REMOVAL & INSTALLATION
| WARNING | Deactivate air bag system before performing any service operation. See AIR BAG RESTRAINT SYSTEMS article. DO NOT apply electrical power to any component on steering column without first deactivating air bag system. Air bag may deploy. |
Removal & Installation (ES300)
Disconnect battery cables. Remove battery and battery tray. (Scheme 4) Remove cruise control actuator. Disconnect starter wiring. Remove starter bolts and starter. To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS.
Scheme 4
Removal & Installation (GS300 & SC300)
Disconnect negative battery cable. On all models, disconnect wiring, remove starter bolts and remove starter. To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .
Note. On GS400, LS400 and SC400, starter is located under lower intake manifold, at rear of engine.
Removal (GS400, LS400 & SC400)
- Disconnect negative battery cable. Remove oil pan guard and engine undercover. Drain cooling system. Remove battery cover. Remove air cleaner inlet. Remove throttle body cover. Remove air cleaner and air intake assembly. Disconnect hose bracket from left upper timing belt cover. Remove left timing belt cover.
- Disconnect accelerator, cruise control and automatic transmission throttle cable(s). Remove accelerator bracket. Disconnect all wire connectors, hoses, and tubes necessary for removal of intake manifold assembly.
- Disconnect fuel delivery and fuel return hoses from fuel rails. Remove data link connector and 2 engine wiring harness connectors from bracket on left fuel rail. Remove 2 bolts, and engine wiring harness protector from right fuel rail. Remove 2 bolts, and wire harness protector from water by-pass pipe.
- Remove 2 bolts attaching fuel return pipe to left cylinder head. Disconnect fuel injector wiring harness connectors. Remove 6 bolts, and 4 nuts attaching intake manifold to cylinder heads. Remove intake manifold assembly and gaskets.
- Disconnect heater hoses from coolant by-pass pipe and remove by-pass pipe. Remove rear coolant by-pass manifold and gaskets. Disconnect starter wiring. Remove 2 starter bolts and starter.
Installation
To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Ensure White mark on intake manifold gasket faces upward. Fill cooling system. Start engine and check for coolant, vacuum and fuel leaks.
Scheme 5
Scheme 6
Scheme 7
| Application | Specification | |
|---|---|---|
| Brush Length | ||
| Standard | .61" (15.5 mm) | |
| Minimum | .39" (10.0 mm) | |
| Brush Spring Tension | 3.9-5.3 Lbs. (1.8-2.4 kg) | |
| Commutator Diameter | ||
| Standard | 1.18" (30.0 mm) | |
| Minimum | 1.14" (29.0 mm) | |
| Commutator Mica Undercut (Minimum) (1) | .008" (.20 mm) | |
| Commutator Runout (Maximum) | .002" (.05 mm) | |
| (1) Depth of groove between each segment of commutator. | ||
| (1) | Depth of groove between each segment of commutator. |
STARTER SPECIFICATIONS (ES300, GS300 & SC300)
| Application | Specification | |
|---|---|---|
| Brush Length | ||
| Standard | .59" (15.0 mm) | |
| Minimum | .35" (9.0 mm) | |
| Brush Spring Tension | 4.8-6.2 Lbs. (2.2-2.8 kg) | |
| Commutator Diameter | ||
| Standard | 1.38" (35.0 mm) | |
| Minimum | 1.34" (34.0 mm) | |
| Commutator Mica Undercut (Minimum) (1) | .008" (.20 mm) | |
| Commutator Runout (Maximum) | .002" (.05 mm) | |
| (1) Depth of groove between each segment of commutator. | ||
| (1) | Depth of groove between each segment of commutator. |
STARTER SPECIFICATIONS (GS400, LS400 & SC400)