Lexus ES300 (1997 year). Service manual — part 546
P10593
SST
P10594
A13164
P10595
SST
P10596
Upward
Downward
SST
ST–12
–
STARTING
STARTER
996
1997 LEXUS ES300 (RM511U)
16.
IF NECESSARY, REPLACE REAR BEARING
(a)
Using SST, remove the bearing.
SST
09286–46011
(b)
Using a press, press in a new bearing.
17.
INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
18.
IF NECESSARY, REPLACE FRONT BEARING
(a)
Using SST, remove the bearing.
SST
09286–46011
(b)
Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST
09820–00030
S05059
Terminal 50
Ohmmeter
Terminal C
Continuity
S05060
Terminal 50
Ohmmeter
Continuity
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ST–13
997
1997 LEXUS ES300 (RM511U)
19.
INSPECT MAGNETIC SWITCH PULL–IN COIL OPEN
CIRCUIT
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
20.
INSPECT MAGNETIC SWITCH HOLD–IN COIL OPEN
CIRCUIT
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
S05061
ST01C–04
S05062
S05063
SST
S06115
ST–14
–
STARTING
STARTER
998
1997 LEXUS ES300 (RM511U)
REPLACEMENT
1.
REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, end cover, gasket and plunger.
2.
INSPECT CONTACT PLATE FOR WEAR
Using vernier calipers, measure the contact plate for depth of
wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
3.
REMOVE TERMINAL KIT PARTS
(a)
Using SST, loosen the terminal nuts.
SST
09810–38140
(b)
Terminal C:
Remove the terminal nut, wave washer, terminal insulator
(outside), O–ring, terminal bolt, contact plate and terminal
insulator (inside).
(c)
Terminal 30:
Remove the terminal nut, wave washer, terminal insulator
(outside), packing, O–ring, terminal bolt, contact plate,
terminal insulator (inside) and insulation paper.
4.
REINSTALL TERMINAL KIT PARTS
(a)
Terminal 30:
Install these new parts:
(1)
Insulation paper
(2)
Terminal insulator (inside)
(3)
Contact plate
(4)
Terminal bolt
(5)
O–ring
(6)
Packing and terminal insulator (outside):
Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7)
Wave washer
(8)
Terminal nut
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
S06116
Long
Short
(7)
(4) (5) (6)
(3)
(2) (1)
→
Inside
S00254
Wooden
Block
Contact Plate
(kgf/cm
2
) =
Ram diameter (cm)
100 kgf
2
x 3.14 (
π
)
2
(psi) =
Ram diameter (in.)
221 lbf
2
x 3.14 (
π
)
2
(kpa) = (kgf/cm
2
) x 98.1
(kpa) = (psi) x 6.9
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999
1997 LEXUS ES300 (RM511U)
(b)
Terminal C:
Install these new parts:
(1)
Terminal insulator (inside)
(2)
Contact plate
(3)
Terminal bolt
(4)
O–ring
(5)
Terminal insulator (outside)
(6)
Wave washer
(7)
Terminal nut
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
(c)
Temporarily tighten the terminal nuts.
5.
TIGHTEN TERMINAL NUT
(a)
Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:
Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when 981 N
(100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
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