STARTER(w/o Stop And Start System) REASSEMBLY

PROCEDURE

  1. INSTALL DUST STARTER PROTECTOR

    1. A285076

      Install the dust starter protector to the starter yoke assembly.

  2. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

    1. A249620C01
      V100135

      High-temperature Grease

      Apply high-temperature grease to the starter pinion drive lever which is in contact with the starter pivot part of the starter pinion drive lever.

    2. A202444C04

      *1

      Starter Pinion Drive Lever

      *2

      Starter Center Bearing Clutch Sub-assembly

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

    3. Install the starter center bearing clutch sub-assembly together with the starter pinion drive lever into the starter drive housing.

    4. A202443

      Install the rubber seal to the starter drive housing.

  3. INSTALL PLANETARY GEAR

    1. A286983C01
      V100135

      High-temperature Grease

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

    2. Install the 3 planetary gears.

  4. INSTALL STARTER ARMATURE ASSEMBLY

    1. A202439

      Install the starter armature to the starter yoke assembly.

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY

    1. A211303

      Push out the 4 brushes from the starter brush holder assembly so that they are held in place by the springs as shown in the illustration.

    2. A211304

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

    3. A206776C05

      *a

      Grommet

      *b

      Plate (Positive Side)

      *c

      Ground Plate (Negative Side)

      Insert the grommet between the ground plate and plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

    1. A285075

      Engage the clamp of the starter brush holder assembly with the starter commutator end frame assembly.

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

      1.5 N*m

      15 kgf*cm

      13 in.*lbf

  7. INSTALL STARTER ARMATURE PLATE

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

    2. Install the starter armature plate so that the cutout is positioned between the tabs.

      A206777C03

      *a

      Tab

      *b

      Cutout

  8. INSTALL STARTER YOKE ASSEMBLY

    1. A202446C02

      *a

      Tab

      *b

      Cutout

      *c

      Rubber Seal

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

    2. A202434

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

      6.0 N*m

      61 kgf*cm

      53 in.*lbf

  9. INSTALL MAGNET STARTER SWITCH ASSEMBLY

    1. A294369C03

      *1

      Starter Pinion Drive Lever

      *a

      Plunger Hook
      V100135

      High-temperature Grease

      Apply high-temperature grease to the plunger hook.

    2. Connect the plunger hook to the starter pinion drive lever.

    3. A202432

      Install the magnet starter switch assembly with the 2 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    4. A198945

      Connect the lead wire to the magnet starter switch assembly with the nut.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  10. INSTALL STARTER TERMINAL

    1. A212164

      Install the starter terminal with the nut.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    2. Close the terminal cap.