STARTER REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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Operation After Replacing Starter (With i-stop)

Note
•  If the number of times the starter can operate exceeds the limit, or there is any malfunction of the i-stop system-related parts, the i-stop warning light (amber) flashes.In addition, DTCs are stored simultaneously.
•  To ensure reliability of the i-stop system, replace the starter with a new one if the number of times the starter can operate has exceeded the upper limit.
•  When replacing the starter, perform the following procedure: When replacing the PCM simultaneously, perform the PCM configuration first. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].) (See PCM CONFIGURATION (USING READ/WRITE FUNCTION) [SKYACTIV-G 2.5T].) (See PCM CONFIGURATION (USING AS-BUILT DATA) [SKYACTIV-G 2.5T].)

Vehicle Identification Number (VIN): JM0 TC*WLA*# 100001—300000, JM6 TC*WLA*# 100001—300000, JM5 TCAWY**# 100001—300000, JM7 TC*WLA*# 100001—300000, JMZ TB*WYA*# 100001—500000, JM7 TCAWY**# 100001—

Step

Action
1
Note
•  Perform the procedures from Step 1 to 5 within 2 min.
?  If the operation exceeds 2 min, switch the ignition off and repeat the procedures from Step 1.
Switch the ignition ON (engine off).
2
Apply the parking brake firmly.
3
Shift the selector lever to the N position.
4
Perform the following work with the brake pedal depressed.
1.  Depress and release the accelerator pedal 6 times.
2.  Verify that the i-stop indicator light (green) flashes.
•  If the light does not flash, switch the ignition off and repeat the procedure from Step 1.
3.  Depress and release the accelerator pedal 6 times.
4.  Verify that the i-stop indicator light (green) changes from flashing to illumination.
•  If the light does not change to illumination, switch the ignition off and repeat the procedure from Step 1.
5
Long-press the i-stop OFF switch.
Wait until the i-stop indicator light (green) turns off (for 5 s or more).
•  If the light does not turn off, switch the ignition off and repeat the procedure from Step 1.
6
Switch the ignition off.
7
Start the engine.
8
Verify that the i-stop warning light (amber) turns off.
•  If the light does not turn off, switch the ignition off and repeat the procedure from Step 1.
9
Switch the ignition off and disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
10
Verifying battery condition initialization setting (i-stop setting). (See BATTERY CONDITION INITIALIZATION SETTING (i-stop SETTING).)

Vehicle Identification Number (VIN): JM0 TC*WLA*# 300001—, JM6 TC*WLA*# 300001—, JM5 TCAWY**# 300001—, JM7 TC*WLA*# 300001—, JMZ TB*WYA*# 600001—

Step

Action
1
Note
•  Perform the procedures from Step 1 to 5 within 2 min.
?  If the operation exceeds 2 min, switch the ignition off and repeat the procedures from Step 1.
Switch the ignition ON (engine off).
2
Apply the parking brake firmly.
3
Shift the selector lever to the N position.
4
Depress and release the accelerator pedal 12 times with the brake pedal depressed.
5
Long-press the i-stop OFF switch (for 5 s or more).
6
Switch the ignition off.
7
Start the engine.
8
Verify that the i-stop warning light (amber) turns off.
•  If the light does not turn off, switch the ignition off and repeat the procedure from Step 1.
9
Switch the ignition off and disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
10
Verifying battery condition initialization setting (i-stop setting). (See BATTERY CONDITION INITIALIZATION SETTING (i-stop SETTING).)


Starter Removal/Installation

Warning
•  Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
•  When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the negative battery terminal before performing the following operation.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the air cleaner, air hose and fresh-air duct component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

3.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

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1
Terminal S connector
2
Terminal B cable
(See Terminal B cable disconnection note.)
3
Starter
(See Starter removal note.)
(See Starter installation note.)

Terminal B cable disconnection note

1.  Remove the two bolts shown in the figure. (Without i-ELOOP)

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2.  Set aside the wiring harness and wiring harness bracket as a single unit. (Without i-ELOOP)

3.  Disconnect the terminal B cable.


Starter removal note

1.  Remove the starter upper bolt from the vehicle upper side.

2.  Remove the wiring harness clips shown in the figure. (With i-ELOOP)

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3.  Remove the starter lower bolt and starter from the vehicle lower side.


Starter installation note

Caution
•  Do not overlap the starter with the end plate (area A shown in figure) when installing. If the starter is not correctly installed, the nut installed to the drive plate may contact the end plate causing abnormal noise.
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