STARTER(for TMMF Made Cold Area Specification Vehicles) REASSEMBLY

PROCEDURE

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *1	Starter Pinion Drive Lever
      *2	Rubber Seal
      *3	Starter Center Bearing Clutch Sub-Assembly
      	High-temperature grease

      Apply grease to the starter pinion drive lever which is in contact with the starter pivot part of the starter pinion drive lever.

   2. Install the starter pinion drive lever and rubber seal into the starter center bearing clutch sub-assembly.

   3. Install the starter center bearing clutch together with the starter pinion drive lever into the starter drive housing assembly.

2. INSTALL PLANET GEAR

   
   

   1. 

      Apply grease to the planet gears and pin parts of the planetary shaft.

      Text in Illustration

      High-temperature grease

   2. Install the 3 planet gears.

3. INSTALL STARTER BRUSH HOLDER ASSEMBLY

   
   

   1. 

      Install the brush holder.

   2. Using a screwdriver, hold the brush spring back, and install the 4 brushes into the brush holder.

4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

   
   

   1. 

      Fit the clamp of the brush holder into the starter commutator end frame assembly.

   2. 

      Install the commutator end frame with the 2 screws.

      Torque:

      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

5. INSTALL STARTER ARMATURE ASSEMBLY

   
   

   1. Align the rubber with the convex cutout of the starter yoke assembly.

   2. 

      Text in Illustration

      *1	Starter Commutator End Frame Assembly
      *2	Starter Armature Assembly
      *3	Starter Yoke Assembly

      Install the starter armature assembly with the brush holder onto the starter yoke assembly.

      Tech Tips

      Support the starter armature so that it is not be pulled out from the starter brush holder by the magnetic force of the starter yoke assembly.

6. INSTALL STARTER ARMATURE PLATE

   
   

   1. Install the starter armature plate onto the starter yoke assembly.

   2. Align the keyway of the starter plate with the key inside the starter yoke, then install the starter plate.

      

      Text in Illustration

      *1

      Key

      *2

      Keyway

7. INSTALL STARTER YOKE ASSEMBLY

   
   

   1. 

      Text in Illustration

      *1	Key
      *2	Keyway

      Align the key of the starter yoke with the keyway located on the starter drive housing assembly.

   2. 

      Using a "TORX" socket wrench T25, install the starter yoke assembly using the 2 through bolts.

      Torque:

      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

8. INSTALL MAGNET STARTER SWITCH ASSEMBLY

   
   

   1. 

      Text in Illustration

      *1	Plunger
      *2	Starter Pinion Drive Lever
      	High-temperature grease

      Apply grease to the hook.

   2. Connect the plunger hook to the starter pinion drive lever.

   3. 

      Install the return spring onto the magnet starter switch assembly.

   4. 

      Install the magnet starter switch assembly with the 3 nuts.

      Torque:

      2.3 N*m  { 24 kgf*cm, 21 in.*lbf }

   5. 

      Connect the lead wire to the starter magnetic switch, then fasten it with the nut.

      Torque:

      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }