INSTALL STARTER CLUTCH SUB-ASSEMBLY

INSTALL STARTER DRIVE HOUSING ASSEMBLY

INSTALL STARTER INTERNAL GEAR

INSTALL STARTER ARMATURE ASSEMBLY

INSTALL STARTER YOKE ASSEMBLY

INSTALL STARTER BRUSH HOLDER ASSEMBLY

INSTALL STARTER CLUTCH PINION

Apply high-temperature grease to the parts indicated by the arrows in the illustration.

Install the starter clutch into the magnet starter switch.

• NOTICE:

• Make sure that the bearing does not disengage from the starter clutch.

Install the 3 starter washers and pinion drive lever with the snap ring.

Apply a light coat of seal packing to the surface of the starter drive housing that contacts the starter magnet switch.

• Seal packing:
• Toyota Genuine Seal Packing 1121C, Three Bond 1121C or equivalent

Install the starter drive housing with the 2 bolts.

• Torque:
• 6.0 N*m{ 61 kgf*cm, 53 in.*lbf}

Apply high-temperature grease to the portion indicated by the arrow in the illustration.

Install the starter internal gear.

• NOTICE:

• Make sure the internal gear protrusion indicated by the arrow in the illustration is aligned with the groove on the bottom side of the magnet starter switch.

Apply high-temperature grease to the planetary gears.

Install the 3 starter planetary gears.

Install the starter washer.

• NOTICE:

• Make sure that the washer is securely seated in the groove.

Apply high-temperature grease to the portion indicated by the arrow in the illustration.

Install the starter plate.

Apply high-temperature grease to the portion indicated by the arrow in the illustration.

Install the starter armature to the starter plate.

Install 2 new O-rings to the starter yoke.

Install the starter yoke to the magnet starter switch.

Place the brush holder on the starter armature.

Using a screwdriver, hold the starter brush spring back and connect the 4 starter brushes to the starter brush holder.

• NOTICE:

• Check that the positive (+) lead wires are not grounded.

Install the starter brush holder into the starter armature.

Apply high-temperature grease to the portion indicated by the arrow in the illustration.

Install the commutator end frame with the 2 screws.

• Torque:
• 3.9 N*m{ 40 kgf*cm, 35 in.*lbf}

Install the 2 through bolts.

• Torque:
• 17 N*m{ 173 kgf*cm, 12 ft.*lbf}

Install the nut to terminal C.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Install the 2 starter hoses to the starter.

Install the spring, starter clutch pinion and pinion stop collar with the snap ring.