Lexus GS300/400 (2000 year). Manual - part 224

ST04Z–01

B01960

B01981

Clamp
Bracket

ST–4

–

STARTING (2JZ–GE)

STARTER

1622

REMOVAL

REMOVE STARTER
(a)

Remove the rubber cap and nut, and disconnect the start-
er wire.

(b)

Disconnect the starter connector.

(c)

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

HINT:
At time of the installation, place refer to the following item.
When installing the upper bolt, tighten it together with the clamp
bracket.

ST050–01

B02814

B01647

B01959

B01970

(1)

(2)

(3)

(4)

(5)

ST0948

Magnetic Finger

–

STARTING (2JZ–GE)

STARTER

ST–5

1623

DISASSEMBLY
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.

HINT:
Align the protrusion of the field frame with the groove of the
magnetic switch.
(d)

Remove the O–ring from the field frame.

HINT:
At the time of installation, please refer to the following items.
Use a new O–ring.

3.

REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR

(a)

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

(b)

Remove these parts from the magnetic switch:
(1)

Starter housing

(2)

Return spring

(3)

Idler gear

(4)

Bearing

(5)

Clutch assembly

4.

REMOVE STEEL BALL

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

B01645

P10568

ST–6

–

STARTING (2JZ–GE)

STARTER

1624

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.

HINT:
At the time of installation, please refer to the following items.
Use a new O–ring.

(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:
Check that the positive (+) lead wires are not grounded.
6.

REMOVE ARMATURE FROM FIELD FRAME

ST051–01

P10584

Ohmmeter

Continuity

P10585

Ohmmeter

No Continuity

P10586

P10587

ST0040

–

STARTING (2JZ–GE)

STARTER

ST–7

1625

INSPECTION

1.

INSPECT ARMATURE COIL

(a)

Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.

If there is no continuity between any segment, replace the ar-
mature.

(b)

Check the commutator for ground.
Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.

If there is no continuity, replace the armature.
2.

INSPECT COMMUTATOR

(a)

Check the commutator for the dirty and burnt surfaces.

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

(b)

Check for the commutator circle runout.
(1)

Place the commutator on V–blocks.

(2)

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.

(c)

Using a vernier caliper, measure the commutator diame-
ter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.412 in.)

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

(d)

Check that the undercut depth is clean and free of foreign
materials. 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.