Starting System: Starter: Replacement

REPLACE REAR BEARING
1. Using SST, remove the bearing. SST 09286-46011
  
  Fig 1: Removing Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a press, press in a new bearing.
  
  Fig 2: Pressing In Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE FRONT BEARING
1. Using SST, remove the bearing. SST 09286-46011
  
  Fig 3: Removing Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in a new bearing.
  NOTE: Be careful of the bearing installation direction.
  
  SST 09820-00031
  
  Fig 4: Pressing In Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
1. Remove the magnetic switch end cover.
  Remove the 3 bolts, the end cover, the gasket and the plunger.
  
  Fig 5: Identifying Magnetic Switch End Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect contact plate for wear.
  Using vernier calipers, measure the contact plate for depth of wear.
  
  Maximum wear: 0.9 mm (0.035 in.)
  
  If the depth of wear is greater than the maximum, replace the contact plate.
  
  Fig 6: Checking Contact Plate Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove terminal kit parts.
  1. Using SST, loosen the terminal nuts.
    SST 09810-38140
  2. Terminal C:
    Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
  3. Terminal 30:
    Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate, terminal insulator (inside).
    
    Fig 7: Loosening Terminal Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install these new terminal 30 kit parts:
  1. Terminal insulator (inside)
  2. Contact plate
  3. Terminal bolt
  4. O-ring
  5. Packing and terminal insulator (outside)
    
    Fig 8: Exploded View Of Terminal 30 Kit Parts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Install the packing to the terminal insulator, and install them.
    
    HINT:
    
    Match the protrusion of the insulator with the indentation of the housing.
  6. Wave washer
  7. Terminal nut
  NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
5. Temporarily install these new terminal C kit parts:
  1. Terminal insulator (inside)
  2. Contact plate
  3. Terminal bolt
  4. O-ring
  5. Terminal insulator (outside)
  6. Wave washer
  7. Terminal nut
  NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
  
  Fig 9: Exploded View Of Terminal C Kit Parts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Temporarily tighten the terminal nuts.
7. Tighten terminal nuts.
  1. Put a wooden block on the contact plate and press it down with a hand press.
    Dimensions of wooden block:
    
    20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
    
    Press force:
    
    981 N (100 kgf, 221 lbf)
    
    Fig 10: Aligning Contact Plates
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied.
    Gauge pressure:
    
    Fig 11: Gauging Pressure Of Hand Press Ram
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
  2. Using SST, tighten the nuts to the specified torque.
    SST 09810-38140
    
    Torque: 17 N.m (170 kgf.cm, 13 ft.lbf)
    
    NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
    
    Fig 12: Tightening Nuts Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Clean contact surfaces of the contact plate and the plunger.
  Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
  
  Fig 13: Identifying Contact Surfaces
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Reinstall the magnetic switch end cover.
  Install the plunger, the new gasket, the end cover and lead clamp with the 3 bolts.
  
  Torque: 3.6 N.m (37 kgf.cm, 32 in.lbf)