OEM 2002 Toyota Celica Starter Motor

2002 Toyota Celica Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2002 Toyota Celica?

  A: Starter motor servicing requires field frame disassembly which starts with removing its magnetic switch assembly components through lead wire disconnect from terminal and removing bolts and screws from frame and end cover. Start by extracting the ring from the field frame and applying a screwdriver to disengage the brush from the brush holder before taking off the brush holder and 4 brushes. The user must first draw out the field frame section from the magnetic switch assembly while also taking away its O-ring. To remove the starter housing and its accompanying components, evacuate two bolts (Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)) from their placement while also pulling out the materials consisting of starter housing, idler gear, bearing, clutch assembly, and return spring from the magnetic switch assembly. A magnetic finger should be used to take out the steel ball through the clutch shaft hole. The armature needs removal from the magnetic switch assembly (1ZZ-FE) or requires press usage for the 2ZZ-GE. When reassembling the device stir high-temperature grease onto all bearings and gears. The armature needs to be installed to the magnetic switch assembly with positioning of the front bearing ring projection correctly for 2ZZ-GE models along with greasing the armature bearings. You must install the grease-coated steel ball into the clutch shaft hole before installing all parts starting with the starter housing and clutch assembly and gears after you apply grease to the return spring and set up a new O-ring and starter clutch assembly and idler gear and bearing on the starter housing to attach it to the magnetic switch using two screws torqued at 9.3 N.m (95 kgf.cm and 82 in.lbf). You must install a new O-ring in the field frame groove. Then place the field frame protrusion into the magnetic switch groove before mounting the field frame. Set the brush holder on the field frame while using a screwdriver to support the brush spring for attaching the brushes but preventing contact between positive lead wires and ground. Begin by installing the new O-ring into the field frame groove then fasten the end cover using two screws that require 3.8 N.m (39 kgf.cm, 34 in.lbf) torque. Proceed by securing the frame and armature assembly using two through bolts at 9.3 N.m (95 kgf.cm, 82 in.lbf) torque then terminate the lead wire at terminal C by attaching the nut with 5.9 N.m (60 kgf.cm, 52 in.lbf) torque. To inspect the bearing first check for resistance when you turn it by hand and to replace it use Special Service Tool: 09286-46011 to remove and Special Service Tool: 09820-00031 together with a press to install new bearings. Unscrew three bolts to remove the end cover of the magnetic switch followed by removal of the gasket and plunger until you can access the contact plate where you should measure its depth with vernier calipers (maximum allowable wear spans to 0.9 mm (0.035 in.)) before potential replacement. Before tightening the terminal nuts apply Special Service Tool: 09810-38140 to free the terminal parts while simultaneously installing new terminal 30 and terminal C kit sections with their terminal insulators properly oriented. Cylinder down the contact plate by using a wooden block (20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)) while applying a press force of 981 N (100 kgf, 221 lbf) to tighten the terminal nuts. Use Special Service Tool: 09810-38140 to sequentially tighten the nuts to 17 N.m (173 kgf.cm, 12 ft.lbf) while cleaning the contact surfaces between the contact plate and plunger. Reinstall the magnetic switch end cover along with its plunger and new gasket and secure it by 3 bolts with Torque: 2.5 N.m (26 kgf.cm, 23 in.lbf).