Section 34 (Starting System (2TR-FE)): Starter: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL STARTER CLUTCH SUB-ASSEMBLY
1. Apply grease to the steel ball and install it onto the starter drive housing.
2. Apply grease to the magnet switch return spring and install it onto the starter drive housing.
3. Apply grease to the starter clutch, and install it onto the starter drive housing.
4. Apply grease to the starter idle gear clutch roller and install it onto the starter idle gear retainer.
5. Apply grease to the starter idle gear retainer and install it onto the starter idle gear pinion.
6. Apply grease to the starter idle gear pinion and install it onto the starter drive housing.
  
  Fig 1: Identifying Starter Clutch Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the starter drive housing with the 2 screws.
  Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply grease to the bearings and install it onto the starter yoke.
  
  Fig 2: Installing Starter Drive Housing With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER BRUSH HOLDER ASSEMBLY
1. Place the brush holder assy on the starter yoke.
2. Using a screwdriver, install the 4 brushes.
3. Install a new O-ring onto the groove of the field frame.
  
  Fig 3: Installing Brushes Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the end frame with the 2 screws.
  
  Fig 4: Installing End Frame With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Install a new O-ring onto the groove of the starter yoke.
2. Align the key of the starter yoke with the groove of the magnet starter switch.
  
  Fig 5: Installing New O-Ring Onto Groove Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten the 2 through bolts.
  Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
4. Connect the lead wire to terminal C with the nut.
  Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)
  
  Fig 6: Connecting Lead Wire To Terminal C With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002