Disassembly and Reassembly

Starter Motor (5VZ-FE):

DISASSEMBLY
1. REMOVE FIELD FRAME WITH ARMATURE FROM MAGNETIC SWITCH ASSEMBLY







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

Torque: 5.9 N.m (60 kg.cm, 52 in.lb)







b. Remove the 2 through bolts. Pull out the field frame with the armature from the magnetic switch assembly.

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

c. Remove the O-ring.

INSTALLATION HINT: Use a new O-ring.







INSTALLATION HINT: Align the protrusion of the field frame with cutout of the magnetic switch.







2. REMOVE STARTER HOUSING FROM MAGNETIC SWITCH ASSEMBLY
a. Remove the 2 screws.

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

b. Remove the starter housing with the pinion gear, idler gear. bearing and clutch assembly.







3. REMOVE CLUTCH ASSEMBLY AND GEARS FROM STARTER HOUSING
Remove these parts from the magnetic switch assembly:
a. Starter housing
b. Roller
c. Retainer
d. Idler Gear
e. Clutch assembly







4. REMOVE STEEL BALL AND SPRING
Using a magnetic finger, remove the spring and steel ball from the clutch shaft hole.

5. REMOVE BRUSHES AND BRUSH HOLDER







a. Remove the 2 screws and pull the end cover with O-ring of the field frame.

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

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.

6. REMOVE ARMATURE FROM FIELD FRAME


ASSEMBLY
Assembly is in the reverse order of disassembly.