Starting System (Service Information): Overview Scion tC II рестайлинг

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [05/2013 - 01/2014]»(ref-615109-S22240423792014050900000).
2. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL
3. REMOVE BATTERY CLAMP Remove the bolt and loosen the nut. Detach the 2 wire harness clamps. Detach the hook of the battery clamp from the front battery bracket, and then remove the battery clamp.
4. REMOVE BATTERY INSULATOR
5. REMOVE BATTERY
6. REMOVE BATTERY TRAY
7. REMOVE BATTERY CARRIER Remove the 4 bolts and front battery carrier.
8. REMOVE STARTER ASSEMBLY Disconnect the starter connector. Open the terminal cap, remove the nut and disconnect the starter wire. Remove the 2 bolts and starter.

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [01/2014 - ]»(ref-615109-S31931454042014050900000).
2. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL
3. REMOVE BATTERY CLAMP Remove the bolt and loosen the nut. Detach the 2 wire harness clamps. Detach the hook of the battery clamp from the front battery bracket, and then remove the battery clamp.
4. REMOVE BATTERY INSULATOR
5. REMOVE BATTERY
6. REMOVE BATTERY TRAY
7. REMOVE BATTERY CARRIER Remove the 4 bolts and battery carrier.
8. REMOVE STARTER ASSEMBLY Disconnect the starter connector. Open the terminal cap, remove the nut and disconnect the starter wire. Remove the 2 bolts and starter assembly.

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1. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the nut and disconnect the lead wire from the magnet starter switch. Remove the 2 nuts holding the magnet starter switch to the repair service starter kit. Remove the magnet starter switch.
2. REMOVE STARTER YOKE ASSEMBLY Remove the 2 through-bolts and pull out the starter yoke together with the starter commutator end frame. Remove the starter yoke from the starter commutator end frame.
3. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke.
4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, pry out the starter commutator end frame cover to remove it.
5. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and washer. TEXT IN ILLUSTRATION *1 Snap Ring Pliers Remove the starter armature from the starter commutator end frame. NOTE: Do not drop the starter armature.
6. REMOVE RUBBER SEAL Remove the rubber seal from the repair service starter kit.
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the repair service starter kit.

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1. REMOVE REPAIR SERVICE STARTER KIT Remove the nut and disconnect the lead wire from the terminal C. Holding the magnet switch to the starter drive housing assembly, remove the 2 screws. Remove the magnet switch. Remove the return spring and plunger from the starter drive housing assembly.
2. REMOVE STARTER YOKE ASSEMBLY Remove the 2 through bolts, and pull out the starter yoke assembly together with the starter commutator end frame assembly. Remove the starter yoke assembly from the starter commutator end frame assembly. TEXT IN ILLUSTRATION *1 Starter Yoke Assembly *2 Starter Commutator End Frame Assembly
3. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly.
4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, pry out the starter commutator end frame cover.
5. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and washer. TEXT IN ILLUSTRATION *a Snap Ring Pliers NOTE: Do not drop the starter armature assembly. Remove the starter armature assembly from the starter commutator end frame assembly.
6. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing 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 be hot and cause injury. NOTE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Perform the pull-in test. Disconnect the lead wire from terminal C. Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear extends. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C If the clutch pinion gear does not move, replace the magnet starter switch assembly. Perform the holding test. Maintain the battery connections of the pull-in test above, but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended. TEXT IN ILLUSTRATION *1 Terminal C If the clutch pinion gear returns inward, replace the magnet starter switch assembly. Check the clutch pinion gear return. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnet starter switch assembly. Perform the no-load performance test. Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Clamp the starter in a vise. Connect the battery and an ammeter to the starter as shown in the illustration. TEXT IN ILLUSTRATION *1 Terminal 30 *2 Terminal 50 Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Then measure the current. Standard current 90 A or less at 11.5 V If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER CLUTCH Check the starter clutch. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. TEXT IN ILLUSTRATION Free Lock If necessary, replace the starter repair service starter kit.
3. INSPECT MAGNET STARTER SWITCH ASSEMBLY Inspect the plunger. Push in the plunger and check that it returns quickly to its 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 50 - Terminal C Always Below 1 ohms TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C 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.
4. INSPECT STARTER ARMATURE ASSEMBLY Inspect the commutator for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Segment Always Below 1 ohms TEXT IN ILLUSTRATION *1 Segment If the result is not as specified, replace the starter armature assembly. Inspect the commutator for a short circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Armature coil core Always 10 kohms or higher TEXT IN ILLUSTRATION *1 Segment *2 Armature Coil Core If the result is not as specified, replace the starter armature assembly. Check the surface of the commutator for dirt and burns. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly. Using a vernier caliper, measure the commutator length. Standard length 3.1 mm (0.122 in.) Maximum length 3.8 mm (0.150 in.) TEXT IN ILLUSTRATION *1 Length If the length is more than the maximum, replace the starter armature assembly.
5. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Using a vernier caliper, measure the brush length. Standard length 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.157 in.) TEXT IN ILLUSTRATION *1 Length If the length is less than the minimum, replace the starter commutator end frame assembly. Inspect the insulation. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Positive (+) brush - Negative (-) brush Always 10 kohms or higher If the result is not as specified, repair or replace the starter commutator end frame 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: Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out. Perform a pull-in test. Remove the nut and disconnect the lead wire from terminal C. Connect a battery to the magnet switch as shown in the illustration. Check that the clutch pinion gear moves outward. TEXT IN ILLUSTRATION *a Terminal 50 *b Terminal C If the clutch pinion gear does not move outward, replace the repair service starter kit. Perform a holding test. While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward. TEXT IN ILLUSTRATION *a Terminal C *b Disconnect If the clutch pinion gear returns inward, replace the repair service starter kit. Perform a clutch pinion gear return test. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward. TEXT IN ILLUSTRATION *a Disconnect If the clutch pinion gear does not return inward, replace the repair service starter kit. Perform a no-load performance test. Connect the lead wire to terminal C with the nut. Make sure that the lead wire is not grounded. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Clamp the starter assembly in a vise between aluminum plates. NOTE: Ensure that the starter assembly is secured in the vise to prevent it from falling out. Connect the battery and an ammeter to the starter assembly as shown in the illustration. TEXT IN ILLUSTRATION *a Terminal 30 *b Terminal 50 NOTE: Do not allow either lead to get caught as the pinion gear operates. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current. Standard Current 90 A or less at 11.5 V If the result is not as specified, repair or replace the starter assembly.
2. INSPECT REPAIR SERVICE STARTER KIT Check the plunger. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the repair service starter kit. Check the pull-in coil for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Terminal C Always Below 1 ohms TEXT IN ILLUSTRATION *a Terminal C *b Terminal 50 If the result is not as specified, replace the repair service starter kit. Check the holding coil for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Magnet switch body Always Below 2 ohms TEXT IN ILLUSTRATION *a Terminal 50 *b Magnet Switch Body If the result is not as specified, replace the repair service starter kit.
3. INSPECT STARTER ARMATURE ASSEMBLY HINT: If there is no continuity between any segments, replace the starter armature assembly. Check the commutator appearance. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or on a lathe. Check the commutator for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Segment Always Below 1 ohms TEXT IN ILLUSTRATION *a Segment If the result is not as specified, replace the starter armature assembly. Check the commutator for a short circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Armature coil core Always 10 kohms or higher TEXT IN ILLUSTRATION *a Segment *b Armature Coil Core If the result is not as specified, replace the starter armature assembly. Using a vernier caliper, measure the commutator length. Standard length 3.1 mm (0.122 in.) Maximum length 3.8 mm (0.150 in.) TEXT IN ILLUSTRATION *a Length If the length is more than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Using a vernier caliper, measure the brush length. Standard length 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.157 in.) TEXT IN ILLUSTRATION *a Length If the length is less than the minimum, replace the starter commutator end frame assembly. Check the brush insulation. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Positive (+) brush - Negative (-) brush Always 10 kohms or higher If the result is not as specified, replace the starter commutator end frame assembly.
5. INSPECT STARTER CLUTCH Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. TEXT IN ILLUSTRATION *a Lock *b Free If necessary, replace the starter drive housing assembly.

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1. INSTALL PLANETARY GEAR Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft. TEXT IN ILLUSTRATION High-temperature grease Install the 3 planetary gears.
2. INSTALL RUBBER SEAL Install the rubber seal to the repair service starter kit.
3. INSTALL STARTER ARMATURE ASSEMBLY Apply high-temperature grease to the washer and a new snap ring and armature shaft. TEXT IN ILLUSTRATION High-temperature grease Install the starter armature to the starter commutator end frame. Install the washer. Using snap ring pliers, securely install a new snap ring to the armature shaft groove. NOTE: Be sure to install the snap ring properly because it easily expands. Using a vernier caliper, measure the length of the snap ring. Maximum length 5.0 mm (0.197 in.) TEXT IN ILLUSTRATION *1 Length If the length is more than the maximum, replace the snap ring with a new one.
4. INSTALL STARTER COMMUTATOR END FRAME COVER Install the starter commutator end frame cover to the starter commutator end frame.
5. INSTALL STARTER ARMATURE PLATE Insert the armature plate into the starter yoke. TEXT IN ILLUSTRATION *1 Keyway *2 Key Align the keyway of the starter armature plate with the key inside the starter yoke, and install the starter armature plate.
6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the rubber of the end frame with the cutout of the starter yoke. TEXT IN ILLUSTRATION *1 Rubber *2 Cutout Install the starter commutator end frame to the starter yoke. NOTE: The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet to break.
7. INSTALL STARTER YOKE ASSEMBLY Align the protrusion of the starter yoke with the cutout of the repair service starter kit. TEXT IN ILLUSTRATION *1 Protrusion *2 Cutout Install the starter yoke with 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 the lever. TEXT IN ILLUSTRATION High-temperature grease Pull the pinion gear and push down the lever. Temporarily install the magnet starter switch by hooking the plunger onto the upper side of the pinion drive lever. TEXT IN ILLUSTRATION *1 Plunger *2 Lever Install the magnet starter switch with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the lead wire to the magnet starter switch with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

See also:
• REMOVAL [05/2013 - 01/2014] - Step 5