TOYOTA SIENNA 2007 Service Repair Manual

IG–122GR-FE IGNITION – IGNITION COIL AND SPARK PLUG
IG
12. INSTALL WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-6)
13. INSTALL FRONT WIPER ARM LH (See page WW-6)
14. INSTALL FRONT WIPER ARM RH (See page WW-7)

ST–82GR-FE STARTING – STARTER
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 in step (a), 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 with the clutch pinion gear extended.
Check that the ammeter reads the specified
current.
Specified current:
90 A or less at 11.5 V
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2GR-FE STARTING – STARTERST–9
ST
2. INSPECT REPAIR SERVICE STARTER KIT
(a) Check the plunger.
(1) Push in the plunger and check that it returns
quickly to its original position.
If necessary, replace the repair service starter
kit.
(b) Check if the pull-in coil has an open circuit.
(1) Measure the resistance between terminals 50
and C.
Resistance:
Below 1
If the result is not as specified, replace the
repair service starter kit.
(c) Check if the hold-in coil has an open circuit.
(1) Measure the resistance between terminal 50
and the switch body.
Resistance:
Below 2
If the result is not as specified, replace the
repair service starter kit.
3. INSPECT STARTER ARMATURE ASSEMBLY
(a) Measure if the commutator has an open circuit.
(1) Check the resistance between the segments of
the commutator.
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.
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.
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ST–102GR-FE STARTING – STARTER
ST
(d) Using a vernier caliper, measure the commutator's
length.
Standard length:
3.3 to 4.0 mm (0.1299 to 0.1575 in.)
If the length is greater than the maximum, replace
the starter armature.
4. INSPECT STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) Using a vernier caliper, measure the brush length.
Specified length:
4.0 to 9.0 mm (0.158 to 0.354 in.)
If the length is less than the minimum, replace the
starter commutator end frame.
(b) Check the brush insulation.
(1) Measure the resistance between the positive
(+) and negative (-) brush.
Resistance:
10 k
or higher
If the result is not as specified, repair or replace
starter commutator end frame.
5. INSPECT REPAIR SERVICE STARTER KIT
(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 service starter kit.
REASSEMBLY
1. INSTALL PLANETARY GEAR
(a) Apply grease to the planetary gears and pin parts of
the planetary shaft.
(b) Install the 3 planetary gears.
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2GR-FE STARTING – STARTERST–11
ST
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 DRIVE HOUSING STARTER BEARING
COVER
(a) Install the drive housing starter bearing cover to the
starter commutator end frame.
4. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter yoke.
(b) Align the keyway of the starter plate with the key
inside the starter yoke, and install the starter plate.
5. INSTALL STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) Align the rubber with the convex cutout of starter
yoke.
(b) Install starter commutator end frame to the starter
yoke.
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ST–122GR-FE STARTING – STARTER
ST
6. INSTALL STARTER YOKE ASSEMBLY
(a) Align the key of the starter yoke with the keyway of
repair service starter kit.
(b) Install the starter yoke with the 2 through bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
7. INSTALL REPAIR SERVICE STARTER KIT
(a) Apply grease to the plunger and the hook.
(b) Hang the plunger hook of the repair service starter
kit to the drive lever.
(c) Install the plunger and return spring.
(d) Install the repair service starter kit with the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(e) Connect the lead wire to the repair service starter kit
with the nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
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2GR-FE STARTING – STARTERST–13
ST
INSTALLATION
1. INSTALL STARTER ASSEMBLY
(a) Install the starter with the 2 bolts.
Torque: 37 N*m (380 kgf*cm, 26 ft.*lbf) for bolt
(b) Connect the starter connector.
(c) Install the terminal nut and cover the nut with the
cap.
Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) for nut
2. INSTALL NO. 1 AIR CLEANER INLET
(a) Install the No. 1 air cleaner inlet with the bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
3. INSTALL AIR CLEANER BRACKET
(a) Remove the 2 bolts and air cleaner bracket.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See
page EM-59)
5. INSTALL AIR CLEANER FILTER ELEMENT (See page
EM-59)
6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page FU-20)
7. INSTALL NO. 2 AIR CLEANER INLET (See page EM-
60)
8. INSTALL BATTERY (See page EM-59)
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2GR-FE STARTING – STARTERST–5
ST
REMOVAL
1. REMOVE BATTERY (See page EM-26)
2. REMOVE NO. 2 AIR CLEANER INLET (See page EM-
28)
3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page FU-13)
4. REMOVE AIR CLEANER FILTER ELEMENT (See page
EM-28)
5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (See
page EM-28)
6. REMOVE AIR CLEANER BRACKET
(a) Remove the 2 bolts and the air cleaner bracket.
7. REMOVE NO. 1 AIR CLEANER INLET
(a) Remove the bolt and the No. 1 air cleaner inlet.
8. REMOVE STARTER ASSEMBLY
(a) Disconnect the starter connector.
(b) Open the terminal cap and remove the nut and the
starter wire.
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ST–62GR-FE STARTING – STARTER
ST
(c) Remove the 2 bolts and the starter.
DISASSEMBLY
1. REMOVE REPAIR SERVICE STARTER KIT
(a) Remove the nut and disconnect the lead wire from
the repair service starter kit.
(b) Remove the 2 screws which are used to secure the
repair service starter kit to the repair service starter
kit.
(c) Remove the repair service starter kit.
(d) Remove the return spring and the plunger from the
repair service starter kit.
2. REMOVE STARTER YOKE ASSEMBLY
(a) Remove the 2 through bolts and pull out the starter
yoke together with the starter commutator end
frame.
(b) Remove the starter yoke from the starter
commutator end frame.
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2GR-FE STARTING – STARTERST–7
ST
3. REMOVE STARTER ARMATURE PLATE
(a) Remove the starter armature plate from the starter
yoke.
4. REMOVE DRIVE HOUSING STARTER BEARING
COVER
(a) Using a screwdriver, remove the drive housing
starter bearing cover.
5. REMOVE STARTER ARMATURE ASSEMBLY
(a) Using snap ring pliers, remove the snap ring and
plate washer.
(b) Remove the starter armature from the commutator
end frame.
6. REMOVE PLANETARY GEAR
(a) Remove the 3 planetary gears from the repair
service starter kit.
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