TOYOTA LAND CRUISER 1996 J80 Workshop Manual

P04683(1) (5)(4)
(2)
(3)
P04515
Magnetic Finger
P23004
P04525
ST−6
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
(b) Remove these parts from the magnetic switch assembly:
(1) Starter housing
(2) Return spring
(3) Bearing
(4) Idler gear
(5) Starter clutch assembly
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
4. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, 2 O −rings 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 (40 kgf·cm, 35 in.·lbf)
HINT:
At the time of reassembly, use new O−rings.
(b) Remove the O−ring from the field frame.
HINT:
At the time of reassembly, use a new O−ring.
(c) Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder. Disconnect the four
brushes and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P10584
OhmmeterContinuity
ST0N8−01
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
−
STARTING STARTER
ST−7
1996 LAND CRUISER (RM451U)
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 ar-
mature.
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
SURFACES
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 V−blocks.
(b) Using a dial gauge, measure 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.
5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter. Standard diameter:
1.4 kW type: 30 mm (1.18 in.)
2.0 kW type: 35 mm (1.38 in.)
Minimum diameter:
1.4 kW type: 29 mm (1.14 in.)
2.0 KW type: 34 mm (1.34 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 mate-
rials. Smooth out the edge.
Standard undercut depth:
1.4 kW type: 0.6 mm (0.024 in.)
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.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P10588
OhmmeterContinuity
P10589
Ohmmeter
No Continuity
Z14910
Brush Holder Side
Field Frame Side Length
Length
ST0019
ST−8
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
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.
8. INSPECT FIELD COIL FOR GROUND
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.
9. 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 (0.394in.)
2.0 KW type: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
1.4 kW type:
17.6 − 23.5 N (1.79 − 2.41 kgf, 4.0 − 5.3 lbf)
2.0 kW type:
21.5 − 27.5 N (2.19 − 2.80 kgf, 4.8 − 6.2 lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P21088
OhmmeterNo Continuity
P10821
Lock
Free
−
STARTING STARTER
ST−9
1996 LAND CRUISER (RM451U)
Minimum spring installed load:
1.4 kW type: 11.8 N (1.20 kgf, 2.7 lbf)
2.0 kW type: 12.7 N (1.29 kgf, 2.9 lbf)
If the installed load is less than minimum replace the brush
springs.
11. 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.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and 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.
13. INSPECT CLUTCH PINION GEAR
Hold the starter clutch and rotate the pinion gear clockwise, and
check that it turns freely. Try to rotate the pinion gear counter-
clockwise and check that it locks.
If necessary, replace the clutch assembly.
14. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
15. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P08508
Ohmmeter
Terminal C
Terminal 50
P08509
Switch Body
Terminal 50
ST−10
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
16. DO PULL−IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
17. DO HOLD−IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P10593
SST
ST0N9−01
P10595
SST
P10596
Upword
Downword SST
−
STARTING STARTER
ST−11
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286−46011
(b) Using a press, press in a new rear bearing.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing. SST 09286−46011
(b) Using a press, press in a new front bearing.
NOTICE:
Be careful of the bearing installation direction. SST 09820−00030
3. REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
4. 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.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

ST−12
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
5. REMOVE TERMINAL KIT PARTS
(a) Using SST, loosen the terminal nuts.
SST 09810−38140
(b) Terminal C: Remove the terminal nut, wave washer , terminal insulator
(outside), O− ring, terminal bolt, contact plate and terminal
insulator (inside).
(c) Terminal 30: Remove the terminal nut, wave washer , terminal insulator
(outside), packing, O−ring, terminal bolt, contact plate,
terminal insulator (inside) and insulation paper.
6. REINSTALL TERMINAL KIT PARTS
(a) Terminal 30: Install these new parts:
(1) Insulation paper
(2) Terminal insulator (inside)
(3) Contact plate
(4) Terminal bolt
(5) O−ring
(6) Packing and terminal insulator (outside)Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing. (7) Wave washer
(8) Terminal nut
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

V06796
−
STARTING STARTER
ST−13
1996 LAND CRUISER (RM451U)
(b) Terminal C:
Install these new 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 insulators (inside) and
wave washers in the correct direction.
(c) Temporarily tighten the terminal nuts.
7. TIGHTEN TERMINAL NUT
(a) 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:
If the contact plate is not pressed down with the specified pres-
sure, the contact plate may tilt due to coil deformation or the
tightening of the nut.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

ST−14
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
8. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
9. 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)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

ST08G−03
−
STARTING STARTER
ST−15
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST−5).
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010