Starting System (Service Information): Overhaul Lexus ES XV60

REASSEMBLY [06/2012 - ]

HINT

Use high-temperature grease to lubricate the bearings, gears and return spring when assembling the starter assembly.

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1. INSTALL PLANETARY GEAR Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft. TEXT IN ILLUSTRATION High-temperature grease Install the 3 planetary gears.
2. INSTALL STARTER ARMATURE ASSEMBLY Apply high-temperature grease to the armature shaft. TEXT IN ILLUSTRATION High-temperature grease Apply high-temperature grease to the washer and bearing as shown in the illustration. TEXT IN ILLUSTRATION High-temperature grease Install the starter armature assembly to the starter commutator end frame assembly. Using snap ring pliers, install the washer and a new snap ring. TEXT IN ILLUSTRATION *a Snap Ring Pliers NOTE: Be sure to install the snap ring in the armature shaft groove securely. Be sure to properly install the snap ring because it expands easily. Using a vernier caliper, measure the length of the snap ring. TEXT IN ILLUSTRATION *a Length Maximum length 5.0 mm (0.197 in.) If the length is greater than the maximum, replace it with a new snap ring.
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 Insert the starter armature plate to the starter yoke assembly. TEXT IN ILLUSTRATION *a Keyway *b Key Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.
5. INSTALL STARTER YOKE ASSEMBLY Align the rubber of the starter commutator end frame assembly with the cutout of the starter yoke assembly. TEXT IN ILLUSTRATION *a Cutout *b Rubber Install the starter commutator end frame assembly to the starter yoke assembly. NOTE: The magnet switch of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet switch to break. Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly. TEXT IN ILLUSTRATION *a Cutout *b Protrusion Install the starter yoke assembly with the 2 through-bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
6. INSTALL REPAIR SERVICE STARTER KIT Apply high-temperature grease to the plunger. TEXT IN ILLUSTRATION High-temperature grease Hang the hook of the plunger on the drive lever. Apply high-temperature grease to the return spring. TEXT IN ILLUSTRATION High-temperature grease Install the plunger and return spring. Install the magnet switch with the 2 screws. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the lead wire to the magnet switch with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)