Starting System (1GR-FE): Overview Toyota 4Runner IV рестайлинг

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1. DISCONNECT BATTERY NEGATIVE TERMINAL (for 2WD) Disconnect the battery negative terminal.
2. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) Remove the 4 bolts and engine rear under cover assembly.
3. REMOVE NO. 2 MANIFOLD STAY (for 2WD) Remove the 3 bolts and No. 2 manifold stay.
4. DISCONNECT WIRE HARNESS (for 2WD) Remove the bolt and disconnect the wire harness from the cylinder block.
5. REMOVE STARTER ASSEMBLY (for 2WD) Disconnect the terminal 50 connector from the starter assembly. Remove the nut and disconnect the wire harness from the terminal 30. Remove the 2 bolts and starter assembly.
6. DISCONNECT BATTERY NEGATIVE TERMINAL (for 4WD) Disconnect the battery negative terminal.
7. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) Remove the 4 bolts and engine rear under cover assembly.
8. REMOVE NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) Disconnect the heated oxygen sensor (bank 2) connector. Remove the 2 bolts, 2 nuts, No. 2 front exhaust pipe assembly and 2 gaskets.
9. REMOVE FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) Remove the 5 clips and front fender rear splash shield LH.
10. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) Loosen the bolt A and remove the bolt B, then separate the No. 2 steering intermediate shaft sub-assembly.
11. REMOVE STARTER ASSEMBLY (for 4WD) Disconnect the terminal 50 connector from the starter assembly. Remove the nut and disconnect the wire harness from the terminal 30. Remove the 2 bolts and starter assembly.

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1. REMOVE REPAIR SERVICE STARTER KIT Remove the nut, and disconnect the lead wire from the repair service starter kit. Remove the 2 screws which are used to secure the repair service starter drive housing. Remove the repair service starter kit. Remove the return spring and plunger.
2. REMOVE STARTER YOKE ASSEMBLY Remove the 2 through bolts, and pull out the starter yoke assembly together with the commutator end frame assembly.
3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY Remove the commutator end frame assembly from the starter yoke assembly.
4. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly.
5. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the cover.
6. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and plate washer. Remove the starter armature assembly from commutator end frame assembly.
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears.
8. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Remove the starter center bearing clutch and drive lever set pin together from the starter drive housing. Remove the drive lever set pin from the starter center bearing clutch.

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1. INSPECT STARTER ASSEMBLY NOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. Do pull-in test (Condition A). Disconnect the field coil lead wire from terminal C. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear protrudes. Do holding test. Disconnect the negative (-) lead from the terminal C with the above condition A is being sustained. Check that the pinion gear remains protruded. Inspect clutch pinion gear return. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. Perform the operation test without load. Connect the field coil lead wire to terminal C. Torque: 10 N*m (102 kgf*cm, 89 ft.*lbf) Hold the starter with a vise. Connect the battery and ammeter to the starter as shown. Check that the ammeter indicates the specified current. Specified current: 90 A or less at 11.5V
2. INSPECT STARTER ARMATURE ASSEMBLY Check the commutator for open circuit. Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segments, replace the armature. Check the commutator for ground. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. Check the commutator for dirty and burn on surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. Using vernier calipers, measure the commutator length. Standard length: 3.1 mm (0.122 in.) Maximum length: 3.8 mm (0.150 in.) If the length is greater than maximum, replace the armature.
3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Using vernier calipers, measure the brash holder length. Standard length: 9.0 mm (0.354 in.) Minimum length: 4.0 mm (0.158 in.) If the length is less than minimum, replace the starter commutator end frame assembly. Check the brush holder. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the starter commutator end frame assembly.
4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Inspect the gear teeth of the planetary gear, and the starter center bearing clutch for wear or damage. If any one of the planetary gear is damaged, replace the planetary gear assembly. If any one of the gears of the starter center bearing clutch is damaged, replace the clutch. Check the clutch pinion gear. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks If necessary, replace the center bearing clutch sub-assembly.
5. INSPECT REPAIR SERVICE STARTER KIT Check the plunger. Plush in the plunger and check that it returns quickly to its original position. If necessary, replace the repair service starter kit. Check the pull-in coil for open circuit. Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the repair service starter kit. Check whether or not the hold-in coil has an open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the repair service starter kit.

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1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Install the drive lever set pin to the starter center bearing clutch. Install the starter center bearing clutch and drive lever set pin together to the starter drive housing.
2. INSTALL PLANETARY GEAR Apply grease to the planetary gears and pin parts of the planetary shaft. Install the 3 planetary gears.
3. INSTALL STARTER ARMATURE ASSEMBLY Apply grease to the plate washer and armature shaft. Install the armature shaft to the starter commutator end frame assembly. Using snap ring pliers, install the plate washer and new snap ring. Using vernier calipers, measure the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than maximum, replace the new snap ring.
4. INSTALL STARTER COMMUTATOR END FRAME COVER Install the starter commutator end frame cover.
5. INSTALL STARTER ARMATURE PLATE Insert the starter armature plate to the starter yoke assembly. Align the keyway of the plate with the key inside the starter yoke, and install the plate.
6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the starter-commutator-rubber-end frame with the convex cutout of starter yoke. Install starter-commutator-end-frame to starter yoke assembly.
7. INSTALL STARTER YOKE ASSEMBLY Align the key of the starter yoke assembly with the keyway of starter drive housing. Install the starter yoke assembly with the 2 through bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
8. INSTALL REPAIR SERVICE STARTER KIT Apply grease to the plunger and hook. Hang the plunger hook of the repair service starter kit to the drive lever. Install the plunger and return spring. Install the repair service starter kit with the 2 screws. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the lead wire to the terminal with the nut. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)