Toyota Corolla Cross: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY	28021		-	-
2	PLANETARY GEAR	-	-	-	-
3	STARTER ARMATURE ASSEMBLY	28160		-	-
4	STARTER BRUSH HOLDER ASSEMBLY	28140		-	-
5	STARTER COMMUTATOR END FRAME ASSEMBLY	-		-	-
6	STARTER ARMATURE PLATE	-		-	-
7	STARTER YOKE ASSEMBLY	28120		-	-
8	PLUNGER	-		-	-
9	REPAIR SERVICE STARTER KIT	28226B		-	-
10	STARTER INRUSH CURRENT REDUCTION RELAY	28249	-	-	-
11	WIRE HARNESS	-	-	-	-
12	HARNESS	-	-	-	-

*1	STARTER DRIVE HOUSING ASSEMBLY	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque		High-temperature grease

PROCEDURE

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

*1	Starter Center Bearing Clutch Sub-assembly	*2	Pinion Drive Lever
*3	Rubber Seal	*4	Starter Drive Housing Assembly
	High-temperature Grease	-	-

(1) Apply high-temperature grease to the pinion drive lever as shown in the illustration.

(2) Install the pinion drive lever and rubber seal to the starter center bearing clutch sub-assembly.

(3) Install the starter center bearing clutch sub-assembly together with pinion drive lever and rubber seal to the starter drive housing assembly.

2. INSTALL PLANETARY GEAR

High-temperature Grease

-

-

3. INSTALL STARTER ARMATURE ASSEMBLY

NOTICE: 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.

(2) Install the starter brush holder assembly to the starter armature assembly and push in the 4 brushes as shown in the illustration.

(3) Fit the protrusion of the grommet between the negative (-) brush holder plate and positive (+) motor lead wire.

5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

(1) Install the starter commutator end frame assembly to the starter yoke assembly.

NOTICE:

Align the 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}

6. INSTALL STARTER ARMATURE PLATE

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

(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.

7. INSTALL STARTER YOKE ASSEMBLY

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

(2) Using a T25 "TORX" socket wrench, install the 2 through bolts.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

8. INSTALL PLUNGER

(1) Hang the hook of the plunger on the pinion drive lever and install the repair service starter kit.

NOTICE:

• Make sure the return spring is not resting on the protrusion of the plunger or pushed between the magnet switch and plunger.
• Install the plunger cover so that the ventilation hole is positioned as shown in the illustration.

9. INSTALL SERVICE STARTER KIT

(1) Install the 2 nuts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

10. INSTALL STARTER INRUSH CURRENT REDUCTION RELAY

Torque:

Bolt :

7.9 N·m {81 kgf·cm, 70 in·lbf}

Nut :

9.0 N·m {92 kgf·cm, 80 in·lbf}

11. INSTALL WIRE HARNESS

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

12. INSTALL HARNESS

READ NEXT: