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Starter ASSY: Replacement

NOTE: Before changing the starter, check the following again:
  • Connector connection
  • Accessory installation (for example, theft deterrent system)
  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See step 4 in  PRECAUTION  ) 
  2. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  3. DISCONNECT BATTERY NEGATIVE TERMINAL 
  4. REMOVE V-BANK COVER 
  5. REMOVE AIR CLEANER INLET NO. 1 
  6. REMOVE INTAKE AIR CONNECTOR PIPE 
  7. REMOVE THROTTLE BODY ASSY (See step 5 in  REPLACEMENT  ) 
  8. REMOVE VACUUM SWITCHING VALVE ASSY 
  9. REMOVE FUEL PIPE SUB-ASSY NO. 2 (See step 12 in  REPLACEMENT  ) 
  10. REMOVE INTAKE MANIFOLD ASSY (See step 51 in  REPLACEMENT  ) 
  11. REMOVE WATER BY-PASS JOINT RR (See step 57 in  REPLACEMENT  ) 
  12. REMOVE WATER BY-PASS PIPE SUB-ASSY 
    1. Remove the bolt.
    2. Pull out the water by-pass pipe from the water pump.
    3. Disconnect the wire clamp from the bracket on the water by-pass pipe.
    4. Remove the O-ring from the water by-pass pipe.
      Fig 1: Removing Water By-Pass Pipe Sub-Assy
      G02999908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE STARTER ASSY 
    1. Remove the 2 bolts holding the starter to the cylinder block.
      Fig 2: Removing Bolts Holding Starter To Cylinder Block
      G02999909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the starter from the cylinder block.
    3. Disconnect the starter connector.
      Fig 3: Disconnecting Starter Connector
      G02999910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut, and disconnect the starter wire.
    5. Remove the bolt, and disconnect the wire clamp from the starter and remove the starter.
  14. INSTALL STARTER ASSY 
    1. Install the wire clamp to the wire bracket with the bolt.
      1. Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 
      Fig 4: Installing Wire Clamp To Wire Bracket
      G02999911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the starter wire with the nut.
      1. Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 
    3. Connect the starter connector.
    4. Install the starter with the 2 bolts.
      1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
      Fig 5: Installing Starter
      G02999912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL WATER BY-PASS PIPE SUB-ASSY 
    1. Install a new O-ring to the water by-pass pipe.
    2. Apply soapy water to the O-ring.
    3. Push in the water by-pass pipe end into the pipe hole of the water pump.
    4. Install the wire clamp to the bracket on the water by-pass pipe.
    5. Install the water by-pass pipe with the bolt.
      1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 
      Fig 6: Installing Water By-Pass Pipe Sub-Assy
      G02999913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL WATER BY-PASS JOINT RR (See step 98 in  REPLACEMENT  ) 
  17. INSTALL INTAKE MANIFOLD ASSY (See step 103 in  REPLACEMENT  ) 
  18. INSTALL FUEL PIPE SUB-ASSY NO. 2 (See step 17 in  REPLACEMENT  ) 
  19. INSTALL VACUUM SWITCHING VALVE ASSY 
  20. INSTALL THROTTLE BODY ASSY (See step 6 in  REPLACEMENT  ) 
  21. INSTALL INTAKE AIR CONNECTOR PIPE 
  22. INSTALL AIR CLEANER INLET NO. 1 
  23. CONNECT BATTERY NEGATIVE TERMINAL 
    NOTE: When disconnecting the negative (-) battery terminal, initialize the following systems after the terminal is reconnected (see INITIALIZATION ).
  24. INSTALL V-BANK COVER 
    1. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) 
  25. REFILL ENGINE COOLANT (See  REPLACEMENT  ) 
  26. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  27. INSPECT FOR FUEL LEAKS (See  PRECAUTION  ) 
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