Reassembly

2AZ-FE STARTING: STARTER: REASSEMBLY

1. INSTALL PLANETARY GEAR

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





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(b) Install the 3 planetary gears into the starter drive housing assembly.

2. INSTALL STARTER ARMATURE ASSEMBLY

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





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





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(c) Install the starter armature assembly into the starter commutator end frame assembly.

(d) 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 groove securely.
* Be sure to install the snap ring properly because it easily expanders.

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





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Maximum length:

5.0 mm (0.197 in.)

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

3. INSTALL STARTER COMMUTATOR END FRAME COVER

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





4. INSTALL STARTER ARMATURE PLATE

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





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5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

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





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

NOTICE:
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.

6. INSTALL STARTER YOKE ASSEMBLY

(a) Align the claw of the starter yoke with the protrusion inside the starter drive housing assembly.





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





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

7. INSTALL MAGNET SWITCH BODY

(a) Apply high-temperature grease to the plunger, return spring and hook.





(b) Hang the plunger hook of the magnet switch body to the drive lever hook.

(c) Install the plunger and the return spring.

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





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

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





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