Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 1998-2003 Approved FSM 12 star insp
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download insp documenatation <<
Text preview - extract from the document
ST-8
STARTING - STARTER
ST01B-04
Ohmmeter INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Continuity
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.
P10584
Ohmmeter 2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
No Continuity 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, correct it with sandpaper (No.400)
or on a lathe.
P10585
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V-blocks.
(b) Using a dial gauge, 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.
P10586
5. INSPECT COMMUTATOR DIAMETER
Using a vernier caliper, measure the commutator diameter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.142 in.)
If the diameter is less than minimum, replace the armature.
P10587
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.
ST0040
2001 SIENNA (RM787U)
Author : Date : 1226
ST-9
STARTING - STARTER
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Ohmmeter Using an ohmmeter, check that there is continuity between the
Continuity lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
P10588
8. INSPECT FIELD COIL FOR GROUND
Ohmmeter
Using an ohmmeter, check that there is no continuity between
No Continuity the field coil end and field frame.
If there is continuity, repair or replace the field frame.
P10589
Brush Holder Side 9. INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 10.0 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and
field frame.
Length
Field Frame Side
Length
Z10079
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.8 - 2.4 kgf, 3.9 - 5.3 lbf)
Minimum spring installed load: 11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is less than minimum, replace the brush
springs.
ST0019
2001 SIENNA (RM787U)
Author : Date : 1227
ST-10
STARTING - STARTER
Ohmmeter 11. INSPECT BRUSH HOLDER INSULATION
No Continuity
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.
P13481
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 drive plate ring gear for wear or
damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the pinion gear counterclock-
wise, and check that it turns freely. Try to rotate the pinion gear
Lock
clockwise and check that it locks.
If necessary, replace the clutch assembly.
Free
B01162
14. IF NECESSARY, REPLACE CLUTCH ASSEMBLY
(a) Disassemble the starter housing and clutch assembly.
(1) Mount a brass bar in a vise, and install the starter
housing and clutch assembly to the brass bar.
B01224
(2) Push down the pinion gear.
(3) Using a plastic-faced hammer, tap down the stop
collar.
B01225
2001 SIENNA (RM787U)
Author : Date : 1228
ST-1 1
STARTING - STARTER
(4) Using a screwdriver, pry out the snap ring.
B01226
Stop Collar (5) Remove these parts:
S Stop collar
Pinion Gear
S Pinion gear
Compression
Spring S Compression spring
B01227
(6) Push down the starter housing, and remove the
spring retainer.
B01228
Starter Housing (7) Disassemble these parts:
Clutch Shaft
S Starter housing
Starter Clutch
S Starter clutch
S Compression spring
S Clutch shaft
Compression
Spring
B01229
Starter Housing (b) Assemble the starter housing and clutch assembly.
Clutch Shaft
(1) Assemble these parts:
Starter Clutch
S Starter housing
S Starter clutch
S Compression spring
S Clutch shaft
Compression
Spring
B01229
2001 SIENNA (RM787U)
Author : Date : 1229
ST-12
STARTING - STARTER
(2) Mount a brass bar in a vise, install the starter hous-
ing and clutch assembly to the brass bar.
B01230
(3) Push down the starter housing, and install these
Stop parts:
Collar
S Spring retainer
Pinion
Gear S Compression spring
S Pinion gear
S Stop collar
Compression
Spring Spring
Retainer B01670
B01231
(4) Push down the pinion gear.
(5) Using snap ring pliers, install a new snap ring.
B01232
(6) Using pliers, compress the snap ring.
(7) Check that the snap ring fits correctly.
B01233
(8) Remove the starter housing and clutch assembly
from the brass bar.
(9) Using a plastic-faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.
B01165
2001 SIENNA (RM787U)
Author : Date : 1230
ST-13
STARTING - STARTER
15. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
A01681
16. IF NECESSARY, REPLACE REAR BEARING
SST (a) Using SST, remove the bearing.
SST 09286-4601 1
P10593
(b) Using a press, press in a new bearing.
P10594
17. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
A01682
18. IF NECESSARY, REPLACE FRONT BEARING
SST (a) Using SST, remove the bearing.
SST 09286-4601 1
P10595
2001 SIENNA (RM787U)
Author : Date : 1231
ST-14
STARTING - STARTER
Upward (b) Using SST and a press, press in a new bearing.
NOTICE:
SST Be careful of the bearing installation direction.
SST 09820-00030
Downward P10596
19. INSPECT MAGNETIC SWITCH PULL-IN COIL OPEN
Ohmmeter CIRCUIT
Using an ohmmeter, check that there is continuity between ter-
Terminal C
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
Terminal 50
Continuity
B01163
20. INSPECT MAGNETIC SWITCH HOLD-IN COIL OPEN
Ohmmeter CIRCUIT
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.
Terminal 50
Continuity
B01164
2001 SIENNA (RM787U)
Author : Date : 1232
◦ Jabse Service Manual Search 2026 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo