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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Starter >> Starting System (W/ Stop And Start System) (2GR-FKS) - Service Information >> STARTER (w/ Stop And Start System) >> Reassembly [12/2019 - 10/2022] >> Procedure

Reassembly [12/2019 - 10/2022]: Procedure

  1. INSTALL RUBBER SEAL 
    1. Install the rubber seal to the starter drive housing assembly.
      GTY691505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL PLANETARY GEAR 
    1. Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter drive housing assembly.
      GTY700924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Install the 3 planetary gears to the starter drive housing assembly.
  3. INSTALL STARTER ARMATURE ASSEMBLY 
    1. Install the starter armature assembly to the starter yoke assembly.
      GTY708984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The magnet of the starter yoke assembly may attract the starter armature assembly when the starter armature assembly is installed, causing the magnet to break.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY 
    1. Hold the brush spring back and set the 4 brushes as shown in the illustration.
      GTY390854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the starter brush holder assembly to the starter armature assembly and push in the 4 brushes as shown in the illustration.
      GTY390851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fit the protrusion of the grommet between the negative (-) brush holder plate and positive (+) motor lead wire.
      GTY687918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      *b Negative (-) Brush Holder Plate
      *c Positive (+) Motor Lead Wire
  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Install the starter commutator end frame assembly to the starter yoke assembly.
      GTY928138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Field Coil Lead Wire Rubber
      *b Cutout
      NOTE:

      Align the field coil lead wire rubber of the starter yoke assembly with the cutout of the starter commutator end frame assembly.

    2. Install the 2 screws.

      Torque: 1.5 N.m (15 kgf/cm, 13 in.lbf) 

      GTY888262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL STARTER ARMATURE PLATE 
    1. Align the starter armature plate so that the protrusion fits between the stoppers of the starter yoke assembly, and install the starter armature plate.
      GTY927912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Starter Yoke Assembly
      *2 Starter Armature Plate
      *a Stopper
      *b Protrusion
      NOTE:

      Make sure the protrusion of the starter armature plate is inserted between the stoppers of the starter yoke assembly.

  7. INSTALL STARTER YOKE ASSEMBLY 
    1. Align the cutout of the starter yoke assembly with the protrusion of the starter drive housing assembly.
      GTY867182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Starter Yoke Assembly
      *2 Starter Drive Housing Assembly
      *a Cutout
      *b Protrusion
    2. Using a T25 "TORX" socket wrench, install the 2 through bolts.

      Torque: 6.0 N.m (61 kgf/cm, 53 in.lbf) 

      GTY888266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL MAGNET STARTER SWITCH ASSEMBLY 
    1. Apply high-temperature grease to the magnet starter switch assembly as shown in the illustration.
      GTY839810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Pinion Drive Lever
      *a Hook
      High-temperature Grease
    2. Hang the hook of the magnet starter switch assembly on the pinion drive lever.
    3. Install the magnet starter switch assembly with the 2 nuts.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

      GTY937209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL STARTER INRUSH CURRENT REDUCTION RELAY 
    1. Install the starter inrush current reduction relay to the starter drive housing assembly with the 2 bolts.

      Torque: 7.9 N.m (81 kgf/cm, 70 in.lbf) 

      GTY888265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the field coil lead wire to terminal M with the nut.

      Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

      GTY888259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL WIRE HARNESS 
    1. Install the wire harness to the starter assembly with the 2 nuts.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

      GTY888258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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