Page 2889 of 4087

EQUIPMENT
Part Name\
\
\
Note
Caliper gauge\
\
HC/CO meter
\
\
\
Compression gauge\
\
\
Cylinder compression pressure
Connecting rod aligner\
\
Cylinder gauge
\
\
\
Dial indicator
\
\
\
Engine turn±up tester\
\
\
Feeler gauge\
\
Micrometer
\
\
\
Precision straight edge\
\
\
Spring tester\
\
Valve spring
Steel square
\
\
\
Valve spring
Torque wrench\
\
\
Vernier caliper\
\
SSM (SPECIAL SERVICE MATERIALS)
Part Name
Part No.
\
\
Use etc. \
\
Camshaft bearing cap \
\
Camshaft bearing ca
Cylinder head semi±circular plug
Seal packing or equivalent
08826±00080
\
\
Cylinder head semi±circular lug
Cylinder head cover Seal acking or equivalent 08826±00080\
\
Cylinder head cover
Rear oil seal retainer \
\
Rear oil seal retainer
Oil pump \
\
Water inlet housing Seal packing 1282B,
Th b d 1282B i l t
08826±00100\
\
Water inlet housing
Water seal plate Three bond 1282B or equivalent 08826±00100\
\
Water seal late
Water pump
Adhesive 1324,
Three bond 1324 or equivalent
08833±00070
\
\
Drive plate mounting bolt
Adhesive 1344,
\
\
Adhesive 1344,
Three bond 1344
,
08833±00080
\
\
No.1 idler pulley mounting bolt Three bond 1344,
Loctite 242 or equivalent 08833±00080\
\
No.1 idler ulley mounting bolt
±
ENGINE MECHANICAL PreparationEM±7
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Page 2890 of 4087

SERVICE SPECIFICATIONS
SERVICE DATA
StarterRated voltage and output power12 V 2.0 kW
No±load characteristicCurrent 120 A or less at 11.5 V
rpm 3,300 rpm or more at 11.5 V
Brush lengthSTD 15.0±15.5 mm0.591±0.610 in.
Limit 9.5 mm0.374 in.
CommutatorOuter diameter STD 35.0 mm1.378 in.
Limit 34.0 mm1.339 in.
Undercut depth STD 0.7±0.9 mm0.028±0.035 in.
Limit 0.2 mm0.008 in.
Circle runout Limit 0.05 mm0.0020 in.
Spring installed load26±32 N
(2.7±3.3 kgf, 6.0±7.3 lbf)
TORQUE SPECIFICATIONS
Part tightenedNVmkgf Vcmft Vlbf
Starter X Cylinder block3940029
Rear water by±pass joint X Cylinder head18185 13
Water by±pass pipe X Cylinder block18185 13
Intake manifold X Cylinder head18185 13
Fuel return pipe X Fuel pressure regulator35360 26
Fuel inlet hose X LH delivery pipe39400 29
for SST 33340 24
Air intake chamber X Intake manifold18185 13
EGR pipe X Air intake chamber18185 13
EGR pipe X RH cylinder head18185 13
Cold start injector tube X RH delivery pipe15150 11
Throttle body X Air intake chamber1818513
ST±36±
STARTING SYSTEM Service Specifications
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Page 2891 of 4087
STARTING SYSTEM
STARTING SYSTEM
NOTE: The specification descriptions ºUSA Spec.º and
º Exc. USA Spec. º used in this section indicate the following
specifications.
USA Spec .: USA (50 States) Specifications
Exc. USA Spec .: USA (except California) and Canadian
Specifications.
ST±1
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Page 2892 of 4087
DESCRIPTION
The starter is a reduction type starter with a small, high±speed motor u\
sed to drive the pinion gear. It is
installed in the center of the V±bank of the cylinder block. ST±2
±
STARTING SYSTEM Description
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Page 2893 of 4087
SYSTEM CIRCUIT
OPERATION
When the ignition switch is turned to START, current flows from terminal 50 to the coil of the solenoid and
the plunger is pulled by the magnetic force of the coil. When the plunger is pulled \
to the left as shown above,
the contact plate of the plunger allows current from the battery to flow di\
rectly from terminal 30 to the motor, and
the starter rotates. When the engine is running and the ignition switch is returned to ON, the ma\
gnetic force of the coil disappears
and the contact plate of the plunger is returned to its original position by the return spring. Battery voltage no
longer flows from terminal 30, so the motor stops.
±
STARTING SYSTEM System Circuit, OperationST±3
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Page 2894 of 4087
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09201±41020Valve Stem Oil
Seal ReplacerArmature rear bearing
09286±46011Injection Pump
Spline Shaft PullerArmature front bearing
09612±24014
Steering Gear
Housing Overhaul
Tool Set
(09617±24011)(Steering Rack
Wrench)Fuel Inlet hose
09950±00020Bearing Remover
Armature rear bearing
RECOMMENDED TOOLS
09082±00015TOYOTA
Electrical Tester
EQUIPMENT
Part NameNote
Dial indicatorCommutator
Vernier caliperCommutator, Brush
Pull scaleBrush spring
Torque wrench
ST±4±
STARTING SYSTEM Preparation
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Page 2895 of 4087
STARTER
COMPONENTS FOR REMOVAL AND
INSTALLATION
±
STARTING SYSTEM StarterST±5
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Page 2896 of 4087

REMOVAL OF STARTER
(See Components on page ST±5)
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
CAUTION: Work must be started after approx. 20 se-
conds or longer from the time the ignition switch is
turned to the ºLOCKº position and the negative (±) termi-
nal cable is disconnected from the battery.
2. DRAIN ENGINE COOLANT
3. REMOVE THROTTLE BODY COVER (a) Remove the mounting cap nut.
(b) Loosen the two bolts, and remove the throttle bodycover.
4. DISCONNECT CONTROL CABLES FROM THROTTLE BODY
Disconnect the following cables:(1) Accelerator cable
(2) A/T throttle control cable
(3) (w/ Cruise Control System) Cruise control actuator cable
5. REMOVE INTAKE AIR CONNECTOR (a) Disconnect the following hoses:(1) Air hose from ISC valve
(2) Air hose (from PS air control valve) from intake air
connector
(b) Remove the bolt holding the intake air connector to the cylinder head cover.
(c) Loosen the two hose clamps.
(d) Disconnect the intake air connector from the throttle
body and air cleaner hose, and remove the intake air
connector.
ST±6
±
STARTING SYSTEM Starter
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