Section 21 (Starting System (2AZ-FE) (Service Information)): Starter: Reassembly: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
  
  Fig 1: Identifying High-Temperature Grease Application Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 planetary gears.
INSTALL STARTER ARMATURE ASSEMBLY
1. Install the starter armature with the brush holder onto the starter yoke assembly.
  
  Fig 2: View Of Starter Armature Assembly And Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 BRUSH HOLDER ASSEMBLY
1. Install the brush holder.
  
  Fig 3: Remove/Install Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a screwdriver, hold the brush springs back, and install the 4 brushes into the brush holder.
  2. Insert the grommet between the positive (+) pole and negative (-) pole.
    
    Fig 4: Inserting Grommet Between Positive (+) Pole And Negative (-) Pole
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Fit the clamp of the brush holder into the starter commutator end frame assembly.
  
  Fig 5: Installing Starter Commutator End Frame Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the commutator end frame with the 2 screws.
  
  Fig 6: View Of Commutator End Frame With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
INSTALL STARTER ARMATURE PLATE
1. Install the starter armature plate onto the starter yoke assembly.
2. Install the starter plate so that the keyway is positioned between the keys.
  
  Fig 7: View Of Keyway Positions On Starter Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the key of the starter yoke with the keyway located on the starter drive housing assembly.
  
  Fig 8: Aligning Key Of Starter Yoke With Keyway Located On Starter Drive Housing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a T25 "TORX" socket wrench, install the drive housing with the 2 bolts.
  
  Fig 9: Remove/Install Starter Commutator End Frame Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
INSTALL MAGNET STARTER SWITCH ASSEMBLY
1. Apply high-temperature grease to the plunger hook.
2. Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side.
  
  Fig 10: Remove/Install Magnet Starter Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the magnet starter switch assembly with the 2 nuts.
  
  Fig 11: Remove/Install Magnet Starter Switch Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf)
4. Connect the lead wire to the magnet starter switch, then fasten it with the nut.
  
  Fig 12: Remove/Install Lead Wire With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)