款丰田凯美瑞2azfe发动机起动系统维修手册英文版可编辑.docx
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款丰田凯美瑞2azfe发动机起动系统维修手册英文版可编辑
2007款丰田凯美瑞2AZ-FE发动机起动系统维修手册（英文版）
ST–1
2AZ-FESTARTING–STARTINGSYSTEM
2AZ-FESTARTINGENGINE
STARTINGSYSTEM
PARTSLOCATION
STARTERR
I
A
P
AT
PARKNEUTRALE
POSITIONSWITCHRENGINEROOMRB
-STARTERRELAY
ECM
-STAM2FUSE
A-ALTFUSE
T
O
INSTRUMENTPANELJBY
-AM1FUSEO
T
ST
MTIGNITIONSWITCH
CLUTCHSTARTSWITCH
A135518E01
ST–2
2AZ-FESTARTING–STARTINGSYSTEM
SYSTEMDIAGRAM
2
2
4
C1
LB
ParkNeutral
P
PositionECM
N
Switch
2
48
RA24STA
A22I
E23ClutchStartSwitch
IgnitionSwitchA
11
P
12
E
ACC
R252
AM1IG1C24NSW
4
ST1ST
AM1AM2IG23A
5T12
ST2
753
O
Y
ALTSTAM2O
TStarter
FLMAIN
111
D1C29C3
12
M
STBattery
1MT
2AT
A135060E01
ST–3
2AZ-FESTARTING–STARTER
2AZ-FESTARTINGENGINE
STARTER
COMPONENTS
AIRCLEANERCAPSUB-ASSEMBLY
AIRCLEANERFILTERELEMENT
505144inlbf
R
STARTER505144inlbf
Ix3
ASSEMBLYA
forManualTransaxle9810087inlbfP
E
121209R
CLUTCHFLEXIBLEAIRCLEANERAIRCLEANERCASE
x2
HOSEBRACKETINLETASSEMBLYSUB-ASSEMBLY
3738028A
T
O
Y
O
T
ST
NmkgfcmftlbfSpecifiedtorque
A133564E01
ST–4
2AZ-FESTARTING–STARTER
STARTERARMATUREASSEMBLY
STARTERCOMMUTATORENDFRAMEASSEMBLY
STARTERCOMMUTATOR
ENDFRAMECOVER
606153inlbf
SNAPRING
REPAIRSERVICE
WASHER
STARTERKITR
-PLUNGERI
-RETURNSPRINGA
606153inlbf
-MAGNETICSWITCHP
E
R
757666inlbfA
T
O101027
Y
O
T
MOTORTERMINALSTARTERKIT
ST
PLANETARYGEAR
NmkgfcmftlbfSpecifiedtorque
STARTERARMATUREPLATE
Non-reusablepart
STARTERYOKEASSEMBLY
ApplyHigh-temperaturegrease
A134900E01
ST–5
2AZ-FESTARTING–STARTER
REMOVAL
1DISCONNECTCABLEFROMNEGATIVEBATTERY
TERMINAL
2REMOVEAIRCLEANERINLETASSEMBLYSee
pageEM-94
3REMOVEAIRCLEANERCAPSUB-ASSEMBLYSee
pageES-416
4REMOVEAIRCLEANERCASESUB-ASSEMBLYSee
pageEM-95
5REMOVESTARTERASSEMBLYforManual
Transaxle
aDisconnecttheterminal50connectorfromthe
starterassembly
bRemovethenutanddisconnectthewireharness
fromterminal30R
I
A133565A
cRemovethe3boltsclutchflexiblehosebracketand
P
starterassembly
E
R
A
Bracket
A133566E01
T
O
6REMOVESTARTERASSEMBLYforAutomatic
YTransaxle
OaDisconnecttheterminal50connectorfromthe
starterassembly
TbRemovethenutanddisconnectthewireharness
fromterminal30
A134876
cRemovethe2boltsandstarterassemblyST
A134877
ST–6
2AZ-FESTARTING–STARTER
DISASSEMBLY
1REMOVEREPAIRSERVICESTARTERKIT
aRemovethenutanddisconnecttheleadwirefrom
terminalC
A079718E05
bRemovethe2screwsthatholdthemagneticswitch
tothemotorterminalstarterkit
cRemovetherepairservicestarterkit
dRemovethereturnspringandtheplungerfromthe
repairservicestarterkit
R
I
A079719E05A
2REMOVESTARTERYOKEASSEMBLY
P
aRemovethe2throughboltsandpulloutthestarter
yokeassemblytogetherwiththestartercommutator
E
endframeassembly
R
A
A079720E05
T
ObRemovethestarteryokeassemblyfromthestarter
Ycommutatorendframeassembly
O
T
A079721E03
3REMOVESTARTERARMATUREPLATE
STaRemovethestarterarmatureplatefromthestarter
yokeassembly
A079722E04
ST–7
2AZ-FESTARTING–STARTER
4REMOVESTARTERCOMMUTATORENDFRAME
COVER
aUsingascrewdriverremovethestartercommutator
endframecover
A079723E03
5REMOVESTARTERARMATUREASSEMBLY
aUsingsnapringpliersremovethesnapringand
platewasher
SnapRingPliers
bRemovethestarterarmatureassemblyfromthe
commutatorendframeassembly
R
I
A082440E07A
6REMOVEPLANETARYGEAR
P
aRemovethe3planetarygearsfromthemotor
terminalstarterkit
E
R
A
A081167E03
T
O
Y
O
T
ST
ST–8
2AZ-FESTARTING–STARTER
INSPECTION
1INSPECTSTARTERASSEMBLY
CAUTION
Makesuretocompleteeachofthefollowingtests
within5secondstopreventthecoilfromburning
out
aPerformpull-intest
1DisconnecttheleadwirefromterminalC
TerminalC
A133511E01
2Connectthebatterytothemagneticswitchas
R
shownintheillustrationCheckthattheclutch
I
piniongearmovesoutward
TerminalC
Iftheclutchpiniongeardoesnotmove
A
outwardreplacetherepairservicestarterkit
P
E
BodyR
Terminal50
A133512E01
bPerformhold-intest
A1Disconnectthenegative-terminalleadfrom
TterminalCundertheconditionsforpull-intest
Checkthatthepiniongearremainsout
TerminalCOIftheclutchpiniongearmovesinwardreplace
Ytherepairservicestarterkit
O
BodyTerminal50T
A133513E01
cInspectclutchpiniongearreturn
1Disconnectthenegative-leadfromthe
starterbodyCheckthattheclutchpiniongear
movesinward
TerminalCIftheclutchpiniongeardoesnotmoveinward
STreplacetherepairservicestarterkit
dPerformno-loadperformancetest
1ConnectthefieldcoilwiretoterminalCwiththe
BodyTerminal50nutMakesurethattheleadisnotgrounded
A133514E01Torque10Nm102kgfcm7ftlbf
2Clampthestarterinavise
ST–9
2AZ-FESTARTING–STARTER
3Connectthebatteryandanammetertothe
starterasshownintheillustration
Ammeter4Checkthatthestarterrotatessmoothlyand
steadilywiththeclutchpiniongearextended
Terminal30Checkthattheammeterreadsthespecified
current
Specifiedcurrent
ConditionSpecifiedcondition
at115V90Aorless
Iftheresultisnotasspecifiedoverhaulthe
starterassembly
Body
Terminal50
A133510E01
2INSPECTREPAIRSERVICESTARTERKIT
aChecktheplungerR
1Pushintheplungerandcheckthatitreturns
quicklytoitsoriginalposition
I
Ifnecessaryreplacetherepairservicestarter
A
kitP
E
A058586E04R
bInspecttheresistanceofthepull-incoil
1Usinganohmmetermeasuretheresistance
TerminalC
Abetweenterminals50andC
TStandardresistance
TesterconnectionSpecifiedcondition
OTerminal50-TerminalCBelow1
Terminal50YIftheresistanceisnotasspecifiedreplacethe
Below1Ω
Orepairservicestarterkit
TA079725E08
cInspecttheresistanceofthehold-incoil
Body
1Usinganohmmetermeasuretheresistance
Below2Ωbetweenterminal50andtheswitchbody
Standardresistance
TesterconnectionSpecifiedcondition
Terminal50-SwitchbodyBelow2ST
Terminal50Iftheresistanceisnotasspecifiedreplacethe
repairservicestarterkit
A079726E07
3INSPECTSTARTERARMATUREASSEMBLY
aCheckthecommutatorsurfacefordirtorburning
Ifthesurfaceisdirtyorburntsmooththesurface
with400-gritsandpaperorleather
ST–10
2AZ-FESTARTING–STARTER
bInspecttheresistanceofthecommutator
1Usinganohmmetermeasuretheresistance
betweenthesegmentsofthecommutator
Standardresistance
TesterconnectionSpecifiedcondition
Below1ΩSegment-SegmentBelow1
Iftheresistanceisnotasspecifiedreplacethe
Segmentstarterarmatureassembly
A058372E04
2Usinganohmmetermeasuretheresistance
betweenthecommutatorandarmaturecoil
10kΩorHighercore
Standardresistance
TesterconnectionSpecifiedcondition
CommutatorCommutator-Armaturecoilcore10korhigher
CoilCoreIftheresistanceisnotasspecifiedreplacethe
R
starterarmatureassembly
I
A058373E04A
cUsingverniercalipersmeasurethecommutator
P
depth
Specifieddepth
E
31mm0122in
R
imumdepth
Depth
38mm0150in
Ifthedepthisgreaterthantheimumreplace
Athestarterarmatureassembly
A058584E09
T
4INSPECTSTARTERCOMMUTATORENDFRAME
O
YASSEMBLY
aCheckthebrushlength
O1Usingverniercalipersmeasurethebrush
TLengthlength
Specifiedlength
90mm0354in
imumlength
40mm0157in
A076677E10Ifthelengthislessthantheminimumreplace
thestartercommutatorendframeassembly
STbChecktheresistance
10kΩorHigher1Usinganohmmetermeasuretheresistance
betweenthepositiveandnegative-
brushes
Resistance
10korhigher
Iftheresistanceisnotasspecifiedrepairor
replacethestartercommutatorendframe
assembly
A079766E10
ST–11
2AZ-FESTARTING–STARTER
5INSPECTMOTORTERMINALSTARTERKIT
Lock
aCheckthestarterclutch
1Rotatetheclutchpiniongearcounterclockwise
andcheckthatitturnsfreelyTrytorotatethe
clutchpiniongearclockwiseandcheckthatit
locks
Ifnecessaryreplacethemotorterminalstarter
kit
Free
A081655E05
REASSEMBLY
1INSTALLPLANETARYGEAR
ApplyGreaseaApplyhigh-temperaturegreasetotheplanetary
gearsandpinpartsoftheplanetaryshaft
bInstallthe3planetarygearstothemotorterminal
starterkitR
A081656E06I
A
2INSTALLSTARTERARMATUREASSEMBLY
aApplyhigh-temperaturegreasetotheplatewasher
P
andthearmatureshaft
SnapRingPliersE
bInstallthestarterarmatureassemblytothestarter
commutatorendframeassembly
R
cUsingsnapringpliersinstalltheplatewasheranda
newsnapring
A
A082440E08
T
OdUsingverniercalipersmeasurethesnapring
Lengthimumlength
Y50mm0197
升级会员 