STARTER(for Cold Area Specification Vehicles) REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE


  1. INSTALL DUST STARTER PROTECTOR

    A01VJW3

    1. Install a new dust starter protector to the starter yoke assembly.

  2. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A01VFRH

      Apply high-temperature grease to the starter pinion drive lever as shown in the illustration.

      Text in Illustration
      A01VL3H High-temperature Grease
    2. A01VDJ7E05
      Text in Illustration
      *1 Starter Pinion Drive Lever
      *2 Starter Center Bearing Clutch Sub-assembly
      *3 Starter Drive Housing

      Install the starter pinion drive lever to the starter center bearing clutch sub-assembly.

    3. Install the starter center bearing clutch sub-assembly together with the starter pinion drive lever to the starter drive housing.

    4. A01VIZU

      Install the rubber seal to the starter drive housing.

  3. INSTALL PLANETARY GEAR


    1. A01VF2T

      Apply high-temperature grease to the 3 planetary gears, 3 planetary shafts and starter center bearing clutch sub-assembly.

      Text in Illustration
      A01VL3H High-temperature grease

    2. Install the 3 planetary gears to the starter center bearing clutch sub-assembly.

  4. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01VIFL

      Apply high-temperature grease to the starter armature assembly shaft.

      Text in Illustration
      A01VL3H High-temperature Grease
    2. A01VLZDE03
      Text in Illustration
      *1 Starter Yoke Assembly
      *2 Starter Armature Assembly

      Install the starter armature assembly to the starter yoke assembly.

      Note

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

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01VDRP

      Push out the 4 brushes from the starter brush holder assembly so that they are held in place by the springs as shown in the illustration.

    2. A01VGZ5

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

      Note

      Check that the positive (+) lead wires are not grounded.

    3. A01VIL8E04
      Text in Illustration
      *a Grommet
      *b Plate (Positive Side)
      *c Ground Plate (Negative Side)

      Insert the grommet between the ground plate and plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01VISQ

      Engage the grommet and install the starter commutator end frame assembly to the starter yoke assembly.

    2. A01VG37

      Install the 2 screws.

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

  7. INSTALL STARTER ARMATURE PLATE


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

      A01VLM5E04
      Text in Illustration
      *a Tab *b Cutout

    2. Install the starter armature plate so that the cutout is positioned between the tabs.

  8. INSTALL STARTER YOKE ASSEMBLY


    1. A01VH6AE04
      Text in Illustration
      *1 Rubber Seal
      *a Tab
      *b Cutout

      Align the tab of the starter yoke assembly with the cutout of the starter drive housing, and install the starter yoke assembly to the starter drive housing.

    2. A01VGLW

      Using a T25 "TORX" socket wrench, install the 2 through bolts.

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

  9. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01VERLE01

      Apply high-temperature grease to the hook.

    2. Hang the hook of the magnet starter switch assembly on the starter pinion drive lever.

      Text in Illustration
      *1 Starter Pinion Drive Lever
      *a Hook
      A01VL3H High-temperature Grease
    3. A01VFUN

      Install the magnet starter switch assembly to the starter drive housing with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A01VFEF

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  10. INSTALL STARTER TERMINAL


    1. A01VH6H

      Install the starter terminal to the magnet starter switch assembly with the nut.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    2. Close the terminal cap.