Starters: Diagnosis Scion xA I

TROUBLE SHOOTING

Note. See STARTER - GENERAL TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING

Note. Before testing, ensure battery is fully charged, battery cables and terminal ends are tight and clean, and engine grounds are secure.

IGNITION SWITCH TEST

See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.

PARK/NEUTRAL SWITCH TEST

Note. If vehicle will not start with shift lever in Park or Neutral position, verify correct park/neutral switch adjustment. See appropriate ADJUSTMENTS in AUTOMATIC TRANSMISSIONS SERVICING article in AUTOMATIC TRANSMISSION/TRANSAXLE. If park/neutral switch is correctly adjusted, verify switch continuity. For continuity inspection of the park/neutral position switch, see appropriate DIAGNOSIS article

STARTER RELAY TEST

1. Remove starter relay located in engine compartment junction block. Starter relay is marked "ST".
2. Using an ohmmeter, verify continuity between relay terminals No. 1 and 2. (Scheme 1) Continuity should not exist between terminals No. 3 and 5. If continuity is not as specified, replace relay.
3. Check relay operation by applying battery voltage through terminals No. 1 and 2. (Scheme 1) Continuity should now exist between terminals No. 3 and 5. If relay does not test as indicated, replace relay.
4. Install starter relay.

Scheme 1

ARMATURE COIL TEST

1. Using an ohmmeter check that there is continuity between the segments of the commutator. (Scheme 2) If any of the segments do not have continuity between them, replace the armature.
2. Check the commutator for ground. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. (Scheme 2) If there is continuity, replace the armature.
3. If the surface is dirty or burnt, correct it with sandpaper (No.400) or a lathe.
4. Using vernier calipers, measure the commutator length. (Scheme 3) If the length is greater than maximum, replace the armature.

Scheme 2

Scheme 3

BRUSHES & SPRINGS TEST

1. Using vernier calipers, measure the brush length. (Scheme 4) Verify length is within specification. See «STARTER SPECIFICATIONS»(ref-168889-S28598216442004070900000). If the length is less than minimum, replace the starter commutator end frame assembly.
2. Using an ohmmeter, verify that there is no continuity between the positive and negative brush holders. (Scheme 5) If there is continuity between the positive and negative brush holders, repair or replace the starter commutator end frame assembly.

Scheme 4

Scheme 5

CLUTCH ASSEMBLY & GEARS TEST

1. Inspect teeth on planetary gear, internal gear, starter clutch pinion gear, and flywheel ring gear for wear or damage. If damaged, fix or replace.
2. Inspect clutch pinion gear by rotating pinion gear counterclockwise. Ensure gear turns freely in counterclockwise direction, but locks up when turned clockwise. (Scheme 6) If not as specified, replace clutch assembly.

Scheme 6

MAGNETIC SWITCH TEST

1. Push in the plunger and check that it returns quickly to its original position. (Scheme 7) If performance is not as specified, replace the repair service starter kit.
2. Check whether the pull-in coil has an open circuit. Using an ohmmeter, check that there is continuity between terminals 50 and terminal "C". (Scheme 7) If there is no continuity, check and replace the magnetic switch.
3. Check whether the pull-in coil has an open circuit. Using an ohmmeter, check that there is continuity between terminals 50 and the switch body. (Scheme 7) If there is no continuity, check and replace the magnetic switch.

Scheme 7

SNAP RING TEST

Using vernier calipers, measure the length of the snap ring end gap. (Scheme 8) Verify end gap is within specification. See STARTER SPECIFICATIONS. If gap is greater than specification, replace with a NEW snap ring.

Scheme 8

SOLENOID TEST

1. Remove the terminal "C" nut and disconnect the field coil lead wire from terminal "C".
2. Clip battery ground to terminal "C" and the main body of the starter, connect the battery positive to the magnetic switch (Terminal 50). Ensure that the clutch pinion gear moves outward. (Scheme 9) If the clutch pinion gear does not move, replace the magnetic switch. If specifications are met, got to step 3.
3. Disconnect the negative lead from terminal "C". (Scheme 9) Verify that the pinion gear remains out. If the clutch pinion gear does not move, replace the magnetic switch. If specifications are met, go to step 4.
4. Disconnect the negative lead from the switch body. (Scheme 9) Verify that the clutch pinion gear returns inward. If the clutch pinion gear does not move, replace the magnetic switch. If specifications are met, go to step 5.
5. Connect the lead wire to terminal "C" with the terminal "C" nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-168889-S17750436622004111900000).

Scheme 9

NO LOAD TEST

1. Remove starter. See «STARTER»(ref-168889-S18607980412004111900000) under REMOVAL & INSTALLATION.
2. Connect ammeter leads between No. 30 (battery terminal) and No. 50 (battery connector) in series with a fully charged 12-volt battery. Connect battery negative lead to starter case ground. (Scheme 10)
3. Starter drive pinion gear should extend quickly and spin smoothly. Verify starter amperage draw is within specifications of 90 amps or less at 11.5 volts.

Scheme 10

Scheme 11

1. Remove right hand engine under cover.
2. Remove left hand engine under cover.
3. Remove flywheel housing side cover. (Scheme 11)
4. Remove starter using the following steps: Remove the starter wire nut and disconnect the starter cable from starter. Disconnect the starter connector. Remove the mounting bolts, and starter.
5. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-168889-S17750436622004111900000).