Toyota Yaris: Starter / Reassembly

Toyota Yaris XP210 (2020-2025) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (starting) / Starter / Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) Apply high-temperature grease to the pinion drive lever as shown in the illustration.

*1

Starter Center Bearing Clutch Sub-assembly

*2

Starter Drive Housing Assembly

*3

Pinion Drive Lever

*4

Rubber Seal

High-temperature Grease

(b) Install the pinion drive lever and rubber seal to the starter center bearing clutch sub-assembly.

(c) Install the starter center bearing clutch sub-assembly together with the pinion drive lever and rubber seal to the starter drive housing assembly.

2. INSTALL PLANETARY GEAR

(a) Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter center bearing clutch sub-assembly.

High-temperature Grease

(b) Install the 3 planetary gears to the starter center bearing clutch sub-assembly.

3. INSTALL STARTER ARMATURE ASSEMBLY

(a) Install the starter armature assembly to the starter yoke assembly.

NOTICE:

The magnet of the starter yoke assembly may attract the starter armature assembly when the starter armature assembly is installed, causing the magnet to break.

4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

(a) Hold the brush spring back and set the 4 brushes as shown in the illustration.

(b) Install the starter brush holder assembly to the starter armature assembly and push in the 4 brushes as shown in the illustration.

(c) Fit the protrusion of the grommet between the negative (-) brush holder plate and positive (+) motor lead wire.

*a

Grommet

*b

Negative (-) Brush Holder Plate

*c

Positive (+) Motor Lead Wire

5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Install the starter commutator end frame assembly to the starter yoke assembly.

NOTICE:

Align the field coil lead wire rubber of the starter yoke assembly with the cutout of the starter commutator end frame assembly.

*a

Field Coil Lead Wire Rubber

*b

Cutout

(b) Install the 2 screws.

Torque:

1.5 N·m {15 kgf·cm, 13 in·lbf}

6. INSTALL STARTER ARMATURE PLATE

(a) Align the starter armature plate so that the protrusion fits between the stoppers of the starter yoke assembly, and install the starter armature plate.

NOTICE:

Make sure the protrusion of the starter armature plate is inserted between the stoppers of the starter yoke assembly.

*1

Starter Yoke Assembly

*2

Starter Armature Plate

*a

Protrusion

*b

Stopper

7. INSTALL STARTER YOKE ASSEMBLY

(a) Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.

*1

Starter Yoke Assembly

*2

Starter Drive Housing Assembly

*a

Cutout

*b

Protrusion

(b) Using a T25 "TORX" socket wrench, install the 2 through bolts.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

*1

Starter Yoke Assembly

*2

Starter Commutator End Frame Assembly

8. INSTALL MAGNET STARTER SWITCH ASSEMBLY

(a) Apply high-temperature grease to the magnet starter switch assembly as shown in the illustration.

*1

Pinion Drive Lever

*a

Hook

High-temperature Grease

(b) Hang the hook of the magnet starter switch assembly on the pinion drive lever.

(c) Install the magnet starter switch assembly with the 2 nuts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

9. INSTALL STARTER INRUSH CURRENT REDUCTION RELAY

(a) Install the starter inrush current reduction relay to the starter drive housing assembly with the 2 bolts.

Torque:

7.9 N·m {81 kgf·cm, 70 in·lbf}

(b) Connect the field coil lead wire to the starter inrush current reduction relay with the nut.

Torque:

9.0 N·m {92 kgf·cm, 80 in·lbf}

10. INSTALL WIRE HARNESS

(a) Install the wire harness to the starter assembly with the 2 nuts.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

    Inspection

    INSPECTION PROCEDURE 1. INSPECT STARTER ASSEMBLY CAUTION: As a large electric current passes through the cable during this inspection, a thick cable must be used...

    Installation

    INSTALLATION PROCEDURE 1. INSTALL STARTER ASSEMBLY (a) Install the wire harness clamp bracket to the starter assembly with the bolt. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} (b) Install the starter assembly to the cylinder block sub-assembly with the 2 bolts...

    Other information:

    Toyota Yaris XP210 (2020-2025) Reapir and Service Manual: ID-BOX Calibration / Parameter Memory Failure (B279046)


    DESCRIPTION When an internal malfunction occurs in the ID code box (immobiliser code ECU), the certification ECU (smart key ECU assembly) stores this DTC. DTC No. Detection Item DTC Detection Condition Trouble Area Note B279046 ID-BOX Calibration / Parameter Memory Failure An internal malfunction occurs in the ID code box (immobiliser code ECU) (EEPROM access malfunction) (1 trip detection logic*)...

    Toyota Yaris XP210 (2020-2025) Reapir and Service Manual: Diagnostic Trouble Code Chart


    DIAGNOSTIC TROUBLE CODE CHART SFI System DTC No. Detection Item MIL Note Link P001013 A Camshaft Position Actuator Bank 1 Circuit Open Comes on SAE: P0010 P001100 Camshaft Position "A" - Timing Over-Advanced or System Performance Bank 1 Comes on SAE: P0011 P001200 Camshaft Position "A" - Timing Over-Retarded Bank 1 Comes on SAE: P0012 P001313 Camshaft Position "B" - Actuator Bank 1 Circuit Open Comes on SAE: P0013 P001400 Camshaft Position "B" - Timing Over-Advanced or System Performance Bank 1 Comes on SAE: P0014 P001500 Camshaft Position "B" - Timing Over-Retarded Bank 1 Comes on SAE: P0015 P001600 Crankshaft Position - Camshaft Position Correlation Bank 1 Sensor A Comes on SAE: P0016 P001700 Crankshaft Position - Camshaft Position Correlation Bank 1 Sensor B Comes on SAE: P0017 P003012 HO2S Heater Control Bank 1 Sensor 1 Circuit Short to Battery Comes on SAE: P0032 P003013 HO2S Heater Control Bank 1 Sensor 1 Circuit Open Comes on SAE: P0031 P003312 Turbocharger / Supercharger Bypass Valve "A" Control Circuit Short to Battery - SAE: P0035 P003314 Turbocharger / Supercharger Bypass Valve "A" Control Circuit Short to Ground or Open - SAE: P0034 P003612 HO2S Heater Control Circuit Bank 1 Sensor 2 Circuit Short to Battery Comes on SAE: P0038 P003613 A/F (O2) Heater Control Circuit Bank 1 Sensor 2 Circuit Open Comes on SAE: P0037 P006D62 Barometric Pressure - Turbocharger/Supercharger Inlet Pressure Correlation Bank 1 Signal Compare Failure - SAE: P006D P007A11 Charge Air Cooler Temperature Sensor Bank 1 Circuit Short to Ground - SAE: P007C P007A15 Charge Air Cooler Temperature Sensor Bank 1 Circuit Short to Battery or Open - SAE: P007D P008700 Fuel Rail / System Pressure - Too Low Comes on SAE: P0087 P008800 Fuel Rail / System Pressure - Too High Comes on SAE: P0088 P008A00 Low Pressure Fuel System Pressure - Too Low - SAE: P008A P008B00 Low Pressure Fuel System Pressure - Too High - SAE: P008B P00CF62 Barometric Pressure - Turbocharger / Supercharger Boost Sensor "A" Signal Compare Failure Comes on SAE: P00CF P010012 Mass or Volume Air Flow Sensor "A" Circuit Short to Battery Comes on SAE: P0103 P010014 Mass or Volume Air Flow Sensor "A" Circuit Short to Ground or Open Comes on SAE: P0102 P010511 Manifold Absolute Pressure / Barometric Pressure Sensor Circuit Short to Ground Comes on SAE: P0107 P010515 Manifold Absolute Pressure / Barometric Pressure Sensor Circuit Short to Battery or Open Comes on SAE: P0108 P011011 Intake Air Temperature Sensor 1 Bank 1 Circuit Short to Ground Comes on SAE: P0112 P011015 Intake Air Temperature Sensor 1 Bank 1 Circuit Short to Battery or Open Comes on SAE: P0113 P011511 Engine Coolant Temperature Sensor 1 Circuit Short to Ground Comes on SAE: P0117 P011515 Engine Coolant Temperature Sensor 1 Circuit Short to Battery or Open Comes on SAE: P0118 P01152A Engine Coolant Temperature Sensor 1 Signal Stuck in Range Comes on SAE: P0116 P012011 Throttle / Pedal Position Sensor / Switch "A" Circuit Short to Ground Comes on SAE: P0122 P012015 Throttle / Pedal Position Sensor / Switch "A" Circuit Short to Battery or Open Comes on SAE: P0123 P01201C Throttle / Pedal Position Sensor / Switch "A" Circuit Voltage Out of Range Comes on SAE: P0121 P012A11 Turbocharger/Supercharger Inlet Pressure Sensor "A" Circuit Low Circuit Short to Ground - SAE: P012C P012A15 Turbocharger/Supercharger Inlet Pressure Sensor "A" Circuit High Circuit Short to Battery or Open - SAE: P012D P013616 A/F (O2) Sensor Circuit Bank 1 Sensor 2 Circuit Current (Voltage) Below Threshold Comes on SAE: P0136 P017100 System Too Lean Bank 1 Comes on SAE: P0171 P017200 System Too Rich Bank 1 Comes on SAE: P0172 P019011 Fuel Rail Pressure Sensor "A" Circuit Short to Ground Comes on SAE: P0192 P019015 Fuel Rail Pressure Sensor "A" Circuit Short to Battery or Open Comes on SAE: P0193 P019511 Engine Oil Temperature Sensor Circuit Short to Ground - SAE: P0197 P019515 Engine Oil Temperature Sensor Circuit Short to Battery or Open - SAE: P0198 P020113 Cylinder 1 Injector "A" Circuit Open Comes on SAE: P0201 P020213 Cylinder 2 Injector "A" Circuit Open Comes on SAE: P0202 P020313 Cylinder 3 Injector "A" Circuit Open Comes on SAE: P0203 P022011 Throttle/Pedal Position Sensor/Switch "B" Circuit Short to Ground Comes on SAE: P0222 P022015 Throttle/Pedal Position Sensor/Switch "B" Circuit Short to Battery or Open Comes on SAE: P0223 P023400 Turbocharger/Supercharger "A" Overboost Condition - SAE: P0234 P023511 Turbocharger/Supercharger Boost Sensor "A" Circuit Short to Ground Comes on SAE: P0237 P023515 Turbocharger/Supercharger Boost Sensor "A" Circuit Short to Battery or Open Comes on SAE: P0238 P02351C Turbocharger/Supercharger Boost Sensor "A" Circuit Voltage Out of Range - SAE: P0236 P024313 Turbocharger/Supercharger Wastegate Solenoid "A" Circuit Open Does not come on SAE: P0243 P030000 Random/Multiple Cylinder Misfire Detected Comes on/Blinks* *: The MIL flashes when a catalyst-damaging misfire is detected...

    Categories

    Turning the Engine Off

    Stop the vehicle completely. Manual transaxle: Shift into neutral and set the parking brake.

    Automatic transaxle: Shift the selector lever to the P position and set the parking brake.

    Press the push button start to turn off the engine. The ignition position is off.

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