1996 TOYOTA T100 engine

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− STARTING (5VZ−FE)STARTER
1188 Author: Date:
1996 TOYOTA T100 (RM449U)

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P20440
− STARTING (5VZ−FE)STARTER
ST−3
1996 TOYOTA T100 (RM449U)
REMOVAL
REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(c) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

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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)

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P04515
Magnetic Finger
P20445
P04525
− STARTING (5VZ−FE)STARTER
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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

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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
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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

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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.