Lexus ES300 (1997 year). Service manual - part 546

P10593

SST

P10594

A13164

P10595

SST

P10596

Upward

Downward

SST

ST–12

–

STARTING

STARTER

996

1997 LEXUS ES300   (RM511U)

16.

IF NECESSARY, REPLACE REAR BEARING

(a)

Using SST, remove the bearing.
SST

09286–46011

(b)

Using a press, press in a new bearing.

17.

INSPECT FRONT BEARING

Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.

18.

IF NECESSARY, 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

S05059

Terminal 50

Ohmmeter

Terminal C

Continuity

S05060

Terminal 50

Ohmmeter

Continuity

–

STARTING

STARTER

ST–13

997

1997 LEXUS ES300   (RM511U)

19.

INSPECT MAGNETIC SWITCH PULL–IN COIL OPEN
CIRCUIT

Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.

20.

INSPECT MAGNETIC SWITCH HOLD–IN COIL OPEN
CIRCUIT

Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

S05061

ST01C–04

S05062

S05063

SST

S06115

ST–14

–

STARTING

STARTER

998

1997 LEXUS ES300   (RM511U)

REPLACEMENT

1.

REMOVE MAGNETIC SWITCH END COVER

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

2.

INSPECT CONTACT PLATE FOR WEAR

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.

3.

REMOVE TERMINAL KIT PARTS

(a)

Using SST, loosen the terminal nuts.
SST

09810–38140

(b)

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

(c)

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

4.

REINSTALL TERMINAL KIT PARTS

(a)

Terminal 30:
Install these new parts:
(1)

Insulation paper

(2)

Terminal insulator (inside)

(3)

Contact plate

(4)

Terminal bolt

(5)

O–ring

(6)

Packing and terminal insulator (outside):
Install the packing to the terminal insulator, and
install them.

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

(7)

Wave washer

(8)

Terminal nut

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

S06116

Long

Short

(7)

(4) (5) (6)

(3)

(2) (1)

→

Inside

S00254

Wooden
Block

Contact Plate

(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

–

STARTING

STARTER

ST–15

999

1997 LEXUS ES300   (RM511U)

(b)

Terminal C:
Install these new parts:
(1)

Terminal insulator (inside)

(2)

Contact plate

(3)

Terminal bolt

(4)

O–ring

(5)

Terminal insulator (outside)

(6)

Wave washer

(7)

Terminal nut

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

Temporarily tighten the terminal nuts.

5.

TIGHTEN TERMINAL NUT

(a)

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 cal-
culate 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.