Starting (Service Information): Overview Lexus ES XV40 facelift

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 11»(/lexus/es/xv40-facelift-2009-2012/remont/mechanical/#engine-mechanical-service-information)
3. REMOVE ENGINE ROOM SIDE COVER LH . Refer to «REMOVAL - Step 12»(/lexus/es/xv40-facelift-2009-2012/remont/mechanical/#engine-mechanical-service-information)
4. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 14»(/lexus/es/xv40-facelift-2009-2012/remont/mechanical/#engine-mechanical-service-information)
5. REMOVE NO. 2 AIR CLEANER INLET . Refer to «REMOVAL - Step 16»(/lexus/es/xv40-facelift-2009-2012/remont/mechanical/#engine-mechanical-service-information)
6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY. Refer to «REMOVAL - Step 8»(ref-396635-S18276233402011050900000)
7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to «REMOVAL - Step 18»(/lexus/es/xv40-facelift-2009-2012/remont/mechanical/#engine-mechanical-service-information)
8. REMOVE NO. 1 AIR CLEANER INLET . Refer to «REMOVAL - Step 19»(/lexus/es/xv40-facelift-2009-2012/remont/mechanical/#engine-mechanical-service-information)
9. REMOVE STARTER ASSEMBLY 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 MAGNETIC SWITCH ASSEMBLY Remove the nut and disconnect the lead wire from terminal C. Remove the 2 screws that hold the magnetic switch assembly to the motor terminal starter kit. Remove the magnetic switch assembly. Remove the return spring and the plunger from the magnetic switch assembly.
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.
3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY Remove the starter yoke assembly from the starter commutator end frame assembly.
4. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly.
5. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the starter commutator end frame cover.
6. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and plate washer. Remove the starter armature assembly from the commutator end frame assembly.
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing assembly.

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1. INSPECT STARTER ASSEMBLY WARNING: Make sure to complete each of the following tests within 5 seconds to prevent the coil from burning out. Perform pull-in test: Disconnect the lead wire from terminal C. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward. If the clutch pinion gear does not move outward, replace the repair service starter kit. Perform hold-in test: Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the repair service starter kit. Inspect clutch pinion gear return: Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward. If the clutch pinion gear does not move inward, replace the repair service starter kit. 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. Connect the battery and an ammeter to the starter as shown in the illustration. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current Condition Specified condition at 11.5 V 90 A or less If the result is not as specified, overhaul the starter assembly.
2. INSPECT MAGNETIC SWITCH ASSEMBLY Check the plunger. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnetic switch assembly. Inspect the resistance of the pull-in coil. Using an ohmmeter, measure the resistance between terminals 50 and C. Standard resistance Tester connection Specified condition Terminal 50 - Terminal C Below 1 ohms If the resistance is not as specified, replace the magnetic switch assembly. Inspect the resistance of the hold-in coil. Using an ohmmeter, measure the resistance between terminal 50 and switch body. Standard resistance Tester connection Specified condition Terminal 50 - Switch body Below 2 ohms If the resistance is not as specified, replace the magnetic switch assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY Check the commutator surface for dirt or burning. If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather. Inspect the resistance of the commutator. Using an ohmmeter, measure the resistance between the segments of the commutator. Standard resistance Tester connection Specified condition Segment - Segment Below 1 ohms If the resistance is not as specified, replace the starter armature assembly. Using an ohmmeter, measure the resistance between the commutator and armature coil core. Standard resistance Tester connection Specified condition Commutator - Armature coil core 10 kohms or higher If the resistance is not as specified, replace the starter armature assembly. Using vernier calipers, measure the commutator depth. Specified depth 3.1 mm (0.122 in.) Maximum depth 3.8 mm (0.150 in.) If the depth is greater than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Check the brush length. Using vernier calipers, measure the brush length. Specified length 9.0 mm (0.354 in.) Maximum 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. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes. Resistance 10 kohms or higher If the resistance is not as specified, repair or replace the starter commutator end frame assembly.
5. INSPECT STARTER CLUTCH 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. 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. Install the 3 planetary gears to the starter drive housing assembly.
2. INSTALL STARTER ARMATURE ASSEMBLY Apply high-temperature grease to the plate washer and the armature shaft. Install the starter armature assembly to the starter commutator end frame assembly. Using snap ring pliers, install the plate washer and a new snap ring. 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 with a new one.
3. INSTALL STARTER COMMUTATOR END FRAME COVER Install the starter commutator end frame cover to the starter commutator end frame assembly.
4. INSTALL STARTER ARMATURE PLATE Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate.
5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the starter commutator end frame rubber with the groove of the starter yoke assembly. 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 groove inside the motor terminal starter kit. Install the starter yoke with the 2 through bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
7. INSTALL MAGNETIC SWITCH ASSEMBLY Apply high-temperature grease to the plunger and the hook. Hang the plunger hook of the magnetic switch assembly to the drive lever hook. Install the plunger and the return spring. Install the repair magnetic switch assembly 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)

See also:
• REMOVAL - Step 11
• REMOVAL - Step 26