STARTER(w/o Stop And Start System) REASSEMBLY

PROCEDURE

  1. INSTALL PLANET CARRIER SHAFT SUB-ASSEMBLY

    1. A105368C03

      *1

      Planet Carrier

      *2

      Planet Carrier Shaft Sub-assembly

      Install the planet carrier shaft sub-assembly to the planet carrier.

    2. A355168

      Install the washer to the planet carrier shaft sub-assembly.

    3. A105363

      Using a screwdriver, install the snap ring to the planet carrier shaft sub-assembly.

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY

    1. A282530C01
      V100135

      High-temperature Grease

      Apply high-temperature grease to the spline of the starter clutch sub-assembly and planet carrier shaft sub-assembly.

    2. Install the starter clutch sub-assembly to the planet carrier shaft sub-assembly.

    3. A104907C01

      *1

      Snap Ring

      *2

      Pinion Stop Collar

      Install the pinion stop collar and a new snap ring.

    4. A104906C05

      *1

      Planet Carrier Shaft Sub-assembly

      *2

      Snap Ring

      Using a vise, compress the snap ring.

    5. A033587C10

      *1

      Snap Ring

      *2

      Pinion Stop Collar

      While holding the starter clutch sub-assembly, lightly tap the planet carrier shaft sub-assembly and install the pinion stop collar onto the snap ring with a plastic hammer.

    6. A165831C05

      *1

      Pinion Drive Lever

      *2

      Starter Drive Housing Cover

      *3

      Starter Drive Housing Assembly

      *4

      Planet Carrier Shaft Sub-assembly with Starter Clutch Sub-assembly and Planet Carrier

      Install the planet carrier shaft sub-assembly with starter clutch sub-assembly and planet carrier, pinion drive lever and starter drive housing cover to the starter drive housing assembly.

    7. A282531C01
      V100135

      High-temperature Grease

      Apply high-temperature grease to the planet carrier.

    8. Install the 3 planetary gears to the planet carrier shaft sub-assembly.

  3. INSTALL STARTER ARMATURE ASSEMBLY

    1. A105361C01

      *1

      Starter Yoke Assembly

      *2

      Starter Armature Assembly

      Install the starter armature assembly to the starter yoke assembly.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

    1. A104844C06

      *1

      Starter Brush Holder Assembly

      *a

      Rubber

      *b

      Spring

      *c

      Cutout

      Secure the starter yoke assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. While compressing the springs, install the starter brush holder assembly to the starter armature assembly.

      Note:

      • Align the cutout of the starter yoke assembly with the rubber and install the starter brush holder assembly.

      • Use caution to prevent the starter armature assembly from dropping.

    3. A104843C06

      *a

      Washer

      *b

      Starter Commutator End Frame

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

      Note:

      Use caution to prevent the starter armature assembly from dropping.

    4. Install the washer to the starter commutator end frame.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

    5. A282532C03

      *a

      Slotted Washer
      V100135

      High-temperature Grease

      Apply high-temperature grease to the slotted washer.

    6. Install the slotted washer.

    7. A104840

      Install the starter commutator end frame cover to the starter commutator end frame with the 2 screws.

      1.4 N*m

      14 kgf*cm

      12 in.*lbf

  5. INSTALL STARTER YOKE ASSEMBLY

    1. A165827C03

      *a

      Planet Carrier

      *b

      Plate

      Install the plate to the planet carrier.

    2. A165841C03

      *1

      Starter Drive Housing Cover

      *a

      Cutout

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

    3. A165802

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

      4.8 N*m

      49 kgf*cm

      42 in.*lbf

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY

    1. A321085C01

      *1

      Pinion Drive Lever

      *a

      Plunger

      *b

      Hook
      V100135

      High-temperature Grease

      Apply high-temperature grease to the hook and pinion drive lever.

    2. Hang the hook of the plunger on the pinion drive lever.

    3. Install the return spring to the magnet switch.

    4. A165798

      Using a T25 "TORX" socket wrench, install the magnet switch to the starter drive housing assembly with the 3 screws.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

    5. A165796

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

      8.0 N*m

      82 kgf*cm

      71 in.*lbf