Reassembly

2AR-FE STARTING: STARTER: REASSEMBLY

1. INSTALL PLANETARY GEAR

(a) Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.





(b) Install the 3 planetary gears.

2. INSTALL RUBBER SEAL

(a) Install the rubber seal to the repair service starter kit.





3. INSTALL STARTER ARMATURE ASSEMBLY

(a) Apply high-temperature grease to the washer and armature shaft.





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





(c) Install the washer.

(d) Using snap ring pliers, securely install a new snap ring to the armature shaft groove.

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

(e) Using a vernier caliper, measure the length of the snap ring.





Maximum length:

5.0 mm (0.197 in.)

If the length is more than the maximum, replace the snap ring with a new one.

4. INSTALL STARTER COMMUTATOR END FRAME COVER

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





5. INSTALL STARTER ARMATURE PLATE

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





(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.





(b) Install the starter commutator 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.





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





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

8. INSTALL MAGNET STARTER SWITCH ASSEMBLY

(a) Apply high-temperature grease to the plunger and lever.





(b) Pull the pinion gear and push down the lever.





(c) Temporarily install the magnet starter switch by hooking the plunger into the upper side of the pinion drive lever.





(d) Install the magnet starter switch with the 2 nuts.





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

(e) Connect the lead wire to the magnet starter switch with the nut.





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