Toyota 28100-0D080-84
Starter

The process to separate the starter motor begins with unfastening the lead wire from the magnet switch body after nut removal before extracting the 2 screws [B] from the starter drive housing to take out the switch with its associated return spring and plunger assembly. The starter yoke assembly requires removal through two through bolts to free the yoke with the end frame so you can split the yoke from the frame. The starter armature plate is extracted from the starter yoke before the starter commutator end frame cover is uninstalled with a screwdriver. To replace the starter armature assembly use snap ring pliers for removing the snap ring followed by extraction of the washer and starter armature from the starter commutator end frame. Take out the 3 planetary gears from the starter center bearing clutch followed by removal of the starter center bearing clutch combined with the starter drive lever set pin from the starter drive housing. Remove the starter drive lever set pin that is situated on the starter center bearing clutch.

The negative terminal disconnection of the battery stands as the first step when servicing the 1ZZ-FE starter motor. Service and repair of the 1ZZ-FE engine starter motor starts by removing the right-hand side engine under cover followed by the left-hand side under cover. Start by disconnecting the starter connector [A] before opening the terminal cover to remove the nut [C] and detach the starter wire and following it up by removing the two bolts to extract the starter assembly.

Remove the nut and the starter wire.

Remove the two through bolts and pull out the starter yoke with the starter commutator end frame, then separate the starter yoke from the frame.

9.8 N.m (100 kgf.cm, 7 ft.lbf).

Close the terminal cover and reconnect the starter connector.

Inspect the kit for proper operation and continuity between terminals 50 and C, and between terminal 50 and the switch body, replacing the kit if necessary.

Take out the 2 screws securing the magnet switch to the starter drive housing and remove the switch along with the return spring and plunger.

Next, disconnect the starter connector, remove the nut and disconnect the starter wire.

Torque the nut to 9.8 N.m (100 kgf.cm, 7 ft.lbf).

Measure the brush length, replacing the frame if it is less than 4.0 mm (0.158 in.), and check the resistance between the positive and negative brushes, repairing or replacing the brush holder if it is below 10 kOhms.

Reconnect the battery negative terminal with a torque of 5.4 N.m (55 kgf.cm, 48 in.lbf).

Apply grease to the planetary gears and pin parts, then install the 3 planetary gears to the starter center bearing clutch.

Remove the engine under covers on both the right and left sides.