ACC CUT RELAY INSPECTION

STARTING (2UZFE) ACC CUT RELAY ACC CUT RELAY INSPECTION 1. REMOVE ACC CUT RELAY Remove the cowl side trim board LH and ACC cut relay. ST21 ST0Q102 Continuity 4 2 1 5 3 No continuity Continuity S04972 2. INSPECT ACC CUT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between 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. (c) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. Battery 1 4 3 No Continuity Continuity 2 5 S04971 3. INSPECT ACC CUT RELAY OPERATION (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (c) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL ACC CUT RELAY 3824

ST2 STARTING (2UZFE) COMPONENTS ST0GK03 Suction Hose MAF Meter Wire Throttle Body Cover PS Air Hose Vacuum Hose PCV Hose Intake Air Connector Nonreusable part B17459 3805

STARTING (2UZFE) ST3 Engine Wire and Clamp Intake Manifold Assembly Injector Connector Fuel Return Hose 10 (102, 7 ) Air Switching Valve No.2 Gasket 10 (102, 7 ) VSV Connector for EVAP Gasket Engine Wire Gasket 10 (102, 7 ) Starter 39 (400, 29) Gasket Starter Connector 10 (102, 7 ) Engine Wire Protector N m (kgf cm, ft lbf) : Specified torque Nonreusable part B17496 3806

ST4 STARTING (2UZFE) 1.4 kw Type Bearing Idler Gear Starter Housing Assembly Dust Protector Front Bearing Armature Magnetic Switch Assembly Starter Clutch Assembly Steel Ball ORing Rear Bearing Return Spring ORing Brush Holder ORing Field Frame (Field Coil) ORing Dust Protector End Cover Magnetic Switch Assembly Terminal Insulator Terminal Nut Contact Plate 17 (170, 13) Wave Washer Terminal Insulator ORing Terminal Bolt Terminal C Kit Part Gasket Lead Terminal Plunger End Cover ORing Packing Terminal Insulator Wave Washer Terminal Bolt Terminal Nut 17 (170, 13) Contact Plate Terminal Insulator Terminal 30 Kit Part N m (kgf cm, ft lbf) : Specified torque Nonreusable part B04888 3807

STARTING (2UZFE) ST5 2.0 kw Type Bearing Idler Gear Starter Housing Assembly Dust Protector Armature Front Bearing Magnetic Switch Assembly Starter Clutch Assembly Steel Ball ORing Rear Bearing Return Spring Brush Holder ORing ORing Field Frame (Field Coil) ORing End Cover Dust Protector Magnetic Switch Assembly Terminal Insulator Terminal Bolt Terminal Nut Contact Plate 17 (170, 13) Wave Washer Terminal Insulator ORing Lead Terminal Gasket Plunger Terminal C Kit Part End Cover Terminal Bolt Contact Plate Terminal Insulator ORing Packing Terminal Insulator Wave Washer Terminal Nut 17 (170, 13) Terminal 30 Kit Part N m (kgf cm, ft lbf) : Specified torque Nonreusable part B04547 3808

Dust Protector STARTING (2UZFE) B04550 ST7 ST08D03 DISASSEMBLY 1. REMOVE 2 DUST PROTECTORS 2. REMOVE FIELD FRAME AND ARMATURE (a) Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 N m (60 kgf cm, 52 in. lbf) (b) Remove the 2 through bolts. Torque: 1.4 kw type: 5.9 N m (60 kgf cm, 52 in. lbf) 2.0 kw type: 9.3 N m (95 kgf cm, 82 in. lbf) B04632 (c) Pull out the field frame together with the armature from the magnetic switch assembly. NOTICE: At the time of notice, please refer to the following items. Align the protrusion of the field frame with the groove of the magnetic switch. (d) Remove the Oring from the field frame. HINT: At the time of assembly, please refer to the following items. Use a new Oring. 3. REMOVE HOUSING, CLUTCH ASSEMBLY AND GEAR (a) 1.4 kw type: Remove the 2 bolts. Torque: 5.9 N m (60 kgf cm, 52 in. lbf) (b) 2.0 kw type: Remove the 2 screws. Torque: 9.3 N m (95 kgf cm, 82 in. lbf) B04551 Idler Gear Return Spring Bearing Starter Housing Starter Clutch Assembly B04552 (c) Remove the starter housing, return spring, idler gear, bearing and starter clutch assembly. HINT: At the time of assembly, please refer to the following item. Apply grease to the return spring and insert the return spring into the clutch shaft hole. 3810

ST8 STARTING (2UZFE) Magnetic Finger 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. HINT: At the time of assembly, please refer to the following item. Apply grease to the steel ball and insert the steel ball into the clutch shaft hole. ST0948 B04654 5. REMOVE BRUSH HOLDER (a) Remove the 2 screws w/ Oring and end cover from the field frame. Torque: 1.4 kw type: 1.5 N m (15 kgf cm, 13 in. lbf) 2.0 kw type: 3.8 N m (39 kgf cm, 34 in. lbf) (b) Remove the Oring from the field frame. HINT: At the time of assembly, please refer to the following item. Use a new Oring. (c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. NOTICE: Check that the positive (+) lead wires are not grounded. 6. REMOVE ARMATURE FROM FIELD FRAME P10568 3811

Continuity STARTING (2UZFE) ST9 ST0GL03 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 armature. S00054 No Continuity S00055 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 Vblocks. (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. S00056 5. INSPECT COMMUTATOR DIAMETER Using vernier calipers, measure the commutator diameter. Standard diameter: 1.4 kw type 30.0 mm (1.181 in.) 2.0 kw type 35.0 mm (1.378 in.) Minimum diameter: 1.4 kw type 29.0 mm (1.142 in.) S00057 2.0 kw type 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 materials. Smooth out the edge. Standard undercut depth: 1.4 kw type 0.6 mm (0.024 in.) ST0040 2.0 kw type 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. 3812

ST10 STARTING (2UZFE) Continuity 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. P10588 No Continuity 8. INSPECT THAT FIELD COIL IS NOT GROUNDED Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. P00299 2.0 kw Type (A) (B) 9. 2.0 kw type: INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B). Resistance: 1.5 to 1.9 Ω at 20 C (68 F) If the resistance is not as specified, replace the field frame. S02267 Z00037 10. INSPECT BRUSH LENGTH Using vernier calipers, measure the brush length. Standard length: 1.4 kw type 15.5 mm (0.610 in.) 2.0 kw type 15.0 mm (0.591 in.) Minimum length: 1.4 kw type 10.0 mm (0.394 in.) 2.0 kw type 9.0 mm (0.354 in.) If the length is less than minimum, replace the brush holder and field frame. 3813

STARTING (2UZFE) ST1 1 11. INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load: 1.4 kw type 17.6 to 23.5 N (1.8 to 2.4 kgf, 4.0 to 5.3 lbf) 2.0 kw type 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf) Minimum spring installed load: ST0019 1.4 kw type 11.8 N (1.2 kgf, 2.7 lbf) 2.0 kw type 12.7 N (1.3 kgf, 2.9 lbf) If the installed load is less than minimum, replace the brush springs. Lock No Continuity Free P21088 12. 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. 13. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idle gear and the clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the drive plate ring gear for wear or damage. 14. INSPECT CLUTCH PINION GEAR Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the clutch assembly. 15. INSPECT FRONT AND REAR BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. P10821 16. DO PULLIN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. Terminal C Terminal 50 Continuity B04553 3814

ST12 STARTING (2UZFE) 17. DO HOLDIN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. Terminal 50 Continuity B04554 3815

Starter Connector Engine Wire Protector STARTING (2UZFE) B04549 INSTALLATION ST19 ST08I05 1. INSTALL (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. B04548 (f) Install the starter with the 2 bolts. Torque: 39 N m (400 kgf cm, 29 ft lbf) 2. INSTALL AIR PUMP ASSEMBLY (See page EC27 ) 3. INSTALL INTAKE MANIFOLD ASSEMBLY (See page EM60 ) 4. CONNECT THROTTLE BODY ASSEMBLY TO INTAKE MANIFOLD (See page SF45 ) 5. INSTALL INTAKE AIR CONNECTOR 6. INSTALL THROTTLE BODY COVER 7. CONNECT CABLE TO NEGATIVE () BATTERY TER MINAL 3822

STARTING (2UZFE) ST17 ST08G05 REASSEMBLY Reassembly is in the reverse order of disassembly (See page ST7 ). HINT: At the time of assembly, use hightemperature grease to lubricate the bearing and gears when assembling the starter. 3820

ST6 STARTING (2UZFE) ST08C05 REMOVAL 1. REMOVE THROTTLE BODY COVER 2. DISCONNECT CABLE FROM NEGATIVE () BATTERY TERMINAL 3. REMOVE INTAKE AIR CONNECTOR 4. DISCONNECT THROTTLE BODY ASSEMBLY FROM INTAKE MANIFOLD (See pege SF44 ) 5. REMOVE INTAKE MANIFOLD ASSEMBLY (See page EM36 ) 6. REMOVE AIR PUMP ASSEMBLY (See page EC23 ) 7. REMOVE (a) Remove the 2 bolts holding the starter to the cylinder block. (b) Disconnect the starter from the cylinder block. B04548 Engine Wire Protector (c) (d) (e) (f) Disconnect the starter connector. Remove the nut, bolt and disconnect the starter wire. Remove the bolt, and disconnect the engine wire protector from the starter. Remove the starter. Starter Connector B04549 3809

SST STARTING (2UZFE) REPLACEMENT 1. REPLACE REAR BEARING (a) Using SST, remove the bearing. SST 092864601 1 ST13 ST08F06 S00058 (b) Using a press, press in a new bearing. S00059 SST 2. REPLACE FRONT BEARING (a) Using SST, remove the bearing. SST 092864601 1 S00060 Upward SST (b) Using SST and a press, press in a new bearing. NOTICE: Be careful of the bearing installation direction. SST 0982000031 Downward S00061 3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS (a) Remove magnetic switch end cover. Remove the 3 bolts, end cover, gasket and plunger. B04542 3816

ST14 STARTING (2UZFE) (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. Wear B04555 SST B04556 (c) Remove terminal kit parts. (1) Using SST, loosen the terminal nuts. SST 0981038140 (2) Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O ring, terminal bolt, contact plate and terminal insulator (inside). (3) Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), O ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper. (3) Long (2) (1) Short Long Short (4) (5) Inside (6) (7) B07949 (d) Install new terminal 30 kit parts. (1) Temporarily install a new terminal insulator (inside). (2) Temporarily install a new contact plate. (3) Temporarily install a new terminal bolt. (4) Temporarily install a new Oring. (5) Temporarily install a new packing and new terminal insulator (outside). Install a new packing to a new terminal insulator, and install them. HINT: Match the protrusion of the insulator with the indentation of the housing. (6) Temporarily install a new wave washer. (7) Temporarily install a new terminal nut. NOTICE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction. 3817

STARTING (2UZFE) ST15 (7) (6) (5) (4) Inside Long (1) Lead Terminal Short (2) (3) B04559 (e) Install new terminal C kit parts. (1) Temporarily install a new terminal insulator (inside). (2) Temporarily install a new contact plate. (3) Temporarily install a new terminal bolt. (4) Temporarily install a new Oring. (5) Temporarily install a new terminal insulator (outside). (6) Temporarily install a new wave washer. (7) Temporarily install a new terminal nut. NOTICE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction. (f) Temporarily tighten the terminal nuts. 40 mm 37 mm Contact Plate 20 mm B04560 (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 calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure: (kgf/cm 2 ) = 100 kgf Ram diameter (cm) 2 2 x 3.14 (π) (psi) = 221lbf Ram diameter (in.) 2 2 x 3.14 (π) (kpa) = (kgf/cm 2 ) x 98.1 (kpa) = (psi) x 6.9 If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut. 3818

ST16 STARTING (2UZFE) SST (2) Using SST, tighten the nuts to the specified torque. SST 0981038140 Torque: 17 N m (170 kgf cm, 13 ft lbf) NOTICE: If the nut is over tightened, it may cause cracks on the inside of the insulator. B04561 B04562 (h) (i) Clean contact surfaces of contact plate and plunger. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. Reinstall magnetic switch end cover. Install the plunger, new gasket, end cover and lead clamp with the 3 bolts. Torque: 1.4 kw type: 2.5 N m (25 kgf cm, 22 in. lbf) 2.0 kw type: 3.6 N m (37 kgf cm, 32 in. lbf) 3819

ST18 Terminal 50 Terminal C Battery STARTING (2UZFE) B04543 ST08H06 TEST NOTICE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. 1. DO PULLIN 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 HOLDIN TEST While connected as above with the pinion gear out, disconnect the negative () lead from terminal C. Check that the pinion gear remains out. Disconnect Terminal C Battery B04544 Disconnect 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative () lead from the starter body. Check that the pinion gear returns inward. Battery B04545 Terminal 50 Terminal 30 Battery Ammeter B04546 4. DO NOLOAD 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: 1.4 kw type 90 A or less at 11.5 V 2.0 kw type 100 A or less at 11.5 V 3821

ST20 STARTING (2UZFE) RELAY RELAY INSPECTION 1. REMOVE RELAY BOX COVER 2. REMOVE RELAY (Marking: ST) ST0PK01 1 Continuity 3 2 5 No Continuity B16388 3. INSPECT RELAY (a) Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. Battery 1 3 2 5 Continuity B16389 (b) Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL RELAY BOX COVER 5. REINSTALL RELAY 3823

STARTING (2UZFE) STARTING SYSTEM ONVEHICLE INSPECTION NOTICE: STARTING SYSTEM Before changing the starter, check these items again: Connector connection Accessory installation, e.g.: engine immobilizer system ST1 ST08A04 3804