Reassembly (08/2010 - 08/2011): Reassembly

INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration.
  
  Fig 1: Applying High Temperature Grease To Planetary Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 planetary gears.
INSTALL STARTER ARMATURE PLATE
1. Insert the plate to the starter center bearing clutch.
  
  Fig 2: Inserting Plate To Starter Center Bearing Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Check that the protrusion of the starter armature plate fits over the notch of the starter center bearing clutch.
INSTALL STARTER ARMATURE ASSEMBLY
1. Install the starter armature to the starter center bearing clutch.
INSTALL STARTER YOKE ASSEMBLY
1. Align the protrusion of the starter center bearing clutch with the notch of the starter yoke, and install the starter yoke.
  
  Fig 3: Aligning Protrusion Of Starter Center Bearing Clutch With Notch Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Install the starter brush holder.
2. Using a screwdriver, hold the brush spring back and connect the brush into the starter brush holder.
  
  Fig 4: Removing/Installing Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 4 brushes.
4. Align the starter commutator end frame groove with the rubber of the starter yoke.
  
  Fig 5: Aligning Starter Commutator End Frame Rubber With Groove Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the starter commutator end frame with the 2 screws.
  
  Fig 6: Locating End Frame Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 3.8 N*m (39 kgf*cm, 33 in.*lbf)
INSTALL STARTER DRIVE HOUSING ASSEMBLY
1. Apply high-temperature grease to the starter pinion drive lever, as shown in the illustration.
  
  Fig 7: Locating High-Temperature Grease To Starter Pinion Drive Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter pinion drive lever to the starter center bearing clutch.
  
  Fig 8: Locating Starter Pinion Drive Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the protrusion of the starter center bearing clutch with the notch inside the starter drive housing.
  
  Fig 9: Aligning Protrusion Of Starter Center Bearing Clutch With Notch Inside Starter Drive Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a T30 "TORX" socket wrench, install the starter drive housing with the 2 bolts.
  
  Fig 10: Locating Starter Drive Housing Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
INSTALL MAGNET STARTER SWITCH ASSEMBLY
1. Temporarily install the magnet starter switch by hooking its tip to the upper side of the pinion drive lever.
  
  Fig 11: Locating Magnet Starter Switch Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 nuts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
3. Connect the lead wire to the terminal with the nut.
  
  Fig 12: Identifying Magnet Starter Switch Assembly Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)