Section 9 (Starting System (2AZ-FE)): Starter: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
2. Install the 3 planetary gears.
  
  Fig 1: Identifying Grease Applying Areas On Planetary Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Install the starter armature with the brush holder onto the starter yoke assembly.
  NOTE: The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet to break.
  
  Fig 2: Identifying Starter Armature Assembly And Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER BRUSH HOLDER ASSEMBLY
1. Install the brush holder.
  1. Using a screwdriver, hold the brush springs back, and install the 4 brushes into the brush holder.
    
    Fig 3: Removing/Installing Brush
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Insert the grommet between the positive (+) pole and negative (-) pole.
    
    Fig 4: Identifying Grommet With Positive (+) And Negative (-) Pole
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Fit the clamp of the brush holder into the starter commutator end frame assembly.
  
  Fig 5: Installing Starter Commutator End Frame Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the commutator end frame with the 2 screws.
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
INSTALL STARTER ARMATURE PLATE
1. Install the starter armature plate onto the starter yoke assembly.
  
  Fig 6: Locating Commutator End Frame Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter plate so that the keyway is positioned between the keys.
  
  Fig 7: Identifying Keyway Positions On Starter Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the key of the starter yoke with the keyway located on the starter drive housing assembly.
  
  Fig 8: Aligning Key Of Starter Yoke With Keyway Located On Starter Drive Housing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a T25 "TORX" socket wrench, install the drive housing with the 2 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
INSTALL MAGNET STARTER SWITCH ASSEMBLY
1. Apply high-temperature grease to the plunger hook.
  
  Fig 9: Locating Drive Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side.
  
  Fig 10: Holding Magnet Starter Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the magnet starter switch assembly with the 2 nuts.
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf)
  
  Fig 11: Locating Magnet Starter Switch Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the lead wire to the magnet starter switch, then fasten it with the nut.
  Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)
  
  Fig 12: Locating Lead Wire With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002