Lexus ES300 (1997 year). Service manual — part 544

ST019–02

S05058

ST–4

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STARTING

STARTER

988

1997 LEXUS ES300 (RM511U)

REMOVAL

1.

REMOVE BATTERY AND TRAY

2.

w/ CRUISE CONTROL SYSTEM:
REMOVE CRUISE CONTROL ACTUATOR

(a)

Disconnect the actuator connector and clamp.

(b)

Remove the 3 bolts, and disconnect the actuator with the
bracket.

3.

REMOVE STARTER

(a)

Disconnect the starter connector.

(b)

Remove the nut, and disconnect the starter wire.

(c)

Remove the 2 bolts and starter.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

ST01A–03

S05343

S05344

S05345

P13527

(1)

(4)

(3)

(2)

P13743

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ST–5

989

1997 LEXUS ES300 (RM511U)

DISASSEMBLY

1.

REMOVE DUST PROTECTOR

2.

REMOVE FIELD FRAME AND ARMATURE

(a)

Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

(b)

Remove the 2 through bolts.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

(c)

Pull out the field frame together with the armature.

NOTICE:
At the time of assembly, please refer to the following item.
Align the protrusion of the field frame with the groove of the
magnetic switch.
(d)

Remove the O–ring from the field frame.

3.

REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR

(a)

Remove the 2 screws.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

(b)

Remove these parts from the magnetic switch:
(1)

Starter housing and clutch assembly

(2)

Return spring

(3)

Idler gear

(4)

Bearing

4.

REMOVE STEEL BALL

Using a magnetic finger, remove the steel ball from the clutch
shaft hole.

P13718

P13528

ST–6

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990

1997 LEXUS ES300 (RM511U)

5.

REMOVE BRUSH HOLDER

(a)

Remove the 2 screws and end cover from the field frame.
Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf)

(b)

Remove the O–ring from the field frame.

(c)

Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush holder.

NOTICE:
At the time of assembly, please refer to the following item.
Check that the positive (+) lead wires are not grounded.
6.

REMOVE ARMATURE FROM FIELD FRAME

ST01B–05

P10584

Ohmmeter

Continuity

P10585

Ohmmeter

No Continuity

P10586

P10587

ST0040

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ST–7

991

1997 LEXUS ES300 (RM511U)

INSPECTION

1.

INSPECT COMMUTATOR FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.

2.

INSPECT COMMUTATOR FOR GROUND

Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3.

INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES

If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.

4.

INSPECT COMMUTATOR CIRCLE RUNOUT

(a)

Place the commutator on V–blocks.

(b)

Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)

If the circle runout is greater than maximum, correct it on a lathe.

5.

INSPECT COMMUTATOR DIAMETER

Using a vernier caliper, measure the commutator diameter.

Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.142 in.)

If the diameter is less than minimum, replace the armature.

6.

INSPECT UNDERCUT DEPTH

Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.

Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)

If the undercut depth is less than minimum, correct it with a
hacksaw blade.