2007款丰田凯美瑞2AZ-FE发动机起动系统维修手册（英文版）ST–12AZ-FE STARTING – STARTINGSYSTEM2AZ-FE STARTINGENGINESTARTING SYSTEMPARTS LOCATIONSTARTER RIAPATPARKNEUTRAL EPOSITION SWITCH R ENGINE ROOM RB-STARTER RELAYECM-STAM2 FUSEA -ALT FUSETOINSTRUMENT PANEL JB Y-AM1 FUSE OTSTMT IGNITION SWITCH CLUTCH START SWITCHA135518E01ST–22AZ-FE STARTING –STARTING SYSTEMSYSTEM DIAGRAM224C1L BParkNeutralPPosition ECMNSwitch248R A24 STAA22IE23 Clutch StartSwitchIgnition Switch A11P1 2EACCR 2 52AM1 IG1 C24 NSW4ST1STAM1 AM2 IG2 3 A5 T 1 2ST275 3OYALT STAM2 OT StarterFL MAIN1 1 1D1 C29 C31 2MST Battery1 MT2 ATA135060E01ST–32AZ-FE STARTING –STARTER2AZ-FE STARTINGENGINESTARTERCOMPONENTSAIR CLEANER CAP SUB-ASSEMBLYAIR CLEANER FILTER ELEMENT50 51 44 inlbfRSTARTER 50 51 44 inlbfI x3ASSEMBLYAfor Manual Transaxle 98 100 87 inlbf PE12 120 9 RCLUTCH FLEXIBLE AIRCLEANER AIR CLEANER CASEx2HOSE BRACKET INLET ASSEMBLY SUB-ASSEMBLY37 380 28 ATOYOTSTNm kgfcm ftlbf Specified torqueA133564E01ST–42AZ-FE STARTING – STARTER STARTER ARMATURE ASSEMBLYSTARTER COMMUTATOR END FRAME ASSEMBLYSTARTER COMMUTATOREND FRAME COVER60 61 53 inlbfSNAP RINGREPAIR SERVICEWASHERSTARTER KIT R-PLUNGER I-RETURN SPRING A60 61 53 inlbf-MAGNETIC SWITCH PER75 76 66 inlbf ATO 10 102 7YOTMOTOR TERMINAL STARTER KITSTPLANETARY GEARNm kgfcm ftlbf Specified torqueSTARTER ARMATUREPLATENon-reusable partSTARTER YOKE ASSEMBLYApply High-temperature greaseA134900E01ST–52AZ-FE STARTING – STARTERREMOVAL1 DISCONNECT CABLE FROM NEGATIVE BATTERYTERMINAL2 REMOVE AIR CLEANER INLET ASSEMBLY Seepage EM-943 REMOVE AIR CLEANER CAP SUB-ASSEMBLY Seepage ES-4164 REMOVE AIR CLEANER CASE SUB-ASSEMBLY Seepage EM-955 REMOVE STARTER ASSEMBLY for ManualTransaxlea Disconnect the terminal 50 connector from thestarter assemblyb Remove the nut and disconnect the wire harnessfrom terminal 30 RIA133565 Ac Remove the 3 bolts clutch flexible hose bracket andPstarter assemblyERABracketA133566E01TO6 REMOVE STARTER ASSEMBLY for AutomaticY TransaxleO a Disconnect the terminal 50 connector from thestarter assemblyT b Remove the nut and disconnect the wire harnessfrom terminal 30A134876c Remove the 2 bolts and starter assembly STA134877ST–62AZ-FE STARTING –STARTERDISASSEMBLY1 REMOVE REPAIR SERVICE STARTER KITa Remove the nut and disconnect the lead wire fromterminal CA079718E05b Remove the 2 screws that hold the magnetic switchto the motor terminal starter kitc Remove the repair service starter kitd Remove the return spring and the plunger from therepair service starter kitRIA079719E05 A2 REMOVE STARTER YOKE ASSEMBLYPa Remove the 2 through bolts and pull out the starteryoke assembly together with the starter commutatorEend frame assemblyRAA079720E05TO b Remove the starter yoke assembly from the starterY commutator end frame assemblyOTA079721E033 REMOVE STARTER ARMATURE PLATEST a Remove the starter armature plate from the starteryoke assemblyA079722E04ST–72AZ-FE STARTING – STARTER4 REMOVE STARTER COMMUTATOR END FRAMECOVERa Using a screwdriver remove the starter commutatorend frame coverA079723E035 REMOVE STARTER ARMATURE ASSEMBLYa Using snap ring pliers remove the snap ring andplate washerSnap Ring Pliersb Remove the starter armature assembly from thecommutator end frame assemblyRIA082440E07 A6 REMOVE PLANETARY GEARPa Remove the 3 planetary gears from the motorterminal starter kitERAA081167E03TOYOTSTST–82AZ-FE STARTING –STARTERINSPECTION1 INSPECTSTARTER ASSEMBLYCAUTIONMake sure to complete each of the following testswithin 5 seconds to prevent the coil from burningouta Perform pull-in test1 Disconnect the lead wire from terminal CTerminal CA133511E012 Connect the battery to the magnetic switch asRshown in the illustration Check that the clutchIpinion gear moves outwardTerminal CIf the clutch pinion gear does not moveAoutward replace the repair service starter kitPEBody RTerminal 50A133512E01bPerform hold-in testA 1 Disconnect the negative - terminal lead fromT terminal C under the conditions for pull-in testCheck that the pinion gear remains outTerminal C O If the clutch pinion gear moves inward replaceY the repair service starter kitOBody Terminal 50 TA133513E01c Inspect clutch pinion gear return1Disconnect the negative - lead from thestarter body Check that the clutch pinion gearmoves inwardTerminal C If the clutch pinion gear does not move inwardSTreplace the repair service starter kitdPerform no-load performance test1Connect the field coil wire to terminal C with theBody Terminal 50 nut Make sure that the lead is not groundedA133514E01 Torque 10 Nm 102 kgfcm 7 ftlbf2 Clamp the starter in a viseST–92AZ-FE STARTING –STARTER3 Connect the battery and an ammeter to thestarter as shown in the illustrationAmmeter 4 Check that the starter rotates smoothly andsteadily with the clutch pinion gear extendedTerminal 30 Checkthat the ammeter reads the specifiedcurrentSpecified currentCondition Specified conditionat 115 V 90 A or lessIfthe result is not as specified overhaul thestarter assemblyBodyTerminal 50A133510E012 INSPECT REPAIR SERVICE STARTER KITa Check the plunger R1 Push in the plunger and check that it returnsquickly to its original positionIIf necessary replace the repair service starterAkitPEA058586E04 Rb Inspect the resistance of the pull-in coil1 Using an ohmmeter measure the resistanceTerminal CA between terminals 50 andCTStandard resistanceTesterconnection Specified conditionO Terminal 50 - Terminal C Below 1Terminal 50 Y If theresistance is not as specified replace theBelow 1 ΩOrepair service starter kitT A079725E08c Inspectthe resistance of the hold-in coilBody1 Using an ohmmeter measure the resistanceBelow 2 Ωbetween terminal 50 and the switch bodyStandard resistanceTester connection Specified conditionTerminal 50 - Switch body Below 2 STTerminal 50 If the resistance is not as specified replace therepair service starter kitA079726E073 INSPECT STARTER ARMATURE ASSEMBLYa Check the commutator surface for dirt or burningIf the surface is dirty or burnt smooth the surfacewith400-grit sandpaper or leatherST–102AZ-FE STARTING –STARTERInspect the resistance of the commutator1 Using an ohmmeter measure the resistancebetween the segments of the commutatorStandard resistanceTester connection Specified conditionBelow 1 Ω Segment - Segment Below 1If the resistance is not as specified replace theSegmentstarter armature assemblyA058372E042Using an ohmmeter measure the resistancebetween the commutator and armature coil10 kΩor Higher coreStandard resistanceTesterconnection Specified conditionCommutator Commutator -Armature coil core 10 k or higherCoil Core If the resistance is not as specified replace theRstarter armature assemblyIA058373E04Ac Usingvernier calipers measure the commutatorPdepthSpecified depthE31 mm 0122 inRimum depthDepth38 mm 0150 inIf the depth is greater than the imum replaceAthe starter armature assemblyA058584E09T4 INSPECT STARTER COMMUTATOR END FRAMEOY ASSEMBLYa Check the brush lengthO 1 Using vernier calipers measure the brushTLengthlengthSpecified length90 mm 0354 inimum length40 mm 0157 inA076677E10 If the length is less than the minimum replacethe starter commutator end frame assemblyST b Check the resistance10 kΩ or Higher 1 Using an ohmmeter measure the resistancebetween the positive and negative -brushesResistance10 k or higherIf the resistance is not as specified repair orreplace the starter commutator end frameassemblyA079766E10ST–112AZ-FE STARTING –STARTER5 INSPECT MOTOR TERMINAL STARTER KITLocka Check the starter clutch1 Rotate the clutch pinion gear counterclockwiseand check that it turns freely Try to rotate theclutch pinion gear clockwise and check that itlocksIf necessary replace the motor terminal starterkitFreeA081655E05REASSEMBLY1 INSTALL PLANETARY GEARApply Grease a Applyhigh-temperature grease to the planetarygears andpin parts of the planetary shaftb Install the3 planetary gears to the motor terminalstarter kit RA081656E06IA2 INSTALL STARTER ARMATURE ASSEMBLYa Applyhigh-temperature grease to the plate washerPand the armature shaftSnap Ring Pliers Eb Install the starter armature assembly to the startercommutator end frame assemblyRc Using snap ring pliers install the plate washer and anew snap ringAA082440E08TO d Using vernier calipers measure the snap ringLength imum lengthY 50 mm 0197 inO If the length is greater than the imum replaceT the snap ring with a new oneA058810E14。