Starting System: Diagnosis Subaru BRZ ZC

How To Troubleshoot

Note. The following is the flowchart to check the troubles of starter main body. For the vehicle with the smart entry & start system, check the smart entry & start system in advance to make sure that there is no fault is found in the smart entry & start system, and then perform the check according to the flowchart.

1. Bring in the car Next
2. Interview and phenomenon check Does the engine start with one cranking? RESULT Result Go to Engine does not start Check (2) Engine starts this time but did not start in the past Check (2) Engine starts B Does the engine crank normally? RESULT Result Go to Engine does not crank normally A Engine cranks normally this time but did not crank normally in the past C Engine cranks normally B B: Starter normal C: Go to Step 4 . A: Go to Next Step
3. Battery check Battery terminal check Check the battery terminals for looseness and damage. Check battery voltage To remove the voltage due to surface charging (ECM capacitor etc.), turn the headlight switch to ON with IG OFF for about 20 or 30 seconds. Measure the battery voltage between the terminals. Voltage: 12.5 V or more (Electrolyte temperature: 20°C) Battery electrolyte level check Check the electrolyte level of each cell and refill distilled water or replace the battery if the level is below the LOW level. Battery electrolyte specific gravity check Check the electrolyte specific gravity in each cell. Standard value: 1.25 to 1.29 (Electrolyte temperature: 20°C) NG: Go to Step 5 . OK: Go to Next Step
4. Starter check Perform the On-vehicle inspection (Refer to «ON-VEHICLE INSPECTION»(ref-619186-S20393500192014053000000) ). NG: Go to Step 6 . OK: Complete
5. Confirmation of past failure history Is there a symptom in which the engine could not be started or did not crank. RESULT Result Go to There was no such symptom A There was the symptom B B: Charge or replace the battery and then go to step 4 A: Charge or replace the battery to complete the check
6. Starter repair or replacement Next: Complete

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Function Inspection

1. Key interlock function check Turn the ignition switch to ON. Depress the brake pedal and place the shift lever in a position other than the P position. Check that the ignition key cannot be turned to the LOCK position. Place the shift lever in the P position and turn the ignition key to the LOCK position to check that the ignition key can be pull out.

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Symptom Table

KEY INTERLOCK SYSTEM

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Circuit description

The control unit relay ASSY outputs a signal to the key interlock solenoid when the ACC signal and P signal are input.

Inspection steps

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1. Check wiring harness and connector (ACC voltage) NOTE: Refer to «INSPECTION PROCEDURES FOR ELECTRICAL CIRCUITS AND HOW TO PERFORM»(ref-619149-S21627727182014053000000) for the inspection procedure and precautions. Disconnect the connector D42 of control unit relay ASSY. Measure the voltage between the terminals. VOLTAGE Inspection terminals Inspection conditions Standard value D42-6 (ACC) - chassis ground IG ON 11 to 14 V NG: Repair or replacement of wiring harness or connector OK: Go to Next Step
2. Wiring harness and connector check (control module relay ASSY - chassis ground) NOTE: Refer to «INSPECTION PROCEDURES FOR ELECTRICAL CIRCUITS AND HOW TO PERFORM»(ref-619149-S21627727182014053000000) for the inspection procedure and precautions. Disconnect the connector D42 of control unit relay ASSY. Measure the resistance between the terminals. RESISTANCE Inspection terminals Inspection conditions Standard value D42-1 (E) - chassis ground Always Less than 1 ohms NG: Repair or replacement of wiring harness or connector OK: Go to Next Step
3. P switch (floor shift, shift lever housing) unit inspection Perform the P switch (floor shift, shift lever housing) unit inspection. (Refer to «UNIT INSPECTION»(ref-619159-S40205187112014053000000) ) NG: P switch (floor shift, shift lever housing) replacement (Refer to «DISASSEMBLY»(ref-619159-S15665817812014053000000) ) OK: Go to Next Step
4. Wiring harness and connector check (control module relay ASSY - P switch (floor shift, shift lever housing)) NOTE: Refer to «INSPECTION PROCEDURES FOR ELECTRICAL CIRCUITS AND HOW TO PERFORM»(ref-619149-S21627727182014053000000) for the inspection procedure and precautions. Disconnect the connector D42 of control unit relay ASSY. Disconnect the connector D28 of P switch (floor shift, shift lever housing). Measure the resistance between the terminals. RESISTANCE (OPEN CIRCUIT CHECK) Inspection terminals Inspection conditions Standard value D42-4 (P) - D28-1 (P) Always Less than 1 ohms RESISTANCE (SHORT CIRCUIT CHECK) Inspection terminals Inspection conditions Standard value D42-4 (P) and D28-1 (P) - other terminals and chassis ground Always 10 k ohmsor more NG: Repair or replacement of wiring harness or connector OK: Go to Next Step
5. Wiring harness and connector check (P switch (floor shift, shift lever housing) - chassis ground) NOTE: Refer to «INSPECTION PROCEDURES FOR ELECTRICAL CIRCUITS AND HOW TO PERFORM»(ref-619149-S21627727182014053000000) for the inspection procedure and precautions. Disconnect the connector D28 of P switch (floor shift, shift lever housing). Measure the resistance between the terminals. RESISTANCE Inspection terminals Inspection conditions Standard value D28-3 (E) - chassis ground Always Less than 1 ohms NG: Repair or replacement of wiring harness or connector OK: Go to Next Step
6. Key interlock solenoid check Disconnect the connector D60 of key interlock solenoid. Measure the resistance between the terminals. RESISTANCE Inspection terminals Inspection conditions Standard value 1 - 2 20°C 13.05 to 15.95 ohms NG: Key interlock solenoid replacement (Refer to «DISASSEMBLY»(ref-619170-S13244134202014053000000) ) OK: Go to Next Step
7. Wiring harness and connector check (control module relay ASSY - key interlock solenoid) NOTE: Refer to «INSPECTION PROCEDURES FOR ELECTRICAL CIRCUITS AND HOW TO PERFORM»(ref-619149-S21627727182014053000000) for the inspection procedure and precautions. Disconnect the connector D42 of control unit relay ASSY. Disconnect the connector D60 of key interlock solenoid. Measure the resistance between the terminals. RESISTANCE (OPEN CIRCUIT CHECK) Inspection terminals Inspection conditions Standard value D42-5 (KLS+) - D60-2 Always Less than 1 ohms RESISTANCE (SHORT CIRCUIT CHECK) Inspection terminals Inspection conditions Standard value D42-5 (KLS+) and D60-2 - Other terminals and chassis ground Always 10 k ohmsor more NG: Repair or replacement of wiring harness or connector OK: Go to Next Step
8. Wiring harness and connector check (key interlock solenoid - Chassis ground) NOTE: Refer to «INSPECTION PROCEDURES FOR ELECTRICAL CIRCUITS AND HOW TO PERFORM»(ref-619149-S21627727182014053000000) for the inspection procedure and precautions. Disconnect the connector D60 of key interlock solenoid. Measure the resistance between the terminals. RESISTANCE Inspection terminals Inspection conditions Standard value D60-1 - chassis ground Always Less than 1 ohms NG: Repair or replacement of wiring harness or connector OK: Control unit relay ASSY replacement (Refer to «REMOVAL»(ref-619186-S07357951732014053000000) )

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1. Disconnection of the battery ground terminal (Refer to «WORKING PRECAUTIONS AND NOTES»(ref-619149-S01292846772014053000000) )
2. Removal of under cover COMPL T/M (Refer to «REMOVAL»(ref-619189-S01819081472014053000000) )
3. Removal of exhaust pipe ASSY FR (Refer to «INSTALLATION»(ref-619189-S26330443752014053000000) )
4. Removal of starter ASSY Disconnect the connector and terminal from the starter ASSY. Remove the wiring harness clamp. Remove the upper mounting bolt. Remove the lower mounting bolt. Remove the ground cable fixing bolt A. Remove the lower mounting bolt B. Remove the starter ASSY.

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1. REMOVE MAGNET STARTER SWITCH ASSEMBLY(for Manual Transmission) Remove the nut and disconnect the lead wire from terminal M. Remove the 2 screws and the magnet starter switch assembly from the starter drive housing assembly.
2. REMOVE MAGNET STARTER SWITCH ASSEMBLY(for Automatic Transmission) Remove the nut and disconnect the lead wire from terminal M. Remove the 2 nuts and the magnet starter switch assembly from the starter drive housing assembly.
3. REMOVE STARTER YOKE ASSEMBLY (for Automatic Transmission) Using a "TORX" socket wrench T25, remove the 2 through bolts. Remove the starter yoke assembly and starter cover from the starter drive housing assembly.
4. REMOVE STARTER COVER (for Manual Transmission) Remove the 2 through bolts and 2 screws, and remove the starter cover.
5. REMOVE STARTER COVER (for Automatic Transmission) Remove the 2 screws. Remove the starter cover from the starter yoke assembly. Text in illustration CAUTION: Hold the lead wire and remove the starter cover. Remove the dust starter protect from the starter yoke assembly.
6. REMOVE STARTER BRUSH HOLDER ASSEMBLY(for Manual Transmission) Remove the starter brush holder assembly. NOTE: Hold the brush with your fingers so that the brush spring does not come flying out.
7. REMOVE STARTER BRUSH HOLDER ASSEMBLY(for Automatic Transmission) Using a screwdriver, disengage the spring from the bush. Disconnect the 4 brush from the starter brush holder assembly. Remove the starter brush holder assembly.
8. REMOVE STARTER YOKE ASSEMBLY (for Manual Transmission) Remove the starter yoke assembly and starter armature assembly together from the starter drive housing assembly.
9. REMOVE STARTER ARMATURE ASSEMBLY (for Manual Transmission) Pull out the starter armature assembly from the starter yoke assembly.
10. REMOVE STARTER ARMATURE ASSEMBLY (for Automatic Transmission) Pull out the starter armature assembly from the starter yoke assembly. Text in Illustration
11. REMOVE STARTER ARMATURE PLATE (for Automatic Transmission) Remove the starter armature plate from the starter yoke assembly and starter drive housing assembly. Text in Illustration
12. REMOVE STARTER HOUSING RUBBER (for Manual Transmission) Remove the starter housing rubber, seal rubber and plate from the starter drive housing assembly. Text in Illustration
13. REMOVE RUBBER SEAL (for Automatic Transmission) Remove the rubber seal from the starter drive housing assembly. Text in Illustration
14. REMOVE STARTER PLANETARY GEAR Remove the 3 starter planetary gears from the starter clutch subassembly.
15. REMOVE STARTER CLUTCH SUB-ASSEMBLY (for Manual Transmission) Remove the starter clutch sub-assembly together with the drive lever set pin from the starter drive housing assembly. Using a deep socket wrench, remove the stopper from snap ring. Text in Illustration Using snap ring pliers, remove the snap ring and stopper. Pull out the over running clutch from the shaft. Remove the internal gear assembly from the shaft. Text in Illustration

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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. CAUTION: The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out. Mount the starter in a vise between aluminum plates. Perform a pull-in test. Remove the nut, and then disconnect the lead wire from terminal M. Connect the battery to the starter as shown in the illustration. Check that the clutch pinion gear extends. Text in Illustration If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it. Perform a holding test. Disconnect the negative (-) terminal lead from terminal M while the conditions specified in the pull-in test above are maintained. Check that the pinion gear remains out. Text in Illustration If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it. Inspect the clutch pinion gear return. Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward. Text in Illustration If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it. Perform an operation test without load. Connect the lead wire to terminal C with the nut. Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf} Connect the battery and an ammeter to the starter as shown in the llustration. Text in Illustration Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then measure the current. STANDARD CURRENT Tester Connection Condition Specified Condition Battery positive terminal - Terminal B - Terminal M 11.5 V Below 90 A If the result is not as specified, inspect the starter assembly. NOTE: Inspect the starter armature assembly, starter commutator end frame assembly and magnet starter switch assembly. If there is a malfunction, replace the part and perform again this test.
2. INSPECT STARTER ARMATURE ASSEMBLY (for Manual Transmission) Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair. Check for runout on the commutator. If excessive, replace the armature. Standard runout: 0.05 mm (0.002 in.) Maximum runout: 0.10 mm (0.004 in.) Text in Illustration Check the depth of the segment mold. If it is not within the standard, replace the armature. Standard depth: 0.05 mm (0.002 in.) Text in Illustration Place the armature on the growler tester to check for short circuits. While slowly turning the armature, support the steel sheet for the armature core. If the circuit of the armature is shorted, the steel sheet will vibrate, causing it to move towards the core. When the steel sheet has moved or vibrated, replace the armature. Text in Illustration Touch the probe of one side to the commutator segment, and the other probe to the shaft. If there is continuity, replace the armature.
3. INSPECT STARTER ARMATURE ASSEMBLY (for Automatic Transmission) Check the commutator for dirt and/or burns on the surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly. Inspect the commutator for an open circuit. Measure the resistance according to the value(s) in the table below. Text in Illustration 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. Inspect the commutator for short circuits. Measure the resistance according to the value(s) in the table below. Text in Illustration STANDARD RESISTANCE Tester Connection Condition Specified Condition Segment - Coil core Always 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair. Check for runout on the commutator. If excessive, replace the armature. Standard runout: 0.02 mm (0.0008 in.) Maximum runout: 0.05 mm (0.002 in.) Text in Illustration If the result is not as specified, replace the starter armature assembly. Using vernier caliper, measure the commutator diameter. Text in Illustration Standard diameter: 29 mm (1.1417 in.) Minimum diameter: 28 mm (1.1024 in.) If the diameter is less than the minimum, replace the starter armature assembly. Using vernier caliper, measure the under cut depth of the segment. If it is not within the standard, replace the starter armature assembly. Standard depthr: 0.7 mm (0.0276 in.) Minimum depth: 0.2 mm (0.0079 in.)
4. INSPECT STARTER YOKE ASSEMBLY (for Manual Transmission) Make sure that the pole is set at the predetermined position.
5. INSPECT STARTER BRUSH HOLDER ASSEMBLY(for Manual Transmission) Visually check the brush. If there is any abnormal wear or cracks, replace the brush. Measure the length of the brush. If it exceeds the service limits, replace the brush. Standard length: 12.3 mm (0.484 in.) Minimum length: 7.0 mm (0.276 in.) Text in Illustration Check that the brush moves smoothly in the brush holder. Measure the brush spring force with a spring scale. Replace the brush holder if below the service limit. Standard brush spring force: 15.9 to 19.5 N (1.6 to 2.0 kgf, 3.6 to 4.4 lbf) Minimum brush spring force: 2.5 N (0.3 kgf, 0.6 lbf)
6. INSPECT STARTER BRUSH HOLDER ASSEMBLY (for Automatic Transmission) Using a vernier caliper, measure the brush length. Text in Illustration Standard length: 14.4 mm (0.5669 in.) Minimum length: 9.0 mm (0.3543 in.) If the length is less than the minimum, replace the starter brush holder assembly. Measure the resistance according to the value(s) in the table below. STANDARD RESISTANCE Tester Connection Condition Specified Condition A - BA - CB - DC - D Always 10 kohms or higher A - DB - C Always Below 1 ohms If the result is not as specified, replace the starter brush holder assembly.
7. INSPECT STARTER CLUTCH SUB-ASSEMBLY (for Manual Transmission) Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage. If any of the gears is damaged, replace the starter center bearing clutch sub-assembly. Check the starter clutch pinion gear. Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. Text in Illustration If necessary, replace the starter clutch subassembly.
8. INSPECT MAGNET STARTER SWITCH ASSEMBLY(for Manual Transmission) Check that there is continuity between terminals 50 and C, and between terminal 50 and ground. Also, check to be sure there is no continuity between terminal C and 30. STANDARD RESISTANCE Tester Connection Condition Specified Condition Terminal M - Terminal B Always Below 1 ohms Terminal B - Switch body Always Below 1 ohms Terminal M - Terminal S Always 1 M ohmsor higher Text in Illustration Using a lead wire, connect the switch assembly terminal 50 to the positive terminal of the battery, and the starter body to the ground terminal of the battery. The pinion should be forced to be pushed out on the shaft. NOTE: With the pinion forced to be pushed out on the shaft, the starter motor can sometimes rotate because the current flows, through pull-in coil, to motor. This is not a problem. Disconnect the connector from terminal M. Then, using a lead wire, connect the positive terminal of the battery and terminal M, and ground terminal to starter body. In this test set up, the pinion should return to its original position even when it is pulled out with a screwdriver. Text in Illustration
9. INSPECT MAGNET STARTER SWITCH ASSEMBLY(for Automatic Transmission) Check the plunger. Push in the plunger and check that it returns quickly to it is 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 M - Terminal B Always Below 1 ohms Text in Illustration 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 B - Switch body Always Below 2 ohms Text in Illustration If the result is not as specified, replace the magnet starter switch assembly.

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1. INSTALL STARTER CLUTCH SUB-ASSEMBLY (for Manual Transmission) Apply grease to the shaft as shown in the illustration. Text in Illustration Install the internal gear to the shaft. Apply grease to the shaft as shown in the illustration. Text in Illustration Install the over running clutch to the shaft. Install the stopper to the shaft. Using snap ring pliers, install the snap ring. Using a press, press the snap ring into the stopper. Text in Illustration Install the starter clutch sub-assembly together with the drive lever set pin to the starter drive housing assembly.
2. INSTALL STARTER PLANETARY GEAR (for Manual Transmission). Apply high-temperature grease to the planetary gears and pins of the planetary shaft. Install the 3 starter planetary gears. Text in Illustration
3. INSTALL STARTER PLANETARY GEAR (for Automatic Transmission) Apply high-temperature grease to the planetary gears and pins of the planetary shaft. Install the 3 starter planetary gears. Text in Illustration
4. INSTALL STARTER HOUSING RUBBER (for Manual Transmission) Install the starter housing rubber, seal rubber and plate to the starter drive housing assembly. Text in Illustration
5. INSTALL RUBBER SEAL (for Automatic Transmission) Install the rubber seal to the starter drive housing assembly. Text in Illustration
6. INSTALL STARTER ARMATURE ASSEMBLY (for Automatic Transmission) Install the starter armature assembly to the starter yoke assembly. Text in Illustration
7. INSTALL STARTER BRUSH HOLDER ASSEMBLY (for Automatic Transmission) Install the 4 brushes and 4 brush springs. Install the starter brush holder assembly to the starter armature assembly. Push the 4 brushs. Insert the grommet between the positive (+) motor read wire and the negative (-) brush holder plate. Text in Illustration
8. INSTALL STARTER COVER (for Automatic Transmission) Install the dust starter protector to the starter yoke assembly. Align the starter brush holder assembly read wire rubber with the groove of the starter cover. Install the starter cover to the starter brush holder assembly with 2 screws. Standard value: T=1.5N.m {15kgf.cm} {1.1ft.lbf}
9. INSTALL STARTER ARMATURE PLATE (for Automatic Transmission) Align the claw of the starter yoke assembly with the groove the starter armature plate. Install the starter armature plate to the starter yoke assembly. Text in Illustration
10. INSTALL STARTER ARMATURE ASSEMBLY (for Manual Transmission) Install the starter armature assembly to the starter yoke assembly.
11. INSTALL STARTER YOKE ASSEMBLY (for Manual Transmission) Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly. Text in Illustration Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly.
12. INSTALL STARTER YOKE ASSEMBLY (for Automatic Transmission) Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly. Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly. Text in Illustration Using a "TORX" socket wrench T25, install the 2 through bolts. Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}
13. INSTALL STARTER BRUSH HOLDER ASSEMBLY (for Manual Transmission) Install a socket to the starter brush holder assembly. Install the starter brush holder assembly to the starter armature assembly.
14. INSTALL STARTER COVER (for Manual Transmission) Install the starter cover with 2 screws and 2 bolts. Torque: Bolt 6.0 N.m {61 kgf.cm} {4.4ft.lbf} Screw 1.4 N.m {14 kgf.cm} {1.0ft.lbf}
15. INSTALL MAGNET STARTER SWITCH ASSEMBLY (for Manual Transmission) Install the magnet starter switch assembly with the 2 screws. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf} Connect the lead wire to terminal C with the nut. Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}
16. INSTALL MAGNET STARTER SWITCH ASSEMBLY (for Automatic Transmission) Apply grease to the plunger and hook as shown in the illustration. Text in Illustration Hook the plunger and hook of the magnet starter switch assembly to the lever of the starter drive housing assembly. Text in Illustration Install the magnet starter switch assembly with the 2 screws. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf} Connect the lead wire to terminal C with the nut. Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}

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1. Installation of starter ASSY Install the starter ASSY to the transmission and temporarily tighten the upper mounting bolt. Lower mounting bolt tightening Tighten the lower mounting bolt A. Standard value: 50 N.m {510 kgf.cm} {36.9 ft.lbf} Tighten the ground cable fixing bolt B. Standard value: 14 N.m {143 kgf.cm} {10.3 ft.lbf} Tighten the upper mounting bolt of starter ASSY using the SST. SST 18283AA000 Standard value: Specified tightening torque T=50N.m {510kgf.cm} {36.9ft.lbf} When using the SST, calculate the torque using the following formula. FORMULA: T2 = L2/(L1 + L2) X T1 T1 50 N.m T2 Tightening torque L1 Length of SST [0.085 m] L2 Torque wrench length [m] NOTE: This torque value is valid when the SST and torque wrench are aligned on a line. Attach the SST and torque wrench so that they are alined on a line. Install the wiring harness clamp. Connect the connector and terminal to the starter ASSY.
2. Installation of exhaust pipe ASSY FR (Refer to «COOLING SYSTEM (FA20)»(ref-619192-S36331344062014053000000) )
3. Installation of under cover COMPL T/M (Refer to «COOLING SYSTEM (FA20)»(ref-619192-S36331344062014053000000) )
4. Connection of the battery ground terminal Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}

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1. Disconnection of the battery ground terminal (Refer to «WORKING PRECAUTIONS AND NOTES»(ref-619149-S01292846772014053000000) )
2. Console box cover FR removal (Refer to «REMOVAL»(ref-619171-S38001368652014053000000) )
3. Push button start switch removal Release the two claws from the back side of console box cover FR and remove the push button start switch.