STARTER(for Cold Area Specification Vehicles) REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Use high-temperature grease to lubricate the bearings, gears and return spring when assembling the starter assembly.

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A01VKAA

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

      Text in Illustration
      A01VL3H High-temperature Grease
    2. A01VFLVE02
      Text in Illustration
      *1 Starter Drive Lever Set Pin
      *2 Starter Center Bearing Clutch Sub-assembly

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

    3. A01VGG6

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

  2. INSTALL PLANETARY GEAR


    1. A01VFSL

      Apply high-temperature grease to the planetary gears and pin parts of the starter center bearing clutch sub-assembly.

      Text in Illustration
      A01VL3H High-temperature Grease

    2. Install the 3 planetary gears to the pins of the planetary shaft.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. Hold the starter commutator end frame assembly in a vise between aluminum plates.

      Note


      • Do not overtighten the vise.

      • Do not drop the starter armature assembly.

    2. A01VIXPE01
      Text in Illustration
      *1 Plate Washer
      *2 Bearing
      A01VL3H High-temperature Grease

      Apply high-temperature grease to the plate washer and bearing.

    3. A01VM7Z

      Apply high-temperature grease to the starter armature assembly as shown in the illustration.

      Text in Illustration
      A01VL3H High-temperature Grease

    4. Install the starter armature assembly to the starter commutator end frame assembly.

    5. Install the plate washer to the starter armature shaft.

    6. A01VJ7UE01
      Text in Illustration
      *1 Snap Ring Pliers

      Using snap ring pliers, install a new snap ring.

      Note


      • Be sure to install the snap ring in the armature shaft groove securely.

      • Be sure to properly install the snap ring because it easily expands.

    7. A01VIFQE01
      Text in Illustration
      *a Length

      Check the snap ring length.


      1. Using a vernier caliper, measure the snap ring length.

        Maximum length
        5.0 mm (0.197 in.)

        If the length is more than the maximum, replace the snap ring.

  4. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. A01VLT3

      Install the starter commutator end frame cover to the starter commutator end frame assembly.

  5. INSTALL STARTER ARMATURE PLATE


    1. A01VG1LE36
      Text in Illustration
      *a Key
      *b Keyway

      Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01VLE4E09
      Text in Illustration
      *a Rubber Part
      *b Groove

      Align the rubber part on the starter commutator end frame assembly 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.

  7. INSTALL STARTER YOKE ASSEMBLY


    1. A01VLPXE02
      Text in Illustration
      *a Groove
      *b Claw

      Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly.

    2. A01VJRX

      Install the starter yoke assembly with the 2 through bolts.

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

  8. INSTALL REPAIR SERVICE STARTER KIT


    1. A01VHLEE02
      Text in Illustration
      *a Hook
      A01VL3H High-temperature Grease

      Apply high-temperature grease to the plunger and return spring.

    2. A01VM4H

      Hang the plunger hook of the repair service starter kit on the starter drive lever set pin.

    3. Install the plunger and return spring.

    4. A01VL35

      Install the repair service starter kit with the 2 screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A01VK3K

      Connect the lead wire to terminal C with the nut.

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