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ST-19 STARTING - ACC CUT RELAY ACC CUT RELAY ST0OU-01 ACC Cut Relay INSPECTION REMOVE ACC CUT RELAY Remove the relay box and ACC cut relay B16462 Ohmmeter (a) Continuity Ohmmeter Continuity Battery Ohmmeter No continuity S04972 Ohmmeter No continuity Continuity S04971 INSPECT ACC CUT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals and If there is no continuity, replace the relay (b) Check that there is no continuity between terminals and If there is continuity, replace the relay (c) Check that there is continuity between terminals and If there is no continuity, replace the relay (a) (b) INSPECT ACC CUT RELAY OPERATION Apply battery positive voltage across terminals and Using an ohmmeter, check that there is no continuity between terminals and If there is continuity, replace the relay (c) Using an ohmmeter, check that there is continuity between terminals and If there is no continuity, replace the relay REINSTALL ACC CUT RELAY 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 Rear Water Bypass Joint Engine Wire Protector EVAP Hose V-Bank Cover Bracket V-Bank Cover Bracket Engine Wire PS Air Hose Gasket V-Bank Cover Bracket V-Bank Cover Bracket Injector Connector Engine Wire Fuel Return Hose VSV Connector for EVAP Intake Manifold Assembly EVAP Hose 39 (400, 29) Gasket Starter Starter Connector Engine Wire Protector Engine Wire Water Bypass Hose Ignition Coil with Igniter Connector Engine Wire Non-reusable part B16458 2004 LAND CRUISER (RM1071U) Author: Date: 1819 ST-4 STARTING Bearing STARTER Starter Housing Idler Gear Assembly Dust Protector Starter Clutch Assembly Magnetic Switch Assembly Front Bearing - Steel Ball O-Ring Armature Rear Bearing Return Spring O-Ring Brush Holder O-Ring Field Frame (Field Coil) O-Ring End Cover Dust Protector Magnetic Switch Assembly Terminal Insulator Contact Plate Terminal Nut Wave Washer Terminal Insulator O-Ring Gasket Terminal C Kit Part Terminal Bolt Lead Terminal Plunger Terminal Bolt End Cover O-Ring Packing Terminal Insulator Wave Washer Terminal Nut Contact Plate Terminal Insulator Terminal 30 Kit Part Non-reusable part B04547 2004 LAND CRUISER (RM1071U) Author: Date: 1820 ST-6 STARTING - STARTER ST08D-04 Dust Protector DISASSEMBLY (a) (b) REMOVE DUST PROTECTORS REMOVE FIELD FRAME AND ARMATURE Remove the nut, and disconnect the lead wire from the magnetic switch terminal Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) Remove the through bolts Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf) 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 (a) REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Remove the screws Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf) B04551 (b) (3) (4) (5) (1) (2) B04552 Magnetic Finger 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 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 ST0948 2004 LAND CRUISER (RM1071U) Author: Date: 1822 ST-7 STARTING (a) - STARTER REMOVE BRUSH HOLDER Remove the screws w/ O-ring and the end cover from the field frame Torque: 3.8 N·m (39 kgf·cm, 34 in.·lbf) Remove the O-ring from the field frame (b) HINT: At the time of assembly, use a new O-ring B04654 (c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder Disconnect the brushes, and remove the brush holder NOTICE: Check that the positive (+) lead wires are not grounded REMOVE ARMATURE FROM FIELD FRAME P10568 2004 LAND CRUISER (RM1071U) Author: Date: 1823 ST-8 STARTING - STARTER ST08E-03 Ohmmeter INSPECTION Continuity 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 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 INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACE If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe No Continuity S00055 (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 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 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 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 Ohmmeter Continuity P10588 Ohmmeter (B) (A) INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B) Resistance: 1.5 - 1.9 Ω at 20°C (68°F) If the resistance is not as specified, replace the field frame S02267 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 P21088 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 2004 LAND CRUISER (RM1071U) Author: Date: 1825 ST-10 STARTING - STARTER 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 Free Lock 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 INSTALLATION Engine Wire Protector (a) (b) Starter Connector B04549 (c) (d) (e) (f) INSTALL STARTER Install the engine wire protector to the starter with the bolt Torque: 9.81 N·m (100 kgf·cm, 84 in.·lbf) Connect the starter wire with the nut Torque: 9.81 N·m (100 kgf·cm, 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 bolts Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) INSTALL INTAKE MANIFOLD ASSEMBLY (See page EM-59 ) INSTALL INTAKE AIR CONNECTOR INSTALL V-BANK COVER 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 REMOVE V-BANK COVER REMOVE INTAKE AIR CONNECTOR REMOVE INTAKE MANIFOLD ASSEMBLY (See page EM-35 ) (a) REMOVE STARTER Remove the bolts holding the starter from the cylinder block Disconnect the starter from the cylinder block (b) B04548 (c) (d) (e) Engine Wire Protector (f) Starter Connector 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 B04549 2004 LAND CRUISER (RM1071U) Author: Date: 1821 ST-1 STARTING - STARTER ST08F-07 REPLACEMENT SST (a) REPLACE REAR BEARING Using SST, remove the bearing SST 09286-4601 (b) Using a press, press in a new bearing (a) REPLACE FRONT BEARING Using SST, remove the bearing SST 09286-4601 S00058 S00059 SST 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 (a) REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS Remove the magnetic switch end cover Remove the 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) 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) (d) 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 SST B04556 Long Short (3) Inside (2) (1) (6) (4) (7) (5) B04557 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 (6) (5) (4) STARTER (e) Long (7) - Short (2) (1) (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 37 mm 20 mm Contact Plate 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: 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 x 3.14 (π) 221lbf (psi) = Ram diameter (in.) 2 x 3.14 (π) (kPa) = (kgf/cm2) x 98.1 (kPa) = (psi) x 6.9 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 (2) Using SST, tighten the nuts to the specified torque SST 09810-38140 Torque: 17 N·m (170 kgf·cm, 13 ft·lbf) NOTICE: If the nut is over tightened, it may cause cracks on the inside of the insulator SST 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 bolts Torque: 3.6 N·m (37 kgf·cm, 32 in.·lbf) B04562 2004 LAND CRUISER (RM1071U) Author: Date: 1830 ST-16 STARTING - STARTER ST08H-07 TEST Terminal 50 Terminal C Battery NOTICE: These tests must be done within to seconds to avoid the coil to be burned-out 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 B04543 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 INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) lead from the starter body Check that the pinion gear returns inward Disconnect Battery B04545 (a) (b) Terminal 30 Terminal 50 Battery Ammeter 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 REMOVE STARTER RELAY (Marking: ”ST”) Remove the relay box cover and starter relay B16459 (a) Continuity Ohmmeter Ohmmeter No Continuity INSPECT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals and If there is no continuity, replace the relay (b) Check that there is no continuity between terminals and If there is continuity, replace the relay B05486 (a) (b) INSPECT RELAY OPERATION Apply battery voltage across terminals and Using an ohmmeter, check that there is continuity between terminals and If there is no continuity, replace the relay REINSTALL STARTER RELAY Ohmmeter Continuity 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: Connector connection Accessory installation, e.g.: theft deterrent system 2004 LAND CRUISER (RM1071U) Author: Date: 1817