Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Starter

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TESTING



These tests must be performed within a 3 to 5 seconds to avoid burning out the coil.

Pull-in

See Figure 1

  1. Disconnect the field coil lead wire from terminal C.
  2.  
  3. Connect the battery to the magnetic switch shown in the diagram.
  4.  



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Fig. Fig. 1: Connect the battery to the magnetic switch as shown here

  1. Check that the clutch pinion gear moves in the outward motion.
  2.  

Hold-in

See Figure 2

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.



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Fig. Fig. 2: Connect the battery as shown here to test the hold-in windings

Inspect Clutch Pinion Gear Return

See Figure 3

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



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Fig. Fig. 3: Disconnect the negative lead from the starter as shown here

No-Load

See Figure 4

  1. Connect the battery ammeter to the starter as shown in the illustration.
  2.  



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Fig. Fig. 4: Make the connections to the battery, ammeter and starter as shown here

  1. Check the rotation of the starter, it must be smooth and steady with the pinion gear moving outwards. Compare the ammeter reading to the starter specifications chart.
  2.  

REMOVAL & INSTALLATION



See Figure 5

Replacing the starter while the engine is cold is recommended. A hot engine can result in personal injury.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the nut and disconnect the battery cable from the magnetic switch on the starter motor.
  4.  
  5. Disconnect the remaining electrical connections at the starter.
  6.  
  7. Remove the nuts and/or bolts securing the starter to the bell housing, then pull the starter toward the front of the vehicle to remove.
  8.  

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.
  2.  
  3. Tighten the attaching hardware to 29 ft. lbs. (39 Nm) and replace all electrical connections.
  4.  



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Fig. Fig. 5: Exploded view of a common starter mounting found on Toyota trucks

  1. Connect the positive battery cable (starter wire) to the starter.
  2.  
  3. Connect the negative battery cable.
  4.  

RELAY REPLACEMENT



See Figure 6

The starter relays on most of your Toyota trucks are located either in the relay block in the engine compartment or on the driver's side junction block. The cover for the relay compartments should be marked, "starter'' or the relay will have a part number with a suffix of 28300-XXXXX. Simply locate the relay, pull it out, and install a new one if needed.



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Fig. Fig. 6: The relay may be located in the driver's side junction block or in the engine compartment relay block

 
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