Toyota 28100-20020-84
Starter

The starter motor disassembly process begins by removing the starter magnetic switch assembly followed by disconnecting its lead wire and then removing the nut then taking out the two screws securing the switch after which you should remove the return spring and plunger from the starter drive housing. Detaching the starter commutator end frame assembly means removing the 2 bolts between it and the starter yoke before removing the starter commutator end frame and extracting the starter armature plate from the yoke separately. Using a thin-bladed screwdriver to remove the starter commutator end frame cover followed by the snap ring pliers to detach the snap ring leads to plate washer removal along with starter armature extraction from the commutator end frame. Separate the 3 planetary gears from the starter drive housing as the final step.

In order to replace or remove the 2AZ-FE engine starter motor begin by disconnecting the negative battery cable. First separate the air cleaner inlet assembly and afterward remove both air cleaner cap sub-assembly and air cleaner case sub-assembly. To perform manual transaxle maintenance start by disconnecting terminal 50 connector from the starter assembly before loosening the nut and disconnecting the wire harness from terminal 30 followed by removal of 3 bolts, clutch flexible hose bracket and starter assembly. The automatic transaxle repair starts with disconnecting the terminal 50 from the starter before removing the nut and wire harness from terminal 30 followed by starter assembly bolt removal.

Disassembly of the starter motor requires users to first disconnect the lead wire from terminal C while removing 2 screws that secure the magnetic switch to the motor terminal starter kit and then removing the magnet switch body together with its return spring and plunger. You must pull out the starter yoke assembly after removing its two through bolts and extracting it from the starter commutator end frame assembly before separating the components widely. You must remove the starter armature plate from the starter yoke assembly before using a screwdriver to separate the starter commutator end frame cover. The starter armature assembly needs snap ring pliers to remove the snap ring together with plate washer so it can be extracted from the commutator end frame assembly. The motor terminal starter kit requires removal of its 3 planetary gears as the last step.

The first step to uninstall and replace the starter motor of the 2AZ-FE engine requires disconnecting the negative battery cable. The starter replacement process begins with disconnecting the mass air flow meter connector before loosening the hose clamp and unlocking the air cleaner assembly clamp and finally removing the cap. The next step requires extraction of the air cleaner filter element sub-assembly from its housing in the air cleaner case sub-assembly. The wire harness clamp needs to be separated before removing the 3 bolts from the air cleaner case sub-assembly. The procedure for manual transaxle includes disconnection of the terminal 50 connector from the starter assembly followed by unfastening the nut to separate wire harness from terminal 30 and final removal of three bolts with the clutch flexible hose bracket and starter assembly. To work with automatic transaxle detach connector 50 from the starter assembly followed by removing bolt holding wire harness at terminal 30 and finishing removal with 2 bolts and the starter assembly.

Start the installation of the 2AZ-FE engine starter motor by fixing the starter assembly through 2 bolts that require 37 Nm (377 kgf-cm, 27 ft-lbf) torque and by connecting the starter connector. Installation requires the terminal nut to be tightened while covering it with a cap before achieving a proper torque of 9.8 Nm (100 kgf-cm, 7 ft-lbf). The installation of the battery bracket reinforcement requires 19 Nm (194 kgf-cm, 14 ft-lbf) torque and includes the front battery bracket attachment with 4 bolts at 19 Nm (194 kgf-cm, 14 ft-lbf) torque while 2 wire harness clamps are applied. Place the battery and its insulator at this time. The battery clamp installation process begins with attaching the hook to the front battery bracket then securing the nut with preliminarily torque until you install the bolt. Tighten the nut and bolt to 5.0 Nm (51 kgf-cm, 44 in-lbf) only after adjusting the battery clamp alignment. The final step includes attaching the two wire harness clamps. The last step involves connecting the cable to start by touching it to the positive battery terminal followed by the negative terminal.

Disconnect the cable from the negative battery terminal and wait at least 90 seconds to prevent airbag and seat belt pretensioner activation.

Remove the starter assembly by disconnecting the starter connector.

Connect the cable to the negative battery terminal.

Separate the wire harness clamp and remove the 3 bolts.

Remove the three planetary gears from the starter drive housing assembly.

Remove the starter armature plate from the field frame, followed by the commutator end frame cover using a screwdriver.

Disconnect the terminal 50 connector from the starter assembly, remove the nut to disconnect the wire harness from terminal 30, and then remove the 2 bolts and starter assembly.

Disconnect the cable from the negative battery terminal and wait at least 90 seconds to prevent airbag and seat belt pretensioner activation.

Remove the 2 bolts securing the starter.

First, secure it along with the clutch flexible hose bracket using 3 bolts, with Bolt A torqued to 37 Nm (377 kgf-cm, 27 ft-lbf) and Bolt B to 12 Nm (120 kgf-cm, 9 ft-lbf). Next, connect the wire harness to terminal 30, install the nut, and attach the terminal cap, ensuring a torque of 9.8 Nm (100 kgf-cm, 87 in-lbf). Then, connect the terminal 50 connector to the starter assembly.

Install the air cleaner bracket with the 2 bolts, torqued to 12 Nm (122 kgf.cm, 9 ft.lbf).

Install the starter assembly and clutch flexible hose bracket with the 3 bolts, torquing Bolt A to 37 N.m and Bolt B to 12 N.m, connect the wire harness to terminal 30, install the nut, attach the terminal cap with a torque of 9.8 N.m, and connect the terminal 50 connector to the starter assembly.

Disconnect the terminal 50 connector from the starter assembly, remove the nut and disconnect the wire harness from terminal 30, and then remove the two bolts and starter assembly.

Connect the terminal 50 connector to the starter assembly.

Align the keyway of the starter plate with the key inside the field frame and install the plate.

Remove the two bolts securing the starter assembly.

Connect the starter connector and attach the starter wire using a nut, ensuring to cover the nut with a cap, torqued to 9.8 Nm (100 kgf-cm, 87 in-lbf).

37 Nm (377 kgf.cm, 27 ft.lbf).

Take out the bolt, loosen the nut, detach the 2 wire harness clamps, and remove the hook of the battery clamp from the battery bracket front.

Ensure not to drop the starter armature assembly.

Position the starter assembly and secure it with the two bolts.

Disconnect the starter connector, open the terminal cap, remove the nut, disconnect the starter wire, and then remove the 2 bolts securing the starter.

Disconnect the starter connector, open the terminal cap, remove the nut, disconnect the starter wire, and then remove the 2 bolts to take out the starter.