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 A New Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE FRONT BEARING
1. Using SST, remove the bearing.
  SST 09286-46011
  
  Fig 3: Removing Front Bearing Using SST
  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 A New Bearing Using SST & A Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
1. Remove the magnetic switch end cover. Remove the 3 nuts, the end cover, the gasket and the plunger.
  NOTE: Do not loosen the 3 stud bolts.
  
  Fig 5: Removing Nuts, End Cover, Gasket & Plunger
  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: Measuring Contact Plate For Depth Of Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove terminal kit parts.
  1. Put a wooden block on the plate, and press it down with a hand press.
    Dimensions of wooden block: 20 X 33 X 40 mm (0.79 X 1.30 X 1.57 in.)
  2. Using SST, loosen the terminal nuts.
    SST 09810-38140
  3. Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
  4. Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.
    
    Fig 7: Putting A Wooden Block On Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install these new terminal 30 kit parts:
  1. Contact plate (*1)
  2. Terminal bolt (*2)
  3. O-ring (*3)
  4. Wave washer (*4)
  5. Terminal nut (*5)
    
    Fig 8: Installing Terminal 30 Kit
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Temporarily install these new terminal C kit parts:
  1. Contact plate (*1)
  2. Terminal bolt (*2)
  3. O-ring (*3)
  4. Wave washer (*4)
  5. Terminal nut (*5)
6. Temporarily tighten the terminal nuts.
  
  Fig 9: Installing Terminal C Kit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 33 x 40 mm (0.79 x 1.30 x 1.57 in.)
    
    Press force: 981 N (100 kgf, 221 lbf)
    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.
    
    Fig 10: Putting A Wooden Block On Contact Plate & Pressing It Down With A Hand Press
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Gauge pressure: kgf/cm ² = 100 kgf / (Ram diameter (cm) / 2) ² x 3.14)
    
    (psi) = 221 lbf / (Ram diameter (in) / 2) ² x 3.14
    
    (kPa) = (kgf/cm ² ) x 98.1
    
    (kPa) = (psi) x 6.9
    
    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 plastic frame.
    
    Fig 11: Tightening Nuts To Specified Torque 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.
9. Reinstall the magnetic switch end cover. Install the plunger, the new gasket and the end cover with the 3 nuts.
  Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf)
  
  Fig 12: Installing Plunger, Gasket & End Cover With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002