Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISSTARTING AND CHARGINGSTARTING SYSTEMSTARTER MOTORTESTING AND INSPECTION
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
Starter Motor: Testing and Inspection
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION Testing and Inspection
INSPECTION
1. STARTER ASSEMBLY
NOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil.
a. Disconnect the field coil lead wire from terminal C.
b. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.
c. With battery connected as above with the clutch pinion gear out disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
d. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward.
e. Connect the lead wire to the terminal C with the nut.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
f. Connect the battery and ammeter to the starter as shown.
g. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current.
Specified current: 90 A or less at 11.5 V
2. STARTER RELAY ASSEMBLY
a. Inspect the relay continuity.
1. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
2. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
b. Inspect the relay operation.
1. Apply battery positive voltage across terminals 1 and 2.
2. Using an ohmmeter, check that there is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
1. STARTER ASSEMBLY
NOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil.
a. Disconnect the field coil lead wire from terminal C.
b. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.
c. With battery connected as above with the clutch pinion gear out disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
d. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward.
e. Connect the lead wire to the terminal C with the nut.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
f. Connect the battery and ammeter to the starter as shown.
g. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current.
Specified current: 90 A or less at 11.5 V
2. STARTER RELAY ASSEMBLY
a. Inspect the relay continuity.
1. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
2. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
b. Inspect the relay operation.
1. Apply battery positive voltage across terminals 1 and 2.
2. Using an ohmmeter, check that there is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.