Page 2809 of 3115

B04559
(1)Long
(2)
(3) (4) (5) (6) (7)
Short
Inside
Lead Terminal
B04560
40 mm
37 mm
20 mm
Contact
Plate
(kgf/cm2)
(psi)
(kPa) = (psi) x 6.9100 kgf
2 Ram diameter (cm)
(kPa) = (kgf/cm
2) x 98.1 ==
x 3.14 (p)
2
221lbf
2 Ram diameter (in.)
x 3.14 (p)
2
- STARTINGSTARTER
ST-13
1829 Author: Date:
2004 LAND CRUISER (RM1071U)
(e) 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) 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 cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
Page 2810 of 3115
B04561
SST
B04562
ST-14
- STARTINGSTARTER
1830 Author: Date:
2004 LAND CRUISER (RM1071U)
(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 in-
side of the insulator.
(h) Clean contact surfaces of the contact plate and the plung-
er.
Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) 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 N´m (37 kgf´cm, 32 in.´lbf)
Page 2811 of 3115

ST08H-07
B04543
Terminal 50
Battery
Terminal C
B04544
Battery
Terminal CDisconnect
B04545
Disconnect
Battery
B04546
Terminal 30
Battery
Ammeter Terminal 50 ST-16
- STARTINGSTARTER
1832 Author: Date:
2004 LAND CRUISER (RM1071U)
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.
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.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the starter body. Check
that the pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) 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
Page 2812 of 3115
B16459
Starter
RelayST08J-07
B05486
1 Ohmmeter
Ohmmeter
2 35 Continuity
No Continuity
B05487
1 Ohmmeter
Continuity
2 35
Battery
ST-18
- STARTINGSTARTER RELAY
1834 Author: Date:
2004 LAND CRUISER (RM1071U)
STARTER RELAY
INSPECTION
1. REMOVE STARTER RELAY (Marking: ºSTº)
Remove the relay box cover and starter relay.
2. INSPECT RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween 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.
3. INSPECT RELAY OPERATION
(a) Apply battery voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY
Page 2813 of 3115
ST08A-01
- STARTINGSTARTING SYSTEM
ST-1
1817 Author: Date:
2004 LAND CRUISER (RM1071U)
STARTING SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
Before changing the starter, check these items again:
Connector connection
Accessory installation, e.g.: theft deterrent system
Page 2814 of 3115
F04811
Vacuum HoseSR0LZ-06
SR-8
- STEERINGAIR CONTROL VALVE
2217 Author: Date:
2004 LAND CRUISER (RM1071U)
AIR CONTROL VALVE
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE-UP
(a) Start the engine and run it at idle.
(b) Fully turn the steering wheel.
(c) Check that the engine rotations decrease when the vacu-
um hose of the air control valve is pinched.
(d) Check that the engine rotations increase when the hose
is released.
Page 2815 of 3115
P06717
SR0LW-04
- STEERINGDRIVE BELT
SR-3
2212 Author: Date:
2004 LAND CRUISER (RM1071U)
DRIVE BELT
INSPECTION
INSPECT DRIVE BELT
Visually check the belt for excessive wear, frayed cords, etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
belt has chunks missing from the ribs, it should be replaced.
Page 2816 of 3115
SR0LX-04
R11229
Normal Abnormal SR-4
- STEERINGPOWER STEERING FLUID
2213 Author: Date:
2004 LAND CRUISER (RM1071U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR-5)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock position and keep it there for 2-3 seconds, then turn
the wheel to the opposite full lock position and keep it
there for 2-3 seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR-5)