TOYOTA AVALON 2001 Service Repair Manual

P10584
Ohmmeter
Continuity
ST04Q-02
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
ST-8
- STARTINGSTARTER
1261 Author
: Date
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2001 AVALON (RM808U)
INSPECTION
1. INSPECT ARMATURE COIL
(a) Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
(b) Check the commutator for ground
Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
2. INSPECT COMMUTATOR
(a) Check the commutator for dirty and burnt surfaces.
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.
(b) Check the commutator circle runout.
(1) Place the commutator on V-blocks.
(2) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
(c) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.142 in.)
If the diameter is less than minimum, replace the armature.
(d) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

P10588
Ohmmeter
Continuity
P10589
Ohmmeter
No Continuity
Z10079
Brush Holder Side
Field Flame Side Length
Length
ST0019
- STARTINGSTARTER
ST-9
1262 Author
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2001 AVALON (RM808U)
3. INSPECT FIELD COIL
(a) Check the field coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
(b) Check the field coil for ground.
Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, repair or replace the field frame.
4. INSPECT BRUSHES
Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 10 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and
field frame.
5. INSPECT BRUSH SPRINGS
Check the brush spring road.
Take the pull scale reading the instant the brush spring
separates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.79 - 2.41 kgf, 4.0 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.20 kgf, 2.7 lbf)
If the installed load is less than minimum replace the brush
springs.

P13481
Ohmmeter
No Continuity
B01162
Lock
Free
B01163
Terminal C
Terminal 50Ohmmeter
Continuity
B01164Terminal 50Ohmmeter
Continuity
ST-10
- STARTINGSTARTER
1263 Author
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2001 AVALON (RM808U)
6. INSPECT BRUSH HOLDER
Check the brush holder insulation.
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
7. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the pinion gear, idler gear and
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.
(b) Check the clutch pinion gear.
Hold the starter clutch and rotate the pinion gear counter-
clockwise, and check that it turns freely. Try to rotate the
pinion gear clockwise and check that it locks.
If necessary, replace the clutch assembly.
8. INSPECT MAGNETIC SWITCH
(a) Check the pull-in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.
(b) Check the hold-in coil open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
9. INSPECT BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing
(See page ST-1 1).

ST04U-01
- STARTINGSTARTER
ST-19
1272 Author
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2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page ST-5).

ST04S-01
- STARTINGSTARTER
ST-17
1270 Author
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2001 AVALON (RM808U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST-6).
HINT:
Use high temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the
starter.

ST04O-02
- STARTINGSTARTER
ST-5
1258 Author
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2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER CAP
2. REMOVE BATTERY AND TRAY
3. REMOVE CRUISE CONTROL ACTUATOR
(a) Disconnect the actuator connector and clamp.
(b) Remove the 3 bolts, and disconnect the actuator with the bracket.
4. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter cable.
(c) Remove the 2 bolts, throttle cable clamp and starter.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)

ST04R-03
B01224
B01225
B01226
B01227
Stop Collar
Pinion Gear
Compression
Spring
B01228
- STARTINGSTARTER
ST-1 1
1264 Author
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2001 AVALON (RM808U)
REPLACEMENT
1. REPLACE CLUTCH ASSEMBLY
(a) Disassemble the starter housing and the clutch assembly.
(1) Mount a brass bar in a vice, and install the starter
housing and clutch assembly to the brass bar.
(2) Push down the pinion gear.
(3) Using a plastic-faced hammer, tap down the stop
collar.
(4) Using a screwdriver, pry out the snap ring.
(5) Remove the stop collar, pinion gear and compres-
sion spring.
(6) Push down the starter housing, and remove the
spring retainer.
(7) Remove the starter clutch from the starter housing.
(8) Remove the clutch shaft and compression spring
from the starter clutch.

B01229
Starter Housing
Starter
ClutchCompression
Spring
Clutch
Shaft
B01230
B01231B01670
Stop
Collar
Pinion
Gear
Compression
SpringSpring
Retainer
B01232
B01233
ST-12
- STARTINGSTARTER
1265 Author
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:
2001 AVALON (RM808U)
(b) Assemble the starter housing and the clutch assembly.
(1) Install the compression spring and clutch shaft to
the starter clutch.
(2) Install the starter clutch to the starter housing.
(3) Mount a brass bar in a vice, install the starter hous-
ing and clutch assembly to the brass bar.
(4) Push down the starter housing, and install the
spring retainer, compression spring, pinion gear
and stop collar.
(5) Push down the pinion gear.
(6) Using snap ring pliers, install a new snap ring.
(7) Using pliers, compress the snap ring.
(8) Check that the snap ring fits correctly.

B01165
P10595
SST
P10596
Upward
DownwardSST
P10593
P10594
- STARTINGSTARTER
ST-13
1266 Author
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:
2001 AVALON (RM808U)
(9) Remove the starter housing and clutch assembly
from the brass bar.
(10) Using a plastic-faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820-00030
3. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using a press, press in a new bearing.

B01234
B01235
B01236
SST
B06430
(1)
(2)(4)
(5)
(6)
Inside
Identation
ProtrusionLong
Short
(3)
(7)
ST-14
- STARTINGSTARTER
1267 Author
: Date
:
2001 AVALON (RM808U)
4. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the 3 bolts, end cover, gasket and plunger.
(b) Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove the terminal kit parts
(1) Using SST, loosen the terminal nuts.
SST 09810-38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O- ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O-ring, terminal bolt,
contact plate, terminal insulator (inside).
(d) Install new terminal 30 kit parts.
(1) Temporarily install a new terminal insulator (inside).
(2) Temporarily install a new contact plate.
(3) Temporarily install a new terminal bolt.
(4) Temporarily install a new O-ring.
(5) Temporarily install a new packing and a new termi-
nal insulator (outside).
Install a new packing to a new terminal insulator,
and install them.