STARTER(for Manual Transmission) REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A004KMN

      Apply high-temperature grease to the shaft as shown in the illustration.

      Text in Illustration
      A004K5G High-temperature Grease
    2. A004HTM

      Install the internal gear to the shaft.

    3. A004HFC

      Apply high-temperature grease to the shaft as shown in the illustration.

      Text in Illustration
      A004K5G High-temperature Grease
    4. A004JLR

      Install the over running clutch to the shaft.

    5. A004HHL

      Install the stopper to the shaft.

      Using snap ring pliers, install the snap ring.

    6. A004JFQE02
      Text in Illustration
      *1 Snap Ring
      *2 Stopper

      Using a press, press the snap ring into the stopper.

    7. A004I4W

      Install the starter clutch sub-assembly together with the drive lever set pin to the starter drive housing assembly.

  2. INSTALL STARTER PLANETARY GEAR

    A004K5X

    1. Apply high-temperature grease to the planetary gears and pins of the planetary shaft.

    2. Install the 3 starter planetary gears.

      Text in Illustration
      A004I9S High-temperature Grease

  3. INSTALL STARTER HOUSING RUBBER


    1. A004JHHE04
      Text in Illustration
      *1 Starter Housing Rubber
      *2 Plate
      *3 Seal Rubber

      Install the starter housing rubber, seal rubber and plate to the starter drive housing assembly.

  4. INSTALL STARTER ARMATURE ASSEMBLY


    1. A004KYT

      Install the starter armature assembly to the starter yoke assembly.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A004ISWE03
      Text in Illustration
      *1 Claw
      *2 Groove

      Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly.

    2. A004IMG

      Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly.

  6. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A004KOH

      Install a 24 mm socket to the starter brush holder assembly.

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

  7. INSTALL STARTER COVER


    1. A004JY8

      Install the starter cover with 2 screws and 2 bolts.

      Torque:
      Bolt
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
      Screw
      1.4 N*m  { 14 kgf*cm, 12 in.*lbf }

  8. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A004KIU

      Install the magnet starter switch assembly with the 2 screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    2. A004HRW

      Connect the lead wire to terminal C with the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }