Section 184 (Starting System (2GR-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 Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply grease to the plate washers and the armature shaft.
2. Install the starter armature assembly to the starter commutator end frame assembly.
3. Using snap ring pliers, install the plate washer and a new snap ring.
  
  Fig 2: Installing Plate Washer And New Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a vernier caliper, measure the 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 starter commutator end frame cover to the starter commutator end frame assembly.
  
  Fig 4: Installing Starter Commutator End Frame Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE
1. Insert the starter armature plate to the starter yoke assembly.
  1. Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature 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 starter end frame assembly with the cutout of the starter yoke assembly.
2. Install the starter commutator end frame assembly to the starter yoke assembly.
  
  Fig 6: Installing Starter Commutator End Frame Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.
  
  Fig 7: Installing Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter yoke assembly with the 2 through-bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 8: Installing Starter Yoke Assembly
  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 assembly on the drive lever.
3. Install the plunger and return spring.
  
  Fig 9: Installing Magnetic Switch Assembly
  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