OEM 2004 Toyota Sienna Starter Motor

2004 Toyota Sienna Starter Motor Parts Q&A

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

  A: The repair service starter kit removal process starts with disconnecting the lead wire and unscrewing bolts and extracting both the kit and its internal components including the return spring and plunger. The starter yoke assembly requires removal by extracting two through bolts so you can pull it outward with its attached starter commutator end frame before separating the starter yoke from the frame. Start by taking the starter armature plate from the starter yoke followed by using a screwdriver to detach the drive housing starter bearing cover. Use snap ring pliers to detach the snap ring and plate washer which enables you to pull out the starter armature from the commutator end frame. This motion should be followed by removing the three planet gears from the repair service starter kit. The examination of the repair service starter kit involves testing the plunger for quick movement and performing an ohmmeter check on both the pull-in coil and hold-in coil before replacing the kit if required. Examine the starter armature assembly by testing commutator segment coupling as well as ground functionality while cleaning burned surfaces with sandpaper tool (No.400) or lathe and replacing the starter armature when commutator depth exceeds 4.0 mm (0.1575 in.). The starter commutator end frame needs inspection by comparing brush holder lengths and checking for any brush holder contact because frame replacement is needed when the length falls below 4.0 mm (0.158 in.) or contact occurs. The starter clutch inspection requires turning the clutch pinion gear counterclockwise to check free movement followed by a clockwise lock and a new kit must be installed if necessary. Before assembly begin by applying grease to all planet gear components and planetary pin parts of the shaft. Then apply grease to the plate washer and armature shaft for the starter armature installation into the commutator end frame. Use a new snap ring to secure the starter armature while checking that the snap ring stays below 5.0 mm (0.197 in.) in length. First mount the drive housing starter bearing cover onto its installation; then install the starter armature plate while pointing it towards the keyway of the starter yoke before putting up the starter commutator end frame assembly that aligns perfectly with the starter yoke. Before installing the plunger hook to the drive lever there is a requirement to grease the plunger and hook components and then install the plunger and return spring. Two screws are required to secure the repair service starter kit with torques reaching 7.5 Nm (76 kgf.cm, 66 in.lbf). Fitting the lead wire to the repair service starter kit requires tightening with a nut to 6.5 Nm (66 kgf.cm, 58 in.lbf).