Starting System: Starter: Reassembly

INSTALL PLANET GEAR
1. Apply high-temperature grease to the planet gears and pin parts of the planetary shaft.
2. Install the 3 planet gears to the motor terminal starter kit.
Fig 1: Installing Planet Gears To Motor Terminal Starter Kit
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INSTALL STARTER ARMATURE ASSEMBLY
1. Apply high-temperature grease to the plate washer and the armature shaft.
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 2: Installing Plate Washer And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using vernier calipers, measure the snap ring.
  Maximum length:
  
  5.0 mm (0.197 in.)
  
  If the length is greater than the maximum, replace the snap ring.
Fig 3: Measuring Snap Ring Length
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INSTALL DRIVE HOUSING STARTER BEARING COVER
1. Install the drive housing starter bearing cover to the starter commutator end frame.
  
  Fig 4: Installing Drive Housing Starter Bearing Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE
1. Align the claw of the armature plate with the groove inside the starter yoke, and install the starter armature plate.
Fig 5: Aligning Claw Of Armature Plate With Groove Inside Starter Yoke
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INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the Starter commutator end frame rubber with the groove of the starter yoke.
2. Install the starter commutator 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.
Fig 6: Aligning Starter Commutator End Frame Rubber With Groove Of Starter Yoke
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INSTALL STARTER YOKE ASSEMBLY
1. Align the claw of the starter yoke with the groove inside the motor terminal starter kit.
  
  Fig 7: Aligning Claw Of Starter Yoke With Groove Inside Motor Terminal Starter Kit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter yoke with the 2 through bolts.
  Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)
  
  Fig 8: Locating Starter Yoke Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REPAIR SERVICE STARTER KIT
1. Apply high-temperature grease to the plunger and the hook.
2. Hang the plunger hook of the repair service starter kit to the drive lever hook.
3. Install the plunger and the return spring.
  
  Fig 9: Installing Plunger And Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install repair service starter kit with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 10: Locating Starter Kit Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the lead wire to the repair service starter kit with the nut.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
Fig 11: Connecting Lead Wire To Repair Service Starter Kit With Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002