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Starter ASSY: Replacement

NOTE: Before changing the starter, check the following again:
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION  ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  3. DRAIN ENGINE COOLANT 
  4. REMOVE INTAKE MANIFOLD ASSY (See  REPLACEMENT  ) 
  5. 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
      G02954171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE STARTER ASSY 
    1. Disconnect the starter connector.
    2. Remove the nut and disconnect the starter cable.
    3. Remove the bolt and disconnect the engine wire protector.
    4. Remove the 2 bolts and starter.
      Fig 2: Removing Starter Assy
      G02954172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL STARTER ASSY 
    1. Install the wire clamp to the wire protector with the bolt.

      Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

      Fig 3: Installing Starter Assy
      G02954173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the starter cable with the nut.

      Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

    3. Connect the starter connector.
    4. Install the starter with the 2 bolts.

      Torque: 39 N.m (398 kgf.cm, 29 ft.lbf) 

      Fig 4: Installing Starter
      G02954174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Fig 5: Installing Water By-Pass Sub-Assy
      G02954175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL INTAKE MANIFOLD ASSY (See  REPLACEMENT  ) 
  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  11. PERFORM INITIALIZATION (See  INITIALIZATION  ) 
    NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  12. ADD ENGINE COOLANT 
  13. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM  ) 
  14. CHECK FOR FUEL LEAKS (See  PRECAUTION  ) 
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