Lexus RX300 (MCU15). Service manual — part 507

B01229

Starter Housing

Starter
Clutch

Compression
Spring

Clutch
Shaft

B01230

B01231

B01670

Spring
Retainer

Pinion
Gear

Stop
Collar

Compression
Spring

B01232

B01233

ST–12

–

STARTING

STARTER

LEXUS RX300 (RM785E)

(b)

Assemble the starter housing and the clutch assembly
(1)

Assemble the starter housing.

(2)

Assemble the starter clutch.

(3)

Assemble the compression spring.

(4)

Assemble the clutch shaft.

(5)

Mount a brass bar in a vise, install the starter hous-
ing and clutch assembly to the brass bar.

(6)

Push down the starter housing, and install the
spring retainer, compression spring, pinion gear
and stop collar.

(7)

Push down the pinion gear.

(8)

Using snap ring pliers, install a new snap ring.

(9)

Using pliers, compress the snap ring.

(10) Check that the snap ring fits correctly.

B01165

P10595

SST

P10596

SST

Upward

Downward

P10593

SST

P10594

–

STARTING

STARTER

ST–13

LEXUS RX300 (RM785E)

(11) Remove the starter housing and clutch assembly

from the brass bar.

(12) Using a plastic–faced hammer, tap the clutch shaft

and install the stop collar onto the snap ring.

2.

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

3.

REPLACE REAR BEARING

(a)

Using SST, remove the bearing.
SST

09286–46011

(b)

Using a press, press in a new bearing.

B01234

B01235

B01236

SST

B11400

(1)

(2)

(3)

(4)

(5)

(6)

Long

Short

Inside

(7)

ST–14

–

STARTING

STARTER

LEXUS RX300 (RM785E)

4.

REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS

(a)

Remove the 3 bolts, end cover, gasket and the plunger.

(b)

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.

(c)

Remove the terminal kit parts.
(1)

Using SST, loosen the terminal nuts.

SST

09810–38140

(2)

Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O–ring, terminal bolt, contact
plate and terminal insulator (inside).

(3)

Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O–ring, terminal bolt,
contact plate, terminal insulator (inside) and insula-
tion paper.

(d)

Temporarily install these new terminal 30 kit parts:
(1)

Install the new terminal insulator (inside).

(2)

Install the new contact plate.

(3)

Install the new terminal bolt.

(4)

Install the new O–ring.

(5)

Install the new packing and terminal insulator (out-
side).
Install the packing to the terminal insulator, and
install them.

B01238

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Long

Short

(7)

Inside

Lead Terminal

B01239

40 mm

Wooden Block

Contact Plate

20 mm

37 mm

(kgf/cm

2

) =

100 kgf

Ram diameter (cm)

2

x 3.14 (π)

2

Ram diameter (in.)

2

x 3.14 (π)

2

(psi) =

221 lbf

(kPa) =

x 98.1

x 6.9

(kgf/cm

2

)

(kPa) = (psi)

–

STARTING

STARTER

ST–15

LEXUS RX300 (RM785E)

HINT:
Match the protrusion of the insulator with the indentation of the
housing.

(6)

Install the new wave washer.

(7)

Install the new terminal nut.

NOTICE:
Be careful to install the terminal insulators
(inside) and wave washers in the correct direction.

(e)

Temporarily install these new terminal C kit parts:
(1)

Install the new terminal insulator (inside).

(2)

Install the new contact plate.

(3)

Install the new terminal bolt.

(4)

Install the new O–ring.

(5)

Install the new terminal insulator (outside).

(6)

Install the new wave washer.

(7)

Install the new terminal nut.

NOTICE:
Be careful to install the terminal insulators
(inside) and wave washers in the correct direction.
(f)

Temporarily tighten the terminal nuts.

(g)

Tighten terminal nuts.
(1)

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:

S

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: