Reassembly

2ZR-FE STARTING: STARTER: REASSEMBLY

REASSEMBLY

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) 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.
(b) Install the starter pinion drive lever and rubber seal into the starter center bearing clutch sub-assembly.
(c) Install the starter center bearing clutch together with the starter pinion drive lever into the starter drive housing assembly.
2. INSTALL PLANETARY GEAR

(a) Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
(b) Install the 3 planetary gears.
3. INSTALL STARTER BRUSH HOLDER ASSEMBLY
(a) Install the brush holder.

(1) Using a screwdriver, hold the brush springs back, and install the 4 brushes into the brush holder.
(2) Install the brush holder to the starter armature.

(3) Insert the grommet between the positive (+) pole and negative (-) pole.
4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Fit the clamp of the brush holder into the starter commutator end frame assembly.

(b) Install the commutator end frame with the 2 screws.
Torque: 1.5 Nm (15 kgf-cm, 13 in-lbf)
5. INSTALL STARTER ARMATURE ASSEMBLY
(a) Align the rubber with the groove of the starter yoke assembly.
(b) Install the starter armature with the brush holder onto 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.
HINT: Support the starter armature so that it may not be pulled out from the starter brush holder by magnetic force of the starter yoke assembly.

6. INSTALL STARTER ARMATURE PLATE
(a) Install the starter armature plate onto the starter yoke assembly.
(b) Install the starter plate so that the keyway is positioned between the keys.

7. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Align the key of the starter yoke with the keyway located on the starter drive housing assembly.

(b) Using a T25 "TORX" socket wrench, install the drive housing with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
8. INSTALL MAGNET STARTER SWITCH ASSEMBLY
(a) Apply high-temperature grease to the plunger hook.

(b) Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side.

(d) Connect the lead wire to the magnet starter switch, then fasten it with the nut.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)