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Reassembly [09/2014 - ]: Procedure

  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY 
    1. Apply high-temperature grease to the pinion drive lever as shown in the illustration.
      GTY504174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Starter Center Bearing Clutch Sub-assembly
      *2 Pinion Drive Lever
      *3 Rubber Seal
      *4 Starter Drive Housing Assembly
      High-temperature Grease
    2. Install the pinion drive lever and rubber seal to the starter center bearing clutch sub-assembly.
    3. Install the starter center bearing clutch sub-assembly together with the pinion drive lever and rubber seal to the starter drive housing assembly.
  2. INSTALL PLANETARY GEAR 
    1. Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter center bearing clutch sub-assembly.
      GTY507633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Install the 3 planetary gears to the starter drive housing assembly.
  3. INSTALL STARTER ARMATURE ASSEMBLY 
    1. Install the starter armature 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.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY 
    1. Hold the brush spring back and set the 4 brushes as shown in the illustration.
      GTY171733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the starter brush holder assembly to the starter armature assembly and push in the 4 brushes as shown in the illustration.
      GTY171711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fit the protrusion of the grommet between the negative (-) brush holder plate and positive (+) motor lead wire.
      GTY513466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      *b Negative (-) Brush Holder Plate
      *c Positive (+) Motor Lead Wire
  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Install the starter commutator end frame assembly to the starter yoke assembly.
      GTY518553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Field Coil Lead Wire Rubber
      *b Cutout
      NOTE:

      Align the field coil lead wire rubber of the starter yoke assembly with the cutout of the starter commutator end frame assembly.

    2. Install the 2 screws.

      Torque: 1.5 N.m (15 kgf/cm, 13 in.lbf) 

  6. INSTALL STARTER ARMATURE PLATE 
    1. Align the starter armature plate so that the protrusion fits between the stoppers of the starter yoke assembly, and install the starter armature plate.
      GTY504833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Starter Yoke Assembly
      *2 Starter Armature Plate
      *a Stopper
      *b Protrusion
      NOTE:

      Make sure the protrusion of the starter armature plate is inserted between the stoppers of the starter yoke assembly.

  7. INSTALL STARTER YOKE ASSEMBLY 
    1. Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.
      GTY501945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Using a T30 "TORX" socket wrench, install the starter yoke assembly with the 2 through bolts.

      Torque: 6.0 N.m (61 kgf/cm, 53 in.lbf) 

  8. INSTALL MAGNET STARTER SWITCH ASSEMBLY 
    1. Apply high-temperature grease to the plunger as shown in the illustration.
      GTY495659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Hang the hook of the magnet starter switch assembly on the pinion drive lever.
    3. Install the magnet starter switch assembly with the 2 nuts.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

    4. Connect the field coil lead wire to the magnet starter switch assembly with the nut.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

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