OEM 2001 Toyota 4Runner Starter Motor

2001 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2001 Toyota 4Runner?

  A: The starter motor repair process should start with mechanical disassembly followed by high-temperature grease application at bearings, gears, return spring along with the steel ball for assembly purposes. The starting process begins by loosening the nut and removing the lead wire from the magnetic switch terminal using 5.9 N.m (60 kgf.cm, 52 in.lbf) torque while you uninstall the two through bolts which require 5.9 N.m (60 kgf.cm, 52 in.lbf) torque for 1.4 kW types and 9.3 N.m (95 kgf.cm, 82 in.lbf) torque for 1.8 kW types. Take the field frame along with the armature out of the magnetic switch assembly while lining up the protrusion with the cutout before you remove and replace the O-ring with a new one. The starter housing clutch assembly and gear can be detached by removing two screws at the same earlier torque settings. Then disconnect the starter housing and return spring along with the bearing idler gear and clutch assembly from the magnetic switch assembly. A magnetic finger tool removes the steel ball which is located inside the clutch shaft hole. The brush holder requires the removal of 2 screws and 2 O-rings before pulling the end frame from the field frame with a torque of 1.5 N.m (15 kgf.cm, 13 in.lbf) for the 1.4 kW type and 3.6 N.m (39 kgf.cm, 34 in.lbf) for the 1.8 kW type. Afterward remove the O-ring from the field frame and disconnect the 4 brushes from the brush holder. Reassemble in reverse order. The magnetic switch end cover replacement process starts with removing three bolts and dismantling the lead clamp and end cover and plunger and gasket in that order. Vernier calipers must inspect the contact plate's depth for wear until it reaches 0.9 mm (0.035 in.). Replacement is required. Special Service Tool: 09810 - 38140 enables the removal of terminal nuts before removing parts from Terminal C and Terminal 30 as per specifications. Apply new parts to both terminals while ensuring terminal insulator orientation and torquing the nuts just loose. The procedure for tightening terminal nut requires placing a 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) wooden block on the contact plate followed by application of 981 N (100 kgf, 221 lbf) force to determine gauge pressure from the hand press ram diameter. To maintain insulator health Special Service Tool 09810-38140 should be used for tightening nuts to a torque of 17 N.m (170 kgf.cm, 12 ft.lbf) while watching for signs of potential insulator cracking. Apply the contact plate plunger to the magnetic switch end cover along with a new gasket and lead clamp while tightening 3 bolts to 2.5 N.m (25 kgf.cm, 22 in.lbf) for 1.4 kW type units and 3.6 N.m (37 kgf.cm, 32 in.lbf) for 1.8 kW type units.