Starting System Toyota Land Cruiser 200

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
5. REMOVE NO. 2 ENGINE UNDER COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
6. REMOVE FRONT FENDER APRON SEAL FRONT RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
7. REMOVE FRONT FENDER APRON SEAL REAR RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
8. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
9. REMOVE TAILPIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
10. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
11. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
12. REMOVE NO. 1 MANIFOLD STAY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
13. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
14. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
15. REMOVE STARTER COVER Remove the 3 bolts and starter cover.
16. REMOVE STARTER ASSEMBLY Disconnect the starter connector. Remove the nut and disconnect the starter wire. Remove the 2 bolts and starter. Remove the flywheel housing side cover.

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1. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the nut, and disconnect the lead wire from the magnet starter switch. Remove the 2 nuts and magnet starter switch.
2. REMOVE STARTER DRIVE HOUSING ASSEMBLY Using a T30 "TORX" socket wrench, remove the 2 bolts. Pull out the yoke and the starter commutator end frame together with the armature.
3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY Remove the starter pinion drive lever. Remove the 2 screws and end frame. NOTE: While holding down the lead wire, remove the starter commutator end frame.
4. REMOVE STARTER ARMATURE ASSEMBLY Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes and remove the brush holder. Remove the starter armature from the yoke.
5. REMOVE STARTER YOKE ASSEMBLY Remove the starter yoke from the starter center bearing clutch.
6. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter center bearing clutch.
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears.

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1. INSPECT STARTER ASSEMBLY NOTE: The following tests must be performed for no more than 5 seconds to prevent the coil from burning out. Perform pull-in test. Disconnect the field coil wire from terminal C. Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear moves outward. If the clutch pinion gear does not move outward, replace the magnet starter switch assembly. Perform holding test. Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the magnet starter switch assembly. Inspect clutch pinion gear return. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward. If the clutch pinion gear does not move inward, replace the magnet starter switch assembly. Perform the operation test without load. Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded. Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf) Clamp the starter in a vise. Connect the battery and an ammeter to the starter as shown in the illustration. Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Then measure the current. Standard current: 190 A or less at 11.5 V If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY Inspect the commutator for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition Commutator Always Below 1 ohms If the result is not as specified, replace the armature assembly. Inspect the commutator for a short circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition Commutator - Armature coil core Always 10 kohms or higher If the result is not as specified, replace the armature assembly. Check the surface of the commutator for dirt and burns. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. 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 armature assembly. Using a dial indicator, measure the commutator runout. Maximum commutator runout: 0.05 mm (0.00197 in.) If the commutator runout is more than the maximum, correct it using a lathe. 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, increase the depth using a hacksaw blade.
3. INSPECT BRUSH Using a vernier caliper, measure the brush length. Standard length: 15.0 mm (0.591 in.) Minimum length: 10.0 mm (0.394 in.) If the brush length is less than the minimum, replace the brush holder and yoke assembly.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY Inspect the insulation. Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION 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 brush holder assembly. Inspect the load of the brush spring. Take a pull scale reading immediately after the brush spring separates from the brush. Standard spring installed load: 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf) Minimum spring installed load: 12.3 N (1.3 kgf, 2.8 lbf) If the installed load is less than the minimum, replace the starter brush holder assembly.
5. INSPECT STARTER YOKE ASSEMBLY Inspect the resistance of the field coil. Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition Terminal C wire - Brushes Always Below 1 ohms If the result is not as specified, repair or replace the yoke assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition Brushes - Starter yoke body Always 10 kohms or higher If the result is not as specified, repair or replace the yoke assembly.
6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage. If any planetary gear is damaged, replace the planetary gear assembly. If any gear of the starter center bearing clutch is damaged, replace the starter center bearing clutch sub-assembly. Check the movement of 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 the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.
7. INSPECT MAGNET STARTER SWITCH ASSEMBLY Inspect the pull-in coil. Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition Terminal 50 - Terminal C Always Below 1 ohms 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 RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition Terminal 50 - Switch body Always Below 2 ohms If the result is not as specified, replace the magnet starter switch assembly.

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1. INSTALL PLANETARY GEAR Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration. Install the 3 planetary gears.
2. INSTALL STARTER ARMATURE PLATE Insert the plate to the starter center bearing clutch. NOTE: Check that the protrusion of the starter armature plate fits over the notch of the starter center bearing clutch.
3. INSTALL STARTER ARMATURE ASSEMBLY Install the starter armature to the starter center bearing clutch.
4. INSTALL STARTER YOKE ASSEMBLY Align the protrusion of the starter center bearing clutch with the notch of the starter yoke, and install the starter yoke.
5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Install the starter brush holder. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder. Connect the 4 brushes. Align the starter commutator end frame groove with the rubber of the starter yoke. Install the starter commutator end frame with the 2 screws. Torque: 3.8 N*m (39 kgf*cm, 33 in.*lbf)
6. INSTALL STARTER DRIVE HOUSING ASSEMBLY Apply high-temperature grease to the starter pinion drive lever, as shown in the illustration. Install the starter pinion drive lever to the starter center bearing clutch. Align the protrusion of the starter center bearing clutch with the notch inside the starter drive housing. Using a T30 "TORX" socket wrench, install the starter drive housing with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
7. INSTALL MAGNET STARTER SWITCH ASSEMBLY Temporarily install the magnet starter switch by hooking its tip to the upper side of the pinion drive lever. Install the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the lead wire to the terminal with the nut. Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)

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1. INSTALL STARTER ASSEMBLY Install the flywheel housing side cover. Install the starter with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Install the starter wire with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Connect the starter connector.
2. INSTALL STARTER COVER Install the starter cover with the 3 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
5. INSTALL NO. 1 MANIFOLD STAY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
6. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
7. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
8. INSTALL TAILPIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. INSPECT FOR EXHAUST GAS LEAK (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
12. INSTALL NO. 2 ENGINE UNDER COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
13. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
14. INSTALL FRONT FENDER APRON SEAL REAR RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
15. INSTALL FRONT FENDER APRON SEAL FRONT RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
16. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
17. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE NO. 2 INSTRUMENT PANEL FINISH PANEL CUSHION (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#interior-panels-trim__removal) )
3. REMOVE LOWER INSTRUMENT PANEL PAD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#interior-panels-trim__removal) )
4. REMOVE ENGINE SWITCH Disconnect the switch connector. Detach the 2 claws and remove the switch.

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1. INSPECT ENGINE SWITCH Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Switch Condition Specified Condition 7 (SS1) - 5 (GND) Not pushed 10 kohms or higher 2 (SS2) - 5 (GND) Not pushed 10 kohms or higher 7 (SS1) - 5 (GND) Pushed Below 1 ohms 2 (SS2) - 5 (GND) Pushed Below 1 ohms If the result is not as specified, replace the engine switch. Apply battery voltage between the terminals of the switch, and check the illumination condition of the switch. HINT: If the positive (+) lead and the negative (-) lead are incorrectly connected, the engine switch indicator will not illuminate. If the voltage is too low, the indicator will not illuminate. OK MEASUREMENT CONDITION AND SPECIFIED CONDITION Measurement Condition Specified Condition Battery positive (+) --> Terminal 11 (SWIL) Battery negative (-) --> Terminal 5 (GND) Illuminates (illumination of lettering) Battery positive (+) --> Terminal 12 (INDS) Battery negative (-) --> Terminal 5 (GND) Illuminates (green) Battery positive (+) --> Terminal 13 (INDW) Battery negative (-) --> Terminal 5 (GND) Illuminates (amber) If the result is not as specified, replace the engine switch.

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1. INSTALL ENGINE SWITCH Attach the 2 claws to install the switch. Connect the switch connector.
2. INSTALL LOWER INSTRUMENT PANEL PAD SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#interior-panels-trim__installation) )
3. INSTALL NO. 2 INSTRUMENT PANEL FINISH PANEL CUSHION (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#interior-panels-trim__installation) )
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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1. INSPECT STARTER RELAY (ST) Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 3-5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the relay.
2. INSPECT STARTER CUT RELAY (ST CUT) Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 3-5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the relay.
3. INSPECT MAIN BODY ECU (ACC RELAY) Measure the resistance of the ACC relay circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 2A-1 - 2D-8 Battery voltage not applied between 2D-45 and 2D-62 10 kohms or higher Battery voltage applied between 2D-45 and 2D-62 Below 1 ohms If the result is not as specified, replace the main body ECU.

See also:
• REMOVAL
• REMOVAL
• REMOVAL
• REMOVAL
• INSTALLATION