Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Engine Starting System & Charging System (2.0L): Starter: Assembly
- Apply grease to the shaft sliding surfaces of the internal gear assembly.
Grease:
Multemp #6129 or equivalent
- Assemble the shaft to the internal gear assembly.
- Assemble the overrunning clutch as follows:
- Apply grease to the spline portion of the shaft.
Grease:
Multemp #6129 or equivalent
- Install the overrunning clutch to shaft.
- Pass stopper (B) through the shaft assembly, and attach snap ring (A).NOTE: Use new stoppers and snap rings.
- Using a press, pressure fit stopper (B) into snap ring (A).
- Apply grease to the spline portion of the shaft.
- Assemble the overrunning clutch, internal gear assembly, shaft and shift lever as a single unit into the starter housing assembly.NOTE: Apply grease to the moving parts of the shift lever.
Grease:
Multemp #6129 or equivalent
- Apply grease to the inside of the internal gear assembly and pinion gear, and attach the pinion gear to the internal gear assembly.NOTE:
- Apply grease evenly to the contact surfaces of each gear.
- Be careful that no debris becomes attached.
Grease:
Molykote® AG650 or equivalent
- Install seal rubber (A), plate (B), and seal rubber (C).
- Assemble the armature assembly to the yoke assembly.
- Attach the armature assembly and yoke assembly to the starter housing assembly together as a single unit.NOTE: As shown in the figure, match the protrusion of the yoke assembly to the cut out of the starter housing assembly.
- Use an appropriate tool (such as correctly sized socket wrenches) and attach the brush holder assembly to the armature assembly.NOTE: Be careful not to damage the brushes.
- Secure starter cover assembly to the brush holder assembly with screws (A).
Tightening torque:
1.4 N.m (0.1 kgf-m, 1.0 ft-lb)
- Tighten through bolts (B) on both sides.
Tightening torque:
6 N.m (0.6 kgf-m, 4.4 ft-lb)
- Attach the magnet switch assembly to the starter housing assembly.
Tightening torque:
7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
- Connect the cable to the terminal M of the magnet switch assembly.
Tightening torque:
10 N.m (1.0 kgf-m, 7.4 ft-lb)
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
