Starting System (Service Information): Other Lexus IS III

PROCEDURE

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 [04/2013 - ]»(ref-665529-S00420865962014102400000)
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 [04/2013 - ]»(ref-665529-S01115916402014102400000)
3. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) Refer to «REMOVAL [04/2013 - ]»(ref-665769-S02231265312014102400000)
4. REMOVE STARTER ASSEMBLY Disconnect the starter connector. *1 Terminal Cap Open the terminal cap, remove the nut and disconnect the wire harness. Remove the 2 bolts and starter assembly.

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

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 COMMUTATOR END FRAME ASSEMBLY Remove the 2 through bolts, and pull out the starter yoke assembly together with the starter commutator end frame assembly.
3. REMOVE STARTER YOKE 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, pry out the starter commutator end frame cover.
6. REMOVE STARTER ARMATURE ASSEMBLY Hold the starter commutator end frame assembly in a vise between aluminum plates. NOTE: Do not overtighten the vise. Using snap ring pliers, remove the snap ring and washer. *a Snap Ring Pliers NOTE: Do not drop the starter armature assembly. Remove the starter armature assembly from the starter commutator end frame assembly.
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing assembly.
8. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Remove the starter center bearing clutch sub-assembly together with the drive lever set pin from the starter drive housing assembly. Remove the drive lever set pin from the starter center bearing clutch sub-assembly.

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

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: 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 moves outward. *a Starter Body *b Terminal 50 *c Terminal C Moves Outward If the clutch pinion gear does not move outward, replace the repair service starter kit. Perform a holding test. *a Terminal C Disconnect While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward. If the clutch pinion gear returns inward, replace the repair service starter kit. Perform a clutch pinion gear return test. Disconnect Returns Inward Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward. 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) Hold the starter assembly in a vise between aluminum plates. NOTE: Ensure that the starter assembly is secured in the vise to prevent it from falling out. Connect the battery and an ammeter to the starter assembly as shown in the illustration. *a Terminal 30 *b Terminal 50 Rotates NOTE: Do not allow any lead to get caught as the pinion gear operates. Check that the starter operates smoothly and steadily while the pinion gear is moving outward. Measure the current according to the value(s) in the table below. Standard Current Tester Connection Condition Specified Condition Battery positive terminal - Terminal 30 - Terminal 50 11.5 V 90 A or less If the result is not as specified, repair or replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY HINT: If there is no continuity between any segments, replace the starter armature assembly. Check the commutator appearance. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or on a lathe. Check the commutator for an open circuit. *a Segment Measure the resistance between the segments of the commutator. Standard Resistance Tester Connection Condition Specified Condition Segment - Segment Always Below 1 ohms If the result is not as specified, replace the starter armature assembly. Check the commutator for a short circuit. *a Commutator *b Armature Coil Core Measure the resistance between the commutator and armature coil core. Standard Resistance Tester Connection Condition Specified Condition Commutator - Coil core Always 10 kohms or higher If the result is not as specified, replace the starter armature assembly. Using a vernier caliper, measure the commutator length. *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.
3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY Using a vernier caliper, measure the brush length. *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. *a Positive (+) Brush *b Negative (-) Brush Measure the resistance between the positive (+) and negative (-) brushes. Standard Resistance Tester Connection Condition Specified Condition Positive (+) brush - Negative (-) brush Always 10 kohms or higher If the result is not as specified, replace the starter commutator end frame assembly.
4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage. If damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage. Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. *a Free *b Lock If necessary, replace the starter drive housing assembly.
5. 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 the pull-in coil for an open circuit. *a Terminal C *b Terminal 50 Measure the resistance between terminals 50 and C. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Terminal C Always Below 1 ohms If the result is not as specified, replace the repair service starter kit. Check the holding coil for an open circuit. *a Magnet Switch Body *b Terminal 50 Measure the resistance between terminal 50 and the magnet switch body. Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Magnet switch body Always Below 2 ohms If the result is not as specified, replace the repair service starter kit.

CAUTION / NOTICE / HINT

HINT

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

Scheme 34

Scheme 35

Scheme 36

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY Apply high-temperature grease to the drive lever set pin as shown in the illustration. High-temperature Grease Install the drive lever set pin onto the starter center bearing clutch sub-assembly. *1 Drive Lever Set Pin *2 Starter Center Bearing Clutch Sub-assembly Install the starter center bearing clutch sub-assembly with drive lever set pin to the starter drive housing assembly.
2. INSTALL PLANETARY GEAR Apply high-temperature grease to the planetary gears and planetary shaft pins. High-temperature Grease Install the 3 planetary gears.
3. INSTALL STARTER ARMATURE ASSEMBLY Hold the starter commutator end frame assembly in a vise between aluminum plates. NOTE: Do not overtighten the vise. Apply high-temperature grease to the new snap ring, washer and bearing as shown in the illustration. *1 Snap Ring *2 Washer *a Bearing High-temperature Grease Apply high-temperature grease to the armature shaft. 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. *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 opening. *a Length Maximum Length 5.0 mm (0.197 in.) If the length is greater than the maximum, replace the snap ring with a new one.
4. INSTALL STARTER COMMUTATOR END FRAME COVER Install the starter commutator end frame cover to the starter commutator end frame assembly.
5. INSTALL STARTER ARMATURE PLATE Insert the starter armature plate to the starter yoke assembly. *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.
6. INSTALL STARTER YOKE ASSEMBLY Align the rubber of the starter commutator end frame assembly with the cutout of the starter yoke assembly. *a Rubber *b Cutout 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.
7. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly. *a Protrusion *b Cutout Install the starter yoke assembly with the 2 through bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
8. INSTALL REPAIR SERVICE STARTER KIT Apply high-temperature grease to the plunger. *a hook High-temperature Grease Hang the hook of the plunger on the drive lever set pin. Apply high-temperature grease to the return spring. 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)

1. INSTALL STARTER ASSEMBLY Install the starter assembly with the 2 bolts. Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) Connect the wire harness, install the nut and close the terminal cap. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Connect the starter connector.
2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH(TWC: Front Catalyst) Refer to «INSTALLATION [04/2013 - ]»(ref-665769-S40226767822014102400000)
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [04/2013 - ]»(ref-665529-S01115916402014102400000)

Scheme 37

Scheme 38

1. REMOVE METER HOOD SUB-ASSEMBLY Refer to «PROCEDURE - Step 8»(ref-665740-S23835794282014102400000)
2. REMOVE ENGINE SWITCH Disengage the 2 claws and remove the engine switch.

Scheme 39

1. INSPECT ENGINE SWITCH Measure the resistance according to the value(s) in the table below. *a Component without harness connected (Engine Switch) Standard Resistance Tester Connection Switch Condition Specified Condition 5 (SS1) - 6 (AGND) 1 (SS2) - 6 (AGND) Not pushed 10 kohms or higher Pushed Below 1 ohms If the result is not as specified, replace the engine switch indicator light. Apply battery voltage between the terminals of the engine switch, and check the illumination condition of the engine switch indicator light. OK Measurement Condition Specified Condition Battery positive (+) --> Terminal 9 (SWIL) Battery negative (-) --> Terminal 6 (AGND) Illuminates HINT: If the positive (+) battery lead and negative (-) battery lead are incorrectly connected, the engine switch indicator light will not illuminate. If the voltage is too low, the engine switch indicator light will not illuminate. If the result is not as specified, replace the engine switch.

1. INSTALL ENGINE SWITCH Engage the 2 claws to install the engine switch.
2. INSTALL METER HOOD SUB-ASSEMBLY Refer to «INSTALLATION [04/2013 - ]»(ref-665740-S21056212972014102400000)

1. INSPECT ST RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 5 Battery voltage not applied between terminals 1 and 2 10 kohms or higher Battery voltage applied between terminals 1 and 2 Below 1 ohms If the resistance is not as specified, replace the ST relay.