Section 172 (Starting System (2AZ-FE)): Starter: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter.

INSTALL PLANETARY GEAR
1. Apply grease to the planetary gears and pin parts of the planetary shaft.
2. Install the 3 planetary gears.
  
  Fig 1: Installing Planetary Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply 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 a vernier caliper, measure length of the snap ring.
  Maximum length: 5.0 mm (0.197 in.)
  
  If the length is greater than the maximum, replace it with a new snap ring.
  
  Fig 3: Measuring Length Of Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME COVER
1. Install the end frame cover to the commutator end frame.
  
  Fig 4: Installing End Frame Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE
1. Insert the armature plate to the starter yoke.
2. Align the keyway of the starter plate with the key inside the starter yoke, and install the starter plate.
  
  Fig 5: Installing Starter Armature Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the rubber of the end frame with the cutout of the starter yoke.
2. Install the end frame to the starter yoke.
  
  Fig 6: Installing End Frame To Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Align the protrusion of the starter yoke with the cutout of the starter drive housing.
  
  Fig 7: Installing Starter Yoke Assembly
  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: Installing Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MAGNETIC SWITCH ASSEMBLY
1. Apply grease to the plunger and the hook.
2. Hang the plunger hook of the magnetic switch to the drive lever.
3. Install the plunger and return spring.
  
  Fig 9: Installing Plunger And Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the magnetic switch with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 10: Installing Magnetic Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the lead wire to the magnetic switch with the nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 11: Connecting Lead Wire To Magnetic Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002