starter 28100-97401 31388 28100-97401 28100-97214 CS1498 228000-9252 442067， 31388N， 115784， CST40164AS S6319S UD16850S 0986026070 115784 FOR Toyota

• Preparation Work

• Disconnect the negative cable of the battery to prevent short - circuits during the installation process.

• Prepare tools such as a jack, socket wrench, and torque wrench.

• Installing the New Starter

• Lift the new starter and align it with the installation position on the engine, sliding the nose of the starter into the hole in the transmission housing.

• Install the fixing bolts of the starter. Generally, the tightening torque of the starter fixing bolts for Toyota pickups is 30 foot - pounds (about 40.6 N·m). However, it may vary for different models, so it is necessary to tighten the bolts according to the specified torque in the vehicle maintenance manual.

• Connecting the Wiring Harness

• Install the wiring harness connector of the starter onto the starter, ensuring that the connector is fully seated.

• Connect the battery cable to the "B" terminal of the starter and tighten the nut.

• Inspection and Testing

• Check whether the starter is firmly installed and whether the wiring harness is correctly connected.

• Connect the negative cable of the battery.

• Try to start the vehicle to check whether the starter is working properly.

I. Safe Operation Specifications

1. Strict Power-off Protection: Before installation, the negative battery cable must be disconnected. Reconnecting the negative terminal is prohibited until all wiring harness connections are completed to avoid sparks, electric shocks, or damage to internal electrical components of the starter caused by short circuits. It is recommended to wear insulating gloves during operation and stay away from other live components in the engine compartment.

2. Avoid Component Damage: The starter contains precision coils and gear structures. It should be handled with care during transportation and installation. Knocking or colliding with the starter housing is prohibited to prevent displacement or damage to internal parts, which may affect transmission and starting performance.

3. Fire and Explosion Prevention: The installation area should be away from flammable and explosive materials (such as fuel containers for gasoline, diesel, etc.). Smoking or using open flames during installation is prohibited to avoid safety accidents caused by sparks from short circuits.

II. Key Points During Installation

1. Accurate Alignment of Installation Position: When sliding the starter nose into the transmission housing hole, ensure precise alignment. Forcible prying or squeezing is avoided to prevent damage to the edge of the transmission housing hole or the sealing structure of the starter nose, which may lead to oil leakage or abnormal noise later.

2. Bolt Tightening in Accordance with Standards

• Original factory or high-strength fixing bolts matching the vehicle model must be used. Bolts with inconsistent specifications are prohibited to prevent insecure installation or uneven force bearing.

• Tighten the fixing bolts strictly according to the torque specified in the vehicle maintenance manual. Excessive torque may cause thread stripping and housing deformation; insufficient torque will result in vibration and displacement of the starter during operation, and may even damage the mounting base.

3. Standardized Wiring Harness Connection

• Before connecting the wiring harness, check whether the wiring harness connector and the starter terminal are oxidized or rusted. If so, polish them clean with fine sandpaper to ensure good contact and avoid startup failure or terminal heating due to poor contact.

• When connecting the battery cable to the "B" terminal, ensure the nut is tightened in place and avoid pinching the cable insulation layer; the wiring harness connector must be fully engaged to prevent loosening and falling off, which may cause circuit faults.

• Distinguish the functions of each wiring harness. Wrong connection or reverse connection is prohibited, especially avoiding reversing the positive and negative poles of the power supply, otherwise the starter coil and the vehicle electrical system will be burned out.

III. Component Adaptation and Condition Inspection

1. Confirm Component Model Matching: The model and power of the new starter must be consistent with the original factory specifications of the vehicle to avoid installation size deviation, circuit incompatibility, or failure to meet the engine starting requirements due to inconsistent models.

2. Component Inspection Before Installation: Before installation, check whether the gear of the new starter rotates flexibly, whether the coil terminal is intact without damage, and whether the sealing ring is complete. If quality problems are found in the components, they should be replaced in a timely manner, and the installation of unqualified products is prohibited.

3. Inspection of Associated Components of Old Parts: If replacing an old starter, it is recommended to simultaneously check the wear condition of the engine flywheel ring gear. If there are problems such as severe wear and tooth breakage on the ring gear surface, it should be replaced together. Otherwise, it will lead to poor meshing between the starter gear and the ring gear, resulting in abnormal startup noise or failure to start.

IV. Post-installation Inspection and Testing

1. Comprehensive Inspection and Confirmation: Before reconnecting the negative battery cable, recheck the tightness of the starter fixing bolts and the correctness of the wiring harness connection to ensure there is no loosening or wrong connection. In addition, the wiring harness should be arranged reasonably to avoid interference with engine rotating components (such as belts, fans, etc.).

2. Phased Test Operation: During the first startup, start the engine briefly and then turn it off immediately to observe whether the starter has abnormal noise, heating, etc. If there is no problem, start the vehicle normally, test the startup response speed and stability of the starter, and confirm there are no faults such as jamming or weakness.

3. Subsequent Condition Monitoring: After the test drive, check the temperature of the starter housing (it should not be excessively hot after normal operation) and whether the terminal has heating or discoloration. If abnormalities occur, stop the machine immediately for inspection to eliminate problems such as poor contact.

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