ST–6 2AZ-FE STARTING – STARTER
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE STARTER ASSEMBLY
Terminal Cap (a) Disconnect the starter connector.
(b) Open the terminal cap.
(c) Remove the nut and disconnect the starter wire.
A095443E02
(d) Remove the 2 bolts and starter.
ST A095444E01
DISASSEMBLY
1. REMOVE STARTER MAGNETIC SWITCH ASSEMBLY
(a) Remove the nut and disconnect the lead wire.
A097479E01
(b) Remove the 2 screws and starter magnetic switch.
A097480E01
2AZ-FE STARTING – STARTER ST–7
(c) Remove the return spring and plunger from the
starter drive housing.
A097482E01
2. REMOVE STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) Remove the 2 bolts and the starter commutator end
frame together with the starter yoke.
A097484E01
(b) Remove the starter commutator end frame from the
starter yoke.
ST
A097758E01
(c) Remove the starter armature plate from the starter
yoke.
A097760E01
3. REMOVE STARTER ARMATURE ASSEMBLY
(a) Using a thin-bladed screwdriver, remove the starter
commutator end frame cover.
A097762E01
ST–8 2AZ-FE STARTING – STARTER
(b) Using snap ring pliers, remove the snap ring.
Snap Ring
Pliers
A097764E03
(c) Remove the plate washer and starter armature from
the starter commutator end frame.
A097765E01
4. REMOVE STARTER PLANETARY GEAR
(a) Remove the 3 planetary gears from the starter drive
housing.
ST
A097766E01
INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTICE:
These tests must be performed within 3 to 5 seconds
to prevent burnout of the coil.
(a) Perform the pull-in test.
(1) Remove the nut and disconnect the lead wire
from terminal C.
A097479E01
(2) Connect the battery to the starter magnetic
Body switch as shown in the illustration. Check that
Terminal C the clutch pinion gear is extended.
If the clutch pinion gear does not move, replace
the starter assembly.
Terminal 50
A095439E02
2AZ-FE STARTING – STARTER ST–9
(b) Perform the hold-in test.
(1) Disconnect the negative (-) lead from terminal
Terminal C C. Check that the clutch pinion gear remains
Disconnect extended.
If the clutch pinion gear returns inward, replace
the starter assembly.
A095440E02
(c) Check the operation.
(1) Disconnect the negative (-) lead from the
starter body. Check that the clutch pinion gear
returns.
If the clutch pinion gear does not return inward,
Body replace the starter assembly.
Disconnect
A095441E02
(d) Perform the no-load performance test.
(1) Connect the lead wire to terminal C. Make sure
that the lead is not grounded.
Torque: 10 N*m (100 kgf*cm, 7 ft.*lbf)
ST
A097479E01
(2) Clamp the starter in a vise.
Terminal 30 (3) Connect the battery and an ammeter to the
Body
starter as shown in the illustration.
(4) Check that the starter rotates smoothly and
steadily with the clutch pinion gear extended.
Check that the ammeter reads the specified
current.
Standard current:
Terminal 50 90 A or less at 11.5 V
A095442E02 If the result is not as specified, replace the
starter.
2. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY
(a) Check the plunger.
(1) Push in the plunger, and then check that it
returns quickly to its original position.
OK:
The plunger moves smoothly.
If the result is not as specified, replace the
starter assembly.
A098206E01
ST–10 2AZ-FE STARTING – STARTER
(b) Check the resistance.
(1) Measure the resistance between terminals 50
and C.
Terminal C Standard resistance:
Below 1 Ω
If the result is not as specified, replace the
starter assembly.
Terminal 50
A097768E02
(2) Measure the resistance between terminals 50
and the body.
Body Standard resistance:
Below 2 Ω
If the result is not as specified, replace the
starter assembly.
Terminal 50
A097769E02
3. INSPECT STARTER ARMATURE ASSEMBLY
Segment (a) Check the resistance.
(1) Measure the resistance between the segments.
Standard resistance:
Below 1 Ω
ST If the results is not as specified, replace the
starter armature.
A097772E02
(2) Measure the resistance between the segments
Coil Core and coil core.
Standard resistance:
10 kΩ or higher
If the result is not as specified, replace the
starter armature.
Segment
A097773E02
(b) Check the commutator.
(1) Using a vernier caliper, measure the depth
indicated in the illustration.
Standard depth:
3.1 mm 3.1 mm (0.122 in.)
Maximum depth:
3.8 mm (0.150 in.)
If the depth is greater than the maximum,
replace the starter armature.
A097774E02
2AZ-FE STARTING – STARTER ST–11
4. INSPECT STARTER COMMUTATOR END FRAME
9.0 mm ASSEMBLY
(a) Check the brush length.
(1) Using vernier calipers, measure the brush
length.
Standard length:
9.0 mm (0.354 in.)
Minimum length:
4.0 mm (0.158 in.)
A097770E02 If the length is less than the minimum, replace
the starter assembly.
(b) Check the resistance.
Positive (+)
(1) Measure the resistance between resistance the
Negative (-) positive (+) and negative (-).
Standard resistance:
10 kΩ or higher
If the results is not as specified, replace the
starter assembly.
A097771E02
5. INSPECT STARTER DRIVE HOUSING ASSEMBLY
(a) Check the starter clutch.
Lock (1) Rotate the clutch pinion gear counterclockwise,
and then check that it turns freely. Try to rotate
the clutch pinion gear clockwise, and then
check that it locks. ST
If necessary, replace the starter assembly.
Free
A097775E01
REASSEMBLY
1. INSTALL STARTER PLANETARY GEAR
Apply Grease (a) Apply grease to the planetary gears and pins parts
of the planet shaft.
A097776E02
(b) Install the 3 planetary hears into the pin of the planet
shaft.
A097766E01
ST–12 2AZ-FE STARTING – STARTER
2. INSTALL STARTER ARMATURE ASSEMBLY
(a) Apply grease to the plate washer, armature shaft
and new snap ring.
(b) Install the starter armature and plate washer into the
starter commutator end frame.
Apply Grease
A097777E02
(c) Using snap ring pliers, install the snap ring.
Snap Ring
Plier
A097764E04
(d) Check the snap ring length.
5.0 mm (1) Using a vernier caliper, measure the snap ring
length.
Maximum length:
5.0 mm (0.197 in.)
ST If the snap ring length is greater than the
maximum, replace the snap ring.
A058810E03
(e) Install the commutator end frame cover into the
starter commutator end frame.
A097763E01
3. INSTALL STARTER COMMUTATOR END FRAME
Rubber ASSEMBLY
(a) Align the rubber of the starter commutator end
frame with the convex cutout of the starter yoke,
and then install the starter commutator end frame
into the starter yoke.
Cutout
A097759E02
2AZ-FE STARTING – STARTER ST–13
(b) Align the keyway of the starter armature plate with
Keyway
the key inside the starter yoke, and then install the
starter armature plate into the starter yoke.
Key
A097761E02
(c) Apply grease to the starter armature gear.
Apply Grease
A098607E02
(d) Align the key of the starter yoke with the keyway of
the starter drive housing, and then install the starter
commutator end frame together with the starter
Keyway yoke into the starter drive housing.
(e) Install the 2 bolts.
Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf) ST
Key
A097757E02
4. INSTALL STARTER MAGNETIC SWITCH ASSEMBLY
(a) Apply grease to the plunger and hook.
Apply Grease
A097778E02
(b) Install the plunger and return spring into the starter
drive housing.
A097483E01
ST–14 2AZ-FE STARTING – STARTER
(c) Install the starter magnetic switch into the starter
drive housing.
(d) Install the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
A097481E01
(e) Connect the lead wire with the nut.
Torque: 10 N*m (100 kgf*cm, 7 ft.*lbf)
A097479E01
INSTALLATION
1. INSTALL STARTER ASSEMBLY
(a) Install the starter with the 2 bolts.
Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf)
ST
A095444E01
(b) Connect the starter wire with the nut.
Terminal Cap Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
(c) Cover the terminal cap.
(d) Connect the starter connector.
2. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
3. PERFORM INITIALIZATION
(a) Perform initialization (see page IN-23).
A095443E02 NOTICE:
Certain systems need to be initialized after
disconnecting and reconnecting the cable from
the negative (-) battery terminal.
