Starter 28100-B1060 28100B1060 2810087402000 28100-97214 Suitable for Daihatsu, Toyota

I. Pre-installation Preparation

1. Safety and Tools: Turn off the ignition switch and remove the key, disconnect the negative cable of the battery (to prevent short circuit and accidental start-up); prepare socket wrench, torque wrench, screwdriver, cleaning agent, new bolts/washers (if old parts are damaged).

2. Component Inspection: Confirm that the model of the new starter is 12V 0.8KW and compatible with the vehicle; check that there is no damage to the appearance, the gear, brush and other components are intact, and the electromagnetic switch functions normally.

3. Removal and Cleaning of Old Parts: Locate the old starter at the junction of the engine and gearbox, mark the positions of wiring harness terminals (e.g., B+, S terminals); remove the fixing bolts, disconnect the wiring harness (first remove the large wire nut, then pull out the small wire plug), take out the old starter; clean oil stains and rust on the mounting surface to ensure flat fitting.

II. Installation Steps

1. Positioning and Fixing: Align the new starter with the mounting holes, insert the fixing bolts, and manually pre-tighten 2-3 turns; fasten according to the vehicle model specifications with a torque wrench (commonly 45±5N·m, subject to the maintenance manual), tighten symmetrically and evenly to avoid housing deformation.

2. Wiring Connection

• First connect the B+ terminal (thick power wire), with the nut torque of about 12±2N·m, and install an insulating protective cover.

• Then connect the S terminal (electromagnetic switch control wire) plug to ensure it is clamped in place without looseness.

• Check the routing of the wiring harness to avoid interference with the flywheel and heat dissipation components, and fix it with cable ties.

3. Reset and Power-on: Refit the wiring harness bracket, clips and other components; connect the negative cable of the battery to ensure good contact.

I. Safety Operation Category

1. Power-off Operation Must Be a PriorityDisconnect the negative cable of the battery before installation (to avoid short circuit burning the ECU, wiring harness or causing accidental start-up), and reset after installation; it is forbidden to plug or unplug wiring harness terminals in the power-on state.
2. Prevention of Mechanical InjuryThe meshing area between the starter gear and the engine flywheel is unprotected; keep hands away from the opening of the flywheel housing during installation; confirm that there are no tools or debris around before testing start-up to prevent entanglement.
3. Fire and Explosion PreventionThe operation area should be away from fuel pipelines and oil leakage points to avoid sparks caused by knocking of metal tools; if the vehicle is parked in an enclosed space (such as a garage), keep ventilation during testing to prevent exhaust gas accumulation.

II. Installation Accuracy Category

1. Positioning and Fitting RequirementsThe starter mounting surface must be clean without oil stains, rust or deformation; gaskets (if any) must be reinstalled in their original positions to ensure the housing fits tightly with the engine/gearbox, otherwise it may lead to uneven stress on bolts, housing cracking or abnormal noise.
2. Bolt Fastening SpecificationsFixing bolts need to be tightened symmetrically and evenly (pre-tighten first, then tighten step by step), and the torque must strictly follow the vehicle model manual (40-50N·m). Loose bolts will cause vibration and falling off, while over-tightening may crack the housing or strip the threads;It is forbidden to use an extended wrench for violent tightening; a torque wrench is recommended for precise operation.
3. Wiring Harness Connection Sequence and TorqueConnect the thick wire first (B+ terminal, torque 10-14N·m), then the thin wire (S terminal plug) to avoid misoperation of the electromagnetic switch caused by connecting the control wire first;The nut of the B+ terminal should be equipped with a flat washer and a spring washer (if originally configured by the factory), and an insulating protective cover should be put on after tightening to prevent short circuit.

III. Component Protection Category

1. No Knocking on the StarterIf jamming occurs during installation alignment, do not knock the housing or gear end (which may damage internal bearings, brush holders or one-way clutches); re-adjust the position or check if the flywheel ring gear is misaligned.
2. Protection of Wiring Harness RoutingWiring should be away from high-temperature components of the engine (such as exhaust pipes and cylinder blocks) and moving parts (such as belts and flywheels), and fixed firmly with cable ties to avoid abrasion of the insulating layer and short circuit.
3. Inspection of Old Part AdaptabilityIf old bolts/gaskets are reused, confirm that there is no deformation, thread slipping or fatigue cracks; the starter model must match (12V 0.8KW, compatible with the number of teeth of the flywheel ring gear and mounting hole positions), and mixing of components of different specifications is prohibited.

IV. Testing and Acceptance Category

1. No-load Test LimitationsIt is forbidden to start the starter with no load for a long time (more than 5 seconds); start again at an interval of 10 seconds after a single test to prevent coil overheating and burning; if start-up fails for many times, cut off the power immediately for troubleshooting to avoid damage to the electromagnetic switch.
2. Inspection of Meshing StateListen to the gear meshing sound during start-up: normal is "clear meshing + stable operation"; if "tooth hitting sound" or "jamming sound" occurs, cut off the power immediately and check the gap between the gear and the flywheel ring gear and whether the starter is mispositioned.
3. Inspection of Terminal Temperature RiseTouch the B+ terminal and wiring harness connector after start-up; no obvious temperature rise (≤40℃) is normal; if it gets hot, re-tighten the terminal or check if the cross-sectional area of the wiring harness matches.

V. Precautions for Special Scenarios

1. Waterlogged/Corroded VehiclesIf the vehicle has been waterlogged, check if the starter terminal is oxidized (green copper rust) before installation, polish it with sandpaper and apply conductive paste to prevent poor contact.
2. Installation in Low-temperature EnvironmentDuring installation in winter, first clean the frost on the mounting surface, apply a small amount of anti-seize agent to the bolts (to avoid thread freezing); if the start-up is weak during testing, check the battery voltage (≥12.4V).

References：

Toyota/Daihatsu Original Factory Maintenance Manuals

General Automotive Industry Maintenance Specifications

Component Installation Technical Documents

Professional Automotive Repair Platform Materials