Reassembly

2GR-FE STARTING: STARTER: REASSEMBLY

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

1. INSTALL PLANETARY GEAR

(a) Apply grease to the planetary gears and pin parts of the planetary shaft.
(b) Install the 3 planetary gears.
2. INSTALL STARTER ARMATURE ASSEMBLY

(a) Apply grease to the plate washers and the armature shaft.
(b) Install the starter armature assembly to the starter commutator end frame assembly.
(c) Using snap ring pliers, install the plate washer and a new snap ring.

(d) Using a vernier caliper, measure the length of the snap ring.
Maximum length:
5.0 mm (0.197 in.)
If the length is greater than the maximum, replace it with a new snap ring.
3. INSTALL STARTER COMMUTATOR END FRAME COVER

(a) Install the starter commutator end frame cover to the starter commutator end frame assembly.
4. INSTALL STARTER ARMATURE PLATE

(a) Insert the starter armature plate to the starter yoke assembly.
(1) Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.
5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Align the rubber of the starter end frame assembly with the cutout of the starter yoke assembly.
(b) Install the starter commutator end frame assembly to the starter yoke assembly.
6. INSTALL STARTER YOKE ASSEMBLY

(a) Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.

(b) Install the starter yoke assembly with the 2 through-bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
7. INSTALL MAGNETIC SWITCH ASSEMBLY

(a) Apply grease to the plunger and the hook.
(b) Hang the plunger hook of the magnetic switch assembly on the drive lever.
(c) Install the plunger and return spring.

(d) Install the magnetic switch with the 2 screws.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)

(e) Connect the lead wire to the magnetic switch with the nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)