Magnetic Switch Terminal Kit

Starter (5VZ-FE):

REPLACEMENT

Magnetic Switch End Cover (5VZ-FE):

1. REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.

Contact Plate (5VZ-FE):

2. 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.

(5VZ-FE):

3. REMOVE TERMINAL KIT PARTS
a. Using SST, loosen the terminal nuts.
SST 09810-38140

b. Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).

c. Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.

Terminal Kit Parts / Terminal #30 (5VZ-FE):

4. REINSTALL TERMINAL KIT PARTS
a. Install these new parts:

Terminal 30:
1. Insulation paper
2. Terminal insulator (inside)

NOTE: Be careful to install the terminal insulator in the correct direction.

3. Contact plate
4. Terminal bolt
5. O-ring
6. 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.

7. Wave washer
8. Terminal nut

Terminal Kit Parts / Terminal #C (5VZ-FE):

Terminal C:
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) in the correct direction.

b. Temporarily tighten the terminal nuts.

5. TIGHTEN TERMINAL NUT
a. Put a wooden block on the contact plate and press it down with a hand press.

Dimensions of wooden block:
20 x 37 x 40mm (0.79 x 1.46 x 1.57 in.)

Press force:
981 N (100 kgf, 221 lbf)

NOTE:
^ Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied.

Gauge pressure:

Gauge Pressure (3RZ-FE):

^ 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.

(5VZ-FE):

b. Using SST, tighten the nuts to the specified torque.
SST 09810-38140

Torque: 17 N.m (170 kgf.cm, 12 ft.lbf)

NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.

Contact Plate & Plunger (5VZ-FE):

6. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.

7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.

Torque:
1.4 kW type: 2.5 N.m (25 kgf.cm, 22 in.lbf)
1.8 kW type: 3.6 N.m (37 kgf.cm, 32 in.lbf)