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Starting System: Starter: Reassembly

  1. INSTALL STARTER ARMATURE ASSEMBLY 
    1. Apply grease to the bearings, and install them onto the stater yoke.
  2. INSTALL STATER BRUSH HOLDER ASSEMBLY 
    1. Install the a new O-ring onto the groove of the starter yoke assembly.
    2. Place the brush holder on the armature.
    3. Using a screwdriver, install 4 brushes.
      Fig 1: Identifying Brushes
      G04963024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the commutator end frame with the 2 screws.

      Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf) 

      Fig 2: Identifying Commutator End Frame Screws
      G04963023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL MAGNET STARTER SWITCH ASSEMBLY 
    1. Apply grease to the steel ball, and install it onto the clutch shaft hole.
    2. Apply grease to parts (2) to (5), and install all the parts below onto the starter drive housing.
      MAGNET STARTER SWITCH PARTS DESCRIPTION TABLE

      (1) Starter magnet switch return spring
      (2) Starter idle gear pinion
      (3) Starter idle gear clutch roller
      (4) Starter idle gear retainer
      (5) Starter clutch
      Fig 3: Identifying Starter Magnet Switch Return Spring, Starter Idle Gear Pinion & Retainer
      G05109959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the magnet starter switch with the 2 screws.

      Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) 

      Fig 4: Identifying Magnet Starter Switch Screws
      G04963020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL STARTER YOKE ASSEMBLY 
    1. Install a new O-ring onto the groove of the starter yoke.
    2. Align the key of the starter yoke with the groove of the magnet starter switch.
      Fig 5: Aligning Key Of Starter Yoke With Groove Of Magnet Starter Switch
      G04963046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the starter yoke and armature with the 2 through bolts.

      Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) 

      Fig 6: Identifying Starter Yoke & Armature Assembly Bolts
      G04963019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the lead wire to terminal C with the nut.

      Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) 

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