Starting System (1GR-FE): Removal & Installation Toyota 4Runner IV рестайлинг

INSTALLATION

1. INSTALL STARTER ASSEMBLY (for 2WD) Install the starter assembly with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Connect the terminal 50 to the starter assembly.
2. CONNECT WIRE HARNESS (for 2WD) Connect the wire harness to the cylinder block and install the bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
3. INSTALL NO. 2 MANIFOLD STAY (for 2WD) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
4. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
5. CONNECT BATTERY NEGATIVE TERMINAL (for 2WD) Connect the battery negative terminal.
6. INSTALL STARTER ASSEMBLY (for 4WD) Install the starter assembly with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Connect the terminal 50 to the starter assembly.
7. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) Install the steering sliding yoke to No. 2 steering intermediate shaft. Install the bolt B and tighten the bolt B and A. Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
8. INSTALL FRONT FENDER REAR SPLASH SHIELD LH(for 4WD) Install the front fender rear splash shield LH with the 5 clips.
9. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) Install 2 new gaskets and No. 2 exhaust manifold with the 2 bolts and 2 nuts. Torque: Nut 62 N*m (630 kgf*cm, 46 ft.*lbf) Bolt 48 N*m (490 kgf*cm, 35 ft.*lbf) Connect the heated oxygen sensor (bank 2) connector.
10. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
11. CONNECT BATTERY NEGATIVE TERMINAL (for 4WD) Connect the battery negative terminal.

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REMOVAL

1. DISCONNECT BATTERY NEGATIVE TERMINAL (for 2WD) Disconnect the negative battery 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 negative battery 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 STARTER YOKE ASSEMBLY Remove the nut, and disconnect the lead wire from the C terminal. Remove the 2 through bolts. Pull out the starter yoke and the armature together. Remove the O-ring from the starter yoke.
2. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the 2 screws and magnet starter switch. Remove the these parts from the starter drive housing. Starter magnet switch return spring (Procedure "A"). Starter idle gear pinion (Procedure "B"). Starter idle gear clutch roller (Procedure "C"). Starter idle gear retainer (Procedure "D"). Starter clutch sub-assembly (Procedure "E"). Using a magnetic finger, remove the steel ball from the clutch shaft hole.
3. REMOVE STARTER BRUSH HOLDER ASSEMBLY Remove the 2 screws and end cover from the starter yoke. Remove the O-ring from the starter yoke. Using a screwdriver, hold the spring back and disconnect the 4 brushes from the brush holder. Remove the brush holder from the armature.
4. REMOVE STARTER ARMATURE ASSEMBLY Remove the starter armature assembly.

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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: for standard area 10 N*m (102 kgf*cm, 89 ft.*lbf) for cold area 5.9 N*m (60 kgf*cm, 52 in.*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 (for standard area): 90 A or less at 11.5V Specified current (for cold area): 100 A or less at 11.5 V
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 segment, 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. Check for the commutator runout. Place the commutator on V-blocks. Using a dial gauge, measure the runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout is greater than maximum, correct it on a lathe. Using vernier calipers, measure the commutator diameter. Standard diameter: 35.0 mm (1.378 in.) Maximum diameter: 34.0 mm (1.339 in.) If the diameter is less than minimum, replace the armature. Check that the undercut depth is clean and free of foreign objects. Smooth out the edge. Standard undercut depth: 0.7 mm (0.028 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade.
3. INSPECT STARTER YOKE ASSEMBLY Check the starter yoke for open circuit. Using an ohmmeter, check that there is continuity between the lead wire and brushes. If there is no continuity, replace the starter yoke. Check the shunt coil for open circuit. Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B). Standard resistance: 1.5 to 1.9 ohms at 20°C (68°F) If the resistance is not as specified, replace the starter yoke.
4. INSPECT BRUSH Check the brushes length. Using vernier calipers, measure the brush length. Standard length: 15.0 mm (0.591 in.) Minimum length: 9.0 mm (0.354 in.) If the length is less than minimum, replace the brush holder and starter yoke.
5. INSPECT STARTER BRUSH HOLDER ASSEMBLY Check the brush holder insulation. 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. Check the brush spring load. Take a pull scale reading at the instant the brush spring separates from the brush. Standard spring load: 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf) Minimum spring load: 12.7 N (1.3 kgf, 2.9 lbf) If the spring load is less than the minimum, replace the brush holder.
6. INSPECT STARTER CLUTCH SUB-ASSEMBLY Check the clutch pinion gear. Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the starter clutch.
7. INSPECT MAGNET STARTER SWITCH ASSEMBLY Check the pull-in coil for open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and C. If there is no continuity, replace the magnet starter switch. Check the holding coil for open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnet starter switch.

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1. INSTALL STARTER ARMATURE ASSEMBLY Apply the grease to the bearings, and install it to the starter yoke.
2. INSTALL STARTER BRUSH HOLDER ASSEMBLY Place the brush holder on the armature. Using a screwdriver, install the 4 brushes. Install a new O-ring to the groove of the field frame. Install the end frame with 2 screws. Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf)
3. INSTALL MAGNET STARTER SWITCH ASSEMBLY Apply grease to the steel ball, and install it to the clutch shaft hole. Apply grease to the these parts "B" to "E", and install them to the starter drive housing. Starter magnet switch return spring (Procedure "A"). Starter idle gear pinion (Procedure "B". Starter idle gear clutch roller (Procedure "C"). Starter idle gear retainer (Procedure "D"). Starter clutch sub-assembly (Procedure "E"). Install the magnet starter switch with the 2 screws.
4. INSTALL STARTER YOKE ASSEMBLY Install a new O-ring to the groove of the starter yoke. Align the key of the starter yoke with the groove of the magnet starter switch. Install the starter yoke and armature with the 2 through bolts. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) Connect the lead wire to the C terminal with the nut. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)

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1. INSTALL STARTER ASSEMBLY (for 2WD) Install the starter assembly with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Connect the terminal 50 to the starter assembly.
2. CONNECT WIRE HARNESS (for 2WD) Connect the wire harness to the cylinder block and install the bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
3. INSTALL NO. 2 MANIFOLD STAY (for 2WD) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
4. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft*lbf)
5. CONNECT BATTERY NEGATIVE TERMINAL (for 2WD) Connect the battery negative terminal.
6. INSTALL STARTER ASSEMBLY (for 4WD) Install the starter assembly with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) Connect the terminal 50 to the starter assembly.
7. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) Install the steering sliding yoke to No. 2 steering intermediate shaft. Install the bolt B and tighten the bolt B and A. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
8. INSTALL FRONT FENDER REAR SPLASH SHIELD LH(for 4WD) Install the front fender rear splash shield LH with the 5 clips.
9. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) Install 2 new gaskets and No. 2 exhaust manifold with the 2 bolts and 2 nuts. Torque: Nut 62 N*m (630 kgf*cm, 46 ft.*lbf) Bolt 48 N*m (490 kgf*cm, 35 ft.*lbf) Connect the heated oxygen sensor (bank 2) connector.
10. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
11. CONNECT BATTERY NEGATIVE TERMINAL (for 4WD) Connect the battery negative terminal.

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1. INSPECT STARTER RELAY ASSEMBLY Continuity inspection. Using an ohmmeter, check for continuity between each terminal Specified condition STARTER RELAY ASSEMBLY Between terminals Specified Condition 1 - 2 Continuity 3 - 5 No continuity Using an ohmmeter, check for continuity between terminals 3 and 5 when voltage is applied across terminals 1 and 2. Specified condition: Continuity

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1. INSPECT ACC CUT RELAY Continuity inspection. Using an ohmmeter, check for continuity between each terminal. Specified condition ACC CUT RELAY Between Terminals Specified Condition 1 - 2 Continuity 3 - 5 No continuity Using an ohmmeter, check for continuity between terminals 3 and 5 when voltage is applied across terminals 1 and 2. Specified condition: Continuity

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1. REMOVE STEERING COLUMN LOWER COVER (See «REMOVAL»(ref-280534-S36128639072008022200000) )
2. REMOVE STEERING COLUMN UPPER COVER Remove the steering column upper cover.
3. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY Disconnect the ignition switch connector and unlock warning switch connector. Remove the clamp. Remove the 2 screws and ignition switch.

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1. INSPECT IGNITION OR STARTER SWITCH ASSEMBLY Inspect the switch continuity. Standard IGNITION OR STARTER SWITCH ASSEMBLY Terminal No. Switch Position Specified Condition Between all terminals LOCK No continuity 2 - 3 ACC Continuity 2 - 3 - 4 6 - 7 ON Continuity 1 - 2 - 4 6 - 7 - 8 START Continuity If the result is not as specified, replace the switch assembly.

1. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY Install the ignition switch with the 2 screws. Install the clamp. Connect the un-lock warning switch connector and ignition switch connector.
2. INSTALL STEERING COLUMN UPPER COVER Install the steering column upper cover.
3. INSTALL STEERING COLUMN LOWER COVER (See «INSTALLATION»(ref-280534-S00251268262008022200000) )