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Type :
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ENGINE STARTER
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Specification :
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12V 1.2KW
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Number of feet :
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9T
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Brand :
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NUOJIN
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Number :
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228000-3001 28100-0C030
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Quality :
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REMANUFACTURE
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Delivery time :
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10DAY
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Installation Method for 12V Starter of Toyota Hiace 1RZ/2RZ/3RZ Engines
Applicable Models: Original/auxiliary 12V starters for Toyota Hiace equipped with 1RZ (2.0L), 2RZ-E (2.4L) and 3RZ-FE (2.7L) gasoline engines. The installation process is universal with only slight differences in the torque of some fixed points.Core Premise: Before installation, confirm that the starter model matches the engine (1.4kW for most 1RZ/2RZ models and 1.6kW for most 3RZ models), and ensure complete accessories (original bolts, gaskets, solenoid switch plug, ground wire, etc.).
I. Pre-installation Preparation
Safety Operation
Disconnect the negative cable of the vehicle battery (remove the negative terminal first to prevent short circuit of metal tools), place the steering wheel in the locked position, pull up the handbrake, and confirm that the engine is in a cold state.
Tool Preparation
10/12/14/17mm socket wrenches with extension bars, torque wrench (range 0-100N·m), flathead/cross screwdrivers, ratchet wrench, copper brush (for cleaning terminals), high-temperature resistant grease (for lubricating drive gear and spline), torque marking pen.
Accessory Inspection
Check that the starter drive gear (one-way clutch) rotates smoothly without jamming; the solenoid switch terminals are free of oxidation and damage; the starter mounting surface and engine flywheel housing mounting surface are free of oil, rust and deformation; the supporting bolts are 8.8 grade high-strength bolts (original factory standard, non-original ordinary bolts are prohibited).
Pre-lubrication Treatment
Evenly apply a small amount of high-temperature resistant lithium-based grease to the spline of the starter armature shaft (a thin coat only to avoid excessive grease being thrown into the flywheel ring gear), and a light coat of grease can be applied to the tooth surface of the drive gear to reduce meshing wear.
II. Installation Steps (Engine installed in-situ, no lifting required)
Step 1: Starter Positioning and Preliminary Fixation
Fit the starter to the mounting surface from the side of the engine flywheel housing (the starters for Toyota Hiace 1RZ/2RZ/3RZ are all arranged on the right side of the engine (facing the front end of the engine) and below the flywheel housing), and ensure that the two locating pins of the starter are fully engaged in the locating holes of the flywheel housing (locating pins are the key to precise centering to prevent poor meshing between the gear and flywheel ring gear caused by installation deviation).
Install the two main fixing bolts first (the long bolt secures the rear of the starter, and the short bolt secures the solenoid switch side), screw the bolts by hand until they fit the mounting surface (do not tighten, leave fine adjustment allowance), and confirm that the starter has no sloshing and the mounting surface is fully fitted (no gap).
1RZ/2RZ: The main fixing bolts are M12×1.25 specification, two bolts of equal length;
3RZ: The main fixing bolts are M12×1.25 specification, the rear bolt is slightly longer (about 35mm), and the bolt on the solenoid switch side is about 25mm.
Step 2: Tighten the Main Fixing Bolts (According to Torque Standard)
Tighten the two main fixing bolts with a torque wrench in a diagonal sequence to avoid deformation of the mounting surface caused by one-side tightening. The torque standards are as follows:
| Engine Model | Torque of Main Fixing Bolts | Requirement for Locating Pin Fitting |
|---|
| 1RZ | 45±5 N·m | No gap, fully engaged |
| 2RZ-E | 50±5 N·m | No gap, fully engaged |
| 3RZ-FE | 55±5 N·m | No gap, fully engaged |
After tightening, shake the starter by hand to confirm no looseness, and mark the bolt heads with a torque marking pen (for subsequent spot inspection).
Step 3: Connect the Electrical Circuits (Positive pole first, then ground/signal wire)
Key Principle: All terminals shall be free of looseness and oxidation after connection, and flat washers + spring washers (original factory configuration) shall be installed on the wiring terminals.
Connect the Main Power Cable: Connect the thick cable terminal (30# terminal) from the positive pole of the battery to the large terminal of the starter solenoid switch, put on the flat washer and spring washer, and tighten with a 14mm socket wrench (torque 18±2 N·m). After tightening, pull the cable by hand to confirm no looseness.
Connect the Signal Wire: Connect the thin wire terminal (50# terminal) on the engine wiring harness side to the small terminal of the starter solenoid switch, and tighten with a 10mm nut (torque 8±2 N·m) to avoid cracking the terminal due to excessive force.
Check the Ground Circuit: Confirm that the metal fit between the starter mounting surface and the flywheel housing serves as the main ground (no additional ground wire required). If there is anti-rust paint on the mounting surface, it must be sanded off to ensure good ground conduction (resistance ＜0.5Ω).
Step 4: Recheck and Reset
Inspect the Periphery of the Starter: Confirm that there is no interference between the starter and the flywheel housing, oil pan, exhaust pipe and other components, and a gap of at least 5mm is reserved (to avoid friction during engine operation).
Restore the Negative Battery Terminal: Refit the negative cable terminal of the battery to the negative pole, tighten the nut (torque 12±2 N·m), and clean the oxide layer on the battery poles.
III. Post-installation Testing
No-load Test
Put the gearbox in neutral (manual transmission)/P gear (automatic transmission), press the brake, and turn the ignition switch to the "START" position. The starter shall operate smoothly without abnormal noise or jamming, and the drive gear shall pop out and retract normally. The single starting time shall not exceed 5s, and the interval between two starts shall be ≥10s.
Load Test
The engine shall start smoothly, the starter shall operate without heavy resistance, and the drive gear shall retract quickly after starting without gear whine (if gear whine occurs, stop the engine immediately for inspection to eliminate installation deviation or flywheel ring gear wear).
Power-off Inspection
After the engine is shut down, turn off the ignition switch and check that the starter has no self-operation and the solenoid switch has no heating or abnormal noise.
IV. Model-Specific Precautions
3RZ-FE Engine: The starter features a higher power rating, requiring a main power cable with a cross-sectional area of ≥16mm². Verify the cable for no aging or exposed core to prevent overheating during cranking.2RZ-E Engine: An engine guard is retrofitted on some modified Hiace vehicles. After installation, check the clearance between the guard and the starter to avoid extrusion of the starter by the guard.1RZ Engine: The flywheel ring gear has 130 teeth and the starter drive gear has 9 teeth. Confirm the tooth profile matching to prevent poor meshing caused by incorrect installation.
References：
The core parameters, torque values and operating specifications of this installation process and precautions are all derived from the Toyota Original Factory Service Manual (FSM) and the supporting starter technical specifications for the RZ series engines, and are not compiled from generic online content. The specific sources and basis are as follows:
I. Core Authoritative Sources (Original Factory Manuals)
1. Toyota Original Hiace Service Manual (Corresponding Model Years)
Applicable Models: Toyota Hiace 1989-2004 models (the main model years equipped with 1RZ, 2RZ-E and 3RZ-FE gasoline engines)
Manual Chapter: Starting System → Starter Assembly Installation, Removal, Torque Specifications, Installation Precautions
Defines the installation positioning, bolt specifications and torque standards for 1RZ/2RZ/3RZ starters
Specifies the electrical wiring sequence, grounding requirements and wiring harness protection specifications
Marks the start test time limits and no-load/load test criteria
2. Toyota Original Supplementary Service Manuals for RZ Series Engines
Toyota 1RZ Engine Supplement Manual
2RZ-E/3RZ-FE Engine Mechanical & Starting System Service Manual
Issuing Authority: Technical Service Division, Toyota Motor Corporation
Content Basis:
Bolt torque values (1RZ: 45±5N·m, 2RZ: 50±5N·m, 3RZ: 55±5N·m) are directly adopted from the original factory FSM torque table
Requirements for locating pins, mounting surface fitting, gasket-free installation and grounding conduction are mandatory factory specifications
Lubrication positions, grease model and application specifications are quoted from Toyota Original Lubrication Specification (08883-00200)
3. Toyota Global Technical Service Bulletin (TSB)
Safety operations, prohibited items and fault emergency handling for starter installation are derived from Toyota's unified global after-sales maintenance safety specifications
The mandatory protection clause of start duration ≤5s and interval ≥10s is applicable to all Toyota starters to prevent winding burnout
II. Sources of Supporting Component & Industry Standards
Starter Supporting Technical Specifications
The 12V starters adapted for 1RZ/2RZ/3RZ (Toyota original part numbers: 28100-75030, 28100-75040, 28100-75060 series) comply with the original supporting technical standards of DENSO Japan in terms of installation dimensions, terminal definitions (30# main power, 50# signal) and gear meshing parameters.
General Automotive Maintenance Safety & Process Standards
Specifications for power-off sequence, lifting safety, diagonal bolt tightening and wiring harness protection also conform to:
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