Starting/Charging Systems (H4SO): Starter: Assembly

Press-fit the rear bearing into end frame.
1. Set an appropriate tool (ø 22 mm) to rear bearing.
2. Press-fit the rear bearing using a press.
NOTE:
- Use a new bearing.
- Use a flat base.
- Press-fit the bearing outer ring until it contact to the base bottom.
  
  Fig 1: Pressing-Fit Bearing Outer Ring
Press-fit the oil less bearing into shock absorber bearing.
1. Set an appropriate tool (ø20 mm) to oil less bearing.
2. Press-fit the oil less bearing using a press.
NOTE:
- Use a new bearing.
- Use a flat base.
- Press-fit the bearing outer ring until it contact to the base bottom.
  
  Fig 2: Pressing-Fit Bearing Outer Ring
Press-fit the front bearing into front bracket.
1. Set the front bearing into front bracket.
2. Set an appropriate tool (2.0 mm thickness plate) to front bracket, and press-fit the front bearing using a press.
NOTE:
- Use a new bearing.
- Measure the protrusion of front bearing after press-fitting, to check if it is within standard value.
Standard 2.0 - 2.4 mm (0.0787 - 0.0945 in)

Fig 3: Identifying Protrusion Of Front Bearing
Assemble the internal gear and wave washer to shock absorber bearing.
NOTE: Align with the pawl position of shock absorber bearing to install internal gear.

Fig 4: Assembling Internal Gear And Wave Washer
Assemble the washer and internal gear to shaft.
NOTE: Apply grease to the both sides of the shaft spline and washer.

Grease:

DENSO HL50

Fig 5: Assembling Washer And Internal Gear To Shaft
Assemble the snap ring.

Fig 6: Assembling Snap Ring
Assemble the overrunning clutch to shaft.
NOTE: Apply grease to the stop ring entire perimeter.

Grease:

DENSO HL50

Fig 7: Identifying Stop Ring
Install the stopper to shaft as follows:
1. Insert the snap ring into the shaft groove by lightly tapping it with an appropriate tool (such as a fit socket wrench).
  NOTE: Use new snap rings.
  
  Fig 8: Inserting Snap Ring Into Shaft Groove
2. Press-fit the stopper to snap ring using a press.
  
  Fig 9: Pressing-Fit Stopper To Snap Ring
Install the shaft assembly to front bracket.
1. Apply grease to the sliding part (A) of lever pin and the pole piece (B) of arm.
  Grease:
  
  DENSO HL50
  
  Fig 10: Identifying Sliding Part Of Lever Pin
2. Insert the lever arm into the position on over running clutch as shown in the figure.
  
  Fig 11: Inserting Lever Arm Into Position
3. Align the shaft assembly to the position on front bracket as shown in the figure.
  
  Fig 12: Aligning Shaft Assembly To Position On Front Bracket
Install the rubber seal.

Fig 13: Identifying Rubber Seal
Install the planetary gear.
1. Apply a grease to the pin (A) and bushing (B).
  
  Fig 14: Identifying Pin And Bushing
2. Assemble the planetary gear to pin.
3. Apply grease to the planetary gear clearance (A) and pin upper part (B).
NOTE:
- Apply grease so that it contacts each gear.
- be careful not to allow dirt to get in.
Grease:

DENSO HL50

Fig 15: Identifying Planetary Gear
Assemble the brush assembly to end frame.
NOTE:
- Be careful not to allow grease to get on brush.
- Align the rubber seal part with end frame groove.
  
  Fig 16: Assembling Brush Assembly To End Frame
Tightening torque:

1.4 N.m (0.14 kgf-m, 1.03 ft-lb)

Fig 17: Locating End Frame Screws
Install the armature to end frame.
NOTE:
- Apply grease to the rear bearing inner circumference.
- Be careful not to allow grease to attach to commutator.
Grease:

DENSO HL50
Set the space ring, then assemble the snap ring.
NOTE:
- Use new snap rings.
- Check the dimension of (A) in the figure after assembling snap ring. If it exceeds 5.0 mm (0.20 in), assemble a new snap ring again.
  
  Fig 18: Inserting Snap Rings
  
  Fig 19: Identifying Snap Ring Dimension
Install the end frame cover.

Fig 20: Installing End Frame Cover
Assemble the armature plate to yoke.
NOTE:
- Align the rotation stopper of armature plate with the drive out part of yoke inner circumference.
- Be careful of the assembly direction of armature plate.
  
  Fig 21: Identifying Armature Plate
Assemble the armature to yoke.
NOTE:
- Be careful not to allow armature plate to move. It is recommendable to support with cylindrical pipe as shown in the figure.
- Align the positions of cutout portion of yoke with the rubber part of end frame.
- Be careful not to damage the magnet.
  
  Fig 22: Assembling Armature To Yoke
  
  Fig 23: Aligning Positions Of Cutout Portion Of Yoke With Rubber Part Of End Frame
Assemble the yoke to front bracket.
NOTE:
- Apply grease to the end surface of yoke (mating surface with front bracket).
- Align the drive out position of yoke outer perimeter with the cutout portion of front bracket.
  
  Fig 24: Aligning Drive Out Position Of Yoke Outer Perimeter
Tighten the through bolts on both sides.
Tightening torque:

6 N.m (0.6 kgf-m, 4.4 ft-lb)

Fig 25: Locating Armature Through-Bolts
Install the rear cover.

Fig 26: Locating Rear Cover Nuts
Install the magnet switch assembly to front bracket.
1. Assemble the plunger hook to lever.
  NOTE: Apply grease to the plunger hook and sleeve inner circumference.
  
  Grease:
  
  DENSO HL50
  
  Fig 27: Identifying Plunger Hook And Lever
2. Assemble the plunger spring and magnet switch to front bracket.
  NOTE: Apply grease to the end surface of magnet switch as shown in the figure.
  
  Grease:
  
  DENSO HL50
  
  Fig 28: Identifying Magnet Switch Clearance
  
  Fig 29: Assembling Plunger Spring And Magnet Switch To Front Bracket
3. Tighten the bolt.
  Tightening torque:
  
  7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
  
  Fig 30: Locating Switch Assembly Bolts
Connect the harness to terminal M of magnet switch assembly.
Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 31: Identifying Terminal M