Starter Solenoid Contacts Replacement DIY (2000 I4)

[haux]

Based on this write-up -> DIY--Replace Solenoid Contacts and Plunger on 00 Camry V6

Did it at night. This new handy light with a magnet base was very helpful!

Took me about an hour for removal (and photos!).
Two hours to clean inside and replace components.
Less than an hour to put starter back in.

The process of replacing the components would have gone faster, but I had to get a ride to AutoZone for electrical cleaner. And then I forgot how the contacts went back together so it took a little bit to get that figured out. Then a 7mm bolt broke and I had to find a replacement.


By this point I had already removed the battery/tray, and secured the positive battery cable with a rag and zip-tie.




10mm bolts.



Remove this connector from the back of the cruise box.



The cable is clipped onto the metal bracket. Use pliers to squeeze the sides (from the back) of the clip to pull it out.





Move the box aside.



Remove this connector from the starter. And take notice of the first Starter bolt.



Remove this cable from the clip for better access to the bolt.



Remove the 14mm Starter bolt number one. This one was tough, so I used a pipe for some extra torque.




Bolt number two is on the other side of the starter. It's a bit more difficult to get at and will likely be a slower process. Putting this one back in will be even slower than removal.




Remove the 12mm nut attaching the battery cable to the bottom side of the starter. You may need to rotate the starter a bit to access this. The nut is covered by a rubber boot.









Unscrew these three 7mm bolts to remove the cover.



Removal of the contacts is fairly straightforward. Just be sure to remember how they go back together. I cleaned the plunger and this inside part of the starter with electrical cleaner. I did not have high temperature grease to re-lubricate the plunger spring and starter gear, so I did not remove the old grease. I just added a bit of new grease (may or may not be high temp) to both of them. Also, carefully remove the gasket for the cover.



Reassembly. One of the cover bolts broke, so I replaced all three of them with stainless steel screws.







Notes:
Had I known there was a gasket for that cover, I would have replaced it as well. Although the existing one is in good shape.

[ghettosled]

great writeup and photos! many kudos.

[ddagsyn]

Excellent write up.. BTW the gasket cover for what its worth the Parts guy at the Toyota Dealership said you don't need to replace it.

[haux]

Originally Posted by ddagsyn

Excellent write up.. BTW the gasket cover for what its worth the Parts guy at the Toyota Dealership said you don't need to replace it.

Yeah I figured the same thing. There's no fluid in there so nothing is going to leak out. But it's something I would have just replaced anyway.

[mattliston]

Using this writeup as a guide for doing the starter removal and contacts replacement on my brothers 2.2 liter equipped celica

[Nervous]

Great write-up! Wow you got OEM starter kit! I tried to find one but failed and bought the one from ebay. How much did you pay? Did you replace the plunger or just copper ring on it (or did nothing but cleaning)? Can you publish OEM part numbers for starter kit parts you got?

(Ouch, the topic is old. But still, would be curious to get answers)

Here is my experience for V6 starter (they are the same, actually): A project car? Camry Wagon V6 LE (pics)

[fenixus]

nice! gj

[mattliston]

well I replced the contacts using generic ones from united autosupply. damn near 100% match.

ot everything hooked back up, took several tries to start. onces started, it made a grating, grinding sound. I cleaned teh plunger and used high temp grease.

is this normal? does it need to "break in" by running?

since it started that one time, ive tried 40 odd times to restart, no luck. 91 celica gts 2.2 manual

I disconnected teh clutch switch and faked it as if the clutch is permanetnly pushed in, via a small piece of twisted wire. no luck. hooked it back up, I listened even closer. UI get clicks of relays, I get the hum of teh fuel pump, and I get the electric bump from the stereo amp under the passenger seat.


bad starter solenoid? bad starter relay?

Im lost

[Nervous]

Have you tested the starter before installing it back? FSM describes full testing procedure, how to test only solenoid, how to test only the motor and how to test everything together off the vehicle.
Have you replaced the plunger or at least the copper ring on it? Because if not - I'd consider only half of work is done. Mine was in pretty bad shape (see the link with pics above).

[mattliston]

FSM?

the plunger's copper ring WAS worn. I sanded it smooth and clean. the spring on the plunger keeps tension for contact, so teh plunger should be fine I think

[Nervous]

FSM - factory service manual at camrystuff.com

[Nervous]

So, ring is thinner now. Don't know, I replaced whole plunger and it works perfectly. I got kit from here: http://cgi.ebay.com/ebaymotors/ws/eB...m=220585074933

[mattliston]

Originally Posted by Nervous

FSM - factory service manual at camrystuff.com

you are awesome

[haux]

Originally Posted by Nervous

Did you replace the plunger or just copper ring on it (or did nothing but cleaning)? Can you publish OEM part numbers for starter kit parts you got?

I only cleaned the plunger.

And the part numbers are actually written on the packaging of the kits (in the photo). =)

I used the other v6 write-up as a guide when I did mine. I just thought I could do a little bit better with the photos.

[Nervous]

Yeah, first time I saw the photos for some reasons I decided OEM numbers are not readable Oh, well.... I still think that plunger should be replaced as well. OEM number 28235-74130, price at partznet.com is $21.07 + shipping. At regular dealer it would be about $28 + tax.