OEM 2002 Toyota Corolla Starter Motor

2002 Toyota Corolla Parts Questions & Experts Answers

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

  A: A proper starter motor service begins with taking apart the components using 5.9 N.m (60 kgf.cm, 52 in.lbf) to detach the lead wire terminal from the magnetic switch and remove the 2 through bolts to pull out the field frame with its armature from the assembly while aligning the field frame protrusion to the cutout when reassembling. The procedure requires discarding the O-ring yet a new one must be used when reassembling the system. The magnetic switch needs the 2 bolts at 5.9 N.m (60 kgf.cm, 52 in.lbf) torque to remove starter housing, clutch assembly and gears before extracting starter housing, idler gear, bearing, clutch assembly and return spring from the magnetic switch. Use a magnetic finger to remove the steel ball from the clutch shaft hole followed by unscrewing the 2 screws and end cover from the field frame at 1.5 N.m (15 kgf.cm, 13 in.lbf). Finally detach the brush holder after taking out the O-ring and holding the spring tank back with a screwdriver. The procedure to assemble the armature into the field frame follows the exact opposite order of disassembly steps while high-temperature grease is used for bearing and spring and steel ball and gear lubrication. Special Service Tool 09286-46011 cuts the bearings before Special Service Tools 09820-00031 along with a press drives in fresh bearings for front and rear positions. Remove the magnetic switch end cover by taking out its 3 bolts and end cover and gasket and plunger followed by checking the contact plate for wear up to 0.9 mm (0.035 in.) and replacing it if necessary. Remove terminal kit parts using Special Service Tool: 09810-38140 to loosen the terminal nuts, then detach components from Terminal C and Terminal 30, temporarily installing new terminal 30 kit parts, ensuring correct orientation of the terminal insulator, and following the same process for Terminal C. Tighten the terminal nuts, applying a wooden block on the contact plate and pressing down with a hand press at a force of 981 N (100 kgf, 221 lbf), calculating the gauge pressure based on the diameter of the hand press ram, and using Special Service Tool: 09810-38140 to tighten the nuts to 17 N.m (173 kgf.cm, 12 ft.lbf) while avoiding over-tightening to prevent cracks in the insulator. Place a dry shop rag onto contact surfaces to clean the contact plate and plunger while installing the magnetic switch end cover together with a new gasket and secure it with three bolts tightened to 2.5 N.m (26 kgf.cm, 23 in.lbf).