Reassembly

2ZR-FE STARTING: STARTER: REASSEMBLY

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

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





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





(c) Install the starter center bearing clutch sub-assembly together with the starter drive lever set pin into the starter drive housing assembly.





2. INSTALL STARTER PLANETARY GEAR





(a) Apply 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 grease to the washer plate and the armature shaft.

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

(c) Using snap ring pliers, install the plate washer and a new snap ring.

NOTICE:
* Be sure to install the snap ring in the armature shaft grove securely.
* Be sure to properly install the snap ring because it easily expands.

(d) Using vernier calipers, measure the snap ring.





Maximum length:

5.0 mm (0.197 in.)

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 onto the starter commutator end frame assembly.

5. INSTALL STARTER ARMATURE PLATE





(a) Insert the starter armature plate into the starter yoke assembly.

(b) Align the cutout of the plate with the inside protrusion of the starter yoke assembly, and install the plate.

6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY





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

(b) Install the starter yoke assembly onto the starter commutator end frame assembly.

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

7. INSTALL STARTER YOKE ASSEMBLY





(a) Align the key located on the starter yoke assembly with the keyway of the starter drive housing assembly.

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





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

8. INSTALL MAGNET SWITCH BODY





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

(b) Hang the plunger hook of the magnet switch body on the starter drive lever set pin.





(c) Install the plunger and the return spring as shown in the illustration.

(d) Install the magnet switch body with the 2 screws.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)





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

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