Toyota Corolla 1988-1997 Repair Guide

Starter

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TESTING




WARNING
This tests must be performed within 3 to 5 seconds to avoid burning out the starter.

Pull-in

See Figure 1

Disconnect the field coil lead from the terminal C. Connect the battery to the solenoid switch as shown. See if the clutch pinion gear movement is outward. If the gear does not move perform the hold-in test.



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Fig. Fig. 1: Pull-in test terminal connections

Hold-in

See Figure 2

Attach the battery to the starter as shown and with the clutch pinion gear out, disconnect the negative lead from terminal C. Check to make sure the pinion gear stays in the outward position. If the clutch gear returns inwards, perform the clutch pinion gear return test.



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Fig. Fig. 2: Hold-in test terminal connections

Clutch Pinion Gear Return

See Figure 3

Disconnect the negative lead from the solenoid body. Check the clutch pinion gear returns inward. If not perform the no-load test.



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Fig. Fig. 3: Clutch pinion gear return terminal connections

No-load

See Figure 4

Attach a battery and ammeter to the starter. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check the ammeter shows the correct current. 90 amps or less at 11.5 volts. If not replace the starter.



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Fig. Fig. 4: No-load terminal connections

REMOVAL & INSTALLATION



4A-F, 4A-FE and 7A-FE Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly (with hose).
  4.  
  5. Disconnect all the wiring from the starter terminals.
  6.  
  7. Remove the starter mounting bolts. Remove the starter.
  8.  

To install:
  1. Attach the connector to the terminal on the solenoid switch. Connect the cable from the battery to the starter and secure with the nut.
  2.  
  3. Place the starter in the flywheel bellhousing, tighten the mounting bolts to 29 ft. lbs. (39 Nm).
  4.  
  5. Install the air cleaner assembly.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Check the starter for proper operation.
  10.  

4A-GE Engine
  1. Disconnect the negative battery cable. Remove the both engine under covers.
  2.  
  3. Remove the front exhaust pipe.
  4.  
  5. Remove the electric cooling fan.
  6.  
  7. Disconnect all the wiring from the starter terminals.
  8.  
  9. Remove the starter mounting bolts. Remove the starter.
  10.  

To install:
  1. Attach the connector to the terminal on the starter solenoid. Connect the cable from the battery to the terminal on the switch and secure with the nut to 29 ft. lbs. (39 Nm)..
  2.  
  3. Install the electric cooling fan.
  4.  
  5. Install the front exhaust pipe.
  6.  
  7. Install the left and right engine under covers.
  8.  
  9. Connec the negative battery cable.
  10.  
  11. Check that the starter works properly.
  12.  

SOLENOID REPLACEMENT



The starter solenoid (magnetic switch) is an integral part of the starter assembly.

  1. Remove the starter from the car. Remove the heat insulator from the starter assembly, if equipped.
  2.  
  3. Disconnect the wire lead from the magnetic switch terminal.
  4.  
  5. Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
  6.  
  7. On 1.0kw starters, remove the felt seal. On 1.4kw starters, remove the O-ring.
  8.  
  9. To remove the starter housing from the magnetic switch assembly:
    1. On 1.0 kw starters, remove the two screws and the starter housing with the idler gear and clutch assembly.
    2.  
    3. On 1.4kw units, remove the two screws and the starter housing with the pinion gear, idler and clutch assembly.
    4.  

  10.  

To install:
  1. If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and:
    1. On 1.0kw starters, place the clutch assembly, idler gear and bearing in the starter housing.
    2.  
    3. On 1.4kw starters, place the clutch assembly, idler gear, bearing and pinion gear in the starter housing.
    4.  

  2.  
  3. Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
  4.  
  5. On 1.0kw units, install the felt seal on the armature shaft. On 1.4kw units, install the O-ring on the field frame.
  6.  
  7. Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts.
  8.  

There is a protrusion or tab on each part; make sure you line them up correctly.

  1. Connect the wire to the terminal on the magnetic switch. Install the heat insulator, if equipped.
  2.  
  3. Reinstall the starter on the vehicle. Check starter system for proper operation.
  4.  

 
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