Lexus SC300 / Lexus SC400. Manual - part 650

(g)  Connect the lead wire to terminal C, and install the nut.

PERFORMANCE TEST OF STARTER

NOTICE: These tests must be performed within 3 to 5 se-
conds to avoid burning out the coil.

1. 

PERFORM PULL–IN TEST
(a)  Disconnect the field coil lead wire from terminal C.
(b) Connect battery to the magnetic switch as shown.

Check that the pinion gear moves outward.

If the pinion gear does not move, replace the magnetic
switch.

2. 

PERFORM HOLD–IN TEST
While connected as above with the pinion gear out, discon-
nect the negative (–) lead from terminal C.
Check that the pinion gear remains out.
If the pinion gear returns inward, replace the magnetic switch.

3. 

INSPECT PLUNGER RETURN
Disconnect the negative (+) lead from the switch body. Check
that the pinion gear returns inward.
If the pinion gear does not return, replace the magnetic
switch.

4. 

PERFORM NO–LOAD PERFORMANCE TEST
(a)  Connect battery and ammeter to the starter as shown.
(b) Check 

that the starter rotates smoothly and steadily with

the pinion gear moving out.
Check the reading on the ammeter.

Standard amperage: 120 A or less at 11.5 V

ST–24

–

STARTING SYSTEM

Starter

INSTALLATION OF STARTER

(See Components on page 

ST–5

)

1. INSTALL 

STARTER

(a)  Connect the wire clamp to the wire bracket.
(b)  Connect the starter wire with the nut.
(c)  Connect the starter connector.

(d)  Install the starter with the two bolts.

Torque: 39 N

⋅

m (400 kgf

⋅

cm, 29 ft

⋅

lbf)

2. 

INSTALL REAR WATER BY–PASS JOINT
(a) Install 

four new gaskets and the water by–pass joint with

the four nuts.

Torque: 18 N

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

(b)  Install the bolt holding the water by–pass pipe to the LH

engine hanger.

3. INSTALL 

WATER 

BY–PASS 

PIPE

(a)  Install a new O–ring to the water by–pass pipe.
(b)  Apply soapy water to the O–ring.
(c)  Push in the water by–pass pipe end into the pipe hole

of the water pump.

(d)  Install the water by–pass pipe with the two bolts.

Torque: 18 N

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

4.  CONNECT HEATER WATER HOSES TO WATER

BY–PASS PIPE AND REAR WATER BY–PASS JOINT

–

STARTING SYSTEM

Starter

ST–25

5. INSTALL 

DELIVERY 

PIPES 

AND 

INTAKE 

MANIFOLD

ASSEMBLY
(a)  Place two new gaskets on the cylinder heads with the

white painted mark facing upward.

NOTICE: Align the port holes of the gasket and cylinder
head. Be careful of the installation direction.

(b)  Place the delivery pipes and intake manifold assembly

in position on the cylinder heads with the arrow mark on
the intake manifold facing forward.

NOTICE: Be careful of the installation direction.
(c)  Install the six mounting bolts and four mounting nuts.

Torque: 18 N

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

HINT: Use bolts 30 mm (1.18 in.) in length.

6. 

INSTALL FUEL RETURN PIPE
Install the return pipe with two new gaskets, union bolt and
bolt.

Torque (Union bolt):

35 N

⋅

m (360 kgf

⋅

cm, 26 ft

⋅

lbf)

7.  INSTALL ENGINE WIRE TO DELIVERY PIPES, REAR

WATER BY–PASS JOINT AND RH CYLINDER HEAD
(a)  Connect the eight injector connectors.
(b) Connect the two engine wire connectors to the

connector bracket on the LH delivery pipe.

ST–26

–

STARTING SYSTEM

Starter

(c)  Install the engine wire to the RH cylinder head with the

two bolts.

(d)  Install the engine wire to the rear water by–pass joint

with the two bolts.

(e)  Install the engine wire to the delivery pipes with the four

bolts.

8. 

INSTALL ENGINE WIRE TO INTAKE MANIFOLD
Install the engine wire with the two bolts.

9.  TEMPORARILY INSTALL EGR PIPE TO RH CYLINDER

HEAD
Temporarily install the EGR pipe with the bolt.

10. CONNECT 

FUEL RETURN HOSE TO FUEL RETURN PIPE

11.  CONNECT FUEL INLET HOSE TO LH DELIVERY PIPE

Using SST, connect the inlet hose with two new gaskets and
pulsation damper.
SST 09612–24014 (09617–24011)

Torque:   39 N

⋅

m (400 kgf

⋅

cm, 29 ft

⋅

lbf)

33 N

⋅

m (340 kgf

⋅

cm, 24 ft

⋅

lbf) for SST

HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).

–

STARTING SYSTEM

Starter

ST–27