Repair and Diagnosis: Electrical: Starter: Starting: Starter: Replacement

REPLACE FRONT BEARING
1. Using SST, remove the bearing.
  1. SST 09286-46011
  Fig 1: Removing 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.
  1. SST 09820-00031
  Fig 2: Pressing In New Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE REAR BEARING
1. Using SST, remove the bearing.
  1. SST 09286-46011
  Fig 3: Removing Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a press, press in a new rear bearing.
  
  Fig 4: Pressing In New Rear Bearing Using Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE MAGNETIC SWITCH TERMINAL PARTS
1. Remove the 3 bolts, end cover, gasket and plunger.
  
  Fig 5: Locating Magnetic Switch Terminal Parts Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using vernier calipers, measure the contact plate for depth of wear.
  1. 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 the terminal kit parts.
  1. Using SST, loosen the terminal nuts.
    1. 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), packing, O-ring, terminal bolt, contact plate and terminal insulator (inside).
    
    Fig 7: Loosening Terminal Nuts Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install new terminal 30 kit parts:
  1. Install a new terminal insulator (inside).
  2. Install a new contact plate.
  3. Install a new terminal bolt.
  4. Install a new O-ring.
  5. Install a new packing and terminal insulator (outside).
    Install the packing to the terminal insulator, and install them.
    
    Fig 8: Installing New Terminal 30 Kit Parts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    Match the protrusion of the insulator with the indentation of the housing.
  6. Install a new wave washer.
  7. Install a new terminal nut.
  NOTE: Be careful to install the terminal insulators in the correct direction.
5. Temporarily install new terminal C kit parts:
  1. Install a new terminal insulator (inside).
  2. Install a new contact plate.
  3. Install a new terminal bolt.
  4. Install a new O-ring.
  5. Install a new terminal insulator (outside).
  6. Install a new wave washer.
  7. Install a new terminal nut.
    
    Fig 9: Installing New Terminal C Kit Parts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE: Be careful to install the terminal insulators in the correct direction.
6. Temporarily tighten the terminal nuts.
7. Tighten the terminal nut
  1. Put a wooden block on the contact plate and press it down with a hand press.
    1. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
    2. Press force: 981 N (100 kgf, 221 lbf)
    Fig 10: Tightening Terminal Nut
    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:
    
    (kgf/cm ² ) = Ω
    
    (psi) = Ω
    
    (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.
    1. SST 09810-38140
    1. Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
    Fig 11: Tightening Nuts To Specified Torque Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
8. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
  
  Fig 12: Cleaning Contact Plate & Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Reinstall the plunger, new gasket, end cover and lead clamp with the 3 bolts.
  1. Torque: 2.5 N.m (26 kgf.cm, 22 in.lbf)