2007款丰田凯美瑞2AZ-FE发动机起动系统维修手册.pdf

2AZ-FE STARTING – STARTING SYSTEMST–1STENGINE2AZ-FE STARTINGSTARTING SYSTEMPARTS LOCATIONIGNITION SWITCHSTARTER-STARTER RELAYCLUTCH START SWITCHPARK/NEUTRAL POSITION SWITCHMT:ECMAT:ENGINE ROOM R/BINSTRUMENT PANEL J/B-AM1 FUSE-ST/AM2 FUSE-ALT FUSEA135518E01STST–22AZ-FE STARTING – STARTING SYSTEMSYSTEM DIAGRAMECMA24 STA484L BPNC1Park/Neutral Position SwitchA22Clutch Start SwitchNSW12(*1) (*1)(*2)(*2)(*2)E23Ignition SwitchACCIG1ST1IG2ST2AM1AM23745AM1ALT ST/AM2FL MAINBattery*1: M/T*2: A/TD1 C29 C3(*1) (*2)StarterM111ST1523C2452(*2)A135060E012AZ-FE STARTING – STARTERST–3STENGINE2AZ-FE STARTINGSTARTERCOMPONENTSSTARTER ASSEMBLYN*m (kgf*cm, ft.*lbf) : Specified torque9.8 (100, 87 in.*lbf)37 (380, 28)12 (120, 9)for Manual Transaxle:CLUTCH FLEXIBLE HOSE BRACKETx2AIR CLEANER CAP SUB-ASSEMBLYAIR CLEANER CASE SUB-ASSEMBLYAIR CLEANER INLET ASSEMBLYAIR CLEANER FILTER ELEMENT5.0 (51, 44 in.*lbf)x35.0 (51, 44 in.*lbf)A133564E01STST–42AZ-FE STARTING – STARTERPLANETARY GEARREPAIR SERVICE STARTER KITSTARTER ARMATURE ASSEMBLYSTARTER ARMATURE PLATESTARTER YOKE ASSEMBLYSTARTER COMMUTATOR END FRAME ASSEMBLYApply High-temperature greaseN*m (kgf*cm, ft.*lbf) : Specified torqueNon-reusable part6.0 (61, 53 in.*lbf)WASHERSNAP RING6.0 (61, 53 in.*lbf)-PLUNGER-RETURN SPRING-MAGNETIC SWITCH7.5 (76, 66 in.*lbf)10 (102, 7)STARTER COMMUTATOR END FRAME COVERMOTOR TERMINAL STARTER KITA134900E012AZ-FE STARTING – STARTERST–5STREMOVAL1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL2. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-94)3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-416)4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See page EM-95)5. REMOVE STARTER ASSEMBLY (for Manual Transaxle)(a) Disconnect the terminal 50 connector from the starter assembly.(b) Remove the nut and disconnect the wire harness from terminal 30.(c) Remove the 3 bolts, clutch flexible hose bracket and starter assembly.6. REMOVE STARTER ASSEMBLY (for Automatic Transaxle)(a) Disconnect the terminal 50 connector from the starter assembly.(b) Remove the nut and disconnect the wire harness from terminal 30.(c) Remove the 2 bolts and starter assembly.A133565BracketA133566E01A134876A134877STST–62AZ-FE STARTING – STARTERDISASSEMBLY1. REMOVE REPAIR SERVICE STARTER KIT(a) Remove the nut and disconnect the lead wire from terminal C.(b) Remove the 2 screws that hold the magnetic switch to the motor terminal starter kit.(c) Remove the repair service starter kit.(d) Remove the return spring and the plunger from the repair service starter kit.2. REMOVE STARTER YOKE ASSEMBLY(a) Remove the 2 through bolts and pull out the starter yoke assembly together with the starter commutator end frame assembly.(b) Remove the starter yoke assembly from the starter commutator end frame assembly.3. REMOVE STARTER ARMATURE PLATE(a) Remove the starter armature plate from the starter yoke assembly.A079718E05A079719E05A079720E05A079721E03A079722E042AZ-FE STARTING – STARTERST–7ST4. REMOVE STARTER COMMUTATOR END FRAME COVER(a) Using a screwdriver, remove the starter commutator end frame cover.5. REMOVE STARTER ARMATURE ASSEMBLY(a) Using snap ring pliers, remove the snap ring and plate washer.(b) Remove the starter armature assembly from the commutator end frame assembly.6. REMOVE PLANETARY GEAR(a) Remove the 3 planetary gears from the motor terminal starter kit.A079723E03Snap Ring PliersA082440E07A081167E03STST–82AZ-FE STARTING – STARTERINSPECTION1. INSPECT STARTER ASSEMBLYCAUTION:Make sure to complete each of the following tests within 5 seconds to prevent the coil from burning out.(a) Perform pull-in test:(1) Disconnect the lead wire from terminal C.(2) Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.If the clutch pinion gear does not move outward, replace the repair service starter kit.(b) Perform hold-in test:(1) Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out.If the clutch pinion gear moves inward, replace the repair service starter kit.(c) Inspect clutch pinion gear return:(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.If the clutch pinion gear does not move inward, replace the repair service starter kit.(d) Perform no-load performance test:(1) Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded.Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)(2) Clamp the starter in a vise.Terminal CA133511E01Terminal CTerminal 50BodyA133512E01BodyTerminal CTerminal 50A133513E01BodyTerminal CTerminal 50A133514E012AZ-FE STARTING – STARTERST–9ST(3) Connect the battery and an ammeter to the starter as shown in the illustration.(4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current.Specified currentIf the result is not as。