OEM 2003 Toyota Echo Starter Motor

2003 Toyota Echo Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2003 Toyota Echo?

  A: A proper repair of the starter motor starts with breaking down the unit. Start by disconnecting the lead wire from the magnetic switch terminal then unfastening its two housing-mounting nuts before lifting the front part to free the plunger hook from contacting the drive lever. Measurements begin with removing the field frame along with its armature through two through bolts used to separate them. Afterward, extract the O-ring from the field frame. The brush holder maintenance starts with unscrewing its two screws and end cover before removing the O-ring while a screwdriver helps to hold the spring in place for brush disconnect then brush holder extraction. The first step involves taking the armature away from the field frame before extracting both the drive lever and starter clutch with shock absorber from the starter housing. The procedure continues with removing the small components which include the plate and three gears and plate washer from the planetary gears. The planetary carrier shaft starter clutch removal process begins with a stop collar tap toward the starter clutch followed by snap ring removal then taking out both stop collar and starter clutch from the shaft. Use snap ring pliers to remove the planetary carrier shaft and internal gear after taking off their snap ring and plate washer. Then align the hollow of the internal gear with the protrusion inside the shock absorber before continuing removal. High temperature-resistant grease must be applied when reassembling the device for lubricating bearings and sliding components. Place the internal gear with planetary carrier shaft into the shock absorber while spreading grease on the internal gear then rotate it until it joins properly. After applying turbine oil to the center bearing users should grease the plate washer before installing it onto the planetary carrier shaft with a snap ring. The installation of the starter clutch involves first greasing the bushing and spline followed by attaching it to the shaft then cooling the snap ring before placing it in a vise for compression. Add grease to the planetary gears as well as the flange pin components before placing the plate washer between them and three gears in position so that the cutout faces the shock absorber. Proceed by installing the drive lever and starter clutch to the shock absorber after applying grease to the drive lever and properly aligning it with the shock absorber. Users should place the armature inside the field frame and conduct brush holder installation by connecting the brush spring through armature positioning and new O-ring placement into field frame groove. Apply turbine oil to the end cover bearing then fasten it with two screws before torquing them to 1.5 N.m (15 kgf.cm, 13 in.lbf). Connect the field frame with armature assembly through new O-ring placement while meshing the cutout section against the shock absorber and perform through bolt torquing to 5.9 N.m (60 kgf.cm, 52 in.lbf). To complete the assembly install the magnetic switch by putting the plunger on the drive lever followed by two nuts that need to be torqued to 8.3 N.m (85 kgf.cm, 73 in.lbf) while connecting the lead wire to the terminal with a nut torqued to 9.8 N.m (100 kgf.cm, 87 in.lbf). The positive brushes serve as the only components for replacement during maintenance operations but they need the brush lead wire cutting followed by a welded mark shaving and terminal dimension corrections before final assembly. The terminal lead wire receives the supply brush plate before soldering it with proper solder distribution that avoids entering either the lead wire or field. Use Special Service Tool: 09221-25026 (09221-00O90) to remove the old center bearing from the unit while the tool presses in a new one.