Toyota 28100-31050-84
Starter

Start with fuel system pressure discharge and engine coolant draining when you remove the starter motor. You need to detach the battery negative connection only after removing the throttle body cover's 2 mounting nuts. Take off the air cleaner hose and proceed to disconnect the fuel hose and two other hose assemblies. Widen the engine wire access by unscrewing fuel injector connectors eight times plus throttle position and water temperature sensor connectors. Pull away the engine wire harness with its 3 bolts. Disconnect the water by-pass hoses from their No. 7 and Number 2 connections. Take out 6 bolts and 4 nuts to dismantle the intake manifold with its 2 gaskets for removal. To access the water by-pass pipe sub-assembly disconnect Number 2 engine wire then remove its securing nut. Dispose of the rear water by-pass joint RH after you remove its 4 nuts, water by-pass joint, and the 2 gaskets. Unplug the air pump components and perform the following steps: disconnect starter connector followed by starter nut removal, unscrew engine wire protector bolt, then take off 2 bolts to extract starter.

The starter motor requires removal by disconnecting the cable from the negative battery terminal first. The technician starts by removing the No. 2 engine under cover assembly through the disconnection of 4 bolts. The third step involves removing the No. 2 exhaust manifold stay after unscrewing its 3 bolts. You should then disconnect the wire harness by removing the bolt while you separate the earth wire harness from the cylinder block. The starter assembly can be removed after disconnecting terminal 50 connector and unfastening the nut at wire harness terminal 30 followed by unscrewing the 2 bolts to free the starter assembly from its position.

Disconnection of the negative battery terminal cable should be the first step before servicing or repairing the starter motor for the 2TR-FE starting system. The procedure starts with removing the starter assembly after disconnecting the terminal cap followed by bolt removal of the starter wire harness and disconnecting the starter connector and finishing with removing the 2 bolts to extract the starter.

The first step to handle the starter motor replacement for the 2TR-FE engine involves cutting off the negative cable from the battery. Start by disconnecting the starter assembly through the terminal cap removal then bolt extraction and unfastening the starter wire harness. After disconnecting the starter connector one should remove the two bolts then extract the starter from its place.

Install a new O-ring to its groove, align the protrusion with the groove of the magnetic switch, and secure the assembly with 2 through bolts, torqued to 9.3 Nm (95 kgf-cm, 82 in-lbf).

The undercut depth should be at least 0.2 mm (0.008 in.); correct with a hacksaw blade if necessary.

1. Install the starter assembly with 2 bolts (Torque: 37 N.m). 2. Connect the wire harness to terminal 30 and install the nut (Torque: 9.8 N.m). 3. Connect terminal 50. 4. Connect the wire harness to the cylinder block and install the bolt (Torque: 13 N.m). 5. Install the No.2 manifold stay with 3 bolts (Torque: 40 N.m). 6. Install the engine rear under cover assembly with 4 bolts (Torque: 29 N.m). 7. Reconnect the battery negative terminal.

Position the starter assy and secure it with the 2 bolts, torquing them to 37 Nm (377 kgf.cm, 27 ft.lbf).

1. Remove the engine rear under cover assembly by taking out 4 bolts. 2. Remove the No. 2 manifold stay by unscrewing 3 bolts. 3. Disconnect the wire harness from the cylinder block by removing the bolt. 4. Disconnect the terminal 50 connector from the starter assembly. 5. Remove the nut and disconnect the wire harness from terminal 30. 6. Remove the 2 bolts to take out the starter assembly.

Check for ground continuity between the commutator and armature coil core.

Ensure the undercut depth is clean and free of foreign objects, with a standard depth of 0.7 mm (0.028 in.) and a minimum of 0.2 mm (0.008 in.), correcting any deficiencies with a hacksaw blade.

Remove the No. 2 engine under cover assembly by taking out the 4 bolts.

Connect the terminal 50 connector to the starter assembly.

Secure the commutator end frame with 2 screws, torqued to 3.8 Nm (39 kgf-cm, 34 in-lbf).

Position the starter with the 2 bolts and torque them to 37 N.m (377 kgf. cm, 27 ft.lbf).

Position the starter assembly and secure it with the 2 bolts, torquing them to 58 N.m (591 kgf.cm, 43 ft.lbf).

Unscrew the 2 screws and end cover from the starter yoke, take out the O-ring, hold the spring back with a screwdriver to disconnect the 4 brushes from the brush holder, and finally remove the brush holder from the armature.

Disconnect the cable from the negative battery terminal.

You should wait at least 90 seconds to allow the navigation system to record memory and settings.

Install the terminal cap.

Remove the starter assembly.

Grease the starter idle gear pinion and install it onto the starter drive housing.

Disconnect the cable from the negative battery terminal.

Reinstall the engine under cover assembly rear and reconnect the cable to the negative (-) battery terminal.

Position the starter and secure it with the 2 bolts, torquing them to 37 N.m (377 kgf.cm, 27 ft.lbf).