Starting System (2AZ-FE): Overview Toyota Corolla X

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (See «ON-VEHICLE INSPECTION»(/toyota/corolla/x-2006-2010/remont/testing-diagnostics/#engine-control-system-2az-fe) )
4. REMOVE AIR CLEANER CASE (See «REMOVAL»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
5. REMOVE BATTERY (See «REMOVAL»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
6. REMOVE BATTERY CARRIER (See «REMOVAL»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
7. DISCONNECT WIRE HARNESS Release the claw, and disconnect the wire harness.
8. REMOVE STARTER ASSEMBLY (for Manual Transaxle) Disconnect the terminal 50 connector from the starter assembly. Remove the nut and disconnect the wire harness from terminal 30. Remove the 3 bolts, clutch accumulator bracket, wire harness clamp bracket and starter assembly.
9. REMOVE STARTER ASSEMBLY (for Automatic Transaxle) Disconnect the terminal 50 connector from the starter assembly. Remove the nut and disconnect the wire harness from terminal 30. Remove the 2 bolts, wire harness clamp bracket and starter assembly.

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1. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the nut, then disconnect the lead wire from the magnet starter switch assembly. Remove the 2 nuts from the starter drive housing assembly while holding the magnet starter switch assembly. Pull the magnet starter switch assembly, and while lifting the front part of the magnet starter switch assembly, release the plunger hook from the drive lever and magnet starter switch assembly.
2. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY Using a T25 "TORX" socket wrench, remove the 2 bolts. Pull out the starter yoke together with the starter commutator end frame assembly. Remove the 2 screws from the starter commutator end frame assembly. Pull the starter yoke assembly out of the starter commutator end frame assembly. NOTE: While holding down the lead wire, remove the starter commutator end frame.
3. REMOVE STARTER ARMATURE ASSEMBLY Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. Remove the starter armature assembly from the starter yoke assembly.
4. REMOVE STARTER ARMATURE PLATE Remove the armature plate from the motor terminal starter kit or the starter yoke assembly.
5. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter center bearing clutch sub-assembly.

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1. INSPECT STARTER ASSEMBLY NOTE: Perform each of the following tests within 3 to 5 seconds. Perform a pull-in test. Disconnect the field coil lead wire from terminal C. Connect the battery to the magnet starter switch as shown in the illustration and check that the pinion gear moves outward. If the clutch pinion gear does not move, replace the magnet starter switch assembly. Perform a hold-in test. Check that the pinion gear does not return inward after the cable is disconnected from terminal C. If the clutch pinion gear returns inward, replace the magnet starter switch assembly. Inspect the clutch pinion gear return. Disconnect the negative (-) lead from the switch body. Check that the pinion gear moves inward. If the clutch pinion gear does not return inward, replace the magnet starter switch assembly. Perform an operation test without load. Connect the field coil lead wire to terminal C. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) Clamp the starter in a vise. Connect the battery and ammeter to the starter as shown in the illustration. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter indicates the specified current. Standard Current TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition Battery positive terminal - Terminal 30 - Terminal 50 11.5V Below 90 A If the result is not as specified, replace the starter assembly.
2. INSPECT MAGNET STARTER SWITCH ASSEMBLY Check the plunger. Push in the plunger, then check that it returns quickly to its original position. If necessary, replace the magnet starter switch assembly. Inspect the resistance of the pull-in coil. Using an ohmmeter, measure the resistance between terminals 50 and C. Standard Resistance TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition Terminal 50 - Terminal C - Below 1 ohms If the result is not as specified, replace the magnet starter switch assembly. Inspect the resistance of the hold-in coil. Using an ohmmeter, measure the resistance between terminal 50 and switch body. Standard Resistance TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition Terminal 50 - Body ground - Below 2 ohms If the result is not as specified, replace the magnet starter switch assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY Inspect the resistance of the commutator. Using an ohmmeter, measure the resistance between any 2 segments of the commutator. Standard Resistance TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition Segment - Segment - Below 1 ohms If the result is not as specified, replace the starter armature assembly. Check the commutator for a short to ground. Using an ohmmeter, measure the resistance between the commutator and the armature coil core. Standard Resistance TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition Commutator - Armature - 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Check the appearance. If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe. Check the commutator circle for runout. Place the commutator on V-blocks. Using a dial indicator, measure the circle runout. Standard runout: 0.02 mm (0.000787 in.) Maximum runout: 0.05 mm (0.00197 in.) If the runout is greater than the maximum, replace the armature assembly. Using vernier calipers, measure the commutator diameter. Standard diameter: 29.0 mm (1.14 in.) Minimum diameter: 28.0 mm (1.10 in.) If the diameter is less than the minimum, replace the armature assembly. Check that the undercut portion is clean and free of foreign matter. Smooth out the edge. Standard undercut depth: 0.7 mm (0.0276 in.) Minimum undercut depth: 0.2 mm (0.00787 in.) If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY Remove the claws of the springs, then remove the 4 brushes. Using a vernier caliper, measure the brush length. Standard length: 14.4 mm (0.567 in.) Minimum length: 9.0 mm (0.354 in.) If the length is less than the minimum, replace the starter brush holder assembly. Check the brush holder. Using an ohmmeter, measure the resistance between the brushes. Standard Resistance TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition A - B - 10 kohms or higher A - C - 10 kohms or higher A - D - Below 1 ohms B - C - Below 1 ohms B - D - 10 kohms or higher C - D - 10 kohms or higher If the result is not as specified, replace the starter brush holder assembly.
5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage. If damaged, replace the gear or clutch assembly. Also check the planetary gears for wear or damage. Inspect the 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 center bearing clutch sub-assembly.

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1. INSTALL PLANETARY GEAR Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft. Install the 3 planetary gears.
2. INSTALL STARTER BRUSH HOLDER ASSEMBLY Install the brush holder. Using a screwdriver, hold the brush springs back, and install the 4 brushes into the brush holder. Install the brush holder to the starter armature. Insert the grommet between the positive (+) pole and negative (-) pole.
3. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Fit the clamp of the brush holder into the starter commutator end frame assembly. Install the commutator end frame with the 2 screws. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
4. INSTALL STARTER ARMATURE ASSEMBLY Align the rubber with the groove of the starter yoke assembly. Install the starter armature with the brush holder onto the starter yoke assembly. NOTE: The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet to break. HINT: Support the starter armature so that it may not be pulled out from the starter brush holder by magnetic force of the starter yoke assembly.
5. INSTALL STARTER ARMATURE PLATE Install the starter armature plate onto the starter yoke assembly. Install the starter plate so that the keyway is positioned between the keys.
6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the key of the starter yoke with the keyway located on the starter drive housing assembly. Using a T25 "TORX" socket wrench, install the drive housing with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
7. INSTALL MAGNET STARTER SWITCH ASSEMBLY Apply high-temperature grease to the plunger hook. Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side. Install the magnet starter switch assembly with the 2 nuts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) Connect the lead wire to the magnet starter switch, then fasten it with the nut. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)

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1. INSTALL STARTER ASSEMBLY (for Manual Transaxle) Install the starter assembly, clutch accumulator bracket and wire harness clamp bracket with the 3 bolts. Torque: Bolt A 37 N*m (377 kgf*cm, 27 ft.*lbf) Bolt B 12 N*m (120 kgf*cm, 9 ft.*lbf) Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Connect the terminal 50 connector to the starter assembly.
2. INSTALL STARTER ASSEMBLY (for Automatic Transaxle) Install the starter assembly and wire harness clamp bracket with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Connect the terminal 50 connector to the starter assembly.
3. INSTALL BATTERY CARRIER (See «INSTALLATION»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
4. INSTALL BATTERY (See «INSTALLATION»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
5. INSTALL WIRE HARNESS Install the claw and wire harness.
6. INSTALL AIR CLEANER CASE (See «INSTALLATION»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (See «INSTALLATION»(/toyota/corolla/x-2006-2010/remont/testing-diagnostics/#engine-control-system-2az-fe) )
8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/corolla/x-2006-2010/remont/mechanical/#engine-mechanical-2az-fe) )
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

HINT

See INSTALLATION.

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See also:
• REMOVAL
• ON-VEHICLE INSPECTION
• REMOVAL