Section 4 (Starting (2GR-FSE)): Starter: Reassembly

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Apply high-temperature grease to the drive lever set pin, as shown in the illustration.
  
  Fig 1: Identifying Grease Points
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the drive lever set pin to the starter center bearing clutch sub-assembly.
3. Install the starter center bearing clutch with the drive lever set pin to the starter drive housing.
  
  Fig 2: Installing Drive Lever Set Pin To Starter Center Bearing Clutch Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration.
  
  Fig 3: Identifying Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 planetary gears.
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply high-temperature grease to the plate washer, new snap ring and bearing, as shown in the illustration.
2. Install the armature assembly to the starter commutator end frame assembly.
3. Install the plate washer to the armature shaft.
  
  Fig 4: Applying High-Temperature Grease To Plate Washer, Snap Ring And Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using snap ring pliers, install the snap ring.
  NOTE:
  - Be sure to install the snap ring in the armature shaft groove securely.
  - Be sure to properly install the snap ring because it easily expands.
  Fig 5: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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 6: 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 assembly.
  
  Fig 7: Installing Starter Commutator End Frame 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 assembly, and install the starter armature plate.
  
  Fig 8: Aligning Claw Of Armature Plate With Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the starter commutator end frame rubber with the groove of the starter yoke assembly.
2. Install the starter commutator end frame to the starter yoke assembly.
  
  Fig 9: Aligning Starter Commutator End Frame Rubber With Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The magnet of the starter yoke assembly may attract the starter armature when the starter commutator end frame assembly is installed, causing magnet breakage.
INSTALL STARTER YOKE ASSEMBLY
1. Align the claw of the starter yoke assembly with the groove inside the starter drive housing.
  
  Fig 10: Aligning Claw Of Starter Yoke Assembly With Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter yoke assembly with the 2 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 11: Tightening Starter Yoke Assembly And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REPAIR SERVICE STARTER KIT
1. Apply high-temperature grease to the plunger and hook, as shown in the illustration.
2. Hang the plunger hook of the repair service starter kit to the drive lever.
3. Install the plunger and the return spring.
  
  Fig 12: Applying High-Temperature Grease To Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the repair service starter kit with the 2 screws.
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf)
  
  Fig 13: Identifying Starter Kit And Screws
  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 14: Connecting Lead Wire To Terminal Tightening Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002