STARTER(w/ Stop And Start System) REASSEMBLY

PROCEDURE

  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

    1. A249300C01

      *1

      Starter Drive Housing Assembly

      *2

      Starter Center Bearing Clutch Sub-assembly

      *3

      Collar Space

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

    2. A288954C02

      *a

      Collar Space End Gap

      Install the collar space into the starter center bearing clutch sub-assembly.

      Note:

      Make sure that the collar space end gap is within +/-10° from the center of the starter drive housing assembly.

  2. INSTALL PLANETARY GEAR AND WASHER

    1. A262316C01

      *1

      Washer
      V100135

      High-temperature Grease

      Apply high-temperature grease to the planetary gears and pins of the planetary shaft as shown in the illustration.

    2. Install the washer and 3 planetary gears.

  3. INSTALL STARTER WITH CLUTCH ARMATURE ASSEMBLY

    1. A256107

      Install the starter with clutch armature assembly onto the starter yoke assembly.

      Note:

      When installing the starter with clutch armature assembly, be sure to hold the front of the armature to prevent the armature from coming off the clutch.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

    1. A249499

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

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

    3. A205233C06

      *a

      Grommet

      *b

      Ground Plate (Negative Side)

      *c

      Plate (Positive Side)

      Insert the grommet between the plate and ground plate.

      Note:

      Make sure that the grommet is properly inserted into the starter yoke assembly.

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

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

    2. A205241

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

      1.5 N*m

      15 kgf*cm

      13 in.*lbf

    3. A205234C01

      *a

      Protrusion

      *b

      Cutout

      Install the starter yoke assembly, starter with clutch armature assembly and starter commutator end frame assembly to the starter drive housing assembly.

      Note:

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

    4. A197906

      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

    5. A278895C04

      *1

      Rubber Seal

      *2

      Starter Drive Housing Assembly

      Install the rubber seal to the starter drive housing assembly.

      Note:

      Make sure that the rubber seal does not protrude more than 2.0 mm (0.0787 in.) from the outer surface of the starter drive housing assembly.

  6. INSTALL REPAIR SERVICE STARTER KIT

    1. A205236C04

      *1

      Cover

      *a

      Protrusion

      *b

      Cutout

      Align the protrusion of the cover with the cutout of the starter drive housing assembly and install the cover.

      Note:

      Make sure that the cover does not overlap the rubber seal.

    2. A197907

      Install the repair service starter kit with the 2 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    3. A293849

      Connect the 2 lead wires to terminal C with the nut.

      10 N*m

      102 kgf*cm

      7 ft.*lbf