Starting System (Service Information): Starter: Reassembly: Reassembly

HINT:

Use high-temperature grease to lubricate the bearing and gears when assembling the starter.

INSTALL PLANETARY GEAR
1. Apply grease to the planetary gears and pin parts of the planetary shaft.
  
  Fig 1: Identifying Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 planetary gears.
INSTALL RUBBER SEAL
1. Install the rubber seal.
  
  Fig 2: Identifying Rubber Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply grease to the plate washer and a new snap ring.
  
  Fig 3: Identifying Plate Washer And New Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure to install the snap ring in the armature shaft groove securely.
  - Be sure to properly install the snap ring because it expands easily.
2. Install the starter armature to the starter commutator end frame.
3. Using snap ring pliers, install the plate washer and a new snap ring.
  
  Fig 4: Removing/Installing Snap Ring And Plate Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Snap Ring Pliers
4. Using a vernier caliper, measure the length of the snap ring.
  
  Fig 5: Measuring Length Of Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Length
  
  Maximum length
  
  5.0 mm (0.196 in.)
  
  If the length is greater than the maximum, replace it with a new snap ring.
INSTALL STARTER COMMUTATOR END FRAME COVER
1. Install the end frame cover to the commutator end frame.
  
  Fig 6: Installing The Drive Housing Starter Bearing & Cover To The Starter Commutator End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL STARTER ARMATURE PLATE

Insert the starter armature plate to the starter yoke.

Fig 7: Aligning Key Way Of Starter Armature Plate With Starter Yoke Key

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Keyway
*2	Key

Align the keyway of the starter armature plate with the key inside the starter yoke, and install the starter armature plate.

INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

Align the rubber of the end frame with the cutout of the starter yoke.

Fig 8: Aligning Rubber Of End Frame With Cutout Of Starter Yoke

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Cutout
*2	Rubber

Install the end frame to the starter yoke.
NOTE:
The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet to break.

INSTALL STARTER YOKE ASSEMBLY

Align the protrusion of the starter yoke with the cutout of the repair service starter kit.

Fig 9: Aligning Protrusion Of Starter Yoke With Cutout Of Starter Drive Housing

TEXT IN ILLUSTRATION

*1	Cutout
*2	Protrusion

Install the starter yoke with the 2 through-bolts.

Fig 10: Location of Starter Yoke Assembly Through-Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL MAGNETIC SWITCH ASSEMBLY
1. Apply grease to the plunger and the hook.
  
  Fig 11: Installing Magnetic Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hang the plunger hook of the magnetic switch to the drive lever.
3. Install the magnetic switch with the 2 nuts.
  
  Fig 12: Location of Magnet Starter Switch Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
4. Connect the lead wire to the magnetic switch with the nut.
  
  Fig 13: Location of Magnetic Switch Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)