Reassembly [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL PLANETARY GEAR

Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	High-temperature grease

Install the 3 planetary gears.

INSTALL RUBBER SEAL

Install the rubber seal.

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INSTALL STARTER ARMATURE ASSEMBLY

Apply high-temperature grease to the washer and armature shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	High-temperature grease

Apply high-temperature grease to the plate washer and a new snap ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	High-temperature grease

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.

Install the starter armature assembly to the starter commutator end frame assembly.

Using snap ring pliers, install the plate washer and a new snap ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Snap Ring Pliers

Using a vernier caliper, measure the length of the snap ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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Length

Maximum length

5.0 mm (0.197 in.)

If the length is greater than the maximum, replace it with a new snap ring.

INSTALL STARTER COMMUTATOR END FRAME COVER

Install the starter commutator end frame cover to the starter commutator end frame assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL STARTER ARMATURE PLATE

Insert the starter armature plate to the starter yoke assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*a	Keyway
*b	Key

Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.

INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*a	Cutout
*b	Rubber

Install the starter commutator end frame 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.

INSTALL STARTER YOKE ASSEMBLY

Align the protrusion of the starter yoke assembly with the cutout of the repair service starter kit.

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*a	Cutout
*b	Protrusion

Install the starter yoke assembly with the 2 through bolts.

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

INSTALL MAGNETIC SWITCH ASSEMBLY

Apply high-temperature grease to the plunger and the pinion drive lever.

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*1	High-temperature grease

Install the magnetic switch assembly by hanging the magnet starter switch plunger on the upper area of the pinion drive lever.

Install the magnetic switch assembly with the 2 nuts.

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

Connect the lead wire to the terminal C with the nut.

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