Starting System (1GR-FE): Overview Toyota Tacoma II

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1. INSPECT STARTER ASSEMBLY NOTE: These tests must be performed within 3 to 5 seconds to prevent burnout of the coil. Perform the pull-in test. Remove the nut, then disconnect the lead wire from terminal C. Connect the battery to the starter magnetic switch (Scheme 42) Check that the clutch pinion gear is extended. If the clutch pinion gear does not move, replace the magnet starter switch. Perform the hold-in test. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear is extended. If the clutch pinion gear returns inward, replace the starter magnet starter switch. Check the operation. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return inward, replace the magnet starter switch. Perform the no-load performance test. Connect the lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) Clamp the starter in a vise. Connect the battery and an ammeter to the starter (Scheme 45) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Standard: 100 A or less at 11.5 V If the result is not as specified, replace the starter.

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE NO.1 ENGINE UNDER COVER SUBASSEMBLY (for Off Road Package) Remove the 4 bolts, then remove the engine under cover.
3. REMOVE NO.2 MANIFOLD STAY Remove the 3 bolts, then remove the manifold stay No. 2.
4. SEPARATE WIRE HARNESS Remove the bolt, then separate the earth wire harness from the cylinder block.
5. REMOVE STARTER ASSEMBLY Disconnect the terminal 50 connector from the starter assy. Remove the nut, then disconnect the wire harness from terminal 30. Remove the 2 bolts, then remove the starter assembly.

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1. REMOVE STARTER YOKE ASSEMBLY Remove the nut, then disconnect the lead wire from terminal C. Remove the 2 through bolts. Pull the starter yoke and the armature out together. Remove the O-ring from the starter yoke.
2. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the 2 screws, then remove the magnet starter switch. Remove these parts from the starter drive housing. PARTS DESCRIPTION TABLE (1) Starter magnet switch return spring (2) Starter idle gear pinion (3) Starter idle gear clutch roller (4) Starter idle gear retainer (5) Starter clutch Using a magnetic finger, remove the steel ball from the clutch shaft hole.
3. REMOVE STARTER BRUSH HOLDER ASSEMBLY Remove the 2 screws, then remove the end frame 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

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1. INSPECT STARTER ARMATURE ASSEMBLY Check the commutator for an open circuit. Using an ohmmeter, measure the resistance between the segments of the commutator. Standard: 1 ohms or lower If the result is not as specified, replace the starter armature. Check the commutator for ground. Using an ohmmeter, measure the resistance between the commutator and armature coil core. Standard: 10 kohms or higher If the result is not as specified, replace the starter armature. Check whether the commutator surface is dirty or burnt. If necessary, clean it with sandpaper (No. 400) or a lathe. Check the commutator for 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 the maximum, correct it on a lathe. Using vernier calipers, measure the commutator diameter. Standard diameter: 35.0 mm (1.378 in.) Minimum diameter: 34.0 mm (1.339 in.) If the diameter is less than the minimum, replace the armature. Check that the undercut portion between the segments is free of foreign objects. Measure its depth. 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 the minimum, correct it with a hacksaw blade.
2. INSPECT STARTER YOKE ASSEMBLY Check the starter yoke for an open circuit. Using an ohmmeter, measure the resistance between the lead wire and brushes. Standard: 1 ohms or lower If the result is not as specified, replace the starter yoke. Check the shunt coil for an open circuit. Using an ohmmeter, measure the resistance between shunt coil terminals A and B. Standard: 1.5 to 1.9 ohms at 20°C (68°F) If the result is not as specified, replace the starter yoke.
3. INSPECT BRUSH Check the brush 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 the minimum, replace the brush holder and starter yoke.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY Check the blush holder insulation. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders. Standard: 10 kohms or higher If the result is not as specified, replace the brush holder. Check the brush spring load. Take the pull scale reading as soon as 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.
5. INSPECT STARTER CLUTCH SUB-ASSEMBLY Check the clutch pinion gear. Hold the starter clutch, 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.
6. INSPECT MAGNET STARTER SWITCH ASSEMBLY Check the pull-in coil for an open circuit. Using an ohmmeter, measure the resistance between terminals 50 and C. Standard: 1 ohms or lower If the result is not as specified, replace the magnet starter switch. Check the holding coil for an open circuit. Using an ohmmeter, measure the resistance between terminal 50 and the switch body. Standard: 2 ohms or lower If the result is not as specified, replace the magnet starter switch.

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1. INSTALL STARTER ARMATURE ASSEMBLY Apply grease to the bearings, and install it onto 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 onto the groove of the field frame. Install the end frame with the 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 onto the clutch shaft hole. Apply grease to parts (2) - (5), and install all the parts below onto the starter drive housing. PARTS DESCRIPTION TABLE (1) Starter magnet switch return spring (2) Starter idle gear pinion (3) Starter idle gear clutch roller (4) Starter idle gear retainer (5) Starter clutch Install 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 onto 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 terminal C with the nut. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)

See also:
• REMOVAL
• INSTALLATION