Lexus GS300/400 (2000 year). Manual — part 222

B01974

40 mm

Contact
Plate

20 mm

37 mm

Wooden
Block

(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

B01975

SST

ST–12

–

STARTING (2JZ–GE)

STARTER

1630

(f)

Temporarily tighten the terminal nuts.

(g)

Tighten the terminal nut
(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:

Check the diameter of the hand press ram. Then
calculate 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.

(2)

Using SST, tighten the nuts to the specified torque.

SST

09810–38140

Torque: 17 N·m (173 kgf·cm, 13 ft·lbf)

NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.

B01972

–

STARTING (2JZ–GE)

STARTER

ST–13

1631

(h)

Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.

(i)

Reinstall the plunger, new gasket, end cover and lead
clamp with the 3 bolts.
Torque: 2.5 N·m (26 kgf·cm, 22 in.·lbf)

ST053–01

ST–14

–

STARTING (2JZ–GE)

STARTER

1632

REASSEMBLY

Reassembly is in the reverse order of disassembly (See page

ST–5

).

HINT:
Use high–temperature grease to lubricate the bearings and gears when assembling the starter.

ST054–01

B01964

Terminal 50

Battery

Terminal C

B01965

Battery

Terminal C

Disconnect

B01966

Disconnect

Battery

B01967

Battery

Terminal 30

Terminal 50

Ammeter

–

STARTING (2JZ–GE)

STARTER

ST–15

1633

TEST

NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1.

DO PULL–IN TEST

(a)

Disconnect the field coil lead wire from terminal C.

(b)

Connect the battery to the magnetic switch as shown.
Check that the pinion gear moves outward.

2.

DO HOLD–IN TEST

While connected as above with the pinion gear out, disconnect
the negative (–) lead from terminal C.
Check that the pinion gear remains out.

3.

INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (–) lead from the starter body.
Check that the pinion gear returns inward.

4.

DO NO–LOAD PERFORMANCE TEST

(a)

Connect the battery and ammeter to the starter as shown.

(b)

Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current: 90 A or less at 11.5 V