Starting System [2GR-FE]: Overview Toyota Sienna III

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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-493943-S13306943882012081000000).
2. REMOVE AIR CLEANER INLET COVER ASSEMBLY SEAL . Refer to «REMOVAL - Step 25»(/toyota/sienna/iii-2010-2014/remont/mechanical/#engine-mechanical-2gr-fe-service-information)
3. REMOVE BATTERY . Refer to «REMOVAL - Step 26»(/toyota/sienna/iii-2010-2014/remont/mechanical/#engine-mechanical-2gr-fe-service-information)
4. REMOVE AIR CLEANER AND HOSE. Refer to «REMOVAL - Step 7»(ref-493957-S11405419122012081000000)
5. REMOVE STARTER ASSEMBLY Disconnect the starter connector. Open the terminal cap. Remove the nut and disconnect the terminal 30. Remove the 2 bolts and the starter assembly.

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1. REMOVE MAGNETIC SWITCH ASSEMBLY Remove the nut and disconnect the lead wire from the terminal C. Remove the 2 nuts that hold the magnetic switch assembly from the starter housing assembly.
2. REMOVE STARTER YOKE ASSEMBLY Remove the 2 through bolts and pull out the starter yoke assembly together with the starter commutator end frame assembly. Remove the starter yoke assembly from the starter commutator end frame assembly.
3. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly.
4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, pry out the starter commutator end frame cover.
5. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and the plate washer. NOTE: Do not drop the starter armature assembly. TEXT IN ILLUSTRATION *1 Snap Ring Pliers Remove the starter armature assembly from the commutator end frame assembly.
6. REMOVE RUBBER SEAL Remove the rubber seal.
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the repair service starter kit.

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1. INSPECT STARTER ASSEMBLY NOTE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Perform a pull-in test. Remove the nut and disconnect the lead wire from terminal C. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear is extended. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C *3 Body If the clutch pinion gear does not move, replace the magnetic switch assembly. Perform a holding test. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C *3 Body If the clutch pinion gear returns inward, replace the magnetic switch assembly. Inspect the clutch pinion gear return. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C *3 Body If the clutch pinion gear does not return inward, replace the magnetic switch assembly. Perform a no-load performance test. Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Clamp the starter in a vise. NOTE: Do not clamp the vise too tightly. Connect the battery and an ammeter to the starter as shown in the illustration. NOTE: Do not allow any lead to get caught as the pinion gear rotates. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal 30 *3 Body Check that the starter rotates smoothly and steadily with the pinion gear extended. Measure the current according to the value(s) in the table below. Standard Current Tester Connection Condition Specified Condition Battery positive terminal - Terminal 30 11.5 V 90 A or less If the result is not as specified, replace the starter assembly.
2. INSPECT MAGNETIC SWITCH ASSEMBLY Check the plunger. Push in the plunger and check that it returns quickly to its original position. TEXT IN ILLUSTRATION *1 Plunger If necessary, replace the magnetic switch assembly. Check if the pull-in coil for an open circuit. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Terminal C Always Below 1 ohms If the result is not as specified, replace the magnetic switch assembly. Check the holding coil for an open circuit. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Body Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Body Always Below 2 ohms If the result is not as specified, replace the magnetic switch assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. Check the commutator. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Commutator Standard Resistance Tester Connection Condition Specified Condition Segment - Segment Always Below 1 ohms If the result is not as specified, replace the starter armature assembly. Check the commutator. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Commutator *2 Armature Coil Core Standard Resistance Tester Connection Condition Specified Condition Commutator - Armature coil core Always 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Using a vernier caliper, measure the commutator length. TEXT IN ILLUSTRATION *a Length Standard length 3.1 to 3.8 mm (0.122 to 0.149 in.) If the length is greater than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Using a vernier caliper, measure the brush length. TEXT IN ILLUSTRATION *a Length Standard length 4.0 to 9.0 mm (0.158 to 0.354 in.) If the length is less than the minimum, replace the starter commutator end frame assembly. Check the brush 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 commutator end frame assembly.
5. INSPECT STARTER CLUTCH SUB-ASSEMBLY Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. TEXT IN ILLUSTRATION *a Lock *b Free If necessary, replace the repair service starter kit.

See also:
• REMOVAL - Step 25
• REMOVAL - Step 23