Section 7 (Starting System (2AZ-FE)): Starter: Reassembly

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INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
2. Install the 3 planetary gears.
Fig 1: Identifying High-Temperature Grease Application Area
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INSTALL STARTER BRUSH HOLDER ASSEMBLY
1. Install the brush holder.
  1. Using a screwdriver, hold the brush springs back, and install the 4 brushes into the brush holder.
  2. Install the brush holder to the starter armature.
    
    Fig 2: Installing Brush Holder
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Insert the grommet between the positive (+) pole and negative (-) pole.
Fig 3: Inserting Grommet Between Positive (+) Pole And Negative (-) Pole
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INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Fit the clamp of the brush holder into the starter commutator end frame assembly.
  
  Fig 4: Fitting Clamp Of Brush Holder Into Starter Commutator End Frame Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the commutator end frame with the 2 screws.
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
INSTALL STARTER ARMATURE ASSEMBLY
1. Align the rubber with the groove of the starter yoke assembly.
2. Install the starter armature with the brush holder onto 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.

Fig 5: Locating Commutator End Frame With Screws
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HINT:

Support the starter armature so that it may not be pulled out from the starter brush holder by magnetic force of the starter yoke assembly.

Fig 6: Identifying Starter Armature, Starter Commutator End Frame, Starter Yoke Assembly
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INSTALL STARTER ARMATURE PLATE
1. Install the starter armature plate onto the starter yoke assembly.
2. Install the starter plate so that the keyway is positioned between the keys.
Fig 7: Installing Starter Armature Plate Onto Starter Yoke Assembly
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INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the key of the starter yoke with the keyway located on the starter drive housing assembly.
  
  Fig 8: Aligning Key Of Starter Yoke With Keyway Located On Starter Drive Housing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a T25 "TORX" socket wrench, install the drive housing with the 2 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
INSTALL MAGNET STARTER SWITCH ASSEMBLY
1. Apply high-temperature grease to the plunger hook.
  
  Fig 9: Locating Starter Commutator End Frame Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side.
  
  Fig 10: Hanging Plunger Of Magnet Starter Switch Assembly Into Drive Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the magnet starter switch assembly with the 2 nuts.
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf)
  
  Fig 11: Locating Starter Drive Housing Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the lead wire to the magnet starter switch, then fasten it with the nut.
  Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)
  
  Fig 12: Locating Magnet Starter Switch Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002