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Reassembly [10/2015 - ]: Procedure

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  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY 
    1. Apply high-temperature grease to the drive lever set pin as shown in the illustration.
      GTY461200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Install the drive lever set pin to the starter center bearing clutch sub-assembly.
      GTY461073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Drive Lever Set Pin
      *2 Starter Center Bearing Clutch Sub-assembly
    3. Install the starter center bearing clutch sub-assembly together with the drive lever set pin to the starter drive housing assembly.
  2. INSTALL PLANETARY GEAR 
    1. Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter center bearing clutch sub-assembly.
      GTY651105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Install the 3 planetary gears to the starter center bearing clutch sub-assembly.
  3. INSTALL STARTER ARMATURE ASSEMBLY 
    1. Secure the starter commutator end frame assembly in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Apply high-temperature grease to the starter armature shaft.
      GTY442069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    3. Apply high-temperature grease to the washer and bearing shown in the illustration.
      GTY430882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    4. Install the starter armature assembly to the starter commutator end frame assembly.
    5. Using snap ring pliers, install the washer and a new snap ring.
      NOTE:
      • Be sure to install the snap ring in the starter armature shaft groove securely.
      • Do not expand the snap ring excessively.
      GTY458197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap Ring Pliers
    6. Using a vernier caliper, measure the width of the snap ring end gap as shown in the illustration.
      GTY436451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Width

      Maximum Width

      5.0 mm (0.197 in.)

      If the width is greater than the maximum, replace the snap ring with a new one.

  4. INSTALL STARTER COMMUTATOR END FRAME COVER 
    1. Install the starter commutator end frame cover to the starter commutator end frame assembly.
      GTY191557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL STARTER ARMATURE PLATE 
    1. Insert the starter armature plate to the starter yoke assembly.
      GTY446921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Keyway
      *b Key
    2. Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.
  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY 
    GTY447035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Rubber
    *b Cutout
    1. Align the rubber of the starter commutator end frame assembly with the cutout of the starter yoke assembly.
    2. Install the starter commutator end frame assembly to the starter yoke assembly.
      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.

  7. INSTALL STARTER YOKE ASSEMBLY 
    1. Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.
      GTY658666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Install the starter yoke assembly with the 2 through bolts.

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

  8. INSTALL REPAIR SERVICE STARTER KIT 
    1. Apply high-temperature grease to the plunger.
      GTY457014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hook
      High-temperature Grease
    2. Hang the hook of the plunger on the drive lever set pin.
    3. Apply high-temperature grease to the return spring.
    4. Install the return spring to the plunger.
    5. Install the magnet switch to the starter drive housing assembly with the 2 screws.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      GTY617796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the lead wire to terminal C with the nut.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

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