STARTER(w/ Stop And Start System) REASSEMBLY

PROCEDURE

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

   1. 

      *1	Starter Center Bearing Clutch Sub-assembly
      *2	Pinion Drive Lever
      *3	Rubber Seal
      *4	Starter Drive Housing Assembly
      	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. 

      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. 

      Install the starter armature assembly to the starter yoke assembly.

4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

   1. 

      Hold the brush spring back and install the 4 brushes to the starter brush holder assembly.

   2. 

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

   3. 

      *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. 

      *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.

      1.5 N*m

      15 kgf*cm

      13 in.*lbf

6. INSTALL STARTER ARMATURE PLATE

   1. 

      *1	Starter Yoke Assembly
      *2	Starter Armature Plate
      *a	Stopper
      *b	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. 

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

      Install the starter yoke assembly to the starter drive housing assembly.

      Note:

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

   2. Install the 2 through bolts.

      6.0 N*m

      61 kgf*cm

      53 in.*lbf

8. INSTALL REPAIR SERVICE STARTER KIT

   

   *1	Pinion Drive Lever
   *2	Plunger
   *3	Return Spring
   *4	Magnet Switch
   *5	Plunger Cover
   *a	Protrusion
   *b	Ventilation Hole
   *c	Hook

   1. 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.

      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.

      7.9 N*m

      81 kgf*cm

      70 in.*lbf

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

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

       6.5 N*m

       66 kgf*cm

       58 in.*lbf