TOYOTA SIENNA 2007 Service Repair Manual

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
A060459E08
A081044E07
A081045E01
A060462E01

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.
A058586
A079725E13
A079726E10
A058372E07
A058373E05

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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A076677E01
A079766E11
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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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A079727E01

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)
A079728E01
A079720
A079729
A079719
A079718

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)
A160252
A160251
A160253
A155041

ST–142GR-FE STARTING – STARTER RELAY
ST
STARTER RELAY
ON-VEHICLE INSPECTION
1. INSPECT STARTER RELAY
(a) Using an ohmmeter, measure the resistance
between each terminal.
Standard resistance
If the result is not as specified, replace the starter
relay assembly.
B060778E26Tester Connection Specified Condition
3 - 5 10 k
or higher
3 - 5Below 1
(when battery voltage is applied to
terminals 1 and 2)

2GR-FE STARTING – IGNITION SWITCHST–15
ST
ENGINE
2GR-FE STARTING
IGNITION SWITCH
COMPONENTS
A160243E01

ST–162GR-FE STARTING – IGNITION SWITCH
ST
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE STEERING COLUMN COVER LOWER
(a) Insert the key into the ignition key cylinder and
release the steering lock.
(b) Turn the steering wheel clockwise to gain access to
the screw and remove the screw.
(c) Turn the steering wheel counterclockwise to gain
access to the screw and remove the screw.
(d) Detach the 4 claws, and remove the steering
column cover lower.
3. REMOVE IGNITION SWITCH ASSEMBLY
(a) Disconnect the ignition switch connector.
(b) Remove the 2 screws and ignition switch.
INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
(a) Measure the resistance of the switch.
Standard resistance
If the result is not as specified, replace the switch
assembly.
A160244
A160245
A160246
A160247E01
Tester Connection Switch Condition Specified Condition
-LOCK10 k
or higher
1 (AM1) - 3 (ACC) ACC Below 1
1 (AM1) - 3 (ACC)
3 (ACC) - 2 (IG1)
1 (AM1) - 2 (IG1)
5 (AM2) - 6 (IG2)ON Below 1
1 (AM1) - 2 (IG1)
5 (AM2) - 6 (IG2)
6 (IG2) - 4 (ST2)
5 (AM2) - 4 (ST2)START Below 1

2GR-FE STARTING – IGNITION SWITCHST–17
ST
INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Install the ignition switch with the 2 screws.
(b) Install the ignition switch connector.
2. INSTALL STEERING COLUMN COVER LOWER
(a) Attach the 4 claws to install the steering column
cover lower.
(b) Insert the key into the ignition key cylinder and
release the steering lock.
(c) Turn the steering wheel counterclockwise and install
the screw.
(d) Turn the steering wheel clockwise and install the
screw.
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
A160246
A160245
A160244