Starting System (2ZR-FE): Starter: Reassembly

INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Apply high-temperature grease to the parts of the starter pinion drive lever that contact the starter pivot part of the starter pinion drive lever.
2. Install the starter pinion drive lever and rubber seal into the starter center bearing clutch sub-assembly.
3. Install the starter center bearing clutch together with the starter pinion drive lever into the starter drive housing assembly.
  
  Fig 1: Identifying Grease Applying Areas On Starter Pinion Drive Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
2. Install the 3 planetary gears.
  
  Fig 2: Identifying Grease Applying Areas On Planetary Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ARMATURE ASSEMBLY
1. Install the starter armature assembly from the starter yoke assembly.
  NOTE: 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.
  
  Fig 3: Identifying Starter Armature Assembly And Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER BRUSH HOLDER ASSEMBLY
1. Install the brush holder.
2. Using a screwdriver, hold the brush springs back, and install the 4 brushes into the brush holder.
  
  Fig 4: Installing Brushes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the grommet between the positive (+) pole and negative (-) pole.
  
  Fig 5: Identifying Grommet With Positive (+) And Negative (-) Pole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Fit the clamp of the brush holder into the starter commutator end frame assembly.
  
  Fig 6: Installing Starter Commutator End Frame Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the commutator end frame with the 2 screws.
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
INSTALL STARTER ARMATURE PLATE
1. Install the starter armature plate onto the starter yoke assembly.
  
  Fig 7: Locating Starter Commutator End Frame Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the starter plate so that the keyway is positioned between the keys.
  
  Fig 8: Identifying Key Positions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Align the key of the starter yoke with the keyway located on the starter drive housing assembly.
  
  Fig 9: Align Key Of Starter Yoke With Keyway On Starter Drive Housing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a T25 "TORX" socket wrench, install the drive housing with the 2 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
INSTALL MAGNET STARTER SWITCH ASSEMBLY
1. Apply high-temperature grease to the plunger hook.
  
  Fig 10: Locating Drive Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side.
  
  Fig 11: Holding Magnet Starter Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the magnet starter switch assembly with the 2 nuts.
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf)
  
  Fig 12: Locating Magnet Starter Switch Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the lead wire to the magnet starter switch, then fasten it with the nut.
  Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)
  
  Fig 13: Locating Lead Wire Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002