Starting System & Charging System (H4SO): Starter: Assembly

Install the armature to yoke.

Fig 1: Removing/Installing Armature
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Install the brush holder assembly to the armature.
NOTE: Spread the brush with your fingers, being careful not to damage the brush.

Fig 2: Removing/Installing Brush Holder Assembly
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Install the starter cover, and then secure it to the brush holder assembly with the screws.

Fig 3: Identifying Starter Cover Screw
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Assemble the shock absorber as follows:
1. Apply grease to the shock absorber (C), and install the internal gear (B) to the shock absorber bearing (A).
  NOTE: Align with the claw position of internal gear to install shock absorber bearing.
  
  Grease: DENSO HL50
  
  Fig 4: Identifying Shock Absorber Bearing, Internal Gear And Shock Absorber
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2. Install the shaft to the internal gear.
  NOTE: Apply grease to the sliding part for the shaft inside the internal gear.
  
  Grease: DENSO HL50
  
  Fig 5: Identifying Shaft
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3. Install the snap ring to shaft.
  NOTE: Use new snap rings.
  
  Fig 6: Identifying Snap Ring
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Install the planetary gear to the internal gear.
1. Apply grease to the planetary gear attachment area.
  Grease: DENSO HL50
2. Install the planetary gear to pin.
3. Apply grease to the planetary gear, internal gear and upper part of the pin.
  NOTE:
  - Apply grease so that it contacts each gear.
  - Be careful not to allow dirt to get in.
  Grease: DENSO HL50
  
  Fig 7: Identifying Planetary Gear
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4. Install the starter plate.
  
  Fig 8: Identifying Starter Plate
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Assemble the overrunning clutch as follows:
1. Apply grease to the spline portion of the shaft.
  Grease: DENSO HL50
2. Install the overrunning clutch to shaft.
  
  Fig 9: Removing/Installing Overrunning Clutch
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3. Install the stopper (B) to the shaft, and install the snap ring (A).
  
  Fig 10: Removing/Installing Snap Ring
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4. Press-fit the stopper (B) to snap ring (A) using a press.
  
  Fig 11: Pressing-Fit Stopper To Snap Ring
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Assemble the overrunning clutch, shock absorber and shaft to the yoke as one unit.

Fig 12: Assembling Overrunning Clutch, Shock Absorber And Shaft To Yoke
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Install the shift lever.
NOTE: Apply grease to the contact portion of the shift lever.

Grease: DENSO HL50

Fig 13: Removing/Installing Shift Lever
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Install the starter housing, and tighten the through bolts on both sides.
Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)

Fig 14: Identifying Starter Housing
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Fig 15: Locating Through Bolts
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Install the starter seal.

Fig 16: Identifying Starter Seal
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Install the magnet switch assembly to the starter housing, and tighten the nuts.
NOTE: Apply grease to the installation part of the shift lever.

Grease: DENSO HL50

Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

Fig 17: Locating Switch Assembly Nuts
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Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut.
Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 18: Identifying Terminal M
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