Section 30 (Starting): Starter: Replacement

1. Using SST, remove the bearing.

   SST 09286-4601 1

   Fig 1: Removing Bearing Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a press, press in a new bearing.
   Fig 2: Installing Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the bearing.

   SST 09286-4601 1

   Fig 3: Removing Front Bearing Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in a new bearing.

SST 09820-00031

Fig 4: Installing Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove magnetic switch end cover.

   Remove the 3 bolts, the end cover, the gasket and the plunger.

   Fig 5: Removing Magnetic Switch End Cover

   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. 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) and insulation paper.

   Fig 7: Removing Terminal Nut Using SST

   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)

      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.
   Fig 8: Installing Terminal 30 Kit Components

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
6. Temporarily tighten the terminal nuts.
   Fig 9: Installing Terminal C Kit Components

   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 37 x 40 mm (0.79 x 1.46 x 1.57 in.) 

      Press force: 

      981 N (100 kgf, 221 lbf) 

      Fig 10: Putting Wooden Block On Contact Plate

      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: Calculating Gauge Pressure

        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 Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Clean contact surfaces of contact plate and plunger.

   Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.

   Fig 13: Cleaning Contact Surfaces

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Reinstall magnetic switch end cover.

   Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.

   Torque: 3.6 N.m (37 kgf.cm, 32 in.lbf)