OEM 2004 Toyota Celica Starter Motor

2004 Toyota Celica Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2004 Toyota Celica?

  A: Start by dismantling the starter motor by disconnecting the lead wire from the magnetic switch terminal followed by removing 2 through bolts and then removing 2 screws and end cover from the field frame and armature. First clear away the O-ring before using a screwdriver to pull back the spring tank in order to disconnect the brush holder from the brushes and extract the field frame from the magnetic switch assembly. Working on the next step entails extraction of two bolts (Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)) from the starter housing and clutch assembly and their accompanying gears. The steel ball can be extracted using a magnetic finger from the clutch shaft hole while removing the armature by either manual method (1ZZ-FE) or press method for 2ZZ-GE. A hand-based examination of the bearing should be performed for resistance detection which indicates replacement. Special Service Tools 09286-46011 provide bearing removal while Special Service Tools 09820-00031 together with a press system allow bearing installation for front and rear bearing positions. Inspection of the contact plate requires the end cover bolt removal with help from the end cover, gasket, and plunger. Verify that the wear has not exceeded the maximum limit of 0.9 mm (0.035 in.) using vernier calipers; replace if necessary. Use Special Service Tool: 09810-38140 to loosen terminal nuts on the parts found within Terminal C and Terminal 30 before extracting all components. Fitting terminal 30 parts requires correct placement of the insulator before tightening nuts while using contact plate pressure from a wooden block at 981 N (100kgf, 221 lbf). Secure the magnetic switch end cover by installing its plunger and new gasket coupled with 3 bolts that require 2.5 N.m (26 kgf.cm, 23 in.lbf) torque using Special Service Tool: 09810-38140. Clean the contact surfaces of the contact plate and plunger before installation. To reinstall replace the armature using a press on 2ZZ-GE models into the magnetic switch assembly and place the steel ball inside the clutch shaft hole after addition of high-temperature grease and install the starter housing using a new O-ring and return spring and clutch assembly with gears following a torque of 9.3 N.m (95 kgf.cm, 82 in.lbf). Place the new O-ring on the field frame before positioning it correctly with the magnetic switch and securing its installation. The brush holder should be mounted on the field frame and brushes should be connected while checking for any unintended contact between positive lead wires and ground. Combine the new O-ring with the end cover while tightening two screws to the field frame by applying 3.8 N.m (39 kgf.cm, 34 in.lbf) torque during installation. Afterward, lock the field frame and armature assembly with two through bolts at 9.3 N.m (95 kgf.cm, 82 in.lbf) torque before connecting lead wire to terminal C using a nut where torque should be 5.9 N.m (60 kgf.cm, 52 in.lbf). Conclude the maintenance by adding a fresh dust protection device.