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Starting System: Other Toyota 4Runner IV

Starter 20 illustrations ~1871 words

NO-START

If a no-start condition exists and battery is known to be good, check main fusible links and large ampere main fuses in engine compartment relay box. If fusible links and fuses are okay, see IGNITION SWITCH CONTINUITY TEST , STARTER RELAY TEST and/or PARK/NEUTRAL SWITCH under ON-VEHICLE TESTING.

PARK/NEUTRAL SWITCH

Note. If vehicle will not start with shift lever in Park/Neutral position, verify correct park/neutral switch adjustment. If park/neutral switch is correctly adjusted and verify switch continuity. See appropriate AUTOMATIC TRANSMISSION SERVICING article in AUTOMATIC TRANSMISSION/TRANSAXLES.

Permanent Magnet Type Starter

  1. Using an ohmmeter, check that there is continuity between the segments of the commutator. If continuity is not present between any of the segments, replace the armature. (Scheme 10)
  2. Using an ohmmeter, verify that continuity is not present between the commutator and armature coil core. If there is continuity, replace the armature. (Scheme 10)

Scheme 10

Scheme 10
Scheme 10

Field Coil Type Starter

  1. Check for continuity between segments of commutator. (Scheme 11) If continuity is not present between any segment, replace armature.
  2. Using ohmmeter, check for continuity between armature coil core and commutator. (Scheme 12) If continuity is present, replace armature.

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

CLUTCH & PINION GEAR

  1. Check the gear teeth on the planetary gear, internal gear and clutch assembly for wear or damage. If damaged, replace the planetary gear or starter housing with clutch assembly. If damaged, also check the drive plate ring gear for wear or damage.
  2. Check the clutch pinion gear. Rotate the clutch pinion gear clockwise, and check that it turns freely. Try to rotate the clutch pinion gear counter clockwise and check that it locks. (Scheme 13) If necessary, replace the starter housing with clutch assembly.

Scheme 13

Scheme 13
Scheme 13

Field Coil Type Starters

  1. Check the commutator for burnt or dirty surfaces. If surfaces are burnt or dirty, correct it with sandpaper (No. 400) or on a lathe.
  2. Place the commutator on "V" blocks and use a dial indicator to measure runout (out-of-round). (Scheme 14) If commutator runout is more than specification, turn commutator on a lathe and proceed to step 3. For specification, see «STARTER SPECIFICATIONS»(ref-163689-S35806438172004070900000).
  3. Measure Commutator diameter. (Scheme 15) If commutator diameter is less than minimum specification, see «STARTER SPECIFICATIONS»(ref-163689-S35806438172004070900000), replace armature.
  4. Ensure undercut depth between commutator segments are clean, free of debris, and that edges are smooth, and within specification (Scheme 16) If undercut depth is less than minimum, use a hacksaw blade to correct it. See «STARTER SPECIFICATIONS»(ref-163689-S35806438172004070900000).

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Permanent Magnet Type Starters

  1. Place commutator on "V" blocks and measure commutator runout. (Scheme 17)
  2. Using vernier calipers, measure the commutator length to ensure it is within specification. See «STARTER SPECIFICATIONS»(ref-163689-S35806438172004070900000). If the length is greater than the maximum, replace the armature. (Scheme 18)
  3. Using vernier calipers, measure the brush holder length. (Scheme 19) If the length is less than minimum, replace the starter commutator end frame assembly.
  4. Using an ohmmeter, Verify that there is no continuity between the positive and negative brush holders. (Scheme 19) If the there is continuity repair or replace the starter commutator end frame assembly.

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19
  1. Use vernier calipers to check brush length. (Scheme 20) If length is less than specification, replace brush holder and field frame. See «STARTER SPECIFICATIONS»(ref-163689-S35806438172004070900000). If brushes are okay, go to step 2.
  2. Check brush spring load using a spring scale. (Scheme 21) Pull the scale and take reading when spring separates from the brush. If the spring load is less that specification, replace the springs. See «STARTER SPECIFICATIONS»(ref-163689-S35806438172004070900000).
  3. Using an ohmmeter, check that there is no continuity between the positive and negative brush holders. (Scheme 20)

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Permanent Magnet

  1. Push in the plunger and check that it returns quickly to its original position. (Scheme 22) If Performance is not as specified, replace the repair service starter kit.
  2. Using an ohmmeter, check that there is continuity between terminals No. 50 and C. (Scheme 22) If there is no continuity, replace the repair service starter kit.
  3. Using an ohmmeter, check. that there is continuity between terminal No. 50 and the switch body. (Scheme 22) If there is no continuity; replace the repair service starter kit.

Scheme 22

Scheme 22
Scheme 22

Field Coil

  1. Check whether the pull-in coil has an open circuit. Using an ohmmeter, check that there is continuity between terminal No. 50 and terminal "C". (Scheme 23) If there is no continuity, check and replace the magnetic switch.
  2. Check whether the pull-in coil has an open circuit. Using an ohmmeter, check that there is continuity between terminals No. 50 and the switch body. (Scheme 23) If there is no continuity, check and replace the magnetic switch.

Scheme 23

Scheme 23
Scheme 23
  1. Remove the terminal "C" nut and disconnect the field coil lead wire from terminal "C".
  2. Pull-In Coil Test - Clip battery ground to terminal "C" and the main body of the starter, connect the battery to the magnetic switch (terminal No. 50). Ensure that the clutch pinion gear moves outward. (Scheme 24)
  3. Hold-In Coil Test - Disconnect the negative lead from terminal "C". (Scheme 24)Verify that the pinion gear remains out.
  4. Pinion Gear Return Test - Disconnect the negative lead from the switch body. (Scheme 24)Verify that the clutch pinion gear returns inward.
  5. Connect the lead wire to terminal "C" with the terminal "C" nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).

Scheme 24

Scheme 24
Scheme 24
  1. Pull-In Coil Test - Disconnect field coil lead from terminal "C". Connect positive battery voltage to terminal No. 50. and ground to starter body and terminal "C" and (Scheme 25) Ensure that the clutch pinion gear moves outward. If not a specified, check and replace the magnetic switch. If there as specified, go to step 2.
  2. Hold-In Coil Test - Disconnect ohmmeter lead from terminal "C". (Scheme 26) Ensure that the pinion gear remains in outward position. Hold ohmmeter lead on body of starter. (Scheme 25) If not a specified, check and replace the magnetic switch. If there as specified, go to step 3.
  3. Pinion Gear Return Test - Disconnect the negative lead from the switch body. (Scheme 27) Verify that clutch pinion gear returns inward. If not a specified, check and replace the magnetic switch. If there as specified, go to step 4.
  4. Connect lead to terminal "C" and install terminal "C" nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

4.0L (2WD)

  1. Remove the 4 bolts and engine under cover assembly rear.
  2. Remove the 3 bolts and manifold stay No. 2.
  3. Remove the bolt and disconnect the wire harness from the cylinder block.
  4. Remove starter assembly: Disconnect the terminal No. 50 connector. Remove the terminal No. 30 nut and disconnect wire harness from terminal No. 30. Remove the starter mounting bolts and the starter. see scheme 24
  5. Install Starter: Install the 2 starter mounting bolts and the starter assembly. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000). Connect the terminal No. 30 wire harness and install terminal No. 30 nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000). Connect the terminal No. 50 to the starter assembly.
  6. Connect the wire harness to the terminal No. 30 and install the nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).
  7. Connect the wire harness to the cylinder block and install the bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).
  8. Install the manifold stay No. 2 with the 3 bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).
  9. Install the engine under cover assembly rear with the 4 bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).

4.0L (4WD)

  1. Disconnect negative battery cable and then positive battery cable.
  2. Remove the 4 bolts and engine under cover assembly rear.
  3. Remove exhaust front pipe assembly No. 2 (See appropriate EXHAUST-G article under GENERAL INFORMATION)
  4. Remove the 5 clips and front fender splash shield rear left side. (Scheme 28)
  5. Loosen the bolt "A", loosen and remove the bolt "B", then separate the steering intermediate shaft No. 2. (Scheme 29)
  6. Remove starter assembly: Disconnect the terminal No. 50 connector from the starter assembly. Remove the nut and disconnect the wire harness from the terminal No. 30. Remove the starter mounting bolts, and starter.
  7. Install starter assembly: Install the starter, and starter mounting bolts. Connect the wire harness to the terminal No. 30 and install the nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000). Connect the terminal No. 50 connector to the starter assembly.
  8. Install steering intermediate shaft sub-assembly No. 2: Install the steering sliding yoke to steering intermediate shaft No. 2. Install the bolt "B" (Scheme 29) Tighten the bolt "B" and "A" to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).
  9. Install the front fender splash shield rear left side with the 5 clips. (Scheme 28)
  10. Install exhaust front pipe assembly No. 2.
  11. Install engine under cover assembly rear with the 4 bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000).

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

4.7L

  1. Relieve pressure from fuel system. See appropriate BASIC DIAGNOSTIC PROCEDURES article under ENGINE PERFORMANCE.
  2. Drain engine coolant.
  3. Disconnect negative battery terminal clamp from the battery.
  4. Remove the 2 cap nuts and throttle body cover subassembly.
  5. remove air cleaner hose assembly.
  6. Disconnect fuel hose.
  7. Disconnect fuel hose No. 2.
  8. Disconnect fuel vapor feed hose assembly.
  9. Separate engine wire: Disconnect 3 fuel injector connectors. Disconnect throttle position sensor connector. Disconnect water temperature sensor connector. Remove the 3 bolts and separate engine wire harness.
  10. Disconnect bypass hose No. 7.
  11. Disconnect bypass hose.
  12. Remove the 6 bolts and 4 nuts, intake manifold assembly and 2 gaskets.
  13. Separate the engine wire No. 2. Remove the nut and water bypass pipe subassembly.
  14. Remove the 4 nuts, water bypass joint and 2 gaskets.
  15. Remove starter assembly: Disconnect the starter connector. Remove the nut and disconnect the starter cable. Remove the bolt and disconnect the engine wire protector. Remove the 2 starter mounting bolts and starter.
  16. Install starter assembly: Install the starter assembly with the 2 starter mounting bolts. Connect the engine wire protector with the bolt. Install the starter cable with the terminal No. 30 nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000) . Connect the starter connector.
  17. Install right rear water bypass joint: Install 2 NEW gaskets to the cylinder head. Install the 4 nuts holding the water bypass joint to the cylinder heads. In incremental steps, alternately tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000) .
  18. Install water bypass pipe subassembly: Apply soapy water to the "O" ring. Install a new "O" ring to the water bypass pipe. Push in the water bypass pipe end into the pipe hole of the water pump. Install the water bypass pipe with the bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000) . Install the wire clamp to the bracket of the water bypass pipe.
  19. Install intake manifold assembly: Instal the 2 new gaskets to cylinder head. Install the intake manifold assembly with the 6 bolts and 2 nuts. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000) .
  20. Connect water bypass hose.
  21. Connect water bypass hose No. 7.
  22. Install battery cable clamp to the negative battery terminal. tighten cable clamp bolt to specification. See «TORQUE SPECIFICATIONS»(ref-163689-S42771503412004070900000) .
  23. Connect fuel vapor feed hose assembly.
  24. Connect fuel hose No. 2.
  25. Connect fuel hose.
  26. Install air cleaner hose assembly.
  27. Install throttle body cover subassembly.
  28. Refill engine coolant.
  29. Inspect vehicle for engine coolant leaks.
  30. Inspect vehicle for fuel leaks.

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