Starting System: Starter: Reassembly

INSTALL PLANETARY GEAR
1. Apply grease to the planetary gears and pin parts of the planetary shaft.
2. Install the 3 planetary gears.
  
  Fig 1: Applying Grease To Planetary Gears And Pin Parts Of Planetary Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Apply grease to the plate washer and the armature shaft.
2. Install the starter armature to the starter commutator end frame.
3. Using snap ring pliers, install the plate washer and a new snap ring.
  
  Fig 2: Installing Plate Washer And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a vernier caliper, measure length of the snap ring.
  Maximum length: 5.0 mm (0.197 in.)
  
  If the length is greater than the maximum, replace it with a new snap ring.
  
  Fig 3: Identifying Length Of Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE HOUSING STARTER BEARING COVER
1. Install the drive housing starter bearing cover to the starter commutator end frame.
  
  Fig 4: Installing Drive Housing Starter Bearing Cover To Starter Commutator End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE PLATE
1. Insert the starter armature plate to the starter yoke.
2. Align the keyway of the starter plate with the key inside the starter yoke, and install the starter plate.
  
  Fig 5: Identifying Keyway And Key
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the rubber with the convex cutout of starter yoke.
2. Install starter commutator end frame to the starter yoke.
  
  Fig 6: Identifying Rubber And Cutout Of Field Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Align the key of the starter yoke with the keyway of repair service starter kit.
  
  Fig 7: Aligning Protrusion Of Starter Field Frame With Cutout Of Starter Drive 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 8: Locating Starter Yoke Through Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REPAIR SERVICE STARTER KIT
1. Apply grease to the plunger and the hook.
2. Hang the plunger hook of the repair service starter kit to the drive lever.
3. Install the plunger and return spring.
  
  Fig 9: Installing Plunger And Return Spring
  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 10: Locating Starter Kit Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the lead wire to the repair service starter kit with the nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 11: Locating Magnetic Switch Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002