Repair and Diagnosis: Electrical: Starter: Starting: Starter: Reassembly

INSTALL STARTER CLUTCH SUB-ASSEMBLY
1. Apply grease to the steel ball, return spring, clutch rollers and starter idler pinions.
2. Install the steel ball.
3. Install a new O-ring to the starter housing.
4. Insert the return spring into the magnet starter switch hole.
5. Install the starter clutch sub-assembly, idler gear and bearing.
  
  Fig 1: Identifying Steel Ball, Return Spring, Clutch Rollers And Starter Idler Pinions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the starter housing to the magnet switch assembly with the 2 screws.
  Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
  
  Fig 2: Locating Starter Housing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER BRUSH HOLDER ASSEMBLY
1. Align the claw of the brush holder with the claw groove of the starter yoke assembly.
2. Place the brush holder on the starter yoke assembly.
3. Using a screwdriver, hold the brush spring back.
4. Connect the brush into the brush holder.
5. Connect the 4 brushes.
  
  Fig 3: Connecting Brush Into Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Check that the positive (+) lead wires are not grounded.
6. Install an O-ring to the groove of the starter yoke.
7. Install 2 new O-rings and the end cover with the 2 screws.
  Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf)
  
  Fig 4: Locating Field Frame Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Install a new O-ring to the groove of the starter yoke assembly.
2. Align the protrusion of the starter yoke assembly with the groove of the magnetic switch.
  
  Fig 5: Aligning Protrusion Of Starter Yoke Assembly With Groove Of Magnetic Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the starter yoke assembly with the 2 through bolts.
  Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
4. Connect the terminal C wire with the nut.
  Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)
  
  Fig 6: Locating Starter Yoke Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002