Starting (Service Information): Overview Scion xD I

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FLYWHEEL HOUSING SIDE COVER Disengage the claw by pulling it outward and remove the flywheel housing side cover.
5. REMOVE STARTER ASSEMBLY Remove the terminal cap. Remove the nut and disconnect terminal 30. Disconnect the connector. Remove the 2 bolts and remove the starter assembly.

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1. REMOVE MAGNET SWITCH BODY Remove the nut, and disconnect the lead wire from the terminal C. Remove the 2 screws and magnet switch body from the starter drive housing assembly. 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 and starter commutator end frame assembly together. Remove the starter yoke assembly from the starter commutator end frame assembly.
3. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the starter commutator end frame cover from the starter commutator end frame.
4. REMOVE STARTER ARMATURE ASSEMBLY Hold the starter commutator end frame in a vise between aluminum plates. NOTE: Do not over tighten the vise. Using snap ring pliers, remove the snap ring and the plate washer. Remove the starter armature assembly from the commutator end frame assembly. NOTE: Do not drop the starter armature assembly.
5. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly.
6. REMOVE STARTER PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing.
7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Remove the starter center bearing clutch sub-assembly with drive lever set pin from the starter drive housing assembly. Remove the drive lever set pin from the starter center bearing clutch sub-assembly.

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1. INSPECT STARTER ASSEMBLY NOTE: The following tests must be performed for no longer then 5 seconds to prevent the coil from burning out. Perform the pull-in test. Remove the nut and disconnect the lead wire from terminal C. Connect the battery to the starter magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward. If the result is not as specified, replace the magnet starter switch assembly. Perform the holding test. Disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out. If the result is not as specified, replace the magnet starter switch assembly. Check the operation. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns in ward. If the result is not as specified, 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 in.*lbf) Clamp the starter in a vise. Connect the battery and an ammeter to the starter as shown in the illustration. Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Check that the ammeter reads the specified current. Standard current Tester connection Condition Specified condition Positive battery terminal - Terminal 30 - Terminal 50 11.5 V Below 90 A If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY Inspect the commutator for open circuits. Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Specified condition Segment - Segment Below 1 ohms If the result is not as specified, replace the starter armature assembly. Inspect the commutator for ground. Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Specified condition Commutator - Armature core 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Inspect the commutator surface for dirt and burns. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe. Using vernier calipers, measure the commutator 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 armature assembly.
3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Using vernier calipers, measure the brush length. Standard length 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.158 in.) If the length is less than the minimum, replace the starter commutator end frame assembly. Inspect the brush holder. Measure the resistance according to the value (s) in the table below. Standard resistance Tester connection Specified condition Positive (+) brush - Negative (-) brush 10 kohms or higher If the result is not as specified, replace the starter commutator end frame assembly.
4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear and damage. If damaged, replace the starter planetary gear or starter center bearing clutch sub-assembly. Also check the starter planetary gear for wear or damage. Inspect the starter clutch. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks. If necessary, replace the starter center bearing clutch sub-assembly.
5. INSPECT MAGNET SWITCH BODY Inspect 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 pull-in coil for open circuits. Measure the resistance according to the value (s) in the table below. Standard resistance Tester connection Specified condition Terminal C - Terminal 50 Below 1 ohms If the result is not as specified, replace the magnet switch body. Check whether the holding coil has an open circuit. Measure the resistance according to the value (s) in the table below. Standard resistance Tester connection Specified condition Terminal 50 - Magnet switch body Below 2 ohms If the result is not as specified, replace the magnet switch body.

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1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Apply grease to the drive lever set pin, as shown in the illustration. Install the drive lever set pin into the starter center bearing clutch sub-assembly. Install the starter center bearing clutch sub-assembly together with the starter drive lever set pin into the starter drive housing assembly.
2. INSTALL STARTER PLANETARY GEAR Apply grease to the planetary gears and pin parts of the planetary shaft as shown in the illustration. Install the 3 planetary gears.
3. INSTALL STARTER ARMATURE ASSEMBLY Apply grease to the washer plate and the armature shaft. Install the armature shaft onto 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 grove securely. Be sure to properly install the snap ring because it easily expands. Using vernier calipers, measure the snap ring. Maximum length 5.0 mm (0.197 in.) If the length is greater than the maximum, replace the snap ring.
4. INSTALL STARTER COMMUTATOR END FRAME COVER Install the starter commutator end frame cover onto the starter commutator end frame assembly.
5. INSTALL STARTER ARMATURE PLATE Insert the starter armature plate into the starter yoke assembly. Align the cutout of the plate with the inside protrusion of the starter yoke assembly, and install the plate.
6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the starter commutator end frame rubber with the cutout of the starter yoke assembly. Install the starter yoke assembly onto the starter commutator end frame assembly. NOTE: The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing magnet breakage.
7. INSTALL STARTER YOKE ASSEMBLY Align the key located on the starter yoke assembly with the keyway of the starter drive housing assembly. Install the starter yoke assembly with the 2 through bolts. Torque: 6.0 N*m ( 61 kgf*cm, 53 ft.*lbf)
8. INSTALL MAGNET SWITCH BODY Apply grease to the plunger and the hook, as shown in the illustration. Hang the plunger hook of the magnet switch body on the starter drive lever set pin. Install the plunger and the return spring as shown in the illustration. Install the magnet switch body with the 2 screws. Torque: 7.5 N*m ( 76 kgf*cm, 66 ft.*lbf) Connect the lead wire to the terminal C with the nut. Torque: 10 N*m ( 102 kgf*cm, 7 in.*lbf)

See also:
• REMOVAL - Step 30