Starting System (Service Information): Overview Scion FR-S I

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL . Refer to «REMOVAL [07/2013 - ] - Step 1»(/scion/fr-s/i-2012-2016/remont/body-electrical/#charging-system-service-information)
2. REMOVE NO. 2 ENGINE UNDER COVER. Refer to «REMOVAL [07/2013 - ] - Step 2»(ref-612378-S00142194672014042900000)
3. REMOVE FRONT EXHAUST PIPE ASSEMBLY. Refer to «REMOVAL [07/2013 - ] - Step 3»(ref-612378-S00142194672014042900000)
4. REMOVE STARTER ASSEMBLY Remove the nut and disconnect the starter wire. Disconnect the starter connector. Disengage the wire clamp. Remove the upper side bolt. Remove the bolt. Remove the lower side bolt, battery cable stay and starter assembly.

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1. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the nut and disconnect the lead wire from terminal C. Remove the 2 nuts and the magnet starter switch assembly from the starter drive housing assembly.
2. REMOVE STARTER YOKE ASSEMBLY Using a "TORX" socket wrench T25, remove the 2 through bolts. Remove the starter yoke assembly and starter cover from the starter drive housing assembly.
3. REMOVE STARTER COVER Remove the 2 screws. Remove the starter cover from the starter yoke assembly. TEXT IN ILLUSTRATION *1 Starter Yoke Assembly *2 Starter Cover NOTE: Hold the lead wire and remove the starter cover. Remove the dust starter protect from the starter yoke assembly.
4. REMOVE STARTER BRUSH HOLDER ASSEMBLY Using a screwdriver, disengage the spring from the bush. Disconnect the 4 brush from the starter brush holder assembly. Remove the starter brush holder assembly.
5. REMOVE STARTER ARMATURE ASSEMBLY Pull out the starter armature assembly from the starter yoke assembly. TEXT IN ILLUSTRATION *1 Starter Yoke Assembly *2 Starter Armature Assembly
6. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly and starter drive housing assembly. TEXT IN ILLUSTRATION *1 Starter Drive Housing Assembly *2 Starter Yoke Assembly *3 Starter Armature Plate
7. REMOVE RUBBER SEAL Remove the rubber seal from the starter drive housing assembly. TEXT IN ILLUSTRATION *1 Rubber Seal
8. REMOVE STARTER PLANETARY GEAR Remove the 3 starter planetary gears from the starter clutch sub-assembly.

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1. INSPECT STARTER ASSEMBLY WARNING: As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury. NOTE: The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out. Mount the starter in a vise between aluminum plates. Perform a pull-in test. Remove the nut, and then disconnect the lead wire from terminal C. Connect the battery to the starter as shown in the illustration. Check that the clutch pinion gear extends. TEXT IN ILLUSTRATION *1 Body *2 Terminal 50 *3 Terminal C If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it. Perform a holding test. Disconnect the negative (-) terminal lead from terminal C while the conditions specified in the pull-in test above are maintained. Check that the pinion gear remains out. TEXT IN ILLUSTRATION *1 Body *2 Terminal 50 *3 Terminal C If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it. Inspect the clutch pinion gear return. Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward. TEXT IN ILLUSTRATION *1 Body *2 Terminal 50 *3 Terminal C If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it. Perform an operation test without load. Connect the lead wire to terminal C with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the battery and an ammeter to the starter as shown in the illustration. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal 30 *3 Ammeter Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then measure the current. Standard Current Tester Connection Condition Specified Condition Battery positive terminal - Terminal 30 - Terminal 50 11.5 V Below 90 A If the result is not as specified, inspect the starter assembly. HINT: Inspect the starter armature assembly, starter commutator end frame assembly and magnet starter switch assembly. If there is a malfunction, replace the part and perform again this test.
2. INSPECT STARTER ARMATURE ASSEMBLY Check the commutator for dirt and/or burns on the surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly. Inspect the commutator for an open circuit. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Segment Standard Resistance Tester Connection Condition Specified Condition Segment - Segment Always Below 1 ohms If the result is not as specified, replace the starter armature assembly. Inspect the commutator for short circuits. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Segment *2 Coil Core Standard Resistance Tester Connection Condition Specified Condition Segment - Coil core Always 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair. Check for runout on the commutator. If excessive, replace the armature. Standard runout 0.02 mm (0.0008 in.) Maximum runout 0.05 mm (0.002 in.) TEXT IN ILLUSTRATION *1 Dial Gauge *2 V-block If the result is not as specified, replace the starter armature assembly. Using vernier caliper, measure the commutator diameter. TEXT IN ILLUSTRATION *a Diameter Standard diameter 29 mm (1.1417 in.) Minimum diameter 28 mm (1.1024 in.) If the diameter is less than the minimum, replace the starter armature assembly. Using vernier caliper, measure the under cut depth of the segment. If it is not within the standard, replace the starter armature assembly. Standard depth 0.7 mm (0.0276 in.) Minimum depth 0.2 mm (0.0079 in.)
3. INSPECT STARTER BRUSH HOLDER ASSEMBLY Using a vernier caliper, measure the brush length. TEXT IN ILLUSTRATION *a Length Standard length 14.4 mm (0.5669 in.) Minimum length 9.0 mm (0.3543 in.) If the length is less than the minimum, replace the starter brush holder assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition A - B A - C B - D C - D Always 10 kohms or higher A - D B - C Always Below 1 ohms If the result is not as specified, replace the starter brush holder assembly.
4. INSPECT MAGNET STARTER SWITCH ASSEMBLY Check the plunger. Push in the plunger and check that it returns quickly to it is original position. If necessary, replace the magnet starter switch assembly. Inspect the pull-in coil. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal C - Terminal 50 Always Below 1 ohms TEXT IN ILLUSTRATION *1 Terminal C *2 Terminal 50 If the result is not as specified, replace the magnet starter switch assembly. Inspect the holding coil. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Switch body Always Below 2 ohms TEXT IN ILLUSTRATION *1 Terminal 50 *2 Switch Body If the result is not as specified, replace the magnet starter switch assembly.

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1. INSTALL STARTER PLANETARY GEAR Apply high-temperature grease to the planetary gears and pins of the planetary shaft. Install the 3 starter planetary gears. TEXT IN ILLUSTRATION High-temperature Grease
2. INSTALL RUBBER SEAL Install the rubber seal to the starter drive housing assembly. TEXT IN ILLUSTRATION *1 Rubber Seal
3. INSTALL STARTER ARMATURE ASSEMBLY Install the starter armature assembly to the starter yoke assembly. TEXT IN ILLUSTRATION *1 Starter Yoke Assembly *2 Starter Armature Assembly
4. INSTALL STARTER BRUSH HOLDER ASSEMBLY Install the 4 brushes and 4 brush springs. Install the starter brush holder assembly to the starter armature assembly. Push the 4 brushs. Insert the grommet between the positive (+) motor read wire and the negative (-) brush holder plate. TEXT IN ILLUSTRATION *1 Grommet *2 Negative (-) Brush Holder Plate *3 Positive (+) Motor Read Wire
5. INSTALL STARTER COVER Install the dust starter protector to the starter yoke assembly. Align the starter brush holder assembly read wire rubber with the groove of the starter cover. Install the starter cover to the starter brush holder assembly with 2 screws. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
6. INSTALL STARTER ARMATURE PLATE Align the claw of the starter yoke assembly with the groove the starter armature plate. Install the starter armature plate to the starter yoke assembly. TEXT IN ILLUSTRATION *1 Claw *2 Groove
7. INSTALL STARTER YOKE ASSEMBLY Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly. Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly. TEXT IN ILLUSTRATION *1 Claw *2 Groove Using a "TORX" socket wrench T25, install the 2 through bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
8. INSTALL MAGNET STARTER SWITCH ASSEMBLY Apply high-temperature grease to the plunger and hook as shown in the illustration. TEXT IN ILLUSTRATION High-temperature grease Hook the plunger and hook of the magnet starter switch assembly to the lever of the starter drive housing assembly. TEXT IN ILLUSTRATION *1 Plunger and Hook *2 Lever Install the magnet starter switch assembly with the 2 screws. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the lead wire to terminal C with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

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1. INSTALL STARTER ASSEMBLY Temporarily install the upper side bolts. Install the lower side bolt. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) Install the bolt. Using SST, install the upper side bolt and starter assembly. SST: 09249-37010 without SST Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) with SST Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 260 mm (10.2 in.). When using a torque wrench with a fulcrum length that is not 260 mm (10.24 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification. Refer to «PRECAUTION [07/2013 - ]»(ref-612229-S41967653852014042900000). Make sure SST and the wrench are connected in a straight line. Engage the wire clamp. Connect the starter connector. Connect the starter wire with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. INSTALL FRONT EXHAUST PIPE ASSEMBLY. Refer to «INSTALLATION [07/2013 - ] - Step 5»(ref-612378-S21479833412014042900000)
3. INSTALL NO. 2 ENGINE UNDER COVER. Refer to «INSTALLATION [07/2013 - ] - Step 9»(ref-612378-S21479833412014042900000)
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL . Refer to «INSTALLATION [07/2013 - ] - Step 3»(/scion/fr-s/i-2012-2016/remont/body-electrical/#charging-system-service-information)

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See also:
• REMOVAL [07/2013 - ] - Step 1