Starting System & Charging System (H4DO): Starter: Assembly

Install the armature to the yoke.

Fig 1: Removing/Installing Armature Yoke
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Install the brush holder assembly to the armature.
NOTE: Spread the brush with your fingers, being careful not to damage the brush.

Fig 2: Removing/Installing Brush Holder Assembly From Armature
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Install the starter cover, and secure it to the brush holder assembly with the screws.

Fig 3: Identifying Starter Cover
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Assemble the planetary gear (A) and washer (B) to the internal gear.
1. Apply grease to the planetary gear installation position.
  Grease:
  
  DENSO HL50
2. Install the planetary gear to the pin.
3. Apply grease to the planetary gear, internal gear, washer, and upper part of the pin.
  NOTE:
  - Apply grease so that it contacts each gear.
  - Be careful not to allow dirt to get in.
  Grease:
  
  DENSO HL50
  
  Fig 4: Identifying Planetary Gear And Washer
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4. Install the starter plate.
  
  Fig 5: Identifying Starter Plate
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Assemble the overrunning clutch assembly to the yoke.

Fig 6: Removing Overrunning Clutch Assembly From Yoke
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Install the shift lever.
NOTE: Apply grease to the contact portion of the shift lever.

Grease:

DENSO HL50

Fig 7: Removing/Installing Starter Shift Lever
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Install the starter housing, and tighten through bolts on both sides.
Tightening torque:

6 N.m (0.6 kgf-m, 4.4 ft-lb)

Fig 8: Identifying Starter Housing
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Fig 9: Locating Starter Housing Mounting Screws
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Install the starter seal.

Fig 10: Identifying Starter Seal
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Install the magnet switch assembly to the starter housing, and tighten the nuts.
NOTE: Apply grease to the shift lever installation position.

Grease:

DENSO HL50

Tightening torque:

7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

Fig 11: Locating Magnet Switch Assembly To Starter Housing Mounting Bolts
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Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut.
Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 12: Identifying Terminal M Holding Nut
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