Toyota Yaris: Starter / Disassembly

Toyota Yaris XP210 (2020-2026) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (starting) / Starter / Disassembly

DISASSEMBLY

PROCEDURE

1. REMOVE WIRE HARNESS

(a) Remove the 2 nuts and wire harness from the starter assembly.

2. REMOVE STARTER INRUSH CURRENT REDUCTION RELAY

(a) Remove the bolt and wire harness from the starter inrush current reduction relay.

(b) Remove the 2 bolts and starter inrush current reduction relay from the starter drive housing assembly.

3. REMOVE REPAIR SERVICE STARTER KIT

(a) While holding the repair service starter kit to the starter drive housing assembly, remove the 2 nuts.

(b) While lifting the rear of the magnet starter switch assembly, remove the hook from the pinion drive lever, then remove the magnet starter switch assembly.

*1	Pinion Drive Lever
*a	Hook

4. REMOVE STARTER YOKE ASSEMBLY

(a) Using a T25 "TORX" socket wrench, remove the 2 through bolts, and pull out the starter yoke assembly together with the starter commutator end frame assembly.

*1	Starter Yoke Assembly
*2	Starter Commutator End Frame Assembly

5. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Remove the 2 screws.

(b) While holding down the field coil lead wire, remove the starter commutator end frame assembly from the starter yoke assembly.

*1	Starter Yoke Assembly
*2	Starter Commutator End Frame Assembly
*a	Field Coil Lead Wire

6. REMOVE STARTER BRUSH HOLDER ASSEMBLY

(a) Using a screwdriver, hold the brush spring back and disconnect the 4 brushes.

*a	Brush Spring
*b	Brush

(b) Remove the starter brush holder assembly from the starter armature assembly.

7. REMOVE STARTER ARMATURE ASSEMBLY

(a) Remove the starter armature assembly from the starter yoke assembly.

*1	Starter Yoke Assembly
*2	Starter Armature Assembly

8. REMOVE STARTER ARMATURE PLATE

(a) Remove the starter armature plate from the starter drive housing assembly or starter yoke assembly.

*1	Starter Yoke Assembly
*2	Starter Drive Housing Assembly
*3	Starter Armature Plate

9. REMOVE PLANETARY GEAR

(a) Remove the 3 planetary gears from the starter drive housing assembly.

10. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) Remove the starter center bearing clutch sub-assembly together with the pinion drive lever and rubber seal from the starter drive housing assembly.

*1	Starter Center Bearing Clutch Sub-assembly
*2	Starter Drive Housing Assembly
*3	Pinion Drive Lever
*4	Rubber Seal

(b) Remove the pinion drive lever and rubber seal from the starter center bearing clutch sub-assembly.

Removal

REMOVAL CAUTION / NOTICE / HINT HINT: When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating...

Inspection

INSPECTION PROCEDURE 1. INSPECT STARTER ASSEMBLY CAUTION: As a large electric current passes through the cable during this inspection, a thick cable must be used...

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