Page 788 of 969
A78528
(d)
(d)
A78525
1
2
A86248
1
2
3
Air Cleaner
CaseAir Cleaner
Inlet No. 1
(b)
(d)
(e)
(b)
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-7
2339 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Remove the 2 bolts, then remove the starter.
9. INSTALL STARTER ASSY
Torque:
37 NVm (380 kgfVcm, 26 ftVlbf) for bolt
9.8 NVm (100 kgfVcm, 7 ftVlbf) for nut
10. INSTALL AIR CLEANER INLET NO.1
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
11. INSTALL AIR CLEANER BRACKET
(a) Install the air cleaner bracket with the 2 bolts. Using sev-
eral steps, tighten the bolts uniformly in the sequence
shown in the illustration.
Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf)
12. INSTALL AIR CLEANER ASSY
(a) Install the air cleaner case to the air cleaner inlet No. 1 as
shown in the illustration.
(b) Install the wire harness to the 2 wire harness clamps.
(c) Using several steps, tighten the 3 bolts uniformly in the
sequence shown in the illustration.
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
(d) Connect the vacuum hose.
(e) Connect the VSV connector.
(f) Install the air cleaner filter element.
(g) Install the air cleaner cap, then tighten the air cleaner
hose clamp bolt.
(h) Tighten the 2 air cleaner cap bolts.
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
(i) Connect the 4 vacuum hoses.
(j) Connect the mass air flow meter connector.
Page 789 of 969
19-8
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2340 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. INSTALL BATTERY TRAY
14. INSTALL BATTERY
Torque:
9.0 NVm (92 kgfVcm, 79 in.Vlbf) for bolt
3.5 NVm (36 kgfVcm, 31 in.Vlbf) for nut
5.4 NVm (55 kgfVcm, 48 in.Vlbf) for terminal
15. INSTALL AIR CLEANER INLET ASSY
Torque: 5.0 NVm (55 kgfVcm, 44 in.Vlbf)
16. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
17. INSTALL RADIATOR SIDE DEFLECTOR RH
18. SYSTEM INITIALIZATION (See page 19-15)
Page 790 of 969
190SH-01
A79718
A79719
A79720
A79721
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-9
2341 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE STARTER MAGNETIC SWITCH ASSY
(a) Remove the nut, then disconnect the lead wire from termi-
nal C.
(b) Remove the 2 screws which secure the starter magnetic
switch to the starter drive housing.
(c) Remove the starter magnetic switch.
(d) Remove the return spring and plunger from the starter
drive housing.
2. REMOVE STARTER FIELD FRAME ASSY
(a) Remove the 2 through bolts, then pull out the field frame
together with the starter commutator end frame.
(b) Remove the starter field frame from the starter commuta-
tor end frame.
Page 791 of 969
A79722
A79723
A82440
Snap Ring
Pliers
A81167
A58586
19-10
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2342 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
3. REMOVE STARTER ARMATURE PLATE
(a) Remove the starter armature plate from the starter field
frame.
4. REMOVE STARTER COMMUTATOR END FRAME
COVER
(a) Using a screwdriver, remove the starter commutator end
frame cover.
5. REMOVE STARTER ARMATURE ASSY
(a) Using snap ring pliers, remove the snap ring and plate
washer.
(b) Remove the starter armature from the commutator end
frame.
6. REMOVE PLANETARY GEAR
(a) Remove the 3 planetary gears from the starter drive hous-
ing.
7. INSPECT STARTER MAGNETIC SWITCH ASSY
(a) Check the operation.
(1) Push in the plunger, then check that it returns quick-
ly to its original position.
If necessary, replace the starter magnetic switch.
Page 792 of 969
A88413
Terminal C
Ohmmeter
Terminal 50
A88414
Terminal 50Ohmmeter Body
A88416
Ohmmeter
Segment
A88417
Ohmmeter
CommutatorCoil Core
A58584
Depth
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-1 1
2343 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Check the continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 50 and C.
If there is no continuity, replace the starter magnetic switch.
(2) Using an ohmmeter, check that there is continuity
between terminal 50 and the body.
If there is no continuity, replace the starter magnetic switch.
8. INSPECT STARTER ARMATURE ASSY
(a) Check the continuity.
(1) Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segments, replace the
starter armature.
(2) Using an ohmmeter, check that there is no continu-
ity between the commutator and armature coil core.
If there is continuity, replace the starter armature.
(b) Check the appearance.
(1) Check the commutator surface for dirt or burn.
If the surface is dirty or burnt, smooth the surface with 400-grit
sandpaper or a lathe.
(c) Inspect the depth.
(1) Using vernier calipers, measure the commutator
depth.
Standard depth: 3.1 mm (0.122 in.)
Maximum depth: 3.8 mm (0.150 in.)
If the depth is greater than maximum, replace the starter arma-
ture.
Page 793 of 969
A76677
Length
A88418
Ohmmeter
A81655
FreeLock
A81656
Apply Grease
A82440
Snap Ring
Pliers
19-12
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2344 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSPECT STARTER COMMUTATOR END FRAME
ASSY
(a) Inspect the length.
(1) Using vernier calipers, measure the brush length.
Standard length: 9.0 mm (0.354 in.)
Minimum length: 4.0 mm (0.158 in.)
If the length is less than minimum, replace the starter commuta-
tor end frame.
(b) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between the positive (+) and negative (- )
brushes.
If there is continuity, repair or replace the starter commutator
end frame.
10. INSPECT STARTER DRIVE HOUSING ASSY (W/
CLUTCH & DRIVE LEVER & CENTER BEARING)
(a) Check the operation.
(1) Rotate the clutch pinion gear counterclockwise,
then check that it turns freely. Try to rotate the clutch
pinion gear clockwise and check that it locks.
If necessary, replace the starter drive housing.
11. INSTALL PLANETARY GEAR
(a) Apply grease to the planetary gears and pin parts of the
planetary shaft.
(b) Install the 3 planetary gears to the starter drive housing.
12. INSTALL STARTER ARMATURE ASSY
(a) Apply grease to the plate washer and armature shaft.
(b) Install the starter armature to the starter commutator end
frame.
(c) Using snap ring pliers, install the plate washer and a new
snap ring.
Page 794 of 969
A58810
Length
A81178
A73991
keyway
Key
A79727
Rubber
Cutout
A79728Key Keyway
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-13
2345 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Inspect the length.
(1) Using vernier calipers, measure the snap ring
length.
Maximum length: 5.0 mm (0.197 in.)
If the length is greater than maximum, replace it with a new snap
ring.
13. INSTALL STARTER COMMUTATOR END FRAME
COVER
(a) Install the starter commutator end frame cover to the
starter commutator end frame.
14. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter field frame.
(b) Align the keyway of the starter plate with the key inside the
starter yoke, then install the starter plate.
15. INSTALL STARTER COMMUTATOR END FRAME
ASSY
(a) Align the rubber with the cutout of the starter field frame.
(b) Install the starter commutator end frame to the starter field
frame.
16. INSTALL STARTER FIELD FRAME ASSY
(a) Align the key of the starter field frame with the keyway of
the starter drive housing.
Page 795 of 969
A79720
A79729
A79719
A79718
19-14
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2346 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the starter field frame with the 2 through bolts.
Torque: 6.0 NVm (61 kgfVcm, 53 in.Vlbf)
17. INSTALL STARTER MAGNETIC SWITCH ASSY
(a) Apply grease to the plunger and hook.
(b) Hook the plunger hook of the starter magnetic switch on
the drive lever.
(c) Install the plunger and return spring.
(d) Install the starter magnetic switch with the 2 screws.
Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf)
(e) Connect the lead wire to terminal C with the nut.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)
