dude.

cut slits in the ends of the starter bolts and you'll have a much easier time getting them back in.

 

http://lextreme.com/forums/showthread.php?t=5896

i posted that when i did mine.

 

New Starter installed, bolts went back in with no problem. What I did was spray the threads with some WD-40 and screw them in the starter before I mounted it. Today I also reinstalled the rear water bypass reusing the 2 gaskets. The original rubber seal on them was worn so what I did was make a new gasket using FORM A GASKET SEALANT NON-HARDENING. This should hold due to the fact that the original seal is thinner than what I made. The gasket shims are three layers of thin metal that are compressed together and get tighter when torqued good enough. I can't find these any where but the dealer and I will not wait any longer. My ride has been off the road for 2 weeks now.

Its X-mas eve all works ends now, will resume in 2 days and complete this bad boy. By then I should have my throttle body gasket. I'll keep you guys posted.

 

I had it tested at the local parts store and got 10 amps, can't recall the voltage.

 

Job done!
I was able to finally complete this project, but not without fustration and a lot of sweat. She hesitated to start at first because the gas had to build pressure, I began to panic. When I saw the engine trying to turn over I pumped the gas pedal a few times and she fired up. Oh what a beautiful feeling after 2 weeks. It wouldn't have taken so long if I had some help and if it did not happen during the Holidays.

I spent a total of $250 on this project

1. Aftermarket reman starter $131 - Lifetime warrenty as long as I own it.
2. Intake manifold gasket set $42
3. Extra tools (added to what I already have) $44
4. New 3/8, 5/16" hoses and clamps $10
5. Toyota coolant $23

Tools:

1. Craftsman 3/8 rachet 12, 10, 14mm sockets, 3/8 exstension bar (various sizes)
2. Needle nose pliers for factory hose clamps
3. Drop light of course for seeing underneath and on top of engine.
4. Hydraulic jack and Jack stands ( I have 2 6-ton capacity)
5. Breaker bar(s)
6. Torque wrench (for proper tightness and not breaking studs like I did)
7. A lot of patience and time....

I used other various little tools to get by, but what I listed is basic to the point. All you true D.I.Yers would know what I'm talking about. Would I do this project again? In the beginning I said no, but yes I would now that I know the steps. The LS is back on the road and I'm happy...

I went with an aftermarket starter because someone @ Carson Toyota told me that they also sell reman. So why pay an extra 100 bucks for a reman from the dealer when I could save and still get a warranty.

 

During nightmare project...

 

After nightmare project...

 

In response to post #20, the starters the dealer sells are remanufactured by Denso AFAIK. Who remanufactured yours?

 

10 amps to crank the motor and start the car? That seems kinda low...anyone here can confirm?

 

Actually the specified current is 11.5v : 100A or less, so therefore the 10 that was on the meter must by a multiple of 10. It tested around 100 amps.

 

Worldwide!

 

good job tackling this project. major kudos to you!

 

good job....very skillfull

 

Nice job, thanks for posting the power reqs. You're on your way to a complete teardown and rebuild of the engine itself FAQ, right?

 

damn man very hard work, nice job