STARTER REASSEMBLY

PROCEDURE


  1. INSTALL RUBBER SEAL


    1. Install the rubber seal to the starter drive housing assembly.

  2. INSTALL PLANETARY GEAR


    1. A01W5DZ

      Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter drive housing assembly.

      Text in Illustration
      B001O8N High-temperature Grease

    2. Install the 3 planetary gears to the starter drive housing assembly.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01W11L

      Install the starter armature assembly to the starter yoke assembly.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01W3UL

      Hold the brush spring back and set the 4 brushes as shown in the illustration.

    2. A01W1LK

      Install the starter brush holder assembly to the starter armature assembly and push in the 4 brushes as shown in the illustration.

    3. A01W5OME06
      Text in Illustration
      *a Grommet
      *b Negative (-) Brush Holder Plate
      *c Positive (+) Motor Lead Wire

      Fit the protrusion of the grommet between the negative (-) brush holder plate and positive (+) motor lead wire.

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01W12HE07
      Text in Illustration
      *a Lead Wire Rubber
      *b Cutout

      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.

    2. Install the 2 screws.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

  6. INSTALL STARTER ARMATURE PLATE


    1. A01VZCIE07
      Text in Illustration
      *1 Starter Yoke Assembly
      *2 Starter Armature Plate
      *a Stopper
      *b Protrusion

      Align the starter armature plate so that the protrusion fits between the stoppers of the starter yoke assembly, and install the starter armature plate.

      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. A01W0FWE02
      Text in Illustration
      *1 Starter Yoke Assembly
      *2 Starter Drive Housing Assembly
      *a Cutout
      *b Protrusion

      Align the cutout of the starter yoke assembly with the protrusion of the starter drive housing assembly.

    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


    1. A01W0Q2E02
      Text in Illustration
      *a Pinion Drive Lever
      *b Plunger
      *c Return Spring
      *d Magnet Switch
      *e Plunger Cover
      *f Protrusion
      *g Ventilation Hole
      *h Hook
      *i 90°

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

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  11. INSTALL WIRE HARNESS


    1. A01W22JE02
      Text in Illustration
      *1 Wire Harness
      *a Nut
      *b Noise Filter Harness

      Connect the noise filter harness to the repair service starter kit.

    2. Install the wire harness to the starter assembly with the 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }