STARTER(w/ Stop And Start System) REASSEMBLY

PROCEDURE

1. Click here

   INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

   
   
   1. 

      Install the starter center bearing clutch sub-assembly into the starter drive housing assembly.

      Table 1. Text in Illustration

      *1	Starter Drive Housing Assembly
      *2	Starter Center Bearing Clutch Sub-assembly
      *3	Collar Space

   2. 

      Install the collar space into the starter center bearing clutch sub-assembly.

      Table 2. Text in Illustration

      *1	Collar Space End Gap

      Note:

      Make sure that the collar space end gap rests within +/- 10° from the center of the starter drive housing assembly.

2. Click here

   INSTALL PLANETARY GEAR AND WASHER

   
   
   1. 

      Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft as shown in the illustration.

      Table 3. Text in Illustration

      	High-temperature Grease
      *1	Washer

   2. Install the washer and 3 planetary gears.

3. Click here

   INSTALL STARTER YOKE ASSEMBLY

   
   
   1. 

      Install the starter yoke assembly onto the starter with clutch armature assembly.

      Note:

      When installing the starter yoke assembly, be sure to hold the front of the armature to prevent the armature from coming off the clutch.

4. Click here

   INSTALL STARTER BRUSH HOLDER ASSEMBLY

   
   
   1. 

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

   2. Install the brush holder to the starter armature.

   3. 

      Insert the grommet between the plate (positive side) and ground plate (negative side).

      Table 4. Text in Illustration

      *1	Grommet
      *2	Ground Plate (Negative Side)
      *3	Plate (Positive Side)

      Note:

      Make sure that the grommet is properly inserted into the starter yoke assembly.

5. Click here

   INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

   
   

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

   2. 

      Install the starter commutator end frame with the 2 screws.

      1.5 N*m

      15 kgf*cm

      13 in.*lbf

   3. 

      Install the starter yoke assembly, starter with clutch armature assembly and end frame with the starter drive housing assembly.

      Table 5. Text in Illustration

      *a	Projection
      *b	Cutout

      Note:

      Align the projection on the starter yoke assembly with the cutout on the starter drive housing assembly.

   4. 

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

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

   5. 

      Install rubber seal to the starter drive housing assembly.

      Table 6. Text in Illustration

      *1	Rubber Seal
      *2	Starter Drive Housing

      Note:

      Make sure that the rubber seal does not protrude more than 2.0 mm (0.0787 in.) from the outer surface of the starter drive housing assembly.

6. Click here

   INSTALL REPAIR SERVICE STARTER KIT

   
   
   1. 

      Install the cover by aligning the projection on the cover with the cutout on the housing.

      Table 7. Text in Illustration

      *1	Cover
      *a	Projection
      *b	Cutout

      Note:

      Make sure that the cover does not overlap the rubber seal.

   2. 

      Install the repair service starter kit with the 2 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

   3. 

      Connect the lead wire to terminal C with the nut.

      10 N*m

      102 kgf*cm

      7 ft.*lbf