OEM 2004 Toyota 4Runner Starter Motor

2004 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to overhaul a 2.0 KW starter motor on 2004 Toyota 4Runner?

  A: You must start the 2.0 KW starter motor overhaul by first disconnecting the C terminal lead wire then removing the two through bolts along with pulling out the starter yoke with armature assembly afterward removing the O-ring from the starter yoke. The procedure requires removal of the magnet starter switch assembly through unscrewing two screws and taking out the switch mount together with its components: starter magnet switch return spring, starter idle gear pinion, starter idle gear clutch roller, starter idle gear retainer and starter clutch by utilizing a magnetic finger to extract the steel ball from the clutch shaft hole. First disconnect the starter brush holder assembly through a sequence of steps which include unscrewing two screws and end cover removal while extracting the O-ring and disconnecting four brushes from the brush holder using a screwdriver for the spring back then removing the brush holder from the armature. A visual open circuit check with an ohmmeter should be conducted on the starter armature assembly by inspecting continuity between commutator segments which indicates replacement of the armature when no continuity is detected. Inspection of ground continuity between commutator and armature coil core must be performed and any present continuity requires armature replacement. The commutator surface should be inspected for dirt and burn marks where sandpaper (No.400) or a lathe can be used for correction until runout is measured on V-blocks with a dial gauge that ensures runout stays under 0.05 mm (0.0020 in.). Using vernier calipers measure the commutator diameter then confirm it remains between 35.0 mm (1.378 in.) and the minimum requirement of 34.0 mm (1.339 in.). A hacksaw will be used to correct any setbacks in undercut depth when it fails to meet the 0.7 mm (0.028 in.) standard or minimum requirement of 0.2 mm (0.008 in.). A replacement starter yoke must be obtained if inspection shows the shunt coil resistance or open circuits exceed 1.9 Ohms at 20 °C (68 °F) but remains between 1.5 - 1.9 Ohms. Check the brush length which must be at least 9.0 mm (0.354 in.) and verify the brush holder insulation has continuous connection between positive and negative brush holders. Perform necessary repairs or replacement if needed. The brush spring load needs assessment with a pull scale to verify its compliance with standards between 21.5 - 27.5 N (2.2 - 2.8 kgf, 4.8 - 6.2 lbf) and should not drop below the minimum of 12.7 N (1.3 kgf, 2.9 lbf). massage the starter clutch sub-assembly by rotating its pinion gear clockwise to confirm it spins effortlessly and verifies it locks when turned counterclockwise. Any faulty starter clutch must be replaced before installation. You should evaluate the magnet starter switch assembly through open circuit checks of both pull-in and holding coils before testing continuity between terminals 50 and C and terminal 50 and the switch body while replacing the switch in case of continuity failure. Assemble the starter armature with greased bearings before adding the starter brush holder unit where you must install all 4 brushes alongside a new O-ring into the field frame groove then fasten the end frame by torquing 2 screws to 3.8 Nm (39 kgf.cm, 34 in.lbf). The magnet starter switch assembly should be installed by greasing the steel ball and relevant components before installing two screws with 9.3 Nm (95 kgf.cm, 82 in.lbf) torque. The installation process ends with assembling the starter yoke by placing a new O-ring into the groove then matching the key to the magnet starter switch groove along with fastening the starter yoke and armature with 2 through bolts at 9.3 Nm (95 kgf.cm, 82 in.lbf) torque and leading the wire to the C terminal with a nut tightened at 5.9 Nm (60 kgf.cm, 52 in.lbf).