Starting System (Service Information): Overview Lexus ES XV60

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1. PRECAUTION NOTE: After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to «PRECAUTION [06/2012 - ]»(ref-598449-S42461431542014021400000) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [06/2012 - ]»(ref-598449-S08309221792014021400000) .
3. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL [06/2012 - ] - Step 1»(ref-598617-S32838744702014021400000)
4. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 17»(ref-598588-S29832633602014021400000)
5. REMOVE INLET NO. 2 AIR CLEANER . Refer to «REMOVAL [06/2012 - ] - Step 18»(ref-598588-S29832633602014021400000)
6. REMOVE INLET NO. 1 AIR CLEANER . Refer to «REMOVAL [06/2012 - ] - Step 23»(ref-598588-S29832633602014021400000)
7. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 7»(ref-598604-S35516938872014021400000)
8. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
9. REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 21»(ref-598588-S29832633602014021400000)
10. REMOVE BATTERY . Refer to «REMOVAL [06/2012 - ] - Step 22»(ref-598588-S29832633602014021400000)
11. REMOVE STARTER ASSEMBLY Disconnect the connector. Open the cap, remove the nut and disconnect the wire harness. Remove the 2 bolts and starter assembly.

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1. REMOVE REPAIR SERVICE STARTER KIT Remove the nut and disconnect the lead wire from the magnet switch. Holding the magnet switch to the starter drive housing assembly, remove the 2 screws. Remove the magnet switch. Remove the return spring and plunger from the starter drive housing 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. Remove the starter yoke assembly from the starter commutator end frame assembly.
3. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly.
4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, pry out the starter commutator end frame cover.
5. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and washer. NOTE: Do not drop the starter armature assembly. TEXT IN ILLUSTRATION *1 Snap Ring Pliers Remove the starter armature assembly from the starter commutator end frame assembly.
6. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing assembly.

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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 became hot and cause injury. NOTE: Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out. Perform a pull-in test. Remove the nut and disconnect the lead wire from terminal C. Connect a battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear extends. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Terminal C If the clutch pinion gear does not extend, replace the repair service starter kit. Perform a hold-in test. While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended. TEXT IN ILLUSTRATION *1 Terminal C *a Disconnect If the clutch pinion gear returns inward, replace the repair service starter kit. Perform a clutch pinion gear return test. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward. TEXT IN ILLUSTRATION *a Disconnect If the clutch pinion gear does not return inward, replace the repair service starter kit. Perform a no-load performance test. Connect the lead 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 assembly in a vise. NOTE: Ensure that the starter is secured firmly in the vise to prevent it from falling out. Connect the battery and an ammeter to the starter assembly as shown in the illustration. NOTE: Do not allow any lead to get caught as the pinion gear operates. TEXT IN ILLUSTRATION *1 Terminal 30 *2 Terminal 50 Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Then measure the current. Standard current 90 A or less at 11.5 V If the result is not as specified, repair or replace the starter assembly.
2. INSPECT REPAIR SERVICE STARTER KIT Check the plunger. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the repair service starter kit. Check if the pull-in coil has an open circuit. TEXT IN ILLUSTRATION *1 Terminal C *2 Terminal 50 Measure the resistance between terminals 50 and C. Standard resistance Below 1 ohms If the result is not as specified, replace the repair service starter kit. Check if the hold-in coil has an open circuit. TEXT IN ILLUSTRATION *1 Terminal 50 *2 Switch Body Measure the resistance between terminal 50 and the switch body. Standard resistance Below 2 ohms If the result is not as specified, replace the repair service starter kit.
3. INSPECT STARTER ARMATURE ASSEMBLY HINT: If these is no continuity between any segments, replace the starter armature assembly. Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. Check if the commutator has an open circuit. TEXT IN ILLUSTRATION *1 Segment Measure the resistance between the segments of the commutator. Standard resistance Below 1 ohms If the result is not as specified, replace the starter armature assembly. Check if the commutator is grounded. TEXT IN ILLUSTRATION *1 Commutator *2 Armature Coil Core Measure the resistance between the commutator and armature coil core. Standard resistance 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Using a vernier caliper, measure the commutator length. TEXT IN ILLUSTRATION *a Length Standard length 3.1 mm (0.122 in.) Maximum length 3.8 mm (0.150 in.) If the length is greater than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Using a vernier caliper, measure the brush length. TEXT IN ILLUSTRATION *a Length Standard length 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.157 in.) If the length is less than the minimum, replace the starter commutator end frame assembly. Check the brush insulation. Measure the resistance between the positive (+) and negative (-) brushes. Standard resistance 10 kohms or higher If the result is not as specified, replace the starter commutator end frame assembly.
5. INSPECT 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. TEXT IN ILLUSTRATION *a Lock *b Free If necessary, replace the starter drive housing assembly.

See also:
• REMOVAL [06/2012 - ] - Step 4