Section 10 (Starting System (1AR-FE)): Starter: Reassembly

HINT:

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

1. 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: Identifying Planetary Gears Grease Applying Areas

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2. INSTALL STARTER ARMATURE ASSEMBLY 
   1. Apply grease to the plate washer and the armature shaft.
      NOTE:

      • Be sure to install the snap ring in the armature shaft groove securely.
      • Be sure to properly install the snap ring because it expands easily.
      Fig 2: Installing Plate Washer And Snap Ring

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   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.
   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: Identifying Length Of Snap Ring

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3. 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 To Starter Commutator End Frame Assembly

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4. INSTALL STARTER ARMATURE PLATE 
   1. Insert the starter armature plate into the starter yoke assembly.
   2. Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.
   Fig 5: Aligning Keyway Of Starter Armature Plate With Key Inside Starter Yoke Assembly

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5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY 
   1. Align the rubber of the end frame assembly with the cutout of the starter yoke assembly.
   2. Install the 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.
   Fig 6: Aligning Rubber Of End Frame Assembly With Cutout Of Starter Yoke Assembly

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6. INSTALL STARTER YOKE ASSEMBLY 
   1. Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing.
      Fig 7: Aligning Protrusion Of Starter Yoke Assembly With Cutout Of Starter Drive Housing

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   2. Install the starter yoke assembly with the 2 through-bolts.

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

   Fig 8: Locating Starter Yoke Assembly Through-Bolts

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7. INSTALL REPAIR SERVICE STARTER KIT 
   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

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   4. Install the magnetic switch with the 2 screws.

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

      Fig 10: Locating Magnetic Switch Screws

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   5. Connect the lead wire to the magnet starter switch with the nut.

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

   Fig 11: Locating Magnet Starter Switch Lead Wire Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002