STARTER(w/ Stop And Start System) REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A01R64YC03
      *1 Starter Center Bearing Clutch Sub-assembly
      *2 Starter Drive Housing Assembly
      *3 Pinion Drive Lever
      *a Rubber Seal
      B0073AQ 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. A01R48SC03
      B0073AQ 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. A01R624

      Install the starter armature 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.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01R5JG

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

    2. A01R5W2

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

    3. A01R5SIC02
      *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. A01R46LC03
      *a Lead Wire Rubber
      *b Cutout

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

      Note

      Align the 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. A01R3TTC11
      *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. A01R607C04
      *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 REPAIR SERVICE STARTER KIT


    1. A01R55MC05
      *1 Pinion Drive Lever
      *a Plunger
      *b Return Spring
      *c Hook
      *d Magnet Switch
      *e Plunger Cover
      *f Protrusion
      *g Ventilation Hole
      *h 90°

      Hang the hook of the plunger on the pinion drive lever and install the repair service starter kit.

      Note


      • Make sure the return spring is not resting on the protrusion of the plunger or pushed between the magnet switch and plunger.

      • Install the plunger cover so that the ventilation hole is positioned as shown in the illustration.

    2. Install the 2 nuts.

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

  9. INSTALL STARTER INRUSH CURRENT REDUCTION RELAY


    1. Install the starter inrush current reduction relay to the starter drive housing assembly with the 2 bolts.

      Torque:
      7.9 N*m  { 81 kgf*cm, 70 in.*lbf }

    2. Connect the lead wire to terminal M with the nut.

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

  10. INSTALL HARNESS


    1. Connect the 2 harness connectors to install the harness.

  11. INSTALL WIRE HARNESS


    1. A01R445C04
      *1 Wire Harness
      *a Nut
      *b Noise Filter Harness

      Connect the noise filter harness to the repair service starter kit.

    2. Install the wire harness to the starter assembly with the 2 nuts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }