Section 10 (Starting System): Starter: Reassembly

WARNING: This page is about a different car, the 2006 Toyota Land Cruiser. 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, return spring, clutch rollers and starter idler pinions.
2. Install the steel ball.
3. Install a new O-ring to the starter housing.
4. Insert the return spring into the magnet starter switch hole.
5. Install the starter clutch, idler gear, retainer and clutch roller.
  
  Fig 1: Installing Starter Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the starter housing to the magnet switch with the 2 screws.
  Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
  
  Fig 2: Installing Starter Housing To Magnet Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Install the starter armature to the starter yoke.
INSTALL STARTER BRUSH HOLDER ASSEMBLY
1. Align the claw of the brush holder with the claw groove of the starter yoke.
  
  Fig 3: Aligning Claw Of Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the brush holder on the starter yoke.
3. Install the 2 starter yoke brushes to the brush holder.
  1. Using a screwdriver, pull back the spring.
  2. Install the brush to the brush holder.
    NOTE: Check that the positive (+) lead wires are not grounded.
4. Install a new O-ring to the groove of the starter yoke.
5. Install the end cover with 2 new O-rings and the 2 screws.
  Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf)
  
  Fig 4: Installing End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Install a new O-ring to the groove of the starter yoke.
2. Align the protrusion of the starter yoke with the groove of the magnetic switch.
  
  Fig 5: Aligning Protrusion Of Starter Yoke With Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the starter yoke with the 2 through bolts.
  Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
  
  Fig 6: Installing Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the lead wire to terminal C with the nut.
  Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)