General information Toyota Matrix E130

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1. INSPECT STARTER ASSY NOTE: These tests must be performed within 3 to 5 seconds to prevent burnout of the coil. Perform the pull-in test. Remove the nut, then disconnect the lead wire from terminal C Connect the battery to the starter repair service kit as shown in the illustration. Check that the clutch pinion gear is extended. If the clutch pinion gear is not extended, replace the magnet switch. Perform the hold-in test. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended. If the clutch pinion gear returns, replace the magnet switch. Check the operation. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnet switch. Perform the no-load performance test. Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) Clamp the starter in a vise. Connect the battery and an 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 reads the specified current. Specified current: 90 A or less at 11.5 V If the current is not as specified, replace the magnet switch.
2. INSPECT STARTER RELAY ASSY Check the starter relay resistance. Using an ohmmeter, measure the resistance between the terminals. STARTER RELAY ASSY TERMINALS RESISTANCE Tester Connection Specified Condition 3-5 10kohm or higher 3-5 Below 1 ohm (Apply battery voltage to terminals 1 and 2) If the result is not as specified, replace the starter relay.
3. INSPECT IGNITION OR STARTER SWITCH ASSY Measure the ignition starter switch resistance. IGNITION STARTER SWITCH TERMINALS RESISTANCE Switch Position Tester Connection Specified Condition LOCK - 10kohm or higher ACC 1-3 Below 1 ohm ON 1 -2-3 5-6 Below 1 ohm START 1-2 4-5-6 Below 1 ohm If the result is not as specified, replace the ignition starter switch.

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE STEERING COLUMN COVER LWR Remove the 3 screws, then remove the steering column cover LWR.
3. REMOVE IGNITION OR STARTER SWITCH ASSY Disconnect the ignition switch connector and unlock the warning switch connector. Disconnect the unlock warning switch connector from the ignition switch assy. Disconnect the wire harness from the steering assy. Remove the 2 screws, then remove the ignition switch assy.
4. INSTALL IGNITION OR STARTER SWITCH ASSY Install the ignition switch assy with the 2 screws. Connect the wire harness to the steering assy. Connect the unlock warning switch connector to the ignition switch assy. Connect the ignition switch connector and unlock the warning switch connector.
5. INSTALL STEERING COLUMN COVER LWR Install the steering column cover LWR with the 3 screws.
6. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf )

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE STARTER ASSY Disconnect the starter connector. Open the terminal cover. Remove the nut, then remove the starter wire. Remove the 2 bolts, then remove the starter.
5. INSTALL STARTER ASSY Install the starter assy with the 2 bolts. Torque: 37 N. m (378 kgf.cm, 27 ft.lbf) Connect the starter wire with the nut. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) Close the terminal cover. Connect the starter connector.
6. INSTALL ENGINE UNDER COVER LH
7. INSTALL ENGINE UNDER COVER RH
8. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N. m (55 kgf.cm, 48 In.lbf)

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1. REMOVE MAGNET SWITCH BODY Remove the nut, then disconnect the lead wire from the magnet switch. Remove the 2 screws which are used to secure the magnet switch to the starter drive housing. Remove the magnet switch. Remove the return spring and plunger from the starter drive housing.
2. REMOVE STARTER YOKE ASSY Remove the 2 through bolts, then pull out the starter yoke together with the starter commutator end frame. Remove the starter yoke from the starter commutator end frame.
3. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke.
4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the starter commutator end frame cover.
5. REMOVE STARTER ARMATURE ASSY Using snap ring pliers, remove the snap ring. Remove the washer and the starter armature from the starter commutator end frame.
6. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter center bearing clutch.
7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSY Remove the starter center bearing clutch together with the starter drive lever set pin from the starter drive housing.
8. REMOVE STARTER DRIVE LEVER SET PIN Remove the starter drive lever set pin from the starter center bearing clutch.
9. INSPECT MAGNET SWITCH BODY Check the operation. Push in the plunger, then check that it returns quickly to its original position. If necessary, replace the magnet switch. Check the resistance. Using an ohmmeter, check that there is resistance between terminals 50 and C. Standard: 1 ohm or lower If the result is not met, replace the magnet switch. Using an ohmmeter, check that there is resistance between terminal 50 and the switch body. Standard: 2.0 ohm or lower If the result is not met, replace the magnet switch.
10. INSPECT STARTER ARMATURE ASSY Check the resistance. Using an ohmmeter, check that there is resistance between the segments of the commutator. Standard: 1 ohm or lower If the result is not met, replace the starter armature. Using an ohmmeter, check that there is no resistance between the commutator and armature coil core. Standard: 10 kohm or higher If the resistance is not as specified, replace the starter armature. Check the commutator surface for dirt or burn. If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or lather. Check the commutator depth. Using vernier calipers, measure the commutator depth. Standard depth: 3.1 mm (0.122 in.) Maximum depth: 3.8 mm (0.150 in.) If the depth is greater than maximum, replace the starter armature.
11. INSPECT STARTER COMMUTATOR END FRAME ASSY Check the brush length. Using vernier calipers, measure the brush length. Standard length: 9.0 mm (0.354 in.) Minimum length: 4.0 mm (0.158 in.) If the length is less than minimum, replace the starter commutator end frame. Check the resistance. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes. Standard: 10 kohm or higher If the resistance is not as specified, repair or replace the brush holder.
12. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSY Check the operation. Turn the clutch pinion gear clockwise, then check that it turns freely. Try to rotate the clutch pinion gear counterclockwise, then check that it locks. If necessary, replace the starter center bearing clutch. Check for wear or damage. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage. If worn or damaged, replace the starter center bearing clutch.
13. INSTALL STARTER DRIVE LEVER SET PIN Install the starter drive lever set pin to the starter center bearing clutch as shown in the illustration.
14. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSY Install the starter center bearing clutch together with the starter drive lever set pin to the starter drive housing.
15. INSTALL PLANETARY GEAR Apply grease to the planetary gears and planetary shaft pins. Install the 3 planetary gears to the starter center bearing clutch.
16. INSTALL STARTER ARMATURE ASSY Apply grease to the washer and armature shaft. Install the starter armature and washer to the starter commutator end frame. Using snap ring pliers, install a new snap ring. Check the snap ring length. Using vernier calipers, measure the snap ring length. Maximum length: 5.0 mm (0.197 in.) If the length is greater than maximum, replace it with a new snap ring.
17. INSTALL STARTER COMMUTATOR END FRAME COVER Install the starter commutator end frame cover to the starter commutator end frame.
18. INSTALL STARTER ARMATURE PLATE Align the keyway of the starter armature plate with the key inside of the starter yoke, then install the armature plate to the starter yoke.
19. INSTALL STARTER COMMUTATOR END FRAME ASSY Align the rubber with the cutout of the starter yoke, then install the starter commutator end frame to the starter yoke.
20. INSTALL STARTER YOKE ASSY Align the key of the starter yoke with the keyway of the starter drive housing, then install the starter yoke to the starter drive housing. Tighten the 2 through bolts. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf )
21. INSTALL MAGNET SWITCH BODY Apply grease to the plunger and hook. Hang the plunger hook of the magnet switch into the starter drive lever set pin. Install the plunger and return spring. Install the magnet switch with the 2 screws. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) Connect the lead wire to terminal C with the nut. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)