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

INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
2. Install the 3 planetary gears to the starter drive housing assembly.
  
  Fig 1: Applying High-Temperature Grease To Planetary Gears And Pin Parts Of Planetary Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 2: Installing Plate Washer And Snap Ring Using Snap Ring Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using vernier calipers, measure the snap ring.
  Maximum length: 5.0 mm (0.197 in.)
  
  If the length is greater than the maximum, replace the snap ring with a new one.
  
  Fig 3: Identifying Snap Ring Gap Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME COVER
1. Install the starter commutator end frame cover to the starter commutator end frame assembly.
  
  Fig 4: Installing Starter Commutator End Frame Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE
1. Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate.
  
  Fig 5: Aligning Claw Of Armature Plate With Groove Inside Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
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.
  
  Fig 6: Aligning Starter Commutator End Frame Rubber With Groove Of Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Align the claw of the starter yoke with the groove inside the motor terminal starter kit.
  
  Fig 7: Aligning Claw Of Starter Yoke With Groove Inside Motor Terminal Starter Kit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter yoke with the 2 through bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 8: Locating Starter Yoke Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MAGNETIC SWITCH ASSEMBLY
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.
  
  Fig 9: Installing Magnetic Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the repair magnetic switch assembly with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 10: Locating Magnetic Switch Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the lead wire to terminal C with the nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 11: Locating Terminal C And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002