Starter Motor for Toyota Prado 2700 Land Cruiser 2810073020 2810075190 28100-75190

I. Core Safety Prerequisites (Mandatory Before Installation)

• Ensure the vehicle is turned off. Disconnect the negative (-) battery cable.

• Wait at least 3-5 minutes to allow the ECU and capacitors to discharge, preventing damage to control units from short circuits during operation.

• Confirm the new starter part number matches the original (Toyota OEM parts usually start with 28100-).

• Check that the starter pinion gear (Bendix) extends and retracts smoothly without sticking.

• Socket wrench set (10mm, 12mm, 14mm, 17mm), Torque wrench, Extension bars, Universal joint (U-joint), Ratchet wrench, Wire brush (for cleaning dust).

II. Mechanical Installation Steps (Including Critical Torque Values)

• Mounting Position: The starter is located at the junction of the engine and transmission (typically on the lower right side of the engine when facing the front of the vehicle).

• Clean Contact Surfaces: Use a wire brush to clean the starter mounting surfaces on the engine and transmission to ensure no oil or thick rust is present, guaranteeing a good ground connection.

• Install Bolts:

• The starter is typically secured by 2 long bolts (some diesel versions may have 3).

• Push the starter into the mounting holes, ensuring the starter gear aligns with the gap in the flywheel ring gear.

• Thread the bolts on by hand to ensure the threads are smooth. Never force them in, as this will damage the threads.

• Alternating Tightening: Gradually tighten the bolts in a crisscross or diagonal sequence.

• Standard Torque:

• 1GR-FE (4.0L V6) Engine: Mounting bolts are typically 32 - 37 N·m.

• 2TR-FE (2.7L L4) Engine: Mounting bolts are typically 25 - 30 N·m.

• Warning: Excessive torque can cause bolts to break or cylinder block threads to strip; insufficient torque will cause resonance and noise during starter operation.

III. Electrical Connections (Sequence is Critical)

• Align the plastic plug on the solenoid with the socket and insert it.

• If it is a hard-wire connection (some older models), slip the terminal lug over the M4/M5 nut and tighten to 4 - 6 N·m.

• Connect the thick positive battery cable to the starter's B terminal (the largest post).

• Install a flat washer and a spring washer (or OEM serrated washer).

• Tighten the nut to 8 - 10 N·m to ensure good contact and prevent loosening.

• Mandatory: Install the red insulating protective cap to prevent short circuits during water crossings or engine washing.

• After confirming all wiring is correct, reconnect the negative battery cable last.

IV. Functional Testing and Verification

• Double-check that the starter wiring harness has no interference and that the bolts are tightened.

• Ensure the vehicle is in Park (P) (Automatic) or Neutral (N) (Manual), and the parking brake is firmly applied.

• Ignite the engine; the starter should turn over powerfully without a "clacking" gear noise.

• The starter should stop working immediately (pinion retracts) after the engine starts.

• Use a multimeter to measure the battery voltage during cranking.

• Standard: Should not drop below 9.6V (at room temperature). If it drops below 9V, the battery may be discharged or the ground wire connection may be poor.

I. Electrical System Safety (Core Taboos)

• Action: The negative battery terminal must be completely disconnected before installing the starter.

• Consequence: The Prado's starter main power cable (B terminal) is directly connected to the battery positive and typically carries a large capacitance. If the B terminal cable is installed while the battery is connected, a wrench slipping and touching the engine block (ground) will create a short circuit current of several thousand amps. This can cause the wrench to melt, the wiring harness to ignite, or even an explosion of the battery.

• Action: It is absolutely forbidden to directly short the B terminal and S terminal on the starter with a screwdriver or wire to test if the starter works.

• Consequence: This brute-force test generates a massive current instantly, which may not only burn out the internal solenoid but also, due to the lack of ECU safety logic (such as gear position signals), cause the vehicle to suddenly start and lurch forward while in gear, resulting in severe mechanical damage or personal injury.

• Detail: The nut for the B terminal on the Prado starter is usually 12mm or 14mm.

• Hazard: If this terminal is loose, the massive current during startup will generate high-temperature arcing, leading to burning of the terminal post, melting of insulation, or even fire.

• Requirement: A flat washer and a spring washer (or OEM serrated lock washer) must be used, tightened to the specified torque (typically 8-10 N·m). Always reinstall the factory-supplied red insulating protective cap to prevent short circuits from water ingress during off-road driving or engine washing.

II. Mechanical Installation & Flywheel Protection (Lifespan Critical)

• Phenomenon: The Prado engine bay is compact, making starter installation space very narrow.

• Check: When pushing the starter into place, the mounting surface of the starter must be perfectly parallel to the transmission housing surface.

• Consequence: If the starter is skewed and bolts are forced in, it will strip the threads (especially on the aluminum transmission housing) or cause the starter gear to mesh eccentrically with the flywheel ring gear. This results in a "clacking" gear noise during startup and accelerates flywheel wear.

• References：

I. Core Authoritative Sources (Toyota OEM System)

• Applicable Chapters:

• Section ST (Starting System): Starter Assembly → Removal/Installation.

• Electrical Specifications: Found in Section ST → Starter → Electrical Connections.

• Core Parameters: Mounting bolts (25-37 N·m, approx. 28 N·m for 2TR-FE, approx. 35 N·m for 1GR-FE), B+ terminal (8-10 N·m), Control terminal (4-6 N·m), Flywheel ring gear meshing specifications, and Neutral Start Switch logic.

• Access: Toyota TIS (Technical Information System) official subscription, authorized dealer DMS systems, or model-specific physical manuals.

• Search Path: Manual Table of Contents → Engine → Starting System → Starter → Installation; or Starting System → Starter → Torque Specifications.

• Applicable Topics: Cases involving weak cranking after starter installation, gear grinding noise, solenoid burnout, and ECU/Dashboard start signal abnormalities.

• Supplementary Points: Includes cleaning specifications for the starter mounting surface on 2TR-FE/1GR-FE engines, J150 idle start signal circuit troubleshooting, and flywheel ring gear wear judgment standards.

• Access: Authorized dealer technical departments, third-party repair databases (e.g., Alldata, Mitchell1).

• Search Path: TSB Database → Search for keywords like "Starter Installation," "Starter No-Crank," or "Flywheel Ring Gear Wear."

• Key Positioning Points: Installation specifications including overrunning clutch pre-checks, solenoid gap, and insulation resistance standards (≥1 MΩ).

• Access: Manufacturer official websites, authorized dealer technical documentation.

• Search Path: Denso Starter Service Guide → Installation Precautions → Mechanical & Electrical Checks.

II. General Standards and Industry Norms

• SAE J563: 12V Starting system electrical safety and performance standard, covering voltage drop (≤0.2V), terminal insulation, and ground circuit requirements.

• ISO 15500: Road vehicle starter installation and maintenance specifications, including mechanical alignment, torque control, and wiring harness protection.

• Toyota Service Data and Specifications (SDS): Defines factory parameters such as starter no-load current and insulation resistance.

III. Verifiable Public Reference Sources

• Third-Party Manual Libraries (ManualsLib, CarManualsHub, etc.): Search for "Toyota Prado Starter Installation Precautions" or "Starting System Torque" to obtain the corresponding chapters.

• Toyota Authorized Dealer Maintenance Materials: Technician work instructions, consistent with factory manuals/TSB content, verifiable through 4S shop technical departments.