ST-19

STARTING ACC CUT RELAY

ACC CUT RELAY

ACC Cut Relay

INSPECTION
1. REMOVE ACC CUT RELAY Remove the relay box and ACC cut relay.

B16462

Ohmmeter 4 1

Continuity 2 Ohmmeter 5

2. (a)

3 Continuity No continuity
S04972

INSPECT ACC CUT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. (c) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 3. (a) (b) INSPECT ACC CUT RELAY OPERATION Apply battery positive voltage across terminals 1 and 2. Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (c) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL ACC CUT RELAY

2 5

Ohmmeter

Battery Ohmmeter

3 No continuity Continuity
S04971

2004 LAND CRUISER (RM1071U)

Author :

Date :

1835

ST-2
STARTING STARTER

STARTER
ST08B-03

COMPONENTS

Intake Air Connector PS Air Hose EVAP Hose

Fuel Return Hose

Air Hose PCV Hose

V-Bank Cover

B16434

2004 LAND CRUISER (RM1071U)

Author :

Date :

1818

ST-3
STARTING STARTER

EVAP Pipe EVAP Hose EVAP Hose

Rear Water Bypass Joint Engine Wire Protector

V-Bank Cover Bracket V-Bank Cover Bracket Engine Wire S Gasket

PS Air Hose V-Bank Cover Bracket V-Bank Cover Bracket

Injector Connector Engine Wire Fuel Return Hose VSV Connector for EVAP EVAP Hose S Gasket Starter
39 (400, 29)

Intake Manifold Assembly

Starter Connector Engine Wire

Engine Wire Protector

Water Bypass Hose

Ignition Coil with Igniter Connector

Engine Wire S Non-reusable part

Author :

Date :

1819

ST-4
STARTING STARTER

Bearing

Starter Housing Idler Gear Assembly

S Dust Protector

Magnetic Switch Assembly S Front Bearing Armature S Rear Bearing

Starter Clutch Assembly Steel Ball O-Ring Return Spring S O-Ring Brush Holder S O-Ring Field Frame (Field Coil)

S O-Ring End Cover S Dust Protector

Magnetic Switch Assembly Terminal Insulator Contact Plate Terminal Nut Wave Washer Terminal Insulator O-Ring S Gasket S Terminal C Kit Part Terminal Bolt

Lead Terminal Plunger

Terminal Bolt End Cover Contact Plate

O-Ring Packing Terminal Insulator Wave Washer Terminal Nut

Terminal Insulator S Terminal 30 Kit Part

S Non-reusable part
2004 LAND CRUISER (RM1071U)

B04547

Author :

Date :

1820

ST-6
STARTING STARTER
ST08D-04

Dust Protector

DISASSEMBLY
1. 2. (a) REMOVE 2 DUST PROTECTORS REMOVE FIELD FRAME AND ARMATURE Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 Nm (60 kgfcm, 52 in.lbf) Remove the 2 through bolts. Torque: 9.3 Nm (95 kgfcm, 82 in.lbf)

(b)
B04550

(c)

Pull out the field frame together with the armature from the magnetic switch assembly. NOTICE: At the time of notice, align the protrusion of the field frame with the groove of the magnetic switch. (d) Remove the O-ring from the field frame. HINT: At the time of assembly, use a new O-ring.
B04632

3. (a)

REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Remove the 2 screws. Torque: 9.3 Nm (95 kgfcm, 82 in.lbf)

B04551

(3)

(b)

(4) (5) (2) (1)

Remove these parts from the magnetic switch assembly: (1) Starter housing (2) Return spring (3) Idler gear (4) Bearing (5) Starter clutch assembly

HINT: At the time of assembly, apply grease to the return spring and insert the return spring into the clutch shaft hole. 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. HINT: At the time of assembly, apply grease to the steel ball and insert the steel ball into the clutch shaft hole.

Magnetic Finger

ST0948

2004 LAND CRUISER (RM1071U)

Author :

Date :

1822

ST-7
STARTING STARTER

5. (a)

(b) HINT: At the time of assembly, use a new O-ring.

REMOVE BRUSH HOLDER Remove the 2 screws w/ O-ring and the end cover from the field frame. Torque: 3.8 Nm (39 kgfcm, 34 in.lbf) Remove the O-ring from the field frame.

(c)

Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. NOTICE: Check that the positive (+) lead wires are not grounded. 6. REMOVE ARMATURE FROM FIELD FRAME

P10568

2004 LAND CRUISER (RM1071U)

Author :

Date :

1823

ST-8
STARTING STARTER
ST08E-03

Ohmmeter

Continuity

INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature.

S00054

Ohmmeter

No Continuity

2. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. 3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACE If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe.
S00055

4. (a) (b)

INSPECT COMMUTATOR CIRCLE RUNOUT Place the commutator on V-blocks. Using a dial indicator the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe.

S00056

5. INSPECT COMMUTATOR DIAMETER 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 minimum, replace the armature.
S00057

ST0040

6. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. 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 minimum, correct it with a hacksaw blade.

2004 LAND CRUISER (RM1071U)

Author :

Date :

1824

ST-9
STARTING STARTER

Ohmmeter Continuity

7. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame.

P10588

Ohmmeter

(A)

(B)

8. INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B). Resistance: 1.5 - 1.9 at 20C (68F) If the resistance is not as specified, replace the field frame.

S02267

9. INSPECT 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 minimum, replace the brush holder and field frame.
Z00037

ST0019

10. INSPECT BRUSH SPRING LOAD Using a pull scale, measure the spring load by pulling the spring from the brush until they are separated. Standard spring installed load: 21.5 - 27.5 N (2.2 - 2.8 kgf, 4.8 - 6.2 lbf) Minimum spring installed load: 12.7 N (1.3 kgf, 2.9 lbf) If the installed load is less than minimum, replace the brush springs. 11. INSPECT BRUSH HOLDER INSULATION Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. 12. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idle gear and the clutch assembly for wear or damage. If any damage is found, replace the gear or clutch assembly, and also check the drive plate ring gear for wear or damage.

Ohmmeter No Continuity

P21088

2004 LAND CRUISER (RM1071U)

Author :

Date :

1825

ST-10
STARTING STARTER

Free Lock

13. INSPECT CLUTCH PINION GEAR Rotate the pinion gear clockwise, and check that it turns freely. Check that it locks by rotating the pinion gear counterclockwise. If necessary, replace the clutch assembly.

P10821

Continuity

Ohmmeter

14. DO PULL-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the magnetic switch.

Terminal 50 Terminal C
B04553

Continuity

Ohmmeter

15. DO HOLD-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch.

Terminal 50
B04554

2004 LAND CRUISER (RM1071U)

Author :

Date :

1826

ST-17
STARTING STARTER
ST08I-04

Engine Wire Protector

INSTALLATION
1. (a) (b) (c) (d) (e) (f) 2. 3. 4. INSTALL STARTER Install the engine wire protector to the starter with the bolt. Torque: 9.81 Nm (100 kgfcm, 84 in.lbf) Connect the starter wire with the nut. Torque: 9.81 Nm (100 kgfcm, 84 in.lbf) Connect the starter connector. Connect the starter to the cylinder block. Connect the engine wire with the bolt. Install the starter with the 2 bolts. Torque: 39 Nm (400 kgfcm, 29 ftlbf) INSTALL INTAKE MANIFOLD ASSEMBLY (See page EM-59 ) INSTALL INTAKE AIR CONNECTOR INSTALL V-BANK COVER

Starter Connector

B04549

B04548

2004 LAND CRUISER (RM1071U)

Author :

Date :

1833

ST-15
STARTING STARTER
ST08G-06

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST-6 ). HINT: At the time of assembly, use high-temperature grease to lubricate the bearing and gears when assembling the starter.

2004 LAND CRUISER (RM1071U)

Author :

Date :

1831

ST-5
STARTING STARTER
ST08C-04

REMOVAL
1. 2. 3. REMOVE V-BANK COVER REMOVE INTAKE AIR CONNECTOR REMOVE INTAKE MANIFOLD ASSEMBLY (See page EM-35 )

4. (a) (b)

REMOVE STARTER Remove the 2 bolts holding the starter from the cylinder block. Disconnect the starter from the cylinder block.

B04548

Engine Wire Protector

(c) (d) (e) (f)

Disconnect the starter connector. Remove the nut, bolt and disconnect the starter wire. Remove the bolt, and disconnect the engine wire protector from the starter. Remove the starter.

Starter Connector

B04549

2004 LAND CRUISER (RM1071U)

Author :

Date :

1821

ST-1 1
STARTING STARTER
ST08F-07

SST

REPLACEMENT
1. (a) REPLACE REAR BEARING Using SST, remove the bearing. SST 09286-4601 1

S00058

(b)

Using a press, press in a new bearing.

S00059

SST

2. (a)

REPLACE FRONT BEARING Using SST, remove the bearing. SST 09286-4601 1

S00060

Upward

SST

(b) Using SST and a press, press in a new bearing. NOTICE: Be careful of the bearing installation direction. SST 09820-00031

Downward
S00061

3. (a)

REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS Remove the magnetic switch end cover. Remove the 3 bolts, the end cover, the gasket and the plunger.

B04542

2004 LAND CRUISER (RM1071U)

Author :

Date :

1827

ST-12
STARTING STARTER

(b)

Inspect contact plate for wear. Using vernier calipers, measure the contact plate for depth of wear. Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate.
Wear
B04555

(c)
SST

B04556

Remove terminal kit parts. (1) Using SST, loosen the terminal nuts. SST 09810-38140 (2) Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O- ring, terminal bolt, contact plate and terminal insulator (inside). (3) Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), O- ring, terminal bolt, contact plate, terminal insulator (inside).

Long (3) (2) (1) Short Inside

(d)

(6) (4) (5) (7)

Temporarily install these new terminal 30 kit parts: (1) Terminal insulator (inside) (2) Contact plate (3) Terminal bolt (4) O-ring (5) Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them.

HINT: Match the protrusion of the insulator with the indentation of the housing. (6) Wave washer (7) Terminal nut NOTICE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.

2004 LAND CRUISER (RM1071U)

Author :

Date :

1828

ST-13
STARTING STARTER

(7) (6) (5) (4)

Long Short (2) (1)

(e)
(3)

Inside Lead Terminal

B04559

Temporarily install these new terminal C kit parts: (1) Terminal insulator (inside) (2) Contact plate (3) Terminal bolt (4) O-ring (5) Terminal insulator (outside) (6) Wave washer (7) Terminal nut NOTICE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction. (f) Temporarily tighten the terminal nuts.

(g)
40 mm Contact Plate

37 mm 20 mm

B04560

Tighten terminal nuts. (1) Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 lbf) NOTICE: S Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure:
(kgf/cm2) = 100 kgf Ram diameter (cm) 2 221lbf (psi) = Ram diameter (in.) 2
2 2

x 3.14 ()

x 3.14 ()

(kPa) = (kgf/cm2) x 98.1 (kPa) = (psi) x 6.9 S

If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.

2004 LAND CRUISER (RM1071U)

Author :

Date :

1829

ST-14
STARTING STARTER

SST

(2) Using SST, tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 Nm (170 kgfcm, 13 ftlbf) NOTICE: If the nut is over tightened, it may cause cracks on the inside of the insulator.

B04561

(h)

(i)

Clean contact surfaces of the contact plate and the plunger. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. Reinstall the magnetic switch end cover. Install the plunger, the new gasket, the end cover and lead clamp with the 3 bolts. Torque: 3.6 Nm (37 kgfcm, 32 in.lbf)

B04562

2004 LAND CRUISER (RM1071U)

Author :

Date :

1830

ST-16
STARTING STARTER
ST08H-07

Terminal 50

TEST
NOTICE: These tests must be done within 3 to 5 seconds to avoid the coil to be burned-out. 1. DO PULL-IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the pinion gear moves outward.

Terminal C

Battery
B04543

2. DO HOLD-IN TEST While connected as above with the pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
Disconnect Terminal C Battery
B04544

Disconnect

3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) lead from the starter body. Check that the pinion gear returns inward.

Battery
B04545

Terminal 30 Terminal 50 Battery Ammeter

4. (a) (b)

DO NO-LOAD PERFORMANCE TEST Connect the battery and ammeter to the starter as shown. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified current: At 11.5 V: 100 A or less

B04546

2004 LAND CRUISER (RM1071U)

Author :

Date :

1832

ST-18
STARTING STARTER RELAY

Starter Relay

STARTER RELAY
ST08J-07

INSPECTION
1. REMOVE STARTER RELAY (Marking: ST) Remove the relay box cover and starter relay.

B16459

Ohmmeter 1

Continuity 5 Ohmmeter

2. (a)

No Continuity 3

INSPECT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.

B05486

Ohmmeter 1 5

3. (a) (b)

Continuity 3

INSPECT RELAY OPERATION Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL STARTER RELAY

2 Battery

B05487

2004 LAND CRUISER (RM1071U)

Author :

Date :

1834

ST-1
STARTING STARTING SYSTEM

STARTING SYSTEM
ST08A-01

ON-VEHICLE INSPECTION
NOTICE: Before changing the starter, check these items again: S Connector connection S Accessory installation, e.g.: theft deterrent system

2004 LAND CRUISER (RM1071U)

Author :

Date :

1817