Starting (2GR-FSE): Starter: Reassembly

INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Apply high-temperature grease to the drive lever set pin, as shown in the illustration.
  
  Fig 1: Identifying Grease Points
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the drive lever set pin onto the starter center bearing clutch.
3. Install the starter center bearing clutch with drive lever set pin to the starter drive housing.
Fig 2: Identifying Starter Center Bearing Clutch With Drive Lever Set Pin
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INSTALL PLANETARY GEAR
1. Apply grease to the planetary gears and planetary shaft pins.
2. Install the 3 planetary gears.
Fig 3: Identifying Planetary Gear
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INSTALL STARTER ARMATURE ASSEMBLY
1. Apply grease to the plate washer and armature shaft.
2. Install the armature shaft onto the starter commutator end frame.
  
  Fig 4: Identifying Plate Washer And Armature Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using snap ring pliers, install the plate washer and snap ring.
  NOTE:
  - Be sure to install the snap ring in the armature shaft groove securely.
  - Be sure to properly install the snap ring because it easily expands.
  Fig 5: Identifying Plate Washer And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a vernier caliper, measure the snap ring length.
  Maximum length:
  
  5.0 mm (0.197 in)
  
  If the length is greater than the maximum, replace the snap ring with a new one.
Fig 6: Measuring Snap Ring Length
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INSTALL STARTER COMMUTATOR END FRAME COVER
1. Install the starter commutator end frame cover to the starter commutator end frame.
Fig 7: Identifying Starter Commutator End Frame Cover To Starter Commutator End Frame
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INSTALL STARTER ARMATURE PLATE
1. Insert the starter armature plate into the starter yoke.
2. Align the cutout of the plate with the inside protrusion of the starter yoke, and install the plate.
Fig 8: Aligning Cutout Of Plate With Inside Protrusion Of Starter Yoke
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INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the rubber of the starter commutator end frame with the cutout of the starter yoke.
2. Install the starter yoke onto the starter commutator end frame.
Fig 9: Aligning Rubber Of Starter Commutator End Frame With Cutout Of Starter Yoke
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INSTALL STARTER YOKE ASSEMBLY
1. Align the key located on the starter yoke with the keyway of the starter housing.
  
  Fig 10: Aligning Key Located On Starter Yoke With Keyway Of Starter Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter yoke with the 2 through bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Fig 11: Locating Starter Yoke With Bolts
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INSTALL REPAIR SERVICE STARTER KIT
1. Apply high-temperature grease to the plunger and hook, as shown in the illustration.
2. Hang the plunger hook of the repair service starter kit to the drive lever.
3. Install the plunger and return spring.
  
  Fig 12: Applying High-Temperature Grease To Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the repair service starter kit with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 13: Locating Repair Service Starter Kit With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the lead wire to terminal C with the nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Fig 14: Locating Terminal C With Nut
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