RM36D0EC _51 Engine / Hybrid System _083065 M20D-FKS STARTING _0402940 STARTER A

M20D-FKS STARTING  STARTER  REASSEMBLY  


PROCEDURE

Hide 28021 1.INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

a.
A414118C01
1.563,0.104 1.708,0.104 1.708,0.104 1.906,0.219 false 2.833,0.74 2.885,0.406 2.885,0.406 3.052,0.406 false 2.615,1.677 3,1.677 false 0.531,1.906 0.531,1.604 false 3.021,1.583 3.333,1.74 0.313,0.156 10 false *1 1.385,0.021 1.698,0.177 0.313,0.156 10 false *2 3.073,0.313 3.385,0.469 0.313,0.156 10 false *3 0.448,1.917 0.76,2.073 0.313,0.156 10 false *4
*1 Starter Center Bearing Clutch Sub-assembly
*2 Pinion Drive Lever
*3 Rubber Seal
*4 Starter Drive Housing Assembly
V100135

High-temperature Grease


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


b.

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


c.

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


Hide 2.INSTALL PLANETARY GEAR

a.
A414119C01
0,0 0,0 false
V100135

High-temperature Grease


Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter center bearing clutch sub-assembly.


b.

Install the 3 planetary gears to the starter center bearing clutch sub-assembly.


Hide 28160 3.INSTALL STARTER ARMATURE ASSEMBLY

A347623C02
1.625,0.469 2.26,0.302 2.26,0.302 2.51,0.302 false 1.594,1.979 1.813,1.979 1.813,1.979 2.042,1.625 false 2.552,0.219 2.865,0.375 0.313,0.156 10 false *1 1.438,1.885 1.75,2.042 0.313,0.156 10 false *2
*1 Starter Yoke Assembly
*2 Starter Armature Assembly


a.

Install the starter armature assembly to the starter yoke 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.



Hide 28140 4.INSTALL STARTER BRUSH HOLDER ASSEMBLY

a.
A211303

Hold the brush spring back and set the 4 brushes as shown in the illustration.


b.
A211304

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


c.
A314282C02
1.396,0.219 1.552,0.219 1.552,0.219 2.458,0.771 true 2.51,0.563 2.938,0.156 2.938,0.156 3.073,0.156 true 2.167,1.542 2.302,1.542 2.302,1.542 2.51,0.958 true 1.208,0.104 1.521,0.26 0.313,0.156 10 false *a 3.146,0.063 3.375,0.219 0.229,0.156 10 false *b 1.99,1.438 2.302,1.594 0.313,0.156 10 false *c
*a Grommet
*b Negative (-) Brush Holder Plate
*c Positive (+) Motor Lead Wire


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


Hide 5.INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

a.
A209964C03
1.885,0.24 2.052,0.24 2.052,0.24 2.219,0.396 false 1.25,2.01 1.51,2.01 1.51,2.01 2.031,1.208 true 0.469,1.813 0.635,1.813 0.635,1.813 1.198,0.885 true 0.281,1.719 0.594,1.875 0.313,0.156 10 false *a 1.083,1.906 1.396,2.104 0.313,0.198 10 false *b 1.729,0.125 2.042,0.281 0.313,0.156 10 false *a
*a Lead Wire Rubber
*b Cutout


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.



b.
A481936

Install the 2 screws.

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


Hide 6.INSTALL STARTER ARMATURE PLATE

a.
A204351C20
3.021,1.448 2.865,1.448 2.865,1.448 2.531,1.885 true 1.552,1.531 1.552,1.875 true 2.458,0.865 2.271,0.865 2.271,0.865 1.865,1.313 true 1.906,0.26 1.719,0.26 1.719,0.26 1.448,0.625 false 3.104,0.792 2.948,0.792 2.948,0.792 2.615,1.229 false 3.167,0.708 3.427,0.948 0.26,0.24 10 false *2 2.521,0.792 2.802,1.01 0.281,0.219 10 false *a 2,0.198 2.313,0.396 0.313,0.198 10 false *1 3.063,1.365 3.375,1.563 0.313,0.198 10 false *b 1.5,1.906 1.781,2.125 0.281,0.219 10 false *a
*1 Starter Yoke Assembly
*2 Starter Armature Plate
*a Stopper
*b Protrusion


Align the starter armature plate so that the protrusion fits between the stoppers of the starter yoke assembly, and install the starter armature plate.

NOTICE:

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



Hide 28120 7.INSTALL STARTER YOKE ASSEMBLY

a.
A505004C01
1.948,0.292 2.365,0.292 false 1.01,0.406 1.229,0.406 1.229,0.406 1.479,0.802 false 2.01,1.938 2.01,1.594 false 2.719,1.865 2.719,1.417 false 0.854,0.323 1.167,0.479 0.313,0.156 10 false *1 1.792,0.208 2.104,0.365 0.313,0.156 10 false *2 1.927,1.958 2.24,2.115 0.313,0.156 10 false *a 2.656,1.885 2.969,2.042 0.313,0.156 10 false *b
*1 Starter Yoke Assembly
*2 Starter Drive Housing Assembly
*a Cutout
*b Protrusion


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


b.
A481935

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

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


Hide 28150 8.INSTALL MAGNET STARTER SWITCH ASSEMBLY

a.
A483259C01
1.76,0.458 1.854,0.135 1.854,0.135 2.063,0.135 false 0.365,0.188 0.49,0.188 0.49,0.188 0.865,0.75 true 2.115,0.021 2.427,0.177 0.313,0.156 10 false *a 0.177,0.115 0.49,0.271 0.313,0.156 10 false *1
*1 Pinion Drive Lever
*a Hook
V100135

High-temperature Grease


Apply high-temperature grease to the magnet starter switch assembly as shown in the illustration.


b.

Hang the hook of the magnet starter switch assembly on the pinion drive lever.


c.
A481933

Install the magnet starter switch assembly with the 2 nuts.

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


Hide 28249 9.INSTALL STARTER INRUSH CURRENT REDUCTION RELAY

A481932C01
0.406,1.365 1.323,1.365 true 0.25,1.25 0.563,1.406 0.313,0.156 10 false *a
*a Lead Wire


a.

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)


b.

Connect the lead wire to terminal M with the nut.

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


Hide 10.INSTALL WIRE HARNESS

a.
A481931

Install the wire harness to the starter assembly with the 2 nuts.

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


Hide 11.INSTALL HARNESS

A481930

a.

Engage the clamp and connect the 2 harness connectors to install the harness.