If the installed load is not as specified, replace the
brush springs.

Brush Holder
INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity
between the positive (+) and negative (-) brush hol-
ders.
If there is continuity, repair or replace the brush
holder.

Clutch and Gears

1. INSPECT PINION GEAR AND SPLINE TEETH
Inspect the pinion gear and spline teeth for wear or
damage.
If damaged, replace and also inspect the flywheel ring
gear for wear or damage.

2. INSPECT STARTER CLUTCH

Rotate the clutch pinion gear clockwise and check
that it turns freely. Try to rotate the clutch pinion gear
counterclockwise and check that it locks.
If necessary, replace the starter clutch.

Magnetic Switch
1. INSPECT PLUNGER
Push in the plunger and replace it. Check that it ret-
urns quickly to its original position.
If necessary, replace the magnetic switch.
ST-10
STARTING SYSTEM - STARTER(Conventional Type)

2. PERFORM PULL-IN COIL OPEN CIRCUIT TEST

Using an ohmmeter, check that there is continuity
between terminals 50 and C.
If there is no continuity, replace the magnetic switch.

3. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST

Using an ohmmeter, check that there is continuity
between terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
 ST-1 1
STARTING SYSTEM - STARTER(Conventional Type)

STARTER ASSEMBLY
(See Components for Disassembly and Assembly)
HINT: Use high temperature-resistant grease to lu-
bricate the bearings and sliding parts when assembl-
ing the starter.

1. INSTALL STARTER CLUTCH TO ARMATURE

(a) Place a new stop collar on the armature shaft.
(b) Tap in the snap ring with a 14 mm socket wrench,
then fit it into the shaft groove.

(c) Using a vise, compress the snap ring.

(d) Make sure that the snap ring fits correctly.

(e) Using a screwdriver, tap the pinion to slide the stop

collar onto the snap ring.

2. INSTALL DRIVE LEVER, FIELD FRAME AND

ARMATURE TO STARTER HOUSING
(a) Apply grease to the drive lever and starter housing
bushing.
(b) Install the drive lever to the starter housing.
(c) Install the field frame on the armature.
ST-12
STARTING SYSTEM - STARTER(Conventional Type)

3. INSTALL BRUSH HOLDER

(a) Place the brush holder over the armature shaft.
(b) Using a piece of steel wire, hold the brush spring back
and connect the brush into the brush holder. Connect
the 4 brushes.
4. INSTALL END COVER
(a) Apply grease to the end cover bushing.
(b) Install the end cover on the armature shaft.

5. INSTALL FIELD FRAME AND ARMATURE

ASSEMBLY
(a) Align the protrusion of the field frame with the drive
lever.
(b) Install the 2 through bolts.
Torque: 7.6 N-m (77 kgf-cm, 67 in.-lbf)

6. INSTALL BEARING COVER

(a) Install the rubber, spring and lock plate.
(b) Using a feeler gauge, measure the armature thrust
clearance between the lock plate and end frame.
Thrust clearance:
0.05 - 0.60 mm (0.0020 - 0.0236 in.)
(c) Install the bearing cover with the 2 screws.
Torque: 1.9 N-m (19 kgf-cm, 17 in.-lbf)

7. INSTALL MAGNETIC SWITCH

(a) Hook the magnetic switch stud underneath the drive
lever spring.
(b) Install the 2 bolts.
Torque: 8.3 N-m (85 kgf-cm, 73 in.-lbf)

(c) Connect the lead wire to the terminal C with the nut.
Torque: 9.8 N-m (100 kgf-cm, 87 in. - lbf)
 ST-13
STARTING SYSTEM - STARTER (Conventional Type)

STARTER PERFORMANCE TEST

NOTICE: These tests must be performed within 3 to 5
seconds to avoid burning out the coil.

1. PERFORM PULL-IN TEST

(a) Disconnect the field coil lead from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the
magnetic switch.

2. PERFORM HOLD-IN TEST

While connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C.
Check that the clutch pinion gear remains out.
If the clutch pinion gear returns inward, replace the
magnetic switch.

3. INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (-) lead from the switch
body. Check that the clutch pinion gear returns
inward.
If the clutch pinion gear does not return, replace the
magnetic switch.

4. INSPECT CLUTCH PINION GEAR CLEARANCE

(a) Connect the battery to the magnetic switch as shown.
ST-14
STARTING SYSTEM - STARTER(Conventional Type)

(b) Move the pinion gear toward the armature to remove

slack and measure the clearance between the pinion
gear end and stop collar.
Standard clearance:
0.1 - 0.4 mm (0.004 - 0.016 in.)

5. PERFORM NO-LOAD PERFORMANCE TEST

(a) Connect the field coil lead to terminal C. Make sure
the lead is not grounded.
(b) Connect the battery and ammeter to the starter as
shown.
(c) Check that the starter rotates smoothly and steadily
with the clutch pinion gear moving out. Check that the
ammeter reads the specified current.
Specified current:
50 A or less at 11 V

STARTER INSTALLATION
1. INSTALL STARTER
(a) Install the starter and ground strap with the 2 bolts.
Torque: 39 N-m (400 kgf-cm, 29 ft-lbf)
(b) Connect the starter wire with the nut.
Torque: 8.8 N-m (90 kgf-cm, 78 in-lbf)
(c) Connect the starter connector.
2. CONNECT NEGATIVE TERMINAL CABLE TO
BATTERY
3. CHECK THAT ENGINE STARTS
 ST-15
STARTING SYSTEM - STARTER (Reduction Type)

STARTER (Reduction Type)

STARTER REMOVAL
1. DISCONNECT NEGATIVE TERMINAL CABLE FROM
BATTERY
CAUTION (w/ SRS): Work must be started after 90 sec-
onds from the time the ignition switch is turned to the ’
LOCK’ position and the negative (-) terminal cable is
disconnected from the battery.
2. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
(c) Remove the 2 bolts and starter.

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ST-16
STARTING SYSTEM - STARTER(Reduction Type)

COMPONENTS FOR DISASSEMBLY AND

ASSEMBLY

STARTER DISASSEMBLY
(See Components for Disassembly and Assembly)
1. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from
the magnetic switch terminal.

(b) Remove the 2 through bolts.

(c) Pull out the field frame together with the armature.
 ST-17
STARTING SYSTEM - STARTER(Reduction Type)

2. REMOVE STARTER HOUSING, CLUTCH

ASSEMBLY AND GEAR
(a) Remove the 2 screws.

(b) Remove the following parts from the magnetic switch:

(1) Starter housing
(2) Idler gear and bearing
(3) Clutch assembly
(4) Return spring

3. REMOVE STEEL BALL

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

4. REMOVE BRUSHES AND BRUSH HOLDER

(a) Remove the 2 screws and end cover from the field
frame.

(b) Using a screwdriver, hold the spring back and discon-

nect the brush from the brush holder. Disconnect the
4 brushes, and remove the brush holder.
ST-18
STARTING SYSTEM - STARTER(Reduction Type)

5. REMOVE ARMATURE FROM FIELD FRAME

STARTER INSPECTION AND REPAIR

Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segment, replace
the armature.

2. INSPECT COMMUTATOR FOR GROUND

Using an ohmmeter, check that there is no continuity
between the commutator and armature coil core.
If there is continuity, replace the armature.

Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACE
If the surface is dirty or burnt, correct it with sandpa-
per (No.400) or on a lathe.

2. INSPECT COMMUTATOR CIRCLE RUNOUT

(a) Place the commutator on V-blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it
on a lathe.
 ST-19
STARTING SYSTEM - STARTER(Reduction Type)

3. INSPECT COMMUTATOR DIAMETER

Using a vernier caliper, measure the commutator di-
ameter.
Standard diameter:
30.0 mm (1.181 in.)
Minimum diameter:
29.0 mm (1.412 in.)
If the diameter is less than minimum, replace the
armature.arrnature.

4. INSPECT UNDERCUT DEPTH

Check that the undercut depth is clean and free of
foreign materials. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it
with a hacksaw blade.

Field Frame (Field Coil)

1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity
between the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.

2. INSPECT FIELD COIL FOR GROUND

Using an ohmmeter, check that there is no continuity
between the field coil end and field frame.
If there is continuity, replace the field frame.
ST-20
STARTING SYSTEM - STARTER(Reduction Type)

Brushes
INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length:
13.5 mm (0.531 in.)
Minimum length:
8.5 mm (0.335 in.)
If the length is less than minimum, replace the brush
holder and field frame.
Brush Springs
INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush
spring separates from the brush.
Spring installed load:
18-24 N (1.79-2.41 kgf,3.9-5.3 lbf)
If the installed load is not as specified, replace the
brush springs.

Brush Holder
INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity
between the positive (+) and negative (-) brush hol-
ders.
If there is continuity, repair or replace the brush
holder.

Clutch and Gears

1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and
the clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for
wear or damage.

2. INSPECT CLUTCH PINION GEAR

Rotate the pinion gear clockwise, and check that it
turns freely. Try to rotate the pinion gear counter-
clockwise and check that it locks.
If necessary, replace the clutch assembly.
 ST-21
STARTING SYSTEM - STARTER(Reduction Type)

Bearings
1. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward
force.
If resistance is felt or the bearing sticks, replace the
bearing.

2. IF NECESSARY, REPLACE FRONT BEARING

(a) Using SST, remove the bearing.
SST 09286-46011

(b) Using a press, press in a new front bearing.

3. INSPECT REAR BEARING

Turn each bearing by hand while applying inward
force.
If resistance is felt or the bearing sticks, replace the
bearing.

4. IF NECESSARY, REPLACE REAR BEARING

(a) Using SST, remove the bearing.
SST 09286-46011
ST-22
STARTING SYSTEM - STARTER(Reduction Type)

(b) Using SST and a press, press in a new bearing.

NOTICE: Be careful of the bearing installation direction.
SST 09820-00030

Magnetic Switch
1. PERFORM PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity
between terminals 50 and C.
If there is no continuity, replace the magnetic switch.
Magnetic Switch

2. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST

Using an ohmmeter, check that there is continuity
between terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

STARTER ASSEMBLY
(See Components for Disassembly and Assembly)
HINT: Use high-temperature grease to lubricate the
bearings and gears when assembling the starter.

1. PLACE ARMATURE INTO FIELD FRAME

Apply grease to the armature bearings, and insert the
armature into the field frame.
 ST-23
STARTING SYSTEM - STARTER(Reduction Type)

2. INSTALL BRUSH HOLDER

(a) Place the brush holder on the armature.
(b) Using a screwdriver, hold the brush spring back, and
connect the brush into the brush holder. Connect the
4 brushes.
NOTICE: Check that the positive (+) lead wires are not
grounded.

(c) Install the end cover to the field frame with the 2
screws.
Torque: 1.5 N-m (15 kgf-cm, 13 in.-lbf)

3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE

(a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole.

4. INSTALL CLUTCH ASSEMBLY, GEAR AND

STARTER HOUSING
(a) Apply grease to the return spring.
(b) Insert the return spring into the magnetic switch hole.

(c) Place the following parts in position on the starter

housing:
(1) Clutch assembly
(2) Idler gear and bearing
ST-24
STARTING SYSTEM - STARTER(Reduction Type)

(d) Install the starter housing to magnetic switch with the 2

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

5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY

(a) Align the protrusion of the field frame with the groove
of the magnetic switch.

(b) Install the field frame and armature assembly with the
2 through bolts.
Torque: 9.3 N-m (95 kgf-cm, 82 in.-lbf)

(c) Connect the lead wire to terminal C with the nut.

Torque: 7.9 N-m (81 kgf-cm, 70 in.- lbf)
 ST-25
STARTING SYSTEM - STARTING SYSTEM = STARTER(Reduction Type)

STARTER PERFORMANCE TEST

NOTICE: These tests must be performed within 3 to 5
seconds to avoid burning out the coil.

1. PERFORM PULL-IN TEST

(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the pinion gear moves outward.
If the pinion gear does not move, replace the magnetic
switch.

2. PERFORM HOLD -IN TEST

While connected as above with the pinion gear out,
disconnect the negative (-) lead from terminal C.
Check that the pinion gear remains out.
If the pinion gear returns inward, replace the magnetic
switch.

3. INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (-) lead from the starter
body.
Check that the pinion gear returns inward.
If the pinion gear does not return, replace the magnet-
ic switch.

4. PERFORM NO-LOAD PERFORMANCE TEST

(a) Connect the battery and ammeter to the starter as
shown.
(b) Check that the starter rotates smoothly and steadily
with the pinion gear moving out. Check that the am-
meter shows the specified current.
Specified current:
90 A or less at 11.5 V
ST-26
STARTING SYSTEM - STARTER (Reduction Type)

STARTER INSTALLATION
1. INSTALL STARTER
(a) Install the starter and ground strap with the 2 bolts.
Torque: 39 N-m (400 kgf-cm, 29 ft-lbf)
(b) Connect the starter wire with the nut.
Torque: 8.8 N-m (90 kgf-cm, 78 in.-lbf)
(c) Connect the starter connector.
2. CONNECT NEGATIVE TERMINAL CABLE TO
BATTERY
3. CHECK THAT ENGINE STARTS
 ST-27
STARTING SYSTEM - STARTER RELAY

STARTER RELAY
STARTER RELAY INSPECTION
1. REMOVE STARTER RELAY

2. INSPECT STARTER RELAY

A. Inspect relay continuity

(a) Using an ohmmeter, check that there is continuity
between terminals 1 and 3.
(b) Check that there is no continuity between terminals 2
and 4.
If continuity is not as specified, replace the relay.

B. Inspect relay operation

(a) Apply battery voltage across terminals 1 and 3.
(b) Using an ohmmeter, check that there is continuity
between terminals 2 and 4.
If operation is not as specified, replace the relay.

3. REINSTALL STARTER RELAY

ST-28
STARTING SYSTEM - CLUTCH START SWITCH (M T)

CLUTCH START SWITCH (M T)

(See page CL-7 )

PARK NEUTRAL POSITION (PNP) SWITCH

(A T)
(See page AX -13)

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 ST-29
STARTING SYSTEM - SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
SERVICE DATA
Starter Rated voltage and output power 12V 0.8 kW
(Conventional No-load characteristics Current 50 A or less at 11 V
type) rpm 5,000 rpm or more
Brush length STD 16.0 mm (0.630 in.)
Limit 10.0 mm (0.394 in.)
10 - 16 N (1.0- 1.6 kgf, 2.2-3.5 lbf)

Spring installed load

Commutator
Diameter STD 28.0 mm (1.102 in.)
Limit 27.0 mm (1.063 in.)
Undercut depth STD 0.6 mm (0.024 in.)
Limit 0.2 mm (0.008 in.)
Circle runout Limit 0.4 mm (0.016 in.)
Armature thrust clearance 0.05 - 0.60 mm (0.0020 - 0.0236 in.)
Clearance between pinion gear and stop collar 0.1 - 0.4 mm (0.004 - 0.016 in.)

Starter Rated voltage and output power 12 V 1.0 kW

(Reduction No-load characteristics Current 90 A or less at 11.5 V
type) rpm 3,000 rpm or more
Brush length STD 13.5 mm (0.531 in.)
Limit 8.5 mm (0.335 in.)
Spring installed load 18 - 24 N (1.79 - 2.41 kgf, 3.9 - 5.3 lbf)
Commutator

Diameter STD 30.0 mm (1.181 in.)

Limit 29.0 mm (1.412 in.)
Undercut depth STD 0.8 mm (0.024 in.)
Limit 0.2 mm (0.008 in.)
Circle runout Limit 0.05 mm (0.0020 in.)

TORQUE SPECIFICATIONS
Part tightened N-m kgf-cm ft-lbf
End cover x Brush holder (Reduction type) 13 in.-lbf
End cover x Starter housing Conventional type 7.6 77 67 in.-lbf
Reduction type 9.3 95 82 in.-lbf

Magnetic switch x Starter housing Conventional type 8.3 85 73 in.-lbf

Reduction type 9.3 95 82 in.-lbf

Bearing cover x Brush holder (Conventional type) 17 in.-lbf

Lead wire of field frame x Magnetic switch Conventional type 9.8 100 87 in.-lbf
Reduction type 7.9 81 70 in.-lbf

Starter wire x Terminal 30 of starter 8.8 78 in.-lbf

Starter x Transaxle 400