Starting System (Service Information): Removal & Installation Scion FR-S I

REMOVAL [07/2013 - ]

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL . Refer to «REMOVAL [07/2013 - ] - Step 1»(ref-612380-S28553140182014042900000)
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 screws and the magnet starter switch assembly from the starter drive housing assembly.
2. REMOVE STARTER COVER Remove the 2 through bolts and 2 screws, and remove the starter cover.
3. REMOVE STARTER BRUSH HOLDER ASSEMBLY Remove the starter brush holder assembly. HINT: Hold the brush with your fingers so that the brush spring does not come flying out.
4. REMOVE STARTER YOKE ASSEMBLY Remove the starter yoke assembly and starter armature assembly together from the starter drive housing assembly.
5. REMOVE STARTER ARMATURE ASSEMBLY Pull out the starter armature assembly from the starter yoke assembly.
6. REMOVE STARTER HOUSING RUBBER Remove the starter housing rubber, seal rubber and plate from the starter drive housing assembly. TEXT IN ILLUSTRATION *1 Starter Housing Rubber *2 Plate *3 Seal Rubber
7. REMOVE STARTER PLANETARY GEAR Remove the 3 starter planetary gears from the starter clutch sub-assembly.
8. REMOVE STARTER CLUTCH SUB-ASSEMBLY Remove the starter clutch sub-assembly together with the drive lever set pin from the starter drive housing assembly. Using a 14 mm deep socket wrench, remove the stopper from snap ring. TEXT IN ILLUSTRATION *1 14 mm Deep Socket Wrench *2 Stopper *3 Snap Ring Using snap ring pliers, remove the snap ring and stopper. Pull out the over running clutch from the shaft. Remove the internal gear assembly from the shaft. TEXT IN ILLUSTRATION *1 Internal Gear Assembly *2 Shaft

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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 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 0.05 mm (0.002 in.) Maximum runout 0.10 mm (0.004 in.) TEXT IN ILLUSTRATION *1 Dial Gauge *2 V-block Check the depth of the segment mold. If it is not within the standard, replace the armature. Standard depth 0.50 mm (0.020 in.) TEXT IN ILLUSTRATION *1 Mold *2 Segment *3 Depth of Mold Place the armature on the growler tester to check for short circuits. While slowly turning the armature, support the steel sheet for the armature core. If the circuit of the armature is shorted, the steel sheet will vibrate, causing it to move towards the core. When the steel sheet has moved or vibrated, replace the armature. TEXT IN ILLUSTRATION *1 Steel Sheet *2 Growler Tester Touch the probe of one side to the commutator segment, and the other probe to the shaft. If there is continuity, replace the armature.
3. INSPECT STARTER YOKE ASSEMBLY Make sure that the pole is set at the predetermined position.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY Visually check the brush. If there is any abnormal wear or cracks, replace the brush. Measure the length of the brush. If it exceeds the service limits, replace the brush. Standard length 12.3 mm (0.484 in.) Minimum length 7.0 mm (0.276 in.) TEXT IN ILLUSTRATION *1 Service Limit Line *2 Brush Check that the brush moves smoothly in the brush holder. Measure the brush spring force with a spring scale. Replace the brush holder if below the service limit. Standard brush spring force 15.9 to 19.5 N (1.6 to 2.0 kgf, 3.6 to 4.4 lbf) Minimum brush spring force 2.5 N (0.3 kgf, 0.6 lbf)
5. INSPECT STARTER CLUTCH SUB-ASSEMBLY Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage. If any of the gears is damaged, replace the starter center bearing clutch sub-assembly. Check the starter clutch pinion gear. Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. TEXT IN ILLUSTRATION *a Free *b Lock If necessary, replace the starter clutch sub-assembly.
6. INSPECT MAGNET STARTER SWITCH ASSEMBLY Check that there is continuity between terminals 50 and C, and between terminal 50 and ground. Also, check to be sure there is no continuity between terminal C and 30. Standard Resistance Tester Connection Condition Specified Condition Terminal C - Terminal 50 Always Below 1 ohms Terminal 50 - Switch body Always Below 1 ohms Terminal C - Terminal 30 Always 1 Mohms or higher TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C *3 Terminal 30 Using a lead wire, connect the switch assembly terminal 50 to the positive terminal of the battery, and the starter body to the ground terminal of the battery. The pinion should be forced to be pushed out on the shaft. HINT: With the pinion forced to be pushed out on the shaft, the starter motor can sometimes rotate because the current flows, through pull-in coil, to motor. This is not a problem. Disconnect the connector from terminal C. Then, using a lead wire, connect the positive terminal of the battery and terminal C, and ground terminal to starter body. In this test set up, the pinion should return to its original position even when it is pulled out with a screwdriver. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C

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1. INSTALL STARTER CLUTCH SUB-ASSEMBLY Apply high-temperature grease to the shaft as shown in the illustration. TEXT IN ILLUSTRATION High-temperature Grease Install the internal gear to the shaft. Apply high-temperature grease to the shaft as shown in the illustration. TEXT IN ILLUSTRATION High-temperature Grease Install the over running clutch to the shaft. Install the stopper to the shaft. Using snap ring pliers, install the snap ring. Using a press, press the snap ring into the stopper. TEXT IN ILLUSTRATION *1 Snap Ring *2 Stopper Install the starter clutch sub-assembly together with the drive lever set pin to the starter drive housing assembly.
2. 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
3. INSTALL STARTER HOUSING RUBBER Install the starter housing rubber, seal rubber and plate to the starter drive housing assembly. TEXT IN ILLUSTRATION *1 Starter Housing Rubber *2 Plate *3 Seal Rubber
4. INSTALL STARTER ARMATURE ASSEMBLY Install the starter armature assembly to the starter yoke assembly.
5. INSTALL STARTER YOKE ASSEMBLY Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly. TEXT IN ILLUSTRATION *1 Claw *2 Groove Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly.
6. INSTALL STARTER BRUSH HOLDER ASSEMBLY Install a 24 mm socket to the starter brush holder assembly. Install the starter brush holder assembly to the starter armature assembly.
7. INSTALL STARTER COVER Install the starter cover with 2 screws and 2 bolts. Bolt Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) Screw Torque: 1.4 N*m (14 kgf*cm, 12 in.*lbf)
8. INSTALL MAGNET STARTER SWITCH ASSEMBLY 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)

INSTALLATION [07/2013 - ]

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»(ref-612380-S33091937532014042900000)

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL . Refer to «REMOVAL [07/2013 - ] - Step 1»(ref-612380-S28553140182014042900000)
2. REMOVE FRONT CONSOLE BOX COVER . Refer to «REMOVAL [12/2013 - ] - Step 3»(ref-612385-S23202594422014042900000)
3. REMOVE ENGINE SWITCH Disengage the 2 claws to remove the engine switch.

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1. INSPECT ENGINE SWITCH Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Switch Condition Specified Condition 5 (SSW1) - 6 (AGND) Pushed Below 1 ohms 1 (SSW2) - 6 (AGND) Pushed Below 1 ohms 5 (SSW1) - 6 (AGND) Not pushed 10 kohms or higher 1 (SSW2) - 6 (AGND) Not pushed 10 kohms or higher TEXT IN ILLUSTRATION *a Component without harness connected (Engine Switch) If the result is not as specified, replace the engine switch. Apply battery voltage to the terminals of the engine switch and check the illumination condition of the engine switch. OK Battery Connection Specified Condition Battery positive (+) --> Terminal 9 (SWIL) Battery negative (-) --> Terminal 6 (AGND) Illuminates If the result is not as specified, replace the engine switch.

INSTALLATION [12/2013 - ]

1. INSTALL ENGINE SWITCH Engage the 2 claws to install the engine switch.
2. INSTALL FRONT CONSOLE BOX COVER . Refer to «INSTALLATION [12/2013 - ] - Step 18»(ref-612385-S11051611872014042900000)
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)

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1. REMOVE INSTRUMENT SIDE PANEL RH . Refer to «REMOVAL [07/2013 - 12/2013] - Step 12»(ref-612385-S20883586192014042900000)
2. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY . Refer to «REMOVAL [07/2013 - 12/2013] - Step 5»(ref-612385-S20883586192014042900000)
3. REMOVE METER HOOD SUB-ASSEMBLY . Refer to «REMOVAL [07/2013 - 12/2013] - Step 14»(ref-612385-S20883586192014042900000)
4. REMOVE UPPER INSTRUMENT PANEL METER ORNAMENT . Refer to «REMOVAL [07/2013 - 12/2013] - Step 15»(ref-612385-S20883586192014042900000)
5. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to «REMOVAL [07/2013 - ] - Step 2»(ref-612384-S35414424312014042900000)
6. REMOVE LOWER STEERING COLUMN COVER . Refer to «REMOVAL [07/2013 - 12/2013] - Step 12»(ref-612396-S32313730132014042900000)
7. REMOVE UPPER STEERING COLUMN COVER . Refer to «REMOVAL [07/2013 - 12/2013] - Step 13»(ref-612396-S32313730132014042900000)
8. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY Disconnect the connector. Remove the 2 screws, and remove the ignition switch.

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1. INSPECT IGNITION OR STARTER SWITCH ASSEMBLY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Switch Condition Specified Condition All combinations of all terminals LOCK 10 kohms or higher 2 (AM2) - 3 (ACC) ACC Below 1 ohms 2 (AM2) - 3 (ACC) - 4 (IG1) 6 (IG2) - 7 (AM1) ON Below 1 ohms 1 (ST1) - 2 (AM2) - 4 (IG1) 6 (IG2) - 7 (AM1) - 8 (ST2) START Below 1 ohms TEXT IN ILLUSTRATION *a Component without harness connected (Ignition or starter Switch Assembly) If the result is not as specified, replace the ignition or starter switch assembly.

1. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY Install the 2 screws, and install the ignition or starter switch. Connect the connector.
2. INSTALL UPPER STEERING COLUMN COVER . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 5»(ref-612396-S28654584202014042900000)
3. INSTALL LOWER STEERING COLUMN COVER . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 6»(ref-612396-S28654584202014042900000)
4. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to «INSTALLATION [07/2013 - ] - Step 3»(ref-612384-S38051038262014042900000)
5. INSTALL UPPER INSTRUMENT PANEL METER ORNAMENT . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 5»(ref-612385-S21876457522014042900000)
6. INSTALL METER HOOD SUB-ASSEMBLY . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 6»(ref-612385-S21876457522014042900000)
7. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 15»(ref-612385-S21876457522014042900000)
8. INSTALL INSTRUMENT SIDE PANEL RH . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 7»(ref-612385-S21876457522014042900000)

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL . Refer to «REMOVAL [07/2013 - ] - Step 1»(ref-612380-S28553140182014042900000)
2. REMOVE INSTRUMENT SIDE PANEL RH . Refer to «REMOVAL [07/2013 - 12/2013] - Step 12»(ref-612385-S20883586192014042900000)
3. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY . Refer to «REMOVAL [07/2013 - 12/2013] - Step 17»(ref-612385-S20883586192014042900000)
4. REMOVE CONTROL UNIT RELAY ASSEMBLY Disconnect the control unit relay assembly connector. Remove the bolt and control unit relay assembly unit.

1. INSTALL CONTROL UNIT RELAY ASSEMBLY Install the control unit relay with the bolt. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
2. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 3»(ref-612385-S21876457522014042900000)
3. INSTALL INSTRUMENT SIDE PANEL RH . Refer to «INSTALLATION [07/2013 - 12/2013] - Step 7»(ref-612385-S21876457522014042900000)
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL . Refer to «INSTALLATION [07/2013 - ] - Step 3»(ref-612380-S33091937532014042900000)

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1. INSPECT ST RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 Battery voltage not applied to terminals 1 and 2 Measurement temperature : 20 °C 93.8 to 136.4 kohms 3 - 5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the starter relay.
2. REMOVE INHIBITOR RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 Battery voltage not applied to terminals 1 and 2 Measurement temperature : 20 °C 93.8 to 136.4 kohms 3 - 5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the starter relay.

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1. INSPECT ST RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 Battery voltage not applied to terminals 1 and 2 Measurement temperature : 20 °C 93.8 to 136.4 kohms 3 - 5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the starter relay.
2. REMOVE INHIBITOR RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 Battery voltage not applied to terminals 1 and 2 Measurement temperature : 20 °C 93.8 to 136.4 kohms 3 - 5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the starter relay.
3. INSPECT ST CUT RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 Battery voltage not applied to terminals 1 and 2 Measurement temperature : 20 °C 93.8 to 136.4 kohms 3 - 4 Battery voltage not applied to terminals 1 and 2 Below 1 ohms Battery voltage applied to terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the starter relay.
4. INSPECT IGS RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 Battery voltage not applied to terminals 1 and 2 Measurement temperature : 20 °C 93.8 to 136.4 kohms 3 - 5 Battery voltage not applied to terminals 1 and 2 10 kohms or higher Battery voltage applied to terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the starter relay.