Page 897 of 2000

2GR-FE IGNITION – IGNITION SYSTEMIG–7
IG
2. CHECK SPARK PLUG
(a) Check the electrode with megohmmeter:
(1) Using a megohmmeter, measure the insulation
resistance.
Standard insulation resistance:
10 M
or more
If the result is 10 M
or less, clean the plug and
measure the resistance again.
(b) Check the electrode without megohmmeter:
(1) Quickly accelerate the engine to 4,000 rpm 5
times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
If the electrode is dry, the spark plug is
functioning properly. If the electrode is damp,
proceed to the next step.
(c) Check the spark plug for any damage on its thread
and insulator.
If there is damage, replace the spark plug.
Recommended spark plug
(d) Check the spark plug electrode gap.
Maximum electrode gap for used spark plug:
1.4 mm (0.055 in.)
If the gap is greater than the maximum, replace the
spark plug.
Electrode gap for new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
If the electrode has traces of wet carbon, clean the
electrode with a spark plug cleaner and then dry it.
Standard air pressure:
588 kPa (6 kgf/cm
2, 85 psi)
Standard duration:
20 seconds or less
HINT:
Only use the spark plug cleaner when the electrode
is free of oil. If the electrode has traces of oil, use
gasoline to clean off the oil before using the spark
plug cleaner.
I039522E10
A088307E02
Manufacturer Spark plug type
DENSO FK20HR11
B002630E04
B062019E01
Page 898 of 2000
ST–62AZ-FE STARTING – STARTER
ST
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. DISCONNECT CABLE FROM POSITIVE BATTERY
TERMINAL
3. REMOVE BATTERY CLAMP
(a) Remove the bolt and loosen the nut.
(b) Detach the 2 wire harness clamps.
(c) Detach the hook of the battery clamp from the
battery bracket front, and then remove the battery
clamp.
4. REMOVE BATTERY INSULATOR
5. REMOVE BATTERY
6. REMOVE FRONT BATTERY BRACKET
(a) Detach the 2 wire harness clamps.
(b) Remove the 4 bolts and bracket front.
7. REMOVE BATTERY BRACKET REINFORCEMENT
(a) Remove the 2 bolts and reinforcement bracket.
A124917E01
A124918
A124919
Page 899 of 2000
2AZ-FE STARTING – STARTERST–7
ST
8. REMOVE STARTER ASSEMBLY
(a) Disconnect the starter connector.
(b) Open the terminal cap, remove the nut and
disconnect the starter wire.
(c) Remove the 2 bolts and starter.
DISASSEMBLY
1. REMOVE MAGNETIC SWITCH ASSEMBLY
(a) Remove the nut and disconnect the lead wire from
the magnetic switch.
(b) Remove the 2 screws holding the magnetic switch
to the starter drive housing.
(c) Remove the magnetic switch.
(d) Remove the return spring and plunger from the
starter drive housing.
2. REMOVE STARTER YOKE ASSEMBLY
(a) Remove the 2 through-bolts, and pull out the starter
yoke together with the commutator end frame.
A124920
A124921
A079718
A079719
A079720
Page 900 of 2000
ST–82AZ-FE STARTING – STARTER
ST
(b) Remove the starter yoke from the commutator end
frame.
3. REMOVE STARTER ARMATURE PLATE
(a) Remove the armature plate from the starter yoke.
4. REMOVE STARTER COMMUTATOR END FRAME
COVER
(a) Using a screwdriver, pry out the commutator end
frame cover.
5. REMOVE STARTER ARMATURE ASSEMBLY
(a) Using snap ring pliers, remove the snap ring and
plate washer.
(b) Remove the armature from the commutator end
frame.
6. REMOVE PLANETARY GEAR
(a) Remove the 3 planetary gears from the starter drive
housing.
A079721
A079722
A079723
A082440E03
A081167
Page 901 of 2000

2AZ-FE STARTING – STARTERST–9
ST
INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTICE:
These tests must be performed within 3 to 5 seconds
to avoid burning out the coil.
(a) Perform the pull-in test.
(1) Disconnect the lead wire from terminal C.
(2) Connect the battery to the magnetic switch as
shown in the illustration. Check that the clutch
pinion gear extends.
If the clutch pinion gear does not move, replace
the magnetic switch.
(b) Perform the hold-in test.
(1) Maintain the battery connections of the pull-in
test above, but disconnect the negative (-) lead
from terminal C. Check that the pinion gear
remains extended.
If the clutch pinion gear returns inward, replace
the magnetic switch.
(c) Check the clutch pinion gear return.
(1) Disconnect the negative (-) lead from the
switch body. Check that the clutch pinion gear
returns.
If the clutch pinion gear does not return,
replace the magnetic switch.
(d) Perform the no-load performance test.
(1) Connect the lead wire to terminal C. Make sure
that the lead is not grounded.
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the
starter as shown in the illustration.
(4) Check that the starter rotates smoothly and
steadily while the pinion gear is moving out.
Then measure the current.
Standard current:
90 A or less at 11.5 V
If result is not as specified, replace the starter
assembly.
A060459E06
A081044E01
A081045E01
A060462E01
Page 902 of 2000

ST–102AZ-FE STARTING – STARTER
ST
2. INSPECT MAGNETIC SWITCH ASSEMBLY
(a) Check the plunger.
(1) Push in the plunger and check that it returns
quickly to its original position.
If necessary, replace the magnetic switch
assembly.
(b) Check if the pull-in coil has an open circuit.
(1) Measure the resistance between terminals 50
and C.
Standard resistance:
Below 1
If the result is not as specified, replace the
magnetic switch assembly.
(c) Check if the hold-in coil has an open circuit.
(1) Measure the resistance between terminal 50
and the switch body.
Standard resistance:
Below 2
If the result is not as specified, replace the
magnetic switch assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY
(a) Check if the commutator has an open circuit.
(1) Measure the resistance between the segments
of the commutator.
Standard resistance:
Below 1
If the result is not as specified, replace the
armature assembly.
(b) Check if the commutator is grounded.
(1) Measure the resistance between the
commutator and armature coil core.
Standard resistance:
10 k
or higher
If the result is not as specified, replace the
armature assembly.
(c) Check the commutator for contamination and burns
on its surface.
If the surface is dirty or burnt, correct it with
sandpaper (No. 400) or a lathe.
A058586
A079725E01
A079726E01
A058372E01
A058373E01
Page 903 of 2000

2AZ-FE STARTING – STARTERST–11
ST
(d) Using a vernier caliper, measure the commutator's
length.
Standard length:
3.1 to 3.8 mm (0.122 to 0.150 in.)
If the length is greater than the maximum, replace
the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) Using a vernier caliper, measure the brush length.
Standard length:
4.0 to 9.0 mm (0.158 to 0.359 in.)
If the length is less than the minimum, replace the
end frame assembly.
(b) Check the brush insulation.
(1) Measure the resistance between the positive
(+) and negative (-) brush.
Standard resistance:
10 k
or higher
If the result is not as specified, repair or replace
the end frame assembly.
5. INSPECT STARTER CLUTCH
(a) Check the starter clutch.
(1) Rotate the clutch pinion gear counterclockwise
and check that it turns freely. Try to rotate the
clutch pinion gear clockwise and check that it
locks.
If necessary, replace the starter drive housing
assembly.
A058584E01
A076677E01
A079766E03
A081655E01
Page 904 of 2000
ST–122AZ-FE STARTING – STARTER
ST
REASSEMBLY
HINT:
Use high-temperature grease to lubricate the bearings,
gears, return spring and steel ball when assembling the
starter.
1. INSTALL PLANETARY GEAR
(a) Apply grease to the planetary gears and pin parts of
the planetary shaft.
(b) Install the 3 planetary gears.
2. INSTALL STARTER ARMATURE ASSEMBLY
(a) Apply grease to the plate washer and the armature
shaft.
(b) Install the starter armature to the starter commutator
end frame.
(c) Using snap ring pliers, install the plate washer and a
new snap ring.
(d) Using a vernier caliper, measure length of the snap
ring.
Maximum length:
5.0 mm (0.197 in.)
If the length is greater than the maximum, replace it
with a new snap ring.
3. INSTALL STARTER COMMUTATOR END FRAME
COVER
(a) Install the end frame cover to the commutator end
frame.
A081656E01
A082440E01
A058810E01
A081178