OEM 2002 Toyota Sienna Starter Motor

2002 Toyota Sienna Parts Questions & Experts Answers

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

  A: A proper starter motor repair starts with unfastening two through bolts to 5.9 N.m (60 kgf.cm, 52 in.lbf) while disconnecting the lead wire from the magnetic switch terminal then removing the dust protector and field frame with armature. The field frame with its armature needs to be extracted first and its protrusion requires placement into the magnetic switch groove while you should replace the old O-ring during reconstruction. To continue the repair process remove the starter housing along with the clutch assembly and gear by loosening the two screws which should maintain a torque value of 5.9 N.m (60 kgf.cm, 52 in.lbf). Dissassemble the starter housing clutch assembly return spring and idler gear with a bearing from the magnetic switch. A magnetic finger should be used to remove the steel ball from the clutch shaft hole before the brush holder and field frame end cover can be unscrewed by 2 screws with 1.5 N.m (15 kgf.cm, 13 in.lbf) torque. After extracting the parts, replace the O-ring during reassembly. Legally remove each 4 brush connection from the brush holder but maintain non-grounded conditions for positive (+) wires throughout the reassembly process. The removal process for the armature from the field frame follows opposite steps of assembly while you need to coat all components including bearings, springs and steel ball and gears with high-temperature grease. The process of replacement starts with removing three bolts together with the gasket and plunger from the magnetic switch end cover before measuring contact plate wear with vernier calipers against a maximum tolerance of 0.9 mm (0.035 in.). The procedure requires Special Service Tool: 09810-38140 for loosening terminal nuts before removing parts from Terminal C and Terminal 30 while installing new components with proper terminal insulator and wave washer positioning. A 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) wooden block should be used to press down the contact plate after entering 981 N (100 kgf, 221 lbf) of force to prevent coil deformation or nut tightening-related plate tilting. Complete the installation by using Special Service Tool: 09810-38140 to tighten the nuts to 17 N.m (170 kgf.cm, 12 ft.lbf) and finish with a cleaning of contact surfaces using a dry shop rag before reinstalling the magnetic switch end cover with plunger and new gasket and 3 bolts tightened to 2.5 N.m (26 kgf.cm, 23 in.lbf).