Toyota Corolla 1970-1987 Repair Guide

Starter

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the cable which runs from the starter to the battery at the battery end.
  4.  
  5. If necessary, remove the air cleaner assembly in order to gain access to the starter.
  6.  

On some models with automatic transmissions, it may be necessary to unfasten the throttle linkage connecting rod

  1. On Corolla 1200 models, disconnect the manual choke cable and the accelerator cable from the carburetor. Unfasten the front exhaust pipe flange from the manifold and then remove the complete manifold assembly.
  2.  

Radiator removal will facilitate starter removal on diesel engines

  1. On Corollas with gasoline engines and automatic transmissions, remove the transmission oil filler tube.
  2.  
  3. Disconnect all of the wiring at the starter. If necessary, tag the wiring to assure proper installation.
  4.  
  5. Unfasten the starter retainers and withdraw the starter assembly from the engine.
  6.  
  7. Installation is in the reverse order of removal.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Disengage any wiring connectors from the starter assembly



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Fig. Fig. 2: If equipped, loosen the retaining nut and remove the ring terminal connector



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Fig. Fig. 3: Loosen the starter retainers, in most cases a long extension will be helpful here



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Fig. Fig. 4: Separate the starter from the engine and remove it from the vehicle

OVERHAUL



See Figures 5 and 6

Direct Drive Type
SOLENOID REPLACEMENT
  1. Remove the starter from the vehicle.
  2.  
  3. Unscrew the two solenoid switch (magnetic switch) retaining screws.
  4.  
  5. Remove the solenoid. In order to unhook the solenoid from the starter drive lever, lift it up at the same time that you are pulling it out of the starter housing.
  6.  
  7. Installation is in the reverse order of removal. Make sure that the solenoid switch is properly engaged with the drive lever before tightening the mounting screws.
  8.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of a common direct-drive starter motor assembly

BRUSH REPLACEMENT
  1. Remove the starter from the vehicle.
  2.  
  3. Remove the solenoid (magnetic switch).
  4.  
  5. Remove the two end frame cap mounting bolts and remove the end frame cap.
  6.  
  7. Remove the O-ring and the lock plate from the armature shaft groove then slide the shims off the shaft.
  8.  
  9. Unscrew the two long housing screws (they are found at the front of the starter) and carefully pull off the end plate.
  10.  
  11. Using a screwdriver, separate the brushes and the brush springs then remove the brushes from the brush holder.
  12.  
  13. Slide the brush holder off of the armature shaft.
  14.  
  15. Crush the old brushes off of the copper braid and file away any remaining solder.
  16.  
  17. Fit the new brushes to the braid and spread the braid slightly.
  18.  

You will need a soldering iron of at least 250 watts

  1. Using radio solder, solder the brush to the braid. Grip the copper braid with flat pliers to prevent the solder from flowing down its length.
  2.  
  3. File off any extra solder and then repeat the procedure for the remaining three brushes.
  4.  
  5. Installation is in the reverse order of removal.
  6.  

When installing the brush holder, make sure that the brushes line up properly

STARTER DRIVE REPLACEMENT
  1. Remove the starter from the vehicle.
  2.  
  3. Remove the solenoid (magnetic switch).
  4.  
  5. Remove the two end frame cap mounting bolts and remove the cap.
  6.  
  7. Remove the O-ring and the lock plate from the armature shaft groove, then slide the shims off the shaft.
  8.  
  9. Unscrew the two long housing screws (they are found at the front of the starter) and carefully pull off the end plate.
  10.  
  11. Using a screwdriver, separate the brushes and the brush springs then remove the brushes from the holder.
  12.  
  13. Slide the brush holder off of the armature shaft.
  14.  
  15. Pull the field frame away from the drive housing and remove it.
  16.  
  17. Remove the drive lever pivot bolt from the drive housing.
  18.  
  19. Pull the armature from the drive housing.
  20.  
  21. Take a 14mm socket and slide it over the armature shaft until it rests on the stop collar.
  22.  
  23. Tap the stop collar down with a hammer.
  24.  
  25. Pry off the exposed stopring and then remove the stop collar from the shaft.
  26.  
  27. Remove the starter drive clutch assembly.
  28.  
  29. Installation is in the reverse order of removal.
  30.  



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of a common gear reduction starter motor

Reduction Gear Type
BRUSH REPLACEMENT
  1. Remove the starter from the vehicle.
  2.  
  3. Disconnect the lead from the solenoid (magnetic switch) terminal.
  4.  
  5. Unscrew the two mounting bolts and remove the field frame assembly from the solenoid housing.
  6.  
  7. Remove the O-ring and the felt seal.
  8.  
  9. Unthread the mounting screws and remove the starter housing from the solenoid housing.
  10.  
  11. Pull out the clutch assembly, then remove the pinion and idler gears.
  12.  
  13. Remove the steel ball from the clutch shaft hole.
  14.  
  15. Using a screwdriver, separate the brushes and the brush springs and then remove the brushes from the holder.
  16.  
  17. Slide the brush holder off of the armature shaft.
  18.  
  19. Crush the old brushes off of the copper braid and file away any remaining solder.
  20.  
  21. Fit the new brushes to the braid and spread the braid slightly.
  22.  

You will need a soldering iron of at least 250 watts

  1. Using radio solder, solder the brush to the braid. Grip the copper braid with flat pliers to prevent the solder from flowing down its length.
  2.  
  3. File off any extra solder and then repeat the procedure for the remaining three brushes.
  4.  
  5. Installation is in the reverse order of removal.
  6.  

When installing the brush holder, make sure that the brushes line up properly

 
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