TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P20446
ST038−04
P20444
P20443
P20441
ST−4
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(b) Remove the 2 through bolts.
Torque:
1.2 kW, 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
1.8 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
(c) Pull out the field frame with the armature from the magnet-
ic switch assembly.
NOTICE:
At the time of reassembly, please refer to the following
item.
Align the protrusion of the field frame with cutout of the
magnetic switch.
(d) Remove the O−ring.
HINT:
At the ime of reassembly, please refer to the following item.
Use a new O−ring.
2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR
(a) Remove the 2 screws.
Torque:
1.2 kW, 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
1.8 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P25577
P04515
Magnetic Finger
P20445
P04525
− STARTING (5VZ−FE)STARTER
ST−5
1996 TOYOTA T100 (RM449U)
(b) Remove these parts from the magnetic switch assembly:
(1) Starter housing
(2) Return spring
(3) Bearing
(4) Idler Gear
(5) Clutch assembly
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
4. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, 2 O−rings and end cover from the
field frame.
Torque:
1.2 kW, 1.4 kW type: 1.5 N·m (15 kgf·cm, 13 in.·lbf)
1.8 kW type: 3.8 N·m (38 kgf·cm, 34 in.·lbf)
(b) Remove the O−ring from the field frame.
HINT:
Use a new O−ring.
(c) Using a screwdriver hold the spring back and disconnect
the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME

Downloaded from www.Manualslib.com manuals search engine P10584
OhmmeterContinuity
ST0NK−01
P10585
OhmmeterNo Continuity
P10586
P10587
ST0040
ST−6
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT COMMUTATOR FOR GROUNDED
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, clean it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V−blocks.
(b) Using a dial indicator, 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.
5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
Standard diameter:
1.2 kW, 1.4 kW type: 30 mm (1.18 in.)
1.8 kW type: 35 mm (1.38 in.)
Minimum diameter:
1.2 kW, 1.4 kW type: 29 mm (1.14 in.)
1.8 kW type: 34 mm (1.34 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH OF SEGMENT
Check that the undercut depth is clean and free of foreign mate-
rial. Smooth out the edge.
Standard undercut depth:
1.2 kW, 1.4 kW type: 0.6 mm (0.024 in.)
1.8 kW type: 0.7 mm (0.028 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

Downloaded from www.Manualslib.com manuals search engine P00300
OhmmeterContinuity
P00299
No continuity
Ohmmeter
Z10079
Length Brush Holder Side
Field Frame Side
Length
ST0019
− STARTING (5VZ−FE)STARTER
ST−7
1996 TOYOTA T100 (RM449U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT THAT FIELD COIL IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.
9. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length:
1.2 kW, 1.4 kW type: 15.5 mm (0.610 in.)
1.8 kW type: 15.0 mm (0.591 in.)
Minimum length:
1.2 kW, 1.4 kW type: 10.0 mm (0.394 in.)
1.8 kW type: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard installed load:
1.2 kW type
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
1.4 kW type
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
1.8 kW type
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)

Downloaded from www.Manualslib.com manuals search engine P00303
No continuity
Ohmmeter
P04514
Free
Lock
P10593
SST
ST−8
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
Minimum installed load:
1.2 kw type: 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kw type: 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kw type: 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
11. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
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 flywheel or drive plate ring gear for
wear or damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
14. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.
15. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286−46011

Downloaded from www.Manualslib.com manuals search engine P10594
P10595
SST
P10596
Upward
DownwardSST
P25578
Terminal C
Terminal 50
ContinuityOhmmeter
P25578
Terminal C
Terminal 50
ContinuityOhmmeter
− STARTING (5VZ−FE)STARTER
ST−9
1996 TOYOTA T100 (RM449U)
(b) Press in a new bearing.
16. INSPECT FRONT BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.
17. IF NECESSARY, REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286−46011
(b) Using SST and a press, press in a new bearing.
SST 09820−00030
NOTICE:
Be careful of the bearing installation direction.
18. DO PULL−IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
19. DO HOLD−IN COIL CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch assembly.

Downloaded from www.Manualslib.com manuals search engine P25592
ST0KV−02
P25599
Wear
P25600
SST
ST−10
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
2. INSPECT CONTACT PLATE FOR WEAR
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.
3. REMOVE TERMINAL KIT PARTS
(a) Using SST, loosen the terminal nuts.
SST 09810−38140
(b) Terminal C:
Remove the terminal nut, wave washer, terminal insulator
(outside), O−ring, terminal bolt, contact plate and terminal
insulator (inside).
(c) Terminal 30:
Remove the terminal nut, wave washer, terminal insulator
(outside), packing, O−ring, terminal bolt, contact plate,
terminal insulator (inside) and insulation paper.

Downloaded from www.Manualslib.com manuals search engine P25641
Long
Short
Indentation
Protrusion
P25598
Long
Short
Lead Terminal
P25602
40 mm
37 mm
20 mm Wooden Block
Contact
Plate
− STARTING (5VZ−FE)STARTER
ST−11
1996 TOYOTA T100 (RM449U)
4. REINSTALL TERMINAL KIT PARTS
(a) Terminal 30:
Install these new parts:
(1) Insulation paper
(2) Terminal insulator (inside)
NOTICE:
Be careful to install the terminal insulator in the correct
direction.
(3) Contact plate
(4) Terminal bolt
(5) O−ring
(6) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nut
(b) Terminal C:
Install these new parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O−ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulator (inside) in the
correct direction.
(c) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)

Downloaded from www.Manualslib.com manuals search engine (kgf/cm2)
=
100 kgf
Ram diameter (cm)
2
2
2Ram diameter (in.) (psi)
=
x 3.14 (Ï€) x 3.14 (Ï€)
2
(kPa) = (kgf/cm
2) x 98.1
(kPa) = (psi) x 6.9221 lbf
P25601
SST
P25591
ST−12
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
NOTICE:
Check the diameter of the hand press ram. Then calculate
the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the specified pres-
sure, the contact plate may tilt due to coil deformation or the
tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
6. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp (1.8
kW type) with the 3 bolts.
Torque:
1.2 kW, 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
1.8 kW type: 3.6 N·m (35 kgf·cm, 30 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine ST03B−03
− STARTING (5VZ−FE)STARTER
ST−13
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST−4).
HINT:
Use high−temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling
the starter.