Prado 120 series starter motor

[aussieranger]

Hi all, anybody had trouble with their starter motor? We have a 4L petrol Prado and recently the starter has began playing up. It's still intermittent but seems like the pinion gear isn't throwing out properly. Any suggestions...is it DIY?
cheers

 

[thisavros]

Hi
Its been a while since the post but I have a similar issue and am looking for a guide on the starter motor removal process.
Did you have any luck with a DIY guide?

Cheers

 

[cloughcarib]

Hi
Its been a while since the post but I have a similar issue and am looking for a guide on the starter motor removal process.
Did you have any luck with a DIY guide?

Cheers

PM me your email and I will try to email the workshop manual to you. I've not been successful in the past, but I'll give it a go

 

[thisavros]

Tks cloughcarib
Will PM you.

Back in the old days of my HQ holden jobs like this were a breeze. Plenty of room and hardly no extra pipes/wires. But these later model engine bays are just crazy.

 

[Big Rig]

Yup guys. It is a common problem. I had the D4D and lost the starter on Vrillia Pt on Cape York. Not a lot of fun but the good thing is, the issue is due to water ingress to the solenoid. Simple solution is to remove the starter then take off the solenoid. You will see a large copper contact pin: that is what corrodes. Use some emery tape and clean up both contacts and voila, your on your way.

 

[cloughcarib]

Yup guys. It is a common problem. I had the D4D and lost the starter on Vrillia Pt on Cape York. Not a lot of fun but the good thing is, the issue is due to water ingress to the solenoid. Simple solution is to remove the starter then take off the solenoid. You will see a large copper contact pin: that is what corrodes. Use some emery tape and clean up both contacts and voila, your on your way.

Thanks for that Mark, I'm still trying to work out how to send the manual, but not too good with this sort of thing

 

[thisavros]

Replacement motor is at the post office which I'll pick up tomorrow.
I've managed to get a hold of the service manual for a few $$.

Toyota recommends you remove the exhaust pipe as well. I'm hoping to avoid that as it will mean extra gaskets and non reusable parts...ugly.

I've attached some pics in a word doc.

Here is what they say.
STARTER ASSY (1GR−FE) 190LJ−02 REPLACEMENT

1. REMOVE ENGINE UNDER COVER ASSY REAR
(a) Remove the 4 bolts and the engine under cover assy rear.

2. REMOVE EXHAUST FRONT PIPE ASSY NO.2 (See page 15−3)

3. REMOVE FRONT FENDER SPLASH SHIELD REAR LH
(a) Remove the 5 clips and the front fender splash shield rear LH.

4. SEPARATE STEERING INTERMEDIATE SHAFT SUB−ASSY NO.2
(LHD STEERING POSITION TYPE)
Loosen bolt A and remove bolt B, then separate the steer-ing intermediate shaft No. 2.

5. REMOVE STARTER ASSY
(a) Disconnect the terminal 50 connector from the starter assy.
(b) Remove the nut and disconnect the wire harness from terminal 30.
(c) Remove the 2 bolts and the starter assy.

** PAGE 15-3
REMOVE EXHAUST FRONT PIPE ASSY NO.2
Remove the 2 bolts, the 2 nuts and the exhaust pipe assy front No. 2.

 

[thisavros]

Ahh the sweet sound of a purring motor that starts first go..
Tackled the job late yesterday. Took about 1hr.

Raised the left side of the vehicle from the high jack lift point on the Bull Bar.
Removed left wheel.
Removed (what was left of) the rear sand/splash shield.
Removed bash plates under the motor.

To remove the Sm connections I had to enter via the wheel arch side.
There wasn't much room for 12mm ring spanner but some patience and what seemed like 500 apply/turn/remove the power cabled was off.
The other connector came off easy as its clip based.

Getting to the 2 main bolts that hold the unit on for me was achieved from underneath. With the right combination of spanners, sockets, extension bar, uni joint extender etc access was achieved and out they came.
The motor itself then comes out with a few turns and maneuvers over the exhaust.

I have some photos of the unit attached.

In summary not a hard job and no need to remove the exhaust.

 

[Malcolmjones]

Ahh the sweet sound of a purring motor that starts first go..
Tackled the job late yesterday. Took about 1hr.

Raised the left side of the vehicle from the high jack lift point on the Bull Bar.
Removed left wheel.
Removed (what was left of) the rear sand/splash shield.
Removed bash plates under the motor.

To remove the Sm connections I had to enter via the wheel arch side.
There wasn't much room for 12mm ring spanner but some patience and what seemed like 500 apply/turn/remove the power cabled was off.
The other connector came off easy as its clip based.

Getting to the 2 main bolts that hold the unit on for me was achieved from underneath. With the right combination of spanners, sockets, extension bar, uni joint extender etc access was achieved and out they came.
The motor itself then comes out with a few turns and maneuvers over the exhaust.

I have some photos of the unit attached.

In summary not a hard job and no need to remove the exhaust.

Thank you very helpful

 

[gslender]

About to tackle this myself... hopefully I'll have no problems having done similar repairs to many other cars before. Damn starter solenoid just decided to stop working, which is annoying because it gave no notice and just stopped engaging. A swift tap-a-tap-a-tapa and she fired up fine. So out she must come and replaced she will be.

 

[Borec]

There is a good thread on Pradopoint about reconditioning the starter motor, which I have followed and managed to get it working again. I had same issue with my D4D 120, it would just click, and nothing would happen. This might happen several times, until it eventually it turns, not a good feeling when driving auto trans in middle of nowhere. It is due to water ingress as mentioned. If you go through deep water crossings, it will start happening eventually. I now carry a spare one with me (second hand one which I took apart and cleaned), if going for a longer trip.

 

[jelbuilder]

If anyone needs help Removing a Starter Motor from a 2003 Toyota Prado 120 Series (Petrol), here's a video I did:

I'm a complete noob with cars, but managed to do it and get the car working again. Hope it helps!