Removal and Installation
REMOVAL1. REMOVE V-BANK COVER
2. DISCONNECT ACCELERATOR CABLE
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY .
5. REMOVE INTAKE MANIFOLD ASSEMBLY.
6. REMOVE REAR WATER BYPASS JOINT.
7. REMOVE WATER BYPASS PIPE
a. Remove the 2 bolts.
b. Pull out the water bypass pipe from the water pump.
c. Disconnect the wire clamp from the bracket on the water bypass pipe.
d. Remove the O-ring from the water bypass pipe.
e. Remove the water bypass pipe bracket from the water bypass pipe.
8. REMOVE STARTER
a. Remove the 2 bolts holding the starter to the cylinder block.
b. Disconnect the starter from the cylinder block.
c. Disconnect the starter connector.
d. Remove the nut, and disconnect the starter wire.
e. Remove the bolt, and disconnect the wire clamp from the starter and remove the starter.
REPLACEMENT
1. REPLACE REAR BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using a press, press in a new bearing.
2. REPLACE FRONT BEARING
a. Using SST remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new bearing.
NOTE: Be careful of the bearing installation direction.
SST 09820-00030
3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove magnetic switch end cover.
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
b. Inspect contact plate for wear.
Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove terminal kit parts.
1. Using SST loosen the terminal nuts.
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), O-ring, terminal bolt, contact plate and terminal insulator (inside).
d. Temporarily install these new terminal 30 kit parts:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
e. Temporarily install these new terminal C kit parts:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. Terminal insulator (outside)
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
f. Temporarily tighten the terminal nuts.
g. Tighten terminal nut.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force: 981 N (100 kg, 221 lb)
NOTE:
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kg, 221 lb) of force is applied.
- 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.
SST 09810-38140
Torque: 17 Nm (170 kg.cm, 13 ft.lb)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
h. Clean contact surfaces of contact plate and plunger.
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall magnetic switch end cover.
Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.
Torque: 3.6 Nm (37 kg.cm, 32 in.lb)
INSTALLATION
1. INSTALL STARTER
a. Install the wire clamp to the wire bracket with the bolt.
Torque: 9.81 Nm (98 kg.cm, 87 in.lb)
b. Connect the starter wire with the nut.
Torque: 9.81 Nm (98 kg.cm, 87 in.lb)
c. Connect the starter connector.
d. Install the starter with the 2 bolts.
Torque: 39 Nm (400 kg.cm, 29 ft.lb)
2. INSTALL WATER BYPASS PIPE
a. Install the water bypass pipe bracket to the water bypass pipe.
b. Install a new O-ring to the water bypass pipe.
c. Apply soapy water to the O-ring.
d. Push in the water bypass pipe end into the pipe hole of the water pump.
e. Install the wire clamp to the bracket on the water bypass pipe.
f. Install the water bypass pipe with the 2 bolts.
Torque: 18 Nm (185 kg.cm, 13 ft.lb)
3. INSTALL REAR WATER BYPASS JOINT
4. INSTALL INTAKE MANIFOLD ASSEMBLY
5. CONNECT THROTTLE BODY
6. INSTALL INTAKE AIR CONNECTOR
7. CONNECT ACCELERATOR CABLE
8. INSTALL V-BANK COVER