Note: Use high temperature grease to lubricate the bearings and gears when assembling the starter.
1. Apply grease to the bearings and insert the anchor into the starter housing.
2. Install the brush holder.
- a) (Starter 2.2 kW) Align the brush holder protrusion with the groove in the starter housing.
- b) Install the brush holder into the starter housing.
Starter 2.2 kW
- c) Using a screwdriver, bend the brush spring back and install the brush into the brush holder.
Note: Make sure that the (+) brush wires do not come into contact with the ground.
- v) (Except for the 2.2 kW starter) Install a new O-ring into the groove of the starter housing.
- g) (Except for the 2.2 kW starter) Install a new O-ring onto the screw.
- d) (Except for the 2.2 kW starter) Install the starter cover on the manifold side and secure it with two screws.
3. Apply grease to the steel ball and insert the ball into the hole of the overrunning clutch shaft.
4. Install the pinion clutch and starter cover on the drive side.
- a) Apply grease to the return spring, overrunning clutch, idler gear and bearing.
- b) Insert the spring into the hole of the traction relay assembly.
- c) Install the following parts:
- (Starter 1.0 kW)
- (1) overrunning clutch assembly,
- (2) intermediate gear,
- (3) bearing.
- (Starter 1.2 kW)
- (1) intermediate gear.
- (2) bearing.
- (Starter 1.4 kW)
- (1) intermediate gear,
- (2) bearing,
- (3) drive gear.
- (Starter 2.2 kW)
- (1) overrunning clutch assembly.
- (2) intermediate gear,
- (3) bearing.
- (4) drive gear.
- d) Connect the starter cover on the drive side to the traction relay, securing it with two screws.
5. Install the starter housing and armature into the assembly.
- a) Install a new O-ring into the groove of the starter housing.
- b) (Except for the 2.2 kW starter) Align the protrusion on the starter housing with the groove on the traction relay.
Except for the 2.2 kW starter
- v) (Starter 2.2 kW) Align the stamped mark (reference point) on the starter housing with the mark on the traction relay housing.
[The original version is published on the website: toyotaman.ru]
Starter 2.2 kW
- d) Install the starter housing and armature assembly, securing them with 2 tie bolts.
- d) Connect the wire to terminal "C" and secure it with a nut.
6. Install the wire terminal Install the wire terminal and secure it with the bolt, spring washer and screw.
7. (3S-FE, 4S-FE) Install the boot.
