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Reassembly [11/2016 - ]: Procedure

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  1. INSTALL RUBBER SEAL 
    1. Install the rubber seal 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 drive housing assembly.
      GTY700924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Install the 3 planetary gears to the starter drive housing assembly.
  3. INSTALL STARTER ARMATURE ASSEMBLY 
    1. Install the starter armature assembly to the starter yoke assembly.
      GTY708984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The magnet of the starter yoke assembly may attract the starter armature assembly when the starter armature assembly is installed causing the magnet to break.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY 
    1. Hold the brush spring back and set the 4 brushes as shown in the illustration.
      GTY390854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the starter brush holder assembly to the starter armature assembly and push in the 4 brushes as shown in the illustration.
      GTY390851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fit the protrusion of the grommet between the negative (-) brush holder plate and positive (+) motor lead wire.
      GTY687918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      *b Negative (-) Brush Holder Plate
      *c Positive (+) Motor Lead Wire
  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Install the starter commutator end frame assembly to the starter yoke assembly.
      NOTE:

      Align the lead wire rubber of the starter yoke assembly with the cutout of the starter commutator end frame assembly.

      GTY705783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lead Wire Rubber
      *b Cutout
    2. Install the 2 screws.

      Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

  6. INSTALL STARTER ARMATURE PLATE 
    1. Align the starter armature plate so that the protrusion fits between the stoppers of the starter yoke assembly, and install the starter armature plate.
      GTY727292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Starter Yoke Assembly
      *2 Starter Armature Plate
      *a Stopper
      *b Protrusion
      NOTE:

      Make sure the protrusion of the starter armature plate is inserted between the stoppers of the starter yoke assembly.

  7. INSTALL STARTER YOKE ASSEMBLY 
    1. Align the cutout of the starter yoke assembly with the protrusion of the starter drive housing assembly.
      GTY740083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Starter Yoke Assembly
      *2 Starter Drive Housing Assembly
      *a Cutout
      *b Protrusion
    2. Using a T25 "TORX" socket wrench, install the 2 through bolts.

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

  8. INSTALL REPAIR SERVICE STARTER KIT 
    GTY689989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Pinion Drive Lever
    *b Plunger
    *c Return Spring
    *d Magnet Switch
    *e Plunger Cover
    *f Protrusion
    *g Ventilation Hole
    *h Hook
    *i 90°
    1. Hang the hook of the plunger on the pinion drive lever and install the repair service starter kit.
      NOTE:
      • Make sure the return spring is not resting on the protrusion of the plunger or pushed between the magnet switch and plunger.
      • Install the plunger cover so that the ventilation hole is positioned as shown in the illustration.
    2. Install the 2 nuts.

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

  9. INSTALL STARTER INRUSH CURRENT REDUCTION RELAY 
    1. Install the starter inrush current reduction relay to the starter drive housing assembly with the 2 bolts.

      Torque: 7.9 N*m (81 kgf*cm, 70 in.*lbf) 

  10. INSTALL HARNESS 
    1. Connect the 2 harness connectors.
    2. Engage the harness clamp.
    3. Connect the noise filter harness to the repair service starter kit.
    4. Connect the lead wire to terminal M with the nut.

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

  11. INSTALL WIRE HARNESS 
    1. Install the wire harness to the starter assembly with the 2 nuts.

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

    2. Close the 2 terminal caps.
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