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

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Disconnect the mass air flow meter connector. Loosen the hose clamp, unlock the air cleaner assembly clamp and remove the air cleaner cap sub-assembly.
3. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Separate the wire harness clamp from the air cleaner case sub-assembly. Remove the 3 bolts and remove the air cleaner case sub-assembly.
5. REMOVE STARTER ASSEMBLY (for Manual Transaxle) Disconnect the terminal 50 connector from the starter assembly. Remove the nut and disconnect the wire harness from terminal 30. Remove the 3 bolts, clutch flexible hose bracket and starter assembly.
6. REMOVE STARTER ASSEMBLY (for Automatic Transaxle) Disconnect the terminal 50 connector from the starter assembly. Remove the nut and disconnect the wire harness from terminal 30. Remove the 2 bolts and starter assembly.

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1. REMOVE MAGNET SWITCH BODY Remove the nut and disconnect the lead wire from terminal C. Remove the 2 screws that hold the magnetic switch to the starter drive housing assembly. Remove the magnet switch body. Remove the return spring and the plunger from the magnet switch body.
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.
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, remove the starter commutator end frame cover.
5. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and plate washer. NOTE: Do not drop the starter armature assembly. TEXT IN ILLUSTRATION *1 Snap Ring Pliers Remove the starter armature assembly from the commutator end frame assembly.
6. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the motor terminal starter kit.

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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 injury. NOTE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Perform pull-in test: Disconnect the lead wire from terminal C. TEXT IN ILLUSTRATION *1 Terminal C Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C *3 Body If the clutch pinion gear does not move outward, replace the magnet switch body. Perform holding test: Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C *3 Body If the clutch pinion gear moves inward, replace the magnet switch body. Inspect clutch pinion gear return: Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C *3 Body If the clutch pinion gear does not move inward, replace the magnet switch body. Perform no-load performance test: Connect the field coil 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. NOTE: Ensure that the starter is secured firmly in the vise to prevent it from falling out. Connect the battery and an ammeter to the starter as shown in the illustration. NOTE: Do not allow any lead to get caught as the pinion gear operates. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal 30 *3 Body *4 Ammeter Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified Current Tester Connection Condition Specified Condition Battery positive terminal - Terminal 30 11.5 V 90 A or less If the result is not as specified, overhaul the starter assembly.
2. INSPECT MAGNET SWITCH BODY Check the plunger. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnet switch body. Inspect the resistance of the pull-in coil. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Terminal C Always Below 1 ohms If the result is not as specified, replace the magnet switch body. Inspect the resistance of the holding coil. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Body Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Switch body Always Below 2 ohms If the result is not as specified, replace the magnet switch body.
3. INSPECT STARTER ARMATURE ASSEMBLY HINT: If these in no continuity between any segments, replace the starter armature assembly. Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. Check the commutator. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Commutator 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. Check the commutator. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Commutator *2 Armature Coil Core Standard Resistance Tester Connection Condition Specified Condition Commutator - Armature coil core Always 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Using a vernier caliper, measure the commutator length. TEXT IN ILLUSTRATION *a Length Standard length 3.1 mm (0.122 in.) Maximum length 3.8 mm (0.150 in.) If the length is greater than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Check the brush length. Using a vernier caliper, measure the brush length. TEXT IN ILLUSTRATION *a Length Standard length 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.157 in.) If the length is less than the minimum, replace the starter commutator end frame assembly. Check the resistance. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Positive brush holder - Negative brush holder Always 10 kohms or higher If the result is not as specified, replace the starter commutator end frame assembly.
5. INSPECT MOTOR TERMINAL STARTER KIT 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 *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 *1 High-temperature grease Install the 3 planetary gears into the starter drive housing assembly.
2. INSTALL STARTER ARMATURE ASSEMBLY Apply high-temperature grease to the washer and armature shaft. TEXT IN ILLUSTRATION High-temperature grease Apply high-temperature grease to the plate washer and the armature shaft. TEXT IN ILLUSTRATION *1 Snap Ring Pliers Install the starter armature assembly into the starter commutator end frame assembly. Using snap ring pliers, install the plate washer and a new snap ring. NOTE: Be sure to install the snap ring in the armature shaft groove securely. Be sure to install the snap ring properly because it easily expanders. Using a vernier caliper, measure the snap ring. TEXT IN ILLUSTRATION *a Length Maximum length 5.0 mm (0.197 in.) If the length is greater than the maximum, replace the snap ring with a new one.
3. INSTALL STARTER COMMUTATOR END FRAME COVER Install the starter commutator end frame cover onto the starter commutator end frame assembly.
4. INSTALL STARTER ARMATURE PLATE Align the keyway of the armature plate with the key inside the starter yoke assembly, and install the starter armature plate. TEXT IN ILLUSTRATION *a Keyway *b Key
5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the starter commutator end frame rubber with the cutout of the starter yoke assembly. TEXT IN ILLUSTRATION *a Cutout *b Rubber Install the starter commutator end frame assembly to the starter yoke assembly. NOTE: The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet to break.
6. INSTALL STARTER YOKE ASSEMBLY Align the claw of the starter yoke with the protrusion inside the starter drive housing assembly. TEXT IN ILLUSTRATION *a Cutout *b Protrusion Install the starter yoke with the 2 through bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
7. INSTALL MAGNET SWITCH BODY Apply high-temperature grease to the plunger, return spring and hook. Hang the plunger hook of the magnet switch body to the drive lever hook. Install the plunger and the return spring. Install the repair service starter kit 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 (for Manual Transaxle) Install the starter assembly and clutch flexible hose bracket with the 3 bolts. Bolt A Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Bolt B Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Connect the terminal 50 connector to the starter assembly.
2. INSTALL STARTER ASSEMBLY (for Automatic Transaxle) Install the starter assembly with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Connect the terminal 50 connector to the starter assembly.
3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Install the air cleaner case sub-assembly with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Install the wire harness clamp to the air cleaner case sub-assembly.
4. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Install the air cleaner filter element sub-assembly onto the air cleaner case sub-assembly.
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Install and lock the air cleaner cap sub-assembly and then tighten the hose clamp. Connect the mass air flow meter connector.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf)

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1. INSPECT STARTER RELAY Measure the resistance of the relay. Standard resistance Tester Connection Condition Specified Condition 3 - 5 Battery voltage not applied 10 kohms or higher 3 - 5 Battery voltage applied to terminals 1 and 2 Below 1 ohms If the resistance is not as specified, replace the relay.