2005 LEXUS ES300 Repair Manual

A86243
Starter Field Frame
Assy Starter Commutator End Frame Assy
Starter Magnetic Switch AssyDrive Housing
Starter Bearing Cover
Starter Armature Assy
Washer
Starter Drive Housing Assy
(w/ Clutch & Drive Lever
& Center Bearing)
7.5 (76, 66 in.Vlbf)
10 (102, 7)

Snap Ring

Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
Starter Armature Plate
Planetary GearStarter Assy
Starter Connector
x237 (380, 26)
9.8 (100, 7)
x2
6.0 (61, 53 in.Vlbf)
x2 19-4
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2336 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

190SG-01
A86308
A86245
(a)
(b)
(c)
(b)
(c)
A81652
(a)
(b)
(b)
(b)
(b)
(c)
(c)
(d)
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-5
2337 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. REMOVE RADIATOR SIDE DEFLECTOR RH
(a) Remove the 8 clips, then remove the radiator lower air de-
flector.
2. REMOVE AIR CLEANER INLET ASSY
(a) Remove the wire harness clamp.
(b) Remove the 2 vacuum hoses from the hose clamp.
(c) Remove the 2 bolts, then remove the air cleaner inlet.
3. REMOVE BATTERY
4. REMOVE BATTERY TRAY
5. REMOVE AIR CLEANER ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the 4 vacuum hoses.
(c) Loosen the 2 air cleaner cap bolts.
(d) Loosen the air cleaner hose clamp bolt, then remove the
air cleaner cap.
(e) Remove the air cleaner filter element.

A86307
(f)
(g)
(h)
(h)(h)
(i)(i)
A78525
A78526
A78527
Terminal Cap
(a)
(c) 19-6
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Disconnect the VSV connector.
(g) Disconnect the vacuum hose.
(h) Remove the 3 bolts.
(i) Remove the wire harness from the 2 wire harness clamps,
then remove the air cleaner case.
6. REMOVE AIR CLEANER BRACKET
(a) Remove the 2 bolts, then remove the air cleaner bracket.
7. REMOVE AIR CLEANER INLET NO.1
(a) Remove the bolt, then remove the air cleaner inlet No. 1.
8. REMOVE STARTER ASSY
(a) Disconnect the starter connector.
(b) Open the terminal cap.
(c) Remove the nut, then disconnect the starter wire.

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
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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.

19-8
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2340 Author
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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)

190SH-01
A79718
A79719
A79720
A79721
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-9
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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.

A79722
A79723
A82440
Snap Ring
Pliers
A81167
A58586
19-10
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2342 Author
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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.

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
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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.