Starting System Toyota Land Cruiser 100 рестайлинг

ENGINE IDENTIFICATION

Engine type is identified by fifth character of Vehicle Identification Number (VIN). VIN is stamped on metal pad on top of left end of instrument panel, near windshield. For more detailed information, see MODEL/YEAR VIN CODE APPLICATIONS in APPLICATION article under ENGINE PERFORMANCE.

VIN

DESCRIPTION & OPERATION

All models use 4-brush, solenoid-actuated, reduction gear type starters, equipped with overrunning clutches. The brush holder assembly retains 4 brushes and springs in the starter housing.

Reduction gear type starters contain an integral solenoid attached to drive housing, a reduction idler gear and bearing installed into starter housing, and a clutch drive assembly. The clutch drive assembly is mounted to starter housing and is driven by the reduction idler gear from armature shaft. The brush holder assembly retains 4 brushes and 4 springs in the end cover of field frame housing.

Starter relay is used to energize starter. It also uses an engine control module and park/neutral switch in the starter relay circuit. On models with an engine immobilizer system, transponder key computer is connected to power for the ignition circuit.

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

NO-START

If a no-start condition exists and battery is known to be good, see IGNITION SWITCH TEST , STARTER RELAY TEST , PARK/NEUTRAL SWITCH TEST and/or ACCESSORY CUT RELAY under ON-VEHICLE TESTING.

ON-VEHICLE TESTING

Note. Before testing, ensure battery is fully charged, battery cables and terminal ends are tight and clean, and engine grounds are secure.

ACCESSORY CUT RELAY

1. Locate and remove accessory cut relay. (Scheme 1)
2. Using an ohmmeter, check that there is continuity across terminals 1 and 2. (Scheme 2) Continuity should not exist across terminals 3 and 5. If relay operates as specified, go to step 3.
3. Using an ohmmeter, check that there is continuity between terminals 3 and 5 when battery voltage is applied across terminals 1 and 2. (Scheme 2) If continuity is not present across terminals 3 and 5, replace the relay.
4. If relay operates as specified, reinstall engine cut relay.

Scheme 1

Scheme 2

IGNITION SWITCH TEST

See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.

STARTER ASSEMBLY

1. Remove the terminal "C" nut and disconnect the field coil lead wire from terminal "C". Go to step 2.
2. Clip ground to terminal "C" and the main body of the starter, connect the battery to the magnetic switch (Terminal 50). Ensure that the clutch pinion gear moves outward. (Scheme 3) If as specified, go to step 3.
3. Disconnect the negative lead from terminal "C". (Scheme 4) Verify that the pinion gear remains out. If as specified, go to step 4.
4. Disconnect the negative lead from the switch body. (Scheme 5) Verify that the clutch pinion gear returns inward. If as specified, go to step 5.
5. Connect the lead wire to terminal "C" with the terminal "C" nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__torque-specifications). Go to step 6.
6. Clip battery negative to the main body of the starter. Connect an ammeter in series with battery positive to terminal 30 and Terminal 50 of the starter. (Scheme 6) Verify starter turns smoothly and the current is within specification of 90 amps or less at 11.5 volts.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

PARK/NEUTRAL SWITCH TEST

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 TRANSMISSIONS/TRANSAXLES.

STARTER RELAY TEST

1. Locate and remove starter relay. Starter relay is marked "ST". Using ohmmeter, verify continuity between relay terminals No. 1 and 2. (Scheme 7) Continuity should not exist between terminals No. 3 and 5. If continuity is not as specified, replace relay.
2. Check relay operation by applying battery voltage through terminals No. 1 and 2. (Scheme 7) Continuity should now exist between terminals No. 3 and 5. If relay does not test as indicated, replace relay.
3. If OK, reinstall starter test relay.

Scheme 7

ARMATURE COIL TEST

1. Using an ohmmeter check that there is continuity between the segments of the commutator. (Scheme 8) If any of the segments do not have continuity between them, replace the armature.
2. Check the commutator for ground. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. (Scheme 9) If there is continuity, replace the armature.
3. If commutator surface is dirty or burnt, it can be polished with No. 400 grit sandpaper or replace the part.
4. Check for the commutator circle runout. (Scheme 10): Place the commutator on V-blocks. Using a dial indicator, measure the circle runout to ensure it is within specification. See «STARTER SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__starter-specifications). If the circle runout is greater than maximum, replace the armature.
5. Measure Commutator diameter. (Scheme 11) If commutator diameter is less than minimum specification, see «STARTER SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__starter-specifications), replace armature.
6. Ensure undercut depth between commutator segments are clean, free of debris, and that edges are smooth, and within specification (Scheme 12) If undercut depth is less than minimum, use a hacksaw blade to correct it. See «STARTER SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__starter-specifications).

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

BRUSH HOLDER ASSEMBLY TEST

1. Using vernier calipers, measure the brush length. (Scheme 13) Verify brush length is within specification. See «STARTER SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__starter-specifications). If the length is less than minimum, replace the brush holder and starter yoke assembly.
2. Using an ohmmeter, Verify that there is no continuity between the positive and negative brush holders. (Scheme 13) If the there is continuity repair or replace the starter commutator end frame assembly.

Scheme 13

CLUTCH ASSEMBLY & GEARS TEST

1. Inspect teeth on pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace gear or clutch assembly.
2. Inspect clutch pinion gear by rotating pinion gear counterclockwise. Ensure gear turns freely in counterclockwise direction, but locks up when turned clockwise. (Scheme 14) If not as specified, replace clutch assembly.

Scheme 14

FIELD COIL TEST

1. Using an ohmmeter, verify that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. (Scheme 15)
2. Using an ohmmeter, verify that there is no continuity between the field coil end and field frame. If continuity is present, replace the field frame. (Scheme 15)
3. Using an ohmmeter, measure the resistance between shunt coil terminals "A" and "B". (Scheme 16) Verify coil resistance is within specification. See «STARTER SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__starter-specifications). If the resistance is not as specified, replace the starter yoke assembly.

Scheme 15

Scheme 16

MAGNET STARTER SWITCH TEST

1. Using an ohmmeter, check that there is continuity between terminals 50 and C. (Scheme 17) If there is no continuity, replace the repair service starter kit.
2. Using an ohmmeter, check. that there is continuity between terminal 50 and the switch body. (Scheme 17) If there is no continuity; replace the repair service starter kit.

Scheme 17

Removal

1. Disconnect negative battery cable and then positive battery cable.
2. Remove valve bank cover.
3. Remove intake air connector.
4. Remove intake manifold assembly.
5. Remove starter assembly: Remove the starter mounting bolts and the starter. Disconnect the starter from the cylinder block. Disconnect the starter connector. Remove the terminal 30 nut and disconnect terminal 30 lead wire. Remove the bolt and disconnect the engine wire protector. Remove the starter.

Installation

1. Install the engine wire protector to the starter with the bolt. Tighten bolt to specification, see «TORQUE SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__torque-specifications). Connect the starter wire with the nut. Tighten nut to specification, see «TORQUE SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__torque-specifications). Connect the starter connector. Connect the starter to the cylinder block. Connect the engine wire with the bolt. Install the starter with the 2 starter mounting bolts. Tighten bolts to specification, see «TORQUE SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/starter/#starting-system__torque-specifications).
2. Install intake manifold assembly. See CYLINDER HEAD & MANIFOLDS under REMOVAL AND INSTALLATION in ENGINES article.
3. Install intake air connector. (Scheme 18)
4. Install valve bank cover.
5. Connect positive battery cable and then negative battery cable.

Scheme 18

OVERHAUL

Note. For overhaul procedure (Scheme 19)

Scheme 19

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

2003

For wiring diagrams, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

2004

For wiring diagrams, see STARTING/CHARGING in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

See also:
• MODEL/YEAR VIN CODE APPLICATIONS
• IGNITION SWITCH TEST
• STARTER RELAY TEST
• PARK/NEUTRAL SWITCH TEST
• ACCESSORY CUT RELAY
• TORQUE SPECIFICATIONS
• STARTER SPECIFICATIONS