Starting & Charging: Removal & Installation Scion tC I

REPLACEMENT

Note. When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.

SYSTEM DESCRIPTION

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE STARTER ASSY Disconnect the starter connector. Open the terminal cap. Remove the nut, then disconnect the starter wire. Remove the 2 bolts, then remove the starter.
3. INSTALL STARTER ASSY Install the starter with the 2 bolts. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) Connect the starter wire with the nut. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) Cover the terminal cap. Connect the starter connector.
4. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

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1. REMOVE STARTER MAGNETIC SWITCH ASSY Remove the nut, then disconnect the lead wire. Remove the 2 screws, then remove the starter magnetic switch. Remove the return spring and plunger from the starter drive housing.
2. REMOVE STARTER COMMUTATOR END FRAME ASSY Remove the 2 bolts, then remove the starter commutator end frame together with the starter yoke. Remove the starter commutator end frame from the starter yoke. Remove the starter armature plate from the starter yoke.
3. REMOVE STARTER ARMATURE ASSY Using a thin-bladed screwdriver, remove the starter commutator end frame cover. Using snap ring pliers, remove the snap ring. Remove the plate washer and starter armature from the starter commutator end frame.
4. REMOVE STARTER PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing.
5. INSPECT STARTER MAGNETIC SWITCH ASSY Check the plunger. Push in the plunger, then check that it returns quickly to its original position. If necessary, replace the starter magnetic switch. Check the resistance. Using an ohmmeter, measure the resistance between terminals 50 and C. Standard: 1 ohm or lower If the result is not as specified, replace the starter magnetic switch. Using an ohmmeter, measure the resistance between terminal 50 and the body. Standard: 2 ohm or lower If the result is not as specified, replace the starter magnetic switch.
6. INSPECT STARTER ARMATURE ASSY Check the resistance. Using an ohmmeter, measure the resistance between the segments. Standard: 1 ohm or lower If the result is not as specified, replace the starter armature. Using an ohmmeter, measure the resistance between the segment and coil core. Standard: 10 Mohm or higher If the result is not as specified, replace the starter armature. Check the commutator depth. Using vernier calipers, measure the commutator depth. Standard: 3.1 mm (0.122 in.) Maximum: 3.8 mm (0.150 in.) If the commutator depth is greater than maximum, replace the starter armature.
7. INSPECT STARTER COMMUTATOR END FRAME ASSY Check the brush length. Using vernier calipers, measure the brush length. Standard: 9.0 mm (0.354 in) Minimum: 4.0 mm (0.158 in) If the brush length is less than minimum, replace the starter commutator end frame. Check the resistance. Using an ohmmeter, measure the resistance between the positive (+) and negative (-). Standard: 10 Mohm or higher If the result is not as specified, replace the starter commutator end frame.
8. INSPECT STARTER DRIVE HOUSING ASSY Check the starter clutch. Rotate the clutch pinion gear counterclockwise, then check that it turns freely. Try to rotate the clutch pinion gear clockwise, then check that it locks. If necessary, replace the starter drive housing.
9. INSTALL STARTER PLANETARY GEAR Apply grease to the planetary gears and pin parts of the planet shaft. Install the 3 planetary gears into the pin of the planet shaft.
10. INSTALL STARTER ARMATURE ASSY Apply grease to the plate washer, armature shaft and new snap ring. Install the starter armature and plate washer into the starter commutator end frame. Using snap ring pliers, install the snap ring. Check the snap ring length. Using vernier calipers, measure the snap ring length. Maximum: 5.0 mm (0.197 in.) If the snap ring length is greater than maximum, replace the snap ring. Install the commutator end frame cover into the starter commutator end frame.
11. INSTALL STARTER COMMUTATOR END FRAME ASSY Align the rubber of the starter commutator end frame with the convex cutout of the starter yoke, then install the starter commutator end frame into the starter yoke. Align the keyway of the starter armature plate with the key inside the starter yoke, then install the starter armature plate into the starter yoke. Apply grease to the starter armature gear. Align the key of the starter yoke with the keyway of the starter dive housing, then install starter commutator end frame together with the starter yoke into the starter drive housing. Tighten the 2 bolts. Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)
12. INSTALL STARTER MAGNETIC SWITCH ASSY Apply grease to the plunger and hook. Install the plunger and return spring into the starter drive housing. Install the starter magnetic switch into the starter drive housing. Tighten the 2 screws. Torque: 7.5 N.m (75 kgf.cm, 66 in.lbf) Connect the lead wire with the nut. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

Note. When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.

SYSTEM DESCRIPTION

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE STEERING COLUMN COVER (See «OVERHAUL»(ref-224783-S00337131492006031100000) )
3. REMOVE IGNITION OR STARTER SWITCH ASSY Disconnect the ignition switch connector. Disconnect the unlock warning switch connector. Remove the band tie. Using a small screwdriver, separate the claw fitting, then remove the connector of the unlock warning switch. Remove the 2 screws, then remove the ignition switch. Remove the screw, then remove the lock stopper.
4. INSTALL IGNITION OR STARTER SWITCH ASSY Install the lock stopper with the screw. Install the ignition switch with the 2 screws. Align the claw position, then install the connector of the unlock warning switch. Install the band tie. Connect the unlock warning switch connector. Connect the ignition switch connector.
5. INSTALL STEERING COLUMN COVER
6. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

Note. When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.

SYSTEM DESCRIPTION

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT FENDER APRON SEAL RH Remove the 2 screws and 3 clips, then remove the front fender apron seal.
3. REMOVE FAN AND GENERATOR V BELT (see «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
4. REMOVE GENERATOR ASSY Disconnect the generator connector. Remove the terminal cap. Remove the nut, then disconnect the generator wire. Remove the 2 wire harness clamps. Remove the 2 bolts, then remove the generator. Remove the bolt, then wire harness clamp bracket.
5. INSTALL GENERATOR ASSY Install the wire harness clamp bracket with the bolt. Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover. Install the generator with the 2 bolts. Torque: 21 N.m (215 kgf.cm, 16 ft.lbf) for bolt A 52 N.m (530 kgf.cm, 38 ft.lbf) for bolt B Install the 2 wire harness clamps. Connect the generator wire with the nut. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) Install the terminal cap. Connect the generator connector.
6. INSTALL FAN AND GENERATOR V BELT (see «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
7. INSTALL FRONT FENDER APRON SEAL RH Install the front fender apron seal with the 3 clips and 2 screws.
8. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

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1. REMOVE GENERATOR PULLEY SST 09820-6301 1 (09820-06010), 09820-06021 HINT: SST DESCRIPTION SST 1-A and B 09820-06010 SST 2 09820-06021 Tighten SST 1-B to the specified torque, then fix SST 1-A on the generator rotor shaft. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) NOTE: Securely fix SST on the generator rotor shaft. Clamp SST 2 in a vise. Insert SST 1-A and B into SST 2, then fix the generator pulley nut into SST 2. Turn SST 1-A in the direction (Scheme 67), then loosen the generator pulley nut. NOTE: If the generator pulley nut is turned by more than a half turn, the generator rotor shaft may be damaged. Remove the generator from SST 2. Fix SST 1-B, then loosen SST 1-A in the direction (Scheme 68) Remove SST 1-A and B from the generator. Remove the generator pulley nut, then remove the generator pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSY Place the generator on the generator pulley. Remove the 3 nuts, then remove the generator rear end cover. Remove the terminal insulator. Remove the 2 screws, then remove the generator brush holder.
3. REMOVE GENERATOR ROTOR ASSY Remove the bolt, then remove the cord clip. Remove the 4 bolts. Using SST, remove the generator drive end frame. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010) Remove the generator rotor from the generator rectifier end frame. Remove the washer from the generator rectifier end frame.
4. INSPECT GENERATOR BRUSH HOLDER ASSY Check the brush length. Using vernier calipers, measure the brush length. Standard: 9.5 to 11.5 mm (0.374 to 0.453 in.) Minimum: 4.5 mm (0.177 in.) If the brush length is less than minimum, replace the generator brush holder.
5. INSPECT GENERATOR ROTOR ASSY Check the resistance. Using an ohmmeter, measure the resistance between the slip rings. Standard: 2.3 to 2.7 ohm at 20°C (68°F) If the result is not as specified, replace the generator rotor. Using an ohmmeter, measure the resistance between the slip ring and rotor core. Standard: 1 Mohm or higher If the result is not as specified, replace the generator rotor. Check the slip ring diameter. Using vernier calipers, measure the slip ring diameter. Standard: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum: 14.0 mm (0.551 in.) If the slip ring diameter is less than minimum, replace the generator rotor. Check the appearance. Check that the bearing is not rough or worn. If necessary, replace the generator rotor.
6. INSPECT GENERATOR DRIVE END FRAME BEARING Check the appearance. Check that the bearing is not rough or worn. If necessary, replace the bearing. Replace the bearing. Remove the 4 screws, then remove the bearing retainer plate. Using SST, push the bearing out of the generator drive end frame. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) Using SST and a press, press a new bearing into the generator drive end frame. SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) Align the protrusions of the bearing retainer plate with the cutouts of the generator drive end frame, then install the bearing retainer plate with the 4 screws. Torque: 2.26 N.m (25 kgf.cm, 20 in.lbf)
7. INSTALL GENERATOR ROTOR ASSY Place the generator drive end frame on the generator pulley. Install the washer onto the generator rectifier end frame. Install the generator rotor onto the generator rectifier end frame. Using a 32 mm socket wrench and press, slowly push the generator drive end frame onto the generator rectifier end frame. Tighten the 4 bolts. Torque: 5.8 N.m (60 kgf.cm, 51 in.lbf) Install the cord clip with the bolt. Torque: 4.56 N.m (45 kgf.cm, 40 in.lbf)
8. INSTALL GENERATOR BRUSH HOLDER ASSY While pushing the 2 brushes into the generator brush holder, insert a pin (+/- 1.0 mm (0.039 in.)) into the generator brush holder. Install the generator brush holder with the 2 screws. Torque: 1.76 N.m (15 kgf.cm, 16 in.lbf) Pull the pin (+/- 1.0 mm (0.039 in.)) out of the generator brush holder. Install the terminal insulator onto the generator rectifier end frame. Install the generator rear end cover with the 3 nuts. Torque: 4.6 N.m (45 kgf.cm, 41 in.lbf)
9. INSTALL GENERATOR PULLEY SST 09820-6301 1 (09820-06010), 09820-06021 HINT: SST DESCRIPTION SST 1-A and B 09820-06010 SST 2 09820-06021 Install the generator pulley onto the generator rotor shaft, then temporarily tighten the generator pulley nut by hand. Tighten SST 1-B to the specified torque, then fix SST 1-A on the generator rotor shaft. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) NOTE: Securely fix SST on the generator rotor shaft. Clamp SST 2 in a vise. Insert SST 1-A and B into SST 2, then fix the generator pulley nut into SST 2. Turn SST 1-A in the direction (Scheme 100), then loosen the generator pulley nut. Torque: 110.3 N.m (1,125 kgf.cm, 82 ft.lbf) Remove the generator from SST 2. Fix SST 1-B, then loosen SST 1-A in the direction (Scheme 101) Remove SST 1-A and B from the generator. Turn the generator pulley, then check that the generator pulley moves smoothly.