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Repair and Diagnosis: Electrical: Starter: Starting: Starter: Reassembly

  1. INSTALL PLANETARY GEAR 
    1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
      Fig 1: Identifying Grease Applying Area Of Planetary Gears
      G04975533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3 planetary gears to the motor terminal starter kit.
  2. INSTALL STARTER ARMATURE ASSEMBLY 
    1. Apply high-temperature grease to the plate washer 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 Snap Ring Using Snap Ring Pliers
      G04975534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using vernier calipers, measure the snap ring.

      Maximum length: 

      5.0 mm (0.197 in.) 

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

      Fig 3: Identifying Snap Ring Length
      G04975535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL STARTER COMMUTATOR END FRAME COVER 
    1. Install the starter commutator end frame cover to the starter commutator end frame assembly.
      Fig 4: Identifying Starter Commutator End Frame Cover & Starter Commutator End Frame Assembly
      G04975536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL STARTER ARMATURE PLATE 
    1. Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate.
      Fig 5: Identifying Claw & Groove
      G04975537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Align the starter commutator end frame rubber with the groove of the starter yoke assembly.
    2. Install the starter commutator 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: Identifying Groove & Rubber
      G04975538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL STARTER YOKE ASSEMBLY 
    1. Align the claw of the starter yoke with the groove inside the motor terminal starter kit.
      2. Fig 7: Identifying Groove And Claw
      G04975539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the starter yoke with the 2 through bolts.

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

      3. Fig 8: Identifying Starter Yoke Bolts
      G04975540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL MAGNETIC SWITCH ASSEMBLY 
    1. Apply high-temperature grease to the plunger and the hook.
      2. Fig 9: Identifying Magnetic Switch Assembly
      G04975541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hang the plunger hook of the magnetic switch assembly to the drive lever hook.
    3. Install the plunger and the return spring.
    4. Install the repair magnetic switch assembly with the 2 screws.

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

      Fig 10: Identifying Repair Magnetic Switch Assembly Screws
      G04975542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the lead wire to terminal C with the nut.

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

      Fig 11: Locating Lead Wire To Terminal C With Nut
      G04975543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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