Toyota 4Runner 2001-06

Starter

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Removal & Installation



1GR-FE Engine
2wd Models
  1. Disconnect the negative battery cable
  2.  
  3. Remove the engine undercover.
  4.  
  5. Disconnect the manifold support for clearance.
  6.  
  7. Disconnect the starter electrical connections.
  8.  
  9. Remove the bolts securing the starter to the bell housing, then pull the starter forward to remove.
  10.  

To install:

  1. Insert the starter into the bell housing being sure that the starter drive teeth are engaged with the flywheel teeth, NOT jammed against the flywheel. Tighten the mounting bolts to 27 ft. lbs. (37 Nm).
  2.  
  3. Reconnect the electrical connections to the starter.
  4.  
  5. Replace the bolts for the manifold support. Tighten the bolts to 30 ft. lbs. (40 Nm).
  6.  
  7. Install the engine undercover. Tighten the bolts to 21 ft. lbs. (29 Nm).
  8.  
  9. Connect the negative battery cable.
  10.  

4wd Models
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine rear undercover.
  4.  
  5. Disconnect the front exhaust pipe assembly for clearance.
  6.  
  7. Remove the clips for the left side front fender splash shield.
  8.  
  9. Separate the steering sliding yoke No. 2 intermediate steering shaft by loosening the upper bolts and removing the lower bolt.
  10.  
  11. Disconnect the starter electrical connections.
  12.  
  13. Remove the bolts securing the starter to the bell housing, then pull the starter forward to remove.

    Click image to see an enlarged view

    Fig. Separate the steering shaft, by loosening bolt A and removing bolt B, for clearance to remove the starter-4.0L (1GR-FE) 4WD models

  14.  

To install:

  1. Insert the starter into the bell housing being sure that the starter drive teeth are engaged with the flywheel teeth, NOT jammed against the flywheel. Tighten the mounting bolts to 27 ft. lbs. (37 Nm).
  2.  
  3. Reconnect the electrical connections to the starter. Tighten the wiring harness nut to 7 ft. lbs. (9.8 Nm).
  4.  
  5. Install the steering sliding yoke to steering intermediate shaft No. 2. Install bolt B and tighten both bolts B and A to 27 ft. lbs. (36 Nm).
  6.  
  7. Replace the left side front fender splash shield and install the 5 clips.
  8.  
  9. Reconnect the front exhaust pipe assembly.
  10.  
  11. Install the rear engine undercover and tighten the mounting bolts to 21 ft. lbs. (29 Nm).
  12.  
  13. Connect the negative battery cable.
  14.  

2UZ-FE Engine


Click image to see an enlarged view

Fig. The starter motor on the 4.7L (2UZ-FE) Engine is installed under the intake manifold between the cylinder heads, making it a lengthy procedure to perform

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Disconnect the accelerator cable and air intake assembly.
  6.  
  7. Remove the intake manifold assembly. For additional information, please refer to the following topic(s): -Engine Mechanical-, -Intake Manifold.-
  8.  
  9. Remove any coolant bypass hoses and joints from the mounting clamps needed for clearance.
  10.  
  11. If the vehicle is equipped with rear air suspension, disconnect the air hoses and electrical connectors from the air pump assembly. Remove the mounting bolts and remove the air pump assembly with the bracket.
  12.  
  13. Remove the two bolts holding the starter motor to the engine block and lift the starter away from the block.
  14.  
  15. Detach the electrical connectors from the starter and remove the starter from the vehicle.
  16.  

To install:

  1. Install the starter and torque the two bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Connect the electrical connections and make sure they are tight and that the harness is secure. Tighten the starter cable with a nut to 86 inch lbs. (9.8 Nm).
  4.  
  5. Install any coolant hoses removed. If a coolant hose was disconnected, the O-ring or gasket used must be replaced with a new one.
  6.  
  7. Install the intake manifold.
  8.  
  9. Install the accelerator cable and air intake assembly.
  10.  
  11. Install the engine appearance cover and tighten the two nuts to 66 inch lbs. (7.5 Nm).
  12.  
  13. Connect the negative battery cable.
  14.  

3RZ-FE
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter electrical connectors
     
    Starter
     

  4.  


    Click image to see an enlarged view

    Fig. Starter mounting-3.4L engine


To install:

  1. Install or connect the following:

    Starter. Tighten the fasteners to 29 ft. lbs. (39 Nm).
     
    Electrical connections
     
    Negative battery cable
     

  2.  

5vz-FE Engine
With 2wd
  1. Remove the rear under-cover.
  2.  
  3. Remove the No.2 manifold support.
  4.  
  5. Disconnect the starter wiring.
  6.  
  7. Remove the 2 bolts and lower the starter.
  8.  
  9. Installation is the reverse of removal. Torque the starter mounting bolts to 27 ft. lbs. (37 Nm). Torque the manifold brace to 30 ft. lbs. (40 Nm). Torque the under-cover to 21 ft. lbs. (29 Nm).
  10.  

With 4wd
  1. Remove the rear under-cover.
  2.  
  3. Remove the front exhaust pipe.
  4.  
  5. Remove the fender splash shield.
  6.  
  7. Disconnect the steering intermediate shaft.
  8.  
  9. Disconnect the starter wiring.
  10.  
  11. Remove the 2 bolts and lower the starter.
  12.  
  13. Installation is the reverse of removal. Torque the starter mounting bolts to 27 ft. lbs. (37 Nm). Torque the intermediate shaft bolts to 27 ft. lbs. (36 Nm). Torque the under-cover to 21 ft. lbs. (29 Nm).
  14.  

Testing & Troubleshooting




WARNING
These tests must be performed within a three to five seconds to avoid burning out the coil.

Hold-In

With the battery connected as in the picture and with the clutch pinion gear out, disconnect the negative ( - ) lead from terminal C. Check that the pinion gear stays in the outward position.

Click image to see an enlarged view

Fig. Connect the battery as shown here to test the hold-in windings

Inspect Clutch Pinion Gear Return

Disconnect the negative lead from the magnetic switch body. Check that the pinion gear returns to the inward position.

Click image to see an enlarged view

Fig. Disconnect the negative lead from the starter as shown here

Pull-In
  1. Disconnect the field coil lead wire from terminal C .
  2.  
  3. Connect the battery to the magnetic switch shown in the diagram.

    Click image to see an enlarged view

    Fig. Connect the battery to the magnetic switch as shown here

  4.  
  5. Check that the clutch pinion gear moves in the outward motion.
  6.  

 
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