STARTER(w/ Stop And Start System) REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A005HUTE01
      Text in Illustration
      *1 Starter Drive Housing Assembly
      *2 Starter Center Bearing Clutch Sub-assembly
      *3 Collar Space

      Install the starter center bearing clutch sub-assembly into the starter drive housing assembly.

    2. A005ID2E02
      Text in Illustration
      *1 Collar Space End Gap

      Install the collar space into the starter center bearing clutch sub-assembly.

      Note

      Make sure that the collar space end gap rests within +/- 10° from the center of the starter drive housing assembly.

  2. INSTALL PLANETARY GEAR AND WASHER


    1. A005JR5E01
      Text in Illustration
      *1 Washer
      A005GO2 High-temperature Grease

      Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft as shown in the illustration.

    2. Install the washer and 3 planetary gears.

  3. INSTALL STARTER YOKE ASSEMBLY


    1. A005LV9

      Install the starter yoke assembly onto the starter armature with clutch assembly.

      Note

      When installing the starter yoke assembly, be sure to hold the front of the armature to prevent the armature from coming off the clutch.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A005HO0

      Using a screwdriver, hold the brush springs back and install the 4 brushes into the starter brush holder assembly.

    2. Install the starter brush holder assembly to the starter armature.

    3. A005INXE03
      Text in Illustration
      *1 Grommet
      *2 Ground Plate (Negative Side)
      *3 Plate (Positive Side)

      Insert the grommet between the plate (positive side) and ground plate (negative side).

      Note

      Make sure that the grommet is properly inserted into the starter yoke assembly.

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. Fit the clamp of the starter brush holder assembly into the starter commutator end frame assembly.

    2. A005KLV

      Install the starter commutator end frame assembly with the 2 screws.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    3. A005JFME04
      Text in Illustration
      *a Projection
      *b Cutout

      Install the starter yoke assembly, starter armature with clutch assembly and end frame assembly with the starter drive housing assembly.

      Note

      Align the projection on the starter yoke assembly with the cutout on the starter drive housing assembly.

    4. A005M89

      Using a "TORX" socket wrench T25, install the starter yoke assembly with the 2 through bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    5. A005J4GE05
      Text in Illustration
      *1 Rubber Seal
      *2 Starter Drive Housing
      *a 2.0 mm (0.0787 in.)

      Install the rubber seal to the starter drive housing assembly.

      Note

      Make sure that the rubber seal does not protrude more than 2.0 mm (0.0787 in.) from the outer surface of the starter drive housing assembly.

  6. INSTALL REPAIR SERVICE STARTER KIT


    1. A005J62E01
      Text in Illustration
      *1 Cover
      *a Projection
      *b Cutout

      Install the cover by aligning the projection on the cover with the cutout on the starter drive housing assembly.

      Note

      Make sure that the cover does not overlap the rubber seal.

    2. A005H49

      Install the repair service starter kit with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    3. A005GU3

      Connect the lead wire to the terminal C with the nut.

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