Section 25 (Starting): Starter: Reassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration
2. Install the 3 planetary gears.
Fig 1: Locating Planetary Gears
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INSTALL STARTER ARMATURE PLATE
1. Insert the starter armature plate to the starter center bearing clutch sub-assembly
NOTE: Check that the tab of the starter armature plate fits over the projection of the starter center bearing clutch sub-assembly.
INSTALL STARTER ARMATURE ASSEMBLY
1. Install the starter armature assembly to the starter center bearing clutch sub-assembly.
INSTALL STARTER YOKE ASSEMBLY
1. Align the tab of the starter center bearing clutch sub-assembly with the notch of the starter yoke assembly, and install the starter yoke assembly.
Fig 3: Aligning Tab Of Starter Center Bearing Clutch With Notch Of Starter Yoke Assembly
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INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Install the starter brush holder assembly.
2. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder
3. Connect the 4 brushes
  
  Fig 4: Connecting Brush Into Brush Holder
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4. Align the starter commutator end frame rubber with the groove of the starter yoke assembly
  
  Fig 5: Identifying Starter Commutator End Frame Rubber
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5. Install the starter commutator end frame assembly with the 2 screws.
  Torque: 3.8 N*m (39 kgf*cm, 33 in.*lbf)
Fig 6: Locating Starter Commutator End Frame Assembly Screws
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INSTALL STARTER DRIVE HOUSING ASSEMBLY
1. Apply high-temperature grease to the starter pinion drive lever, as shown in the illustration.
  
  Fig 7: Locating Grease Applying Area Of Starter Pinion Drive Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter pinion drive lever to the starter center bearing clutch sub-assembly.
  
  Fig 8: Locating Starter Pinion Drive Lever
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3. Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly
  
  Fig 9: Aligning Claw Of Starter Yoke Assembly With Groove Inside Starter Drive Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a T30 "TORX" socket wrench, install the starter drive housing assembly with the 2 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Fig 10: Locating Starter Drive Housing Assembly Bolts
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INSTALL STARTER MAGNETIC SWITCH ASSEMBLY
1. Temporarily install the starter magnetic switch assembly by hooking its tip to the upper side of the starter pinion drive lever
2. Install the 2 nuts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 11: Locating Starter Magnetic Switch Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the lead wire to the terminal with the nut
  Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
Fig 12: Locating Lead Wire Nut
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