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

INSTALL PLANETARY GEAR

Fig 1: Applying Grease To Planet Gears & Pin Parts Of Planetary Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
2. Install the 3 planetary gears to the motor terminal starter kit.
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply high-temperature grease to the plate washer and the armature shaft.
2. Install the starter armature assembly to the starter commutator end frame assembly.
3. Using snap ring pliers, install the plate washer and a new snap ring.
4. Using vernier calipers, measure the snap ring.
  
  Fig 3: Identifying Snap Ring Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum length:
  
  5.0 mm (0.197 in.)
  
  If the length is greater than the maximum, replace the snap ring with a new one.
INSTALL STARTER COMMUTATOR END FRAME COVER
1. Install the starter commutator end frame cover to the starter commutator end frame assembly.
  
  Fig 4: Identifying Starter Commutator End Frame Cover & Starter Commutator End Frame Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE

Fig 5: Identifying Claw & Groove
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate.
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

Fig 6: Identifying Groove & Rubber
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Align the starter commutator end frame rubber with the groove of the starter yoke assembly.
2. Install the starter commutator end frame assembly to the starter yoke assembly.
  NOTE: The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet to break.
INSTALL STARTER YOKE ASSEMBLY

Fig 7: Aligning Claw Of Starter Yoke With Groove
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Align the claw of the starter yoke with the groove inside the motor terminal starter kit.
2. Install the starter yoke with the 2 through bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
INSTALL MAGNETIC SWITCH ASSEMBLY

Fig 9: Identifying Magnetic Switch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply high-temperature grease to the plunger and the hook.
2. Hang the plunger hook of the magnetic switch assembly to the drive lever hook.
3. Install the plunger and the return spring.
4. Install the repair magnetic switch assembly with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
5. Connect the lead wire to terminal C with the nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)