Starting System (1ZZ-FE): Starter: Reassembly

INSTALL STARTER DRIVE LEVER SET PIN
1. Install the starter drive lever set pin to the starter center bearing clutch as shown in the illustration.
  
  Fig 1: Identifying Starter Drive Lever Set Pin And Starter Center Bearing Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Install the starter center bearing clutch together with the starter drive lever set pin to the starter drive housing.
  
  Fig 2: Identifying Starter Center Bearing Clutch Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PLANETARY GEAR
1. Apply grease to the planetary gears and planetary shaft pins.
2. Install the 3 planetary gears to the starter center bearing clutch.
  
  Fig 3: Locating Planetary Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply grease to the washer and armature shaft.
2. Install the starter armature and washer to the starter commutator end frame.
3. Using snap ring pliers, install a new snap ring.
  
  Fig 4: Installing Snap Ring Using Snap Ring Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the snap ring length.
  1. Using vernier calipers, measure the snap ring length.
    Maximum length:
    
    5.0 mm (0.197 in.)
    
    If the length is greater than maximum, replace it with a new snap ring.
    
    Fig 5: Identifying Snap Ring 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.
  
  Fig 6: Installing Starter Commutator End Frame Cover To Starter Commutator End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE
1. Align the keyway of the starter armature plate with the key inside of the starter yoke, then install the armature plate to the starter yoke.
  
  Fig 7: Aligning Keyway Of Starter Armature Plate With Key Inside Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the rubber with the cutout of the starter yoke, then install the starter commutator end frame to the starter yoke.
  
  Fig 8: Identifying Rubber And Cutout Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Align the key of the starter yoke with the keyway of the starter drive housing, then install the starter yoke to the starter drive housing.
  
  Fig 9: Identifying Key Of Starter Yoke And Keyway Of Starter Drive Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 2 through bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 10: Locating Through Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MAGNET SWITCH BODY
1. Apply grease to the plunger and hook.
2. Hang the plunger hook of the magnet switch into the starter drive lever set pin.
3. Install the plunger and return spring.
  
  Fig 11: Installing Plunger And Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the magnet switch with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 12: Locating Screws On Magnet Switch
  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 13: Locating Lead Wire On Magnet Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002