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

Identifying Starting System Parts Location (1 Of 2). Scheme 53

Identifying Starting System Parts Location (2 Of 2). Scheme 54

Starting System Diagram (1 Of 3). Scheme 55

Starting System Diagram (2 Of 3). Scheme 56

Starting System Diagram (3 Of 3). Scheme 57

Identifying Starter Components With Torque Specification (1 Of 2). Scheme 58

Identifying Starter Components With Torque Specification (2 Of 2). Scheme 59

Scheme 60

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) HINT: See «REMOVAL»(ref-338645-S22712104222009082800000).
3. REMOVE STARTER ASSEMBLY Remove the terminal cap. Remove the nut and disconnect terminal 30. Disconnect the connector. Remove the 2 bolts and starter assembly. (Scheme 60): Locating Starter Assembly And Bolts

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1. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the nut, then disconnect the lead wire from the magnet starter switch assembly. (Scheme 61): Locating Magnet Starter Switch Assembly Nut Remove the 2 nuts from the starter drive housing assembly while holding the magnet starter switch assembly. (Scheme 62): Locating Starter Drive Housing Assembly And Nuts 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. (Scheme 63): Pulling Magnet Starter Switch Assembly
2. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY Using a T25 "TORX" socket wrench, remove the 2 bolts. (Scheme 64): Locating Starter Commutator End Frame Bolts Pull out the starter yoke together with the starter commutator end frame assembly. (Scheme 65): Pulling Out Starter Yoke Remove the 2 screws from the starter commutator end frame assembly. (Scheme 66): Locating Starter Commutator End Frame Assembly Screws 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. (Scheme 67): Pulling Starter Yoke Assembly Out Of Starter Commutator End Frame Assembly
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. (Scheme 68): Removing Brush Holder Remove the starter armature assembly from the starter yoke assembly. (Scheme 69): Identifying Starter Armature Assembly
4. REMOVE STARTER ARMATURE PLATE Remove the armature plate from the starter drive housing assembly or the starter yoke assembly. (Scheme 70): Identifying Armature Plate, Starter Yoke Assembly And Housing Assembly
5. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter center bearing clutch sub-assembly. (Scheme 71): Locating Planetary Gears
6. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Remove the starter center bearing clutch sub-assembly with starter pinion drive lever from the starter drive housing assembly. Remove the starter center bearing clutch sub-assembly, rubber seal, and the starter pinion drive lever. (Scheme 72): Identifying Starter Center Bearing Clutch Sub-Assembly, Rubber Seal, And Starter Pinion Drive Lever

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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 switch assembly. (Scheme 73): Checking Starter Assembly - Pull-In Test 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. (Scheme 74): Checking Starter Assembly - Hold-In Test 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 lead wire to terminal C. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) Clamp the starter in a vise. (Scheme 75): Checking Starter Assembly - Clutch Pinion Gear Return 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 11.5 V Below 90 A (Scheme 76): Checking Starter Assembly - With Out Load
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. (Scheme 77): Pushing In Plunger 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 (Scheme 78): Measuring Resistance Between Magnet Starter Switch Terminals 50 And C 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. (Scheme 79): Measuring Resistance Between Magnet Starter Switch Terminals 50 And Switch Body
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 (Scheme 80): Measuring Resistance Between Segments Of Commutator 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. (Scheme 81): Measuring Resistance Between Commutator And Armature Coil Core Check the appearance. If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe. Check the commutator circuit 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. (Scheme 82): Measuring Circle Runout Using a vernier caliper, measure the commutator diameter. Standard diameter: 29 mm (1.14 in.) Minimum diameter: 28 mm (1.10 in.) If the diameter is less than the minimum, replace the armature. (Scheme 83): Measuring Commutator Diameter Check that the undercut portion is clean and free of foreign matter. Smooth out the edges. 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. (Scheme 84): Measuring Commutator Undercut Depth
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY Remove the claw of the spring, 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. (Scheme 85): Measuring Brush Length 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. (Scheme 86): Identifying Brushes
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. (Scheme 87): Rotating Clutch Pinion Gear

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1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Apply high-temperature grease to the parts of the starter pinion drive lever that contact the starter pivot part of the starter pinion drive lever. Install the starter pinion drive lever and rubber seal into the starter center bearing clutch sub-assembly. Install the starter center bearing clutch together with the starter pinion drive lever into the starter drive housing assembly. (Scheme 88): Identifying Starter Pinion Drive Lever, Rubber Seal And Starter Center Bearing Clutch Sub-Assembly
2. INSTALL PLANETARY GEAR Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft. Install the 3 planetary gears. (Scheme 89): Locating Planetary Gears
3. 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. (Scheme 90): Identifying Starter Brush Holder Assembly Insert the grommet between the positive (+) pole and negative (-) pole. (Scheme 91): Inserting Grommet Between Positive (+) Pole And Negative (-) Pole
4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Fit the clamp of the brush holder into the starter commutator end frame assembly. (Scheme 92): Installing 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)
5. 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. (Scheme 93): Locating Commutator End Frame With Screws 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. (Scheme 94): Identifying Starter Armature Starter Yoke And Commutator End Frame Assembly
6. 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. (Scheme 95): Installing Starter Armature Plate Onto Starter Yoke Assembly
7. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the key of the starter yoke with the keyway located on the starter drive housing assembly. (Scheme 96): Aligning Key Of Starter Yoke With Keyway 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)
8. INSTALL MAGNET STARTER SWITCH ASSEMBLY Apply high-temperature grease to the plunger hook. see scheme 45: Locating Starter Commutator End Frame Bolts Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side. see scheme 46: Hanging Plunger Of Magnet Starter Switch Assembly Into Drive Lever Install the magnet starter switch assembly with the 2 nuts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) see scheme 47: Locating Starter Drive Housing Assembly And Nuts 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) (Scheme 97): Locating Magnet Starter Switch Nut

See also:
• INSTALLATION
• REMOVAL