Starting System (2TR-FE) (Service Information): Overview Toyota 4Runner V

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected, refer to «INITIALIZATION»(ref-421949-S36027747902011092600000) .
2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY . Refer to «REMOVAL - Step 7»(ref-422095-S32501303202011092600000)
3. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY . Refer to «REMOVAL - Step 2»(ref-422112-S29114312082011092600000)
4. REMOVE STARTER ASSEMBLY Disconnect the starter connector. Remove the terminal cap. Remove the nut and disconnect the starter wire. Remove the 2 bolts and starter.

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1. REMOVE STARTER YOKE ASSEMBLY Remove the nut, and then disconnect the lead wire from terminal C. Remove the 2 through bolts. Pull out the starter yoke together with the starter armature. Remove the O-ring from the starter yoke.
2. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the 2 screws and magnet starter switch. Remove the idle gear, retainer, clutch roller, return spring and starter clutch from the starter drive housing. TEXT IN ILLUSTRATION *1 Starter Drive Housing *2 Starter Clutch *3 Return Spring *4 Clutch Roller *5 Retainer *6 Idle Gear Using a magnet hand, remove the steel ball from the starter clutch hole. TEXT IN ILLUSTRATION *1 Magnet Hand
3. REMOVE STARTER BRUSH HOLDER ASSEMBLY Remove the 2 screws and commutator end frame from the starter yoke. Remove the O-ring from the starter yoke. Disconnect the 4 brushes from the starter brush holder. Using a screwdriver, hold back the brush spring. Disconnect the brush from the brush holder. Remove the brush holder from the starter yoke.
4. REMOVE STARTER ARMATURE ASSEMBLY Remove the starter armature from the starter yoke.

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1. INSPECT STARTER ASSEMBLY WARNING: As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury. NOTE: The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out. Mount the starter in a vise between aluminum plates. Perform a pull-in test. Remove the nut, and then disconnect the lead wire from terminal C. Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear extends. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C If the clutch pinion gear does not move, replace the magnet starter switch assembly. Perform a holding test. Disconnect the negative (-) terminal lead from terminal C with the conditions specified in the pull-in test above being maintained. Check that the pinion gear remains extended. TEXT IN ILLUSTRATION *1 Terminal C If the clutch pinion gear returns inward, replace the magnet starter switch assembly. Inspect the clutch pinion gear return. Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward. If the clutch pinion gear does not return inward, replace the magnet starter switch assembly. Perform an operation test without load. Connect the lead wire to terminal C. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) Connect the battery and an ammeter to the starter as shown in the illustration. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal 30 Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current. Standard current 100 A or less at 11.5 V If the result is not as specified, inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly.
2. INSPECT MAGNET STARTER SWITCH ASSEMBLY Inspect the pull-in coil. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Terminal C Always Below 1 ohms TEXT IN ILLUSTRATION *1 Terminal C *2 Terminal 50 If the result is not as specified, replace the magnet starter switch assembly. Inspect the holding coil. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Switch body Always Below 2 ohms TEXT IN ILLUSTRATION *1 Switch Body *2 Terminal 50 If the result is not as specified, replace the magnet starter switch assembly.
3. INSPECT BRUSH Using a vernier caliper, measure the brush length. Standard length 15.0 mm (0.591 in.) Minimum length 9.0 mm (0.354 in.) TEXT IN ILLUSTRATION *A Brush Holder Side *B Starter Yoke Side *1 Length If the length is less than the minimum, replace the starter brush holder assembly and starter yoke assembly.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY Check the brush spring load. Take a pull scale reading as soon as the brush spring separates from the brush. Standard spring load 22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf) Minimum spring load 12 N (1 kgf, 2.8 lbf) TEXT IN ILLUSTRATION *1 Brush Spring *2 Brush If the spring load is less than the minimum, replace the starter brush holder assembly. Inspect the insulation. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Positive (+) brush holder - Negative (-) brush holder Always 10 kohms or higher If the result is not as specified, replace the starter brush holder assembly.
5. INSPECT STARTER YOKE ASSEMBLY Inspect the field coil for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Lead wire - Brush Always Below 1 ohms If the result is not as specified, replace the starter yoke assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal A - Terminal B 20°C (68°F) 1.5 to 1.9 ohms TEXT IN ILLUSTRATION *1 Terminal A *2 Terminal B If the result is not as specified, replace the starter yoke assembly.
6. INSPECT STARTER ARMATURE ASSEMBLY Check the commutator for dirt and/or burns on the surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly. Inspect the commutator for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Segment Always Below 1 ohms TEXT IN ILLUSTRATION *1 Segment If the result is not as specified, replace the starter armature assembly. Inspect the commutator for a short circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Coil core Always 10 kohms or higher TEXT IN ILLUSTRATION *1 Segment *2 Coil Core If the result is not as specified, replace the starter armature assembly. Check the commutator circle runout. Place the commutator on V-blocks. Using a dial indicator, measure the circle runout. Maximum runout 0.05 mm (0.00197 in.) If the circle runout is more than the maximum, replace the starter armature assembly. Check the commutator diameter. Using a vernier caliper, measure the commutator diameter. Standard diameter 35.0 mm (1.38 in.) Minimum diameter 34.0 mm (1.34 in.) If the diameter is less than the minimum, replace the starter armature assembly. Check the undercut depth. Using a vernier caliper, measure the undercut depth of the commutator. Standard undercut depth 0.7 mm (0.0276 in.) Minimum undercut depth 0.2 mm (0.00787 in.) If the undercut depth is less than the minimum, replace the starter armature assembly.
7. INSPECT STARTER CLUTCH SUB-ASSEMBLY Rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. TEXT IN ILLUSTRATION Free Lock If the result is not as specified, replace the starter clutch sub-assembly. Turn the pinion gear by hand while applying inward force and check the movement of the bearing. If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.

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1. INSTALL STARTER ARMATURE ASSEMBLY Install the starter armature to the starter yoke.
2. INSTALL STARTER BRUSH HOLDER ASSEMBLY Install the starter brush holder. Connect the 4 brushes to the starter brush holder. Using a screwdriver, hold back the spring. Connect the brush to the brush holder. NOTE: Check that the positive (+) lead wires are not grounded. Install a new O-ring to the groove of the starter yoke. Install the commutator end frame with the 2 screws. Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf)
3. INSTALL MAGNET STARTER SWITCH ASSEMBLY Apply high-temperature grease to the idle gear, steel ball, return spring, clutch roller and retainer. Insert the steel ball into the starter clutch hole. Insert the return spring into the starter clutch hole. Install the starter clutch, idle gear, retainer and clutch roller to the starter drive housing. Install the starter drive housing to the magnet starter switch with the 2 screws. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
4. INSTALL STARTER YOKE ASSEMBLY Install a new O-ring to the groove of the starter yoke. Align the claw of the starter yoke with the groove of the starter switch. TEXT IN ILLUSTRATION *1 Claw *2 Groove Install the starter yoke to the magnet starter switch with the 2 through bolts. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) Connect the lead wire to terminal C with the nut. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)