STARTER(for Cold Area Specification Vehicles) REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

   
   

   1. 

      High-temperature Grease

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

   2. 

      *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. 

      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. 

      High-temperature Grease

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

   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. 

      *1	Plate Washer
      *2	Bearing
      	High-temperature Grease

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

   3. 

      High-temperature Grease

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

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

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

   6. 

      *a	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. 

      *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. 

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

5. INSTALL STARTER ARMATURE PLATE

   
   
   1. 

      *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. 

      *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. 

      *a	Groove
      *b	Claw

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

   2. 

      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. 

      *a	Hook
      	High-temperature Grease

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

   2. 

      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. 

      Install the repair service starter kit with the 2 screws.

      Torque:

      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

   5. 

      Connect the lead wire to terminal C with the nut.

      Torque:

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