Reassembly

2GR-FSE STARTING: STARTER: REASSEMBLY

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) Apply high-temperature grease to the drive lever set pin, as shown in the illustration.





(b) Install the drive lever set pin to the starter center bearing clutch sub-assembly.





Text in Illustration





(c) Install the starter center bearing clutch with the drive lever set pin to the starter drive housing.

2. INSTALL PLANETARY GEAR

(a) Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration.





(b) Install the 3 planetary gears.

3. INSTALL STARTER ARMATURE ASSEMBLY

(a) Apply high-temperature grease to the plate washer, new snap ring and bearing, as shown in the illustration.





Text in Illustration





(b) Install the armature assembly to the starter commutator end frame assembly.

(c) Apply high-temperature grease to the armature shaft.





(d) Install the plate washer to the armature shaft.

NOTICE:
Do not damage starter commutator end frame.

(e) Using snap ring pliers, install the snap ring.





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NOTICE:
* Be sure to install the snap ring in the armature shaft groove securely.
* Be sure to properly install the snap ring because it easily expands.
(f) Using a vernier caliper, measure the snap ring.





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Maximum length:

5.0 mm (0.197 in.)

(g) If the length is greater than the maximum, replace the snap ring.

4. INSTALL STARTER COMMUTATOR END FRAME COVER

(a) Install the starter commutator end frame cover to the starter commutator end frame assembly.





5. INSTALL STARTER ARMATURE PLATE

(a) Insert the starter armature plate to the starter yoke.





Text in Illustration





(b) Align the keyway of the starter armature plate with the key inside the starter yoke, and install the starter armature plate.

6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Align the rubber of the end frame with the cutout of the starter yoke.





Text in Illustration





(b) Install the end frame to the starter yoke.

NOTICE:
The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet to break.

7. INSTALL STARTER YOKE ASSEMBLY

(a) Align the protrusion of the starter yoke with the cutout of the repair service starter kit.





Text in Illustration





(b) Install the starter yoke with the 2 through-bolts.





Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

8. INSTALL REPAIR SERVICE STARTER KIT

(a) Apply high-temperature grease to the plunger and hook, as shown in the illustration.





(b) Hang the plunger hook of the repair service starter kit to the drive lever.

(c) Apply high-temperature grease to the return spring.

(d) Install the plunger and the return spring.

(e) Install the repair service starter kit with the 2 screws.





Torque : 7.5 Nm (77 kgf-cm, 66 in-lbf)

(f) Connect the lead wire to terminal C with the nut.





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)