OEM 2006 Toyota 4Runner Starter Motor

2006 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to overhaul the starter motor assembly (2.0KW) on 2006 Toyota 4Runner?

  A: The procedure for overhauling the starter motor assembly (2.0KW) begins with disconnecting the lead wire from C terminal followed by unscrewing the 2 through bolts before pulling out the starter yoke with armature together while removing the O-ring from the starter yoke. After removing two screws and a switch from the magnet starter switch assembly proceed to clear the steel ball from the clutch shaft opening with a magnetic finger. The starter brush holder assembly removal method starts by unscrewing its 2 screws and end cover followed byRemoving the O-ring and holding the spring with a screwdriver to separate the 4 brushes before finally removing the brush holder from the armature frame. Inspect the starter armature assembly by using an ohmmeter which checks commutator segment continuity and you should replace the armature in the event of open circuits. Verify the circuit between the commutator and armature coil core through ground continuity testing. Continuous resistance indicates the armature needs to be replaced. Verify the commutator surface for signs of dirt and burning using sandpaper (No.400). If using a lathe proves necessary for correction. You need to measure commutator runout with V-blocks and a dial gauge to keep the measurement below 0.05 mm (0.0020 in.). If the runout exceeds this value you should correct it on a lathe. Vernier calipers must measure the commutator diameter to a minimum of 34.0 mm (1.339 in.) yet any measurement under this threshold calls for armature replacement. Use a hacksaw blade for necessary correction when inspecting the undercut depth to achieve a minimum depth of 0.2 mm (0.008 in.). A replacement of the starter yoke will be required if shunt coil resistance does not fall within 1.5 to 1.9 Ohms at 20 degrees Celsius (68 degrees Fahrenheit). All tests need verification through multi-meter inspections for open circuits. The brush length measurement should be at minimum 9.0 mm (0.354 in.); the brush holder and starter yoke requires replacement in case the measurement falls short. Examine the brush holder insulation for electrical connections between the positive and negative brush holders and conduct repairs and replacements of the brush holder if necessary. With a brush spring load between 21.5 and 27.5 Newtons (2.2 to 2.8 kilograms force or 4.8 to 6.2 pounds force) the replacement of the brush holder will be needed if the load drops below 12.7 Newtons (1.3 kilograms force or 2.9 pounds force). The starter clutch sub-assembly requires inspection to check clutch pinion gear movement between clockwise free rotation and counterclockwise locking motion. If failure occurs, substitute the part. To test continuity in the magnet starter switch assembly one must check both pull-in and holding coils between terminals and the switch body and replace the switch if no continuity is detected. Start by applying grease to starter bearings before installing the starter armature assembly. The starter brush holder assembly needs proper installation of all brushes and 2 screws should fasten the end frame with 3.8 N.m (39 kgf.cm, 34 in.lbf). Secure the magnet starter with grease by applying it to steel balls and related components while installing two screws that require a torque of 9.3 N.m (95 kgf.cm, 82 in.lbf). Secure the starter yoke with two through bolts using 9.3 N.m torque. The key must fit into the groove of the magnet starter switch before installation. Then apply a new O-ring before installation. Form a proper connection between the C terminal and its lead wire through the nut which requires 5.9 N.m torque.