Disassembly and Reassembly

STARTER DISASSEMBLY

Starter Motor (5VZ-FE) Exploded View:

1. REMOVE FIELD FRAME AND ARMATURE







a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)







b. Remove the 2 through bolts.

Torque:
1.2 kW, 1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf)
1.8 kW type: 9.3 N.m (95 kgf.cm, 82 in.lbf)







c. Pull out the field frame with the armature from the magnetic switch assembly.

ASSEMBLY NOTE: Align the protrusion of the field frame with cutout of the magnetic switch.

d. Remove the O-ring.

ASSEMBLY HINT: Use a new O-ring.

2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR







a. Remove the 2 screws.

Torque:
1.2 kW, 1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf)
1.8 kW type: 9.3 N.m (95 kgf.cm, 82 in.lbf)







b. Remove these parts from the magnetic switch assembly:
1. Starter housing
2. Return spring
3. Bearing
4. Idler Gear
5. Clutch assembly







3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.


4. REMOVE BRUSH HOLDER







a. Remove the 2 screws and end cover from the field frame.

Torque:
1.2 kW, 1.4 kW type: 1.5 N.m (15 kgf.cm, 13 in.lbf)
1.8 kW type: 3.8 N.m (38 kgf.cm, 34 in.lbf)

b. Remove the O-ring from the field frame.

ASSEMBLY HINT: Use a new O-ring.







c. Using a screwdriver hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.

5. REMOVE ARMATURE FROM FIELD FRAME

HINT: Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter.


STARTER ASSEMBLY
Assembly is in the reverse order of disassembly.