STARTER(for Denso Made with Stop and Start System) REASSEMBLY

Info Added 2017-10-06

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A001Y52C02
      *1 Starter Center Bearing Clutch Sub-assembly
      *2 Starter Drive Housing Assembly
      *a Pinion Drive Lever
      *b Rubber Seal
      B00495X High-temperature Grease

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

    2. Install the pinion drive lever and rubber seal to the starter center bearing clutch sub-assembly.

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

  2. INSTALL PLANETARY GEAR


    1. A001X85C02
      B00495X High-temperature Grease

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

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

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. A001U7V

      Install the starter armature assembly to the starter yoke assembly.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A001TWC

      Hold the brush spring back and set the 4 brushes as shown in the illustration.

    2. A001SHZ

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

    3. A001TJ7C02
      *a Grommet
      *b Negative (-) Brush Holder Plate
      *c Positive (+) Motor Lead Wire

      Fit the protrusion of the grommet between the negative (-) brush holder plate and positive (+) motor lead wire.

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A001W2YC03
      *a Field Coil Lead Wire Rubber
      *b Cutout

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

      Note

      Align the field coil lead wire rubber of the starter yoke assembly with the cutout of the starter commutator end frame assembly.

    2. Install the 2 screws.

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

  6. INSTALL STARTER ARMATURE PLATE


    1. A001VT6C11
      *1 Starter Yoke Assembly
      *a Starter Armature Plate
      *b Stopper
      *c Protrusion

      Align the starter armature plate so that the protrusion fits between the stoppers of the starter yoke assembly, and install the starter armature plate.

      Note

      Make sure the protrusion of the starter armature plate is inserted between the stoppers of the starter yoke assembly.

  7. INSTALL STARTER YOKE ASSEMBLY


    1. A001UTPC04
      *1 Starter Yoke Assembly
      *2 Starter Drive Housing Assembly
      *a Cutout
      *b Protrusion

      Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.

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

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

  8. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A001TPMC02
      *a Hook
      *b Pinion Drive Lever
      B00495X High-temperature Grease

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

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

    3. Install the magnet starter switch assembly with the 2 nuts.

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

    4. Connect the field coil lead wire to terminal C with the nut.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }