Starting System (Service Information): Overview Lexus GX J150

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: w/ Navigation System: After the engine switch is turned off, the display and navigation module display (navigation system) records various types of memory and settings. As a result, after turning the engine switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) battery terminal. Waiting Time before Disconnecting Cable from Negative (-) Battery Terminal Condition Waiting Time Vehicle enrolled in safety connect system 6 minutes Vehicle not enrolled in safety connect system 1 minute When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-524109-S13936590332013012800000) .
2. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Remove the exhaust manifold sub-assembly RH. Refer to «REMOVAL»(/lexus/gx/j150-2009-2013/remont/exhaust/#exhaust-system-service-information) .
3. REMOVE STARTER COVER Remove the 3 bolts and starter cover.
4. REMOVE STARTER ASSEMBLY Detach the starter wire clamp. Remove the nut and disconnect the starter wire. Disconnect the starter connector. Remove the 2 bolts and starter.
5. REMOVE FLYWHEEL HOUSING SIDE COVER

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1. REMOVE MAGNET STARTER SWITCH ASSEMBLY Remove the nut and disconnect the lead wire from the magnet starter switch. Remove the 2 nuts and magnet starter switch.
2. REMOVE STARTER DRIVE HOUSING ASSEMBLY Using a T30 "TORX" socket wrench, remove the 2 bolts. Pull out the starter yoke and starter commutator end frame assembly together with the starter armature.
3. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Remove the starter pinion drive lever. Remove the starter center bearing clutch sub-assembly from the starter yoke.
4. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY Remove the 2 screws and starter commutator end frame. NOTE: While holding down the lead wire, remove the starter commutator end frame. Remove the dust starter protector from the starter commutator end frame.
5. REMOVE STARTER ARMATURE ASSEMBLY Disconnect the 4 brushes from the starter brush holder. Using a screwdriver, hold back the brush spring. Disconnect the brush from the starter brush holder. Remove the starter brush holder. Remove the starter armature from the starter yoke.
6. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter center bearing clutch. TEXT IN ILLUSTRATION *1 Starter Armature Plate
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter center bearing clutch.

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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 become hot and cause injury. NOTE: The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out. Mount the starter in a vise between aluminum plates. Perform a pull-in test. Remove the nut, and then disconnect the lead wire from terminal C. Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear extends. TEXT IN ILLUSTRATION *1 Terminal C *2 Terminal 50 If the clutch pinion gear does not move, replace the magnet starter switch assembly. Perform a holding test. Disconnect the negative (-) terminal lead from terminal C with the conditions specified in the pull-in test above being maintained. Check that the pinion gear remains out. TEXT IN ILLUSTRATION *1 Terminal C If the clutch pinion gear returns inward, replace the magnet starter switch assembly. Inspect the clutch pinion gear return. Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward. If the clutch pinion gear does not return inward, replace the magnet starter switch assembly. Perform an operation test without load. Connect the lead wire to terminal C with the nut. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) Connect the battery and an ammeter to the starter as shown in the illustration. TEXT IN ILLUSTRATION *1 Terminal 30 *2 Terminal 50 Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current. Standard current 190 A or less at 11.5 V If the result is not as specified, inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY Check the commutator for dirt and/or burns on the surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly. Inspect the commutator for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Segment Always Below 1 ohms TEXT IN ILLUSTRATION *1 Segment If the result is not as specified, replace the starter armature assembly. Inspect the commutator for a short circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Segment - Coil core Always 10 kohms or higher TEXT IN ILLUSTRATION *1 Segment *2 Coil Core If the result is not as specified, replace the starter armature assembly. Using a vernier caliper, measure the commutator diameter. Standard diameter 35.0 mm (1.38 in.) Minimum diameter 34.0 mm (1.34 in.) If the diameter is less than the minimum, replace the starter armature assembly. Check the commutator circle runout. Place the commutator on V-blocks. Using a dial indicator, measure the circle runout. Maximum commutator runout 0.05 mm (0.00197 in.) If the circle runout is more than the maximum, replace the starter armature assembly. Using a vernier caliper, measure the undercut depth of the commutator. Standard undercut depth 0.7 mm (0.0276 in.) Minimum undercut depth 0.2 mm (0.00787 in.) If the undercut depth is less than the minimum, replace the starter armature assembly.
3. INSPECT BRUSH Using a vernier caliper, measure the brush length. Standard length 15.0 mm (0.591 in.) Minimum length 9.0 mm (0.354 in.) TEXT IN ILLUSTRATION *A Brush Holder Side *B Starter Yoke Side *1 Length If the brush length is less than the minimum, replace the starter yoke assembly.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY Inspect the insulation. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Positive (+) brush holder - Negative (-) brush holder Always 10 kohms or higher If the result is not as specified, replace the starter yoke assembly. Check the brush spring load. Take a pull scale reading immediately after the brush spring separates from the brush. Standard spring installed load 22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf) Minimum spring installed load 12 N (1 kgf, 2.8 lbf) TEXT IN ILLUSTRATION *1 Brush *2 Brush Spring If the spring load is less than the minimum, replace the starter yoke assembly.
5. INSPECT STARTER YOKE ASSEMBLY Inspect the field coil for an open circuit. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Lead wire - Brush Always Below 1 ohms If the result is not as specified, replace the starter yoke assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Starter yoke body - Brush Always 10 kohms or higher If the result is not as specified, replace the starter yoke assembly.
6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage. If any planetary gear is damaged, replace the planetary gear assembly. If any gear of the starter center bearing clutch is damaged, replace the starter center bearing clutch sub-assembly. Check the movement of the clutch pinion gear. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks. TEXT IN ILLUSTRATION Free Lock If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.
7. INSPECT MAGNET STARTER SWITCH ASSEMBLY Inspect the pull-in coil. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminals 50 - Terminal C Always Below 1 ohms TEXT IN ILLUSTRATION *1 Terminal C *2 Terminal 50 If the result is not as specified, replace the magnet starter switch assembly. Inspect the holding coil. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Switch body Always Below 2 ohms TEXT IN ILLUSTRATION *1 Terminal 50 *2 Switch Body If the result is not as specified, replace the magnet starter switch assembly.

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1. INSTALL PLANETARY GEAR Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft as shown in the illustration. Install the 3 planetary gears to the starter center bearing clutch.
2. INSTALL STARTER ARMATURE PLATE Align the protrusion of the starter center bearing clutch sub-assembly with the notch of the starter armature plate. TEXT IN ILLUSTRATION *1 Protrusion *2 Notch Insert the starter armature plate to the starter center bearing clutch.
3. INSTALL STARTER ARMATURE ASSEMBLY Install the starter armature to the starter center bearing clutch.
4. INSTALL STARTER YOKE ASSEMBLY Align the protrusion of the starter center bearing clutch with the notch of the starter yoke and install the starter yoke. TEXT IN ILLUSTRATION *1 Protrusion *2 Notch
5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Install the starter brush holder. Connect the 4 brushes to the starter brush holder. Using a screwdriver, hold back the brush spring. Connect the brush to the starter brush holder. NOTE: Check that the positive (+) lead wires are not grounded. Install a new dust starter protector. Align the starter commutator end frame rubber with the groove of the starter yoke. TEXT IN ILLUSTRATION *1 Rubber *2 Groove Install the starter commutator end frame with the 2 screws. Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf)
6. INSTALL STARTER DRIVE HOUSING ASSEMBLY Apply high-temperature grease to the starter pinion drive lever as shown in the illustration. Install the starter pinion drive lever to the starter center bearing clutch. Align the protrusion of the starter center bearing clutch with the notch inside the starter drive housing. TEXT IN ILLUSTRATION *1 Protrusion *2 Notch Using a T30 "TORX" socket wrench, install the starter drive housing with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
7. INSTALL MAGNET STARTER SWITCH ASSEMBLY Temporarily install the magnet starter switch by hooking its tip onto the upper side of the starter pinion drive lever. Install the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the lead wire to terminal C with the nut. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf)

See also:
• REMOVAL
• REMOVAL - Step 18