STARTER REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. Apply high-temperature grease to the parts indicated by the arrows in the illustration.

      A01WPY9
      Text in Illustration
      B0018FC High-temperature Grease - -

    2. Install the starter clutch sub-assembly into the magnet starter switch assembly.

      Note

      Make sure that the bearing does not disengage from the starter clutch sub-assembly.

    3. Install the 3 starter washers and pinion drive lever with the snap ring.

  2. INSTALL STARTER DRIVE HOUSING ASSEMBLY


    1. A01WU9QE02
      Text in Illustration
      *a Seal Packing

      Apply a light coat of seal packing to the surface of the starter drive housing assembly that contacts the starter magnet switch assembly.

      Seal packing
      Toyota Genuine Seal Packing 1121C, Three Bond 1121C or equivalent

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

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

  3. INSTALL STARTER INTERNAL GEAR


    1. A01WS4M

      Apply high-temperature grease to the portion indicated by the arrow in the illustration.

      Text in Illustration
      B0018FC High-temperature Grease
    2. A01WSVF

      Install the starter internal gear to the magnet starter switch assembly.

      Note

      Make sure the internal gear protrusion indicated by the arrow in the illustration is aligned with the groove on the bottom side of the magnet starter switch assembly.

    3. A01WTP0

      Apply high-temperature grease to the 3 starter planetary gears.

      Text in Illustration
      B0018FC High-temperature Grease

    4. Install the 3 starter planetary gears to the starter clutch sub-assembly.

  4. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01WWVL

      Install the starter washer to the magnet starter switch assembly.

      Note

      Make sure that the starter washer is securely seated in the groove.

    2. A01WTM1

      Apply high-temperature grease to the portion indicated by the arrow in the illustration.

      Text in Illustration
      B0018FC High-temperature Grease

    3. Install the starter plate to the magnet starter switch assembly.

    4. A01WWIP

      Apply high-temperature grease to the portion indicated by the arrow in the illustration.

      Text in Illustration
      B0018FC High-temperature Grease

    5. Install the starter armature assembly to the starter plate.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. Install 2 new O-rings to the starter yoke assembly.

    2. A01WPYN

      Install the starter yoke assembly to the magnet starter switch assembly.

  6. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. Place the starter brush holder assembly on the starter armature assembly.

    2. Using a screwdriver, hold the starter brush spring back and connect the 4 starter brushes to the starter brush holder assembly.

      Note

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

    3. Install the starter brush holder into the starter armature assembly.

    4. A01WPPV

      Apply high-temperature grease to the portion indicated by the arrow in the illustration.

      Text in Illustration
      B0018FC High-temperature Grease

    5. Install the commutator end frame with the 2 screws.

      Torque:
      3.9 N*m  { 40 kgf*cm, 35 in.*lbf }

    6. Install the 2 through bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }

    7. Install the nut to terminal C.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    8. A01WRR3E02
      Text in Illustration
      *a Mark
      *b White Mark

      Install the 2 starter hoses to the starter assembly.

  7. INSTALL STARTER CLUTCH PINION


    1. A01WRL8

      Install the starter drive spring, starter clutch pinion and pinion stop collar with the snap ring.