Page 2801 of 3115

ST08E-03
S00054
Ohmmeter
Continuity
S00055
Ohmmeter No Continuity
S00056
S00057
ST0040
ST-8
- STARTINGSTARTER
1824 Author: Date:
2004 LAND CRUISER (RM1071U)
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 ar-
mature.
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.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V-blocks.
(b) 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.
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.
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. 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.
Page 2802 of 3115

P10588
Ohmmeter
Continuity
S02267
Ohmmeter
(A)(B)
Z00037
ST0019
P21088
Ohmmeter
No Continuity
- STARTINGSTARTER
ST-9
1825 Author: Date:
2004 LAND CRUISER (RM1071U)
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.
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 W at 20°C (68°F)
If the resistance is not as specified, replace the field frame.
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.
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.
Page 2803 of 3115
P10821
Free
Lock
B04553Terminal CTerminal 50
ContinuityOhmmeter
B04554
Continuity Ohmmeter
Terminal 50
ST-10
- STARTINGSTARTER
1826 Author: Date:
2004 LAND CRUISER (RM1071U)
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.
14. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, replace the magnetic switch.
15. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
Page 2804 of 3115
ST08I-04
B04549
Starter
Connector
Engine Wire Protector
B04548
- STARTINGSTARTER
ST-17
1833 Author: Date:
2004 LAND CRUISER (RM1071U)
INSTALLATION
1. INSTALL STARTER
(a) Install the engine wire protector to the starter with the bolt.
Torque: 9.81 N´m (100 kgf´cm, 84 in.´lbf)
(b) Connect the starter wire with the nut.
Torque: 9.81 N´m (100 kgf´cm, 84 in.´lbf)
(c) Connect the starter connector.
(d) Connect the starter to the cylinder block.
(e) Connect the engine wire with the bolt.
(f) Install the starter with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
2. INSTALL INTAKE MANIFOLD ASSEMBLY
(See page EM-59)
3. INSTALL INTAKE AIR CONNECTOR
4. INSTALL V-BANK COVER
Page 2805 of 3115
ST08G-06
- STARTINGSTARTER
ST-15
1831 Author: Date:
2004 LAND CRUISER (RM1071U)
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.
Page 2806 of 3115
ST08C-04
B04548
B04549
Starter
Connector
Engine Wire Protector
- STARTINGSTARTER
ST-5
1821 Author: Date:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. REMOVE V-BANK COVER
2. REMOVE INTAKE AIR CONNECTOR
3. REMOVE INTAKE MANIFOLD ASSEMBLY
(See page EM-35)
4. REMOVE STARTER
(a) Remove the 2 bolts holding the starter from the cylinder
block.
(b) Disconnect the starter from the cylinder block.
(c) Disconnect the starter connector.
(d) Remove the nut, bolt and disconnect the starter wire.
(e) Remove the bolt, and disconnect the engine wire protec-
tor from the starter.
(f) Remove the starter.
Page 2807 of 3115
ST08F-07
S00058
SST
S00059
S00060
SST
S00061
SST Upward
Downward
B04542
- STARTINGSTARTER
ST-1 1
1827 Author: Date:
2004 LAND CRUISER (RM1071U)
REPLACEMENT
1. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using a press, press in a new bearing.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820-00031
3. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the magnetic switch end cover.
Remove the 3 bolts, the end cover, the gasket and the
plunger.
Page 2808 of 3115

B04555
Wear
B04556
SST
B04557
(2)
(1)
(4) (3)
(7)
(5)(6)
Long
Short
Inside
ST-12
- STARTINGSTARTER
1828 Author: Date:
2004 LAND CRUISER (RM1071U)
(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.
(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 in-
sulator (outside), O- ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (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.
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.