Starting System: Starter: Reassembly

HINT:

Use high-temperature grease to lubricate the bearings and gears when assembling the starter.

INSTALL ARMATURE TO MAGNETIC SWITCH ASSEMBLY
1. Apply grease to the armature bearings.
2. Install the armature to the magnetic switch assembly.
INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
1. Apply grease to the steel ball.
2. Insert the steel ball into the clutch shaft hole.
  
  Fig 1: Inserting Steel Ball Into Clutch Shaft Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
1. Apply grease to the return spring.
2. Insert the return spring into the magnetic switch hole.
  
  Fig 2: Inserting Return Spring Into Magnetic Switch Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the starter clutch assembly on the starter housing.
4. Place idler on the starter housing.
5. Place bearing on the starter housing.
6. Install the starter housing to the magnetic switch with the 2 bolts.
  Torque: 5.9 N.m (60 kgf-cm, 52 in. lbf)
INSTALL FIELD FRAME
1. Install a new O-ring to the groove of the filed frame.
2. Align the protrusion of the field frame with the groove of the magnetic switch, and install the field frame.
INSTALL BRUSH HOLDER
1. Place the brush holder on the field frame.
2. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes.
NOTE: Check that the positive (+) lead wires are not grounded.

Fig 3: Installing Brush Holder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL END COVER
1. Install a new O-ring to the groove of the field frame.
2. Install the end cover to the field frame with the 2 screws.
  Torque: 1.5 N.m (15 kgf cm, 13 in. lbf)
3. Install the field frame and armature assembly with the 2 through bolts.
  Torque: 5.9 N.m (60 kgf cm, 52 in. lbf)
4. Connect the lead wire to terminal C with the nut.
  Torque: 5.9 N.m (60 kgf cm, 52 in. lbf)