ES300 1992-1997

Starter

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Removal & Installation



Specific to:

Lexus ES300 1992-1997

  1. Disconnect the negative and positive battery cables.
    CAUTION
    On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

  2.  
  3. Remove the battery and tray.
  4.  
  5. On models with cruise control, remove the actuator cover, disconnect the electrical connector, and remove the cruise control actuator.
  6.  
  7. Disconnect the starter connector from the starter.
  8.  
  9. Remove the nut and disconnect the starter wire.
  10.  
  11. Remove the 2 bolts and starter.

    Click image to see an enlarged view

    Fig. Remove the starter

  12.  

To install:

  1. Installation is the reverse of removal. Tighten the mounting bolts to 27 ft. lbs. (37 Nm).
  2.  
  3. Verify proper starter operation.
  4.  

1mz-FE & 3vz-FE Engines
  1. Disconnect the negative and positive battery cables.
    CAUTION
    On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

  2.  
  3. Remove the battery from the vehicle by removing the battery clamp.
  4.  
  5. On models with cruise control, remove the actuator cover and disconnect the electrical connector.
  6.  
  7. Remove the three bolts and then lift out the cruise control actuator.
  8.  
  9. Disconnect the starter connector from the starter.
  10.  
  11. Remove the nut and disconnect the starter wire.
  12.  
  13. Support the starter by hand and remove the two mounting bolts.
  14.  
  15. Remove the starter from the transaxle.
  16.  

To install:

  1. Place the starter motor in the transaxle and support it by hand.
  2.  
  3. Install the two mounting bolts and torque them to 30 ft. lbs. (41 Nm).
  4.  
  5. Place the starter wire into position and tighten the nut.
  6.  
  7. Connect the electrical connector to the starter.
  8.  
  9. If removed, install the cruise control actuator and the three mounting bolts. Connect the electrical connector to the actuator and install the actuator cover.
  10.  
  11. Install the battery and tighten down the battery clamp.
  12.  
  13. Connect the negative and positive battery cables.
  14.  
  15. Verify proper starter operation.
  16.  

Testing



Specific to:

Lexus ES250 1990-1991

Lexus ES300 1992-1999


WARNING
These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

  1. Perform the pull-in test:
    1. Disconnect the field coil lead wire from terminal C.
    2.  
    3. Connect battery to the magnetic switch as shown.
    4.  
    5. Check that the clutch pinion gear moves outward.
    6.  
    7. If the clutch pinion gear does not move, replace the magnetic switch.

      Click image to see an enlarged view

      Fig. Perform the pull-in test

    8.  

  2.  
  3. Perform the hold-in test:
    1. While connected as above with the clutch pinion gear out, disconnect the negative lead from terminal C.
    2.  
    3. Check that the pinion gear remains out.
    4.  
    5. If the clutch pinion gear returns inward, replace the magnetic switch.

      Click image to see an enlarged view

      Fig. Perform the hold-in test

    6.  

  4.  
  5. Inspect plunger return:
    1. Disconnect the negative lead from the switch body.
    2.  
    3. Check that the clutch pinion gear returns inward.
    4.  
    5. If the clutch piston gear does not return, replace the magnetic switch.

      Click image to see an enlarged view

      Fig. Inspect plunger return

    6.  

  6.  
  7. Perform no-load performance test:
    1. Connect battery and ammeter to the starter as shown.
    2.  
    3. Check that the starter rotates smoothly and steadily with the clutch pinion gear moving out.
    4.  
    5. Check the reading on the ammeter. Standard amperage: 90 A or less at 11.5 V

      Click image to see an enlarged view

      Fig. Perform no-load performance test

    6.  

  8.  

 
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