STARTER REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Apply high-temperature grease to the bushing and spline of the starter center bearing clutch sub-assembly and pinion stop nut.

    2. A005GOI

      Place the starter center bearing clutch sub-assembly and pinion stop nut on the planetary carrier.

    3. Apply high-temperature grease to a new snap ring, and install it onto the planetary carrier groove.

    4. A005KTP

      Using a vise, compress the snap ring.

    5. A005IZ1

      While holding the starter clutch sub-assembly, tap the planetary carrier and install the pinion stop nut onto the snap ring with a plastic-faced hammer.

    6. A005M3NE02
      Text in Illustration
      *1 Pinion Drive Lever
      *2 Rubber Seal
      *3 Starter Center Bearing Clutch Sub-assembly
      A005GO2 High-temperature grease

      Apply high-temperature grease to the parts of the pinion drive lever that contact the starter pivot part of the pinion drive lever.

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

    8. Install the starter center bearing clutch together with the pinion drive lever into the starter drive housing assembly.

  2. INSTALL PLANETARY GEAR


    1. A005INZ

      Apply high-temperature grease to the 3 planetary gears and pin parts of the planetary carrier.

      Text in Illustration
      A005GO2 High-temperature grease

    2. Install the 3 planetary gears.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. Install the starter armature assembly with the starter brush holder assembly onto the starter yoke assembly.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A005IDW

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

    2. A005HC2

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

    3. A005JU8E08
      Text in Illustration
      *1 Grommet
      *2 Negative (-) Pole
      *3 Positive (+) Pole

      Insert the grommet between the positive (+) pole and negative (-) pole.

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A005JFD

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

    2. A005H82

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

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

  6. INSTALL STARTER ARMATURE PLATE


    1. Install the starter armature plate onto the starter yoke assembly.

    2. A005J8NE02
      Text in Illustration
      *1 Key
      *2 Keyway

      Install the starter plate so that the keyway is positioned between the keys.

  7. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A005IQQE01
      Text in Illustration
      *1 Key
      *2 Keyway

      Align the key of the starter yoke with the keyway located on the starter drive housing assembly.

    2. A005KHA

      Install the starter drive housing assembly with the 2 through bolts.

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

  8. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. Apply high-temperature grease to the plunger hook.

    2. A005L8Y

      Hang the plunger of the magnet starter switch assembly into the pinion drive lever from the upper side.

    3. A005GPZ

      Install the magnet starter switch assembly with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A005I23

      Connect the lead wire to the magnet starter switch, then fasten it with the nut.

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

  9. INSTALL STARTER INRUSH CURRENT REDUCTION RELAY

    A005IRQ

    1. Install the starter inrush current reduction relay with the bolt.

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

    2. Connect the lead wire with the 2 nuts.

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

  10. INSTALL WIRE HARNESS

    A005I1G

    1. Install the wire harness with the bolt.

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

    2. Connect the 2 connectors.

  11. INSTALL HARNESS BRACKET


    1. A005JX7

      Install the harness bracket with the bolt.

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