Starting and Charging PDF

19-1
STARTING & CHARGING - STARTING SYSTEM (3MZ-FE)
STARTING SYSTEM (3MZ-FE)

190SE-01
INSPECTION
1. INSPECT STARTER ASSY

NOTICE:
These tests must be performed within 3 to 5 seconds to
prevent burnout of the coil.
(a) Perform the pull-in test.
(1) Remove the nut, then disconnect the lead wire from
terminal C.
A79718
(2) Connect the battery to the repair service starter kit

as shown in the illustration. Check that the clutch
Terminal C
pinion gear is extended.
If the clutch pinion gear does not move, replace the starter mag-
netic switch.
Body
Battery
Terminal 50 A86236
(b) Perform the hold-in test.

(1) Disconnect the negative (-) lead from terminal C
Disconnect
with the lead wire disconnected from terminal C.
Check that the clutch pinion gear remains ex-
tended.
If the clutch pinion gear returns inward, replace the starter mag-
netic switch.
Battery
Terminal C A86239
(c) Check the operation.

(1) Disconnect the negative (-) lead from the switch
Body
body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return inward, replace the
starter magnetic switch.
Disconnect
Battery
A86238
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Author: Date: 2333

19-2
STARTING & CHARGING - STARTING SYSTEM (3MZ-FE)
(d) Perform the no-load performance test.

(1) Connect the lead wire to terminal C. Make sure that
the lead is not grounded.
Torque: 10 Nm (102 kgfcm, 7 ftlbf)
A79718
(2) Clamp the starter in a vise.

Terminal 30 (3) Connect the battery and an ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily
Ammeter
with the clutch pinion gear extended. Check that the
ammeter reads the specified current.
Specified current: 90 A or less at 11.5 V
Body Battery If the current is not as specified, replace the starter.
Terminal 50
A86237
2. INSPECT STARTER RELAY ASSY

(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
Battery tween the terminals.
Ohmmeter Standard:
Tester Connection Specified Condition
3-5 10 k or higher
Below 1
3-5
(Apply battery voltage to terminals 1 and 2
A86241
If the result is not as specified, replace the starter relay.
Author: Date: 2334

19-3
STARTING & CHARGING - STARTER ASSY (3MZ-FE)
STARTER ASSY (3MZ-FE)

190SF-01
COMPONENTS
Clip
x7 Clip
Radiator Lower Air Deflector

9.0 (92, 79 in.lbf) Air Cleaner Hose
3.5 (36, 31 in.lbf) No. 1
Mass
Vacuum Hose Air Flow Meter
Connector
VSV Connector
Battery Clamp Sub-assy
Vacuum Hose
Battery
5.0 (51, 44 in.lbf)
5.0 (51, 44 in.lbf)
x2 Air Cleaner Cap
Sub-assy
x3
Air Cleaner Inlet
Assy Air Cleaner Filter
5.0 (51, 44 in.lbf)
Element Sub-assy
Battery Tray
5.0 (51, 44 in.lbf)

Air Cleaner Case
Air Cleaner Inlet
Sub-assy
No. 1
x2 7.5 (76, 66 in.lbf)
Air Cleaner Bracket
Nm (kgfcm, ftlbf) : Specified torque

A86242
Author: Date: 2335

19-4
Starter Assy
Starter Connector
9.8 (100, 7)
37 (380, 26)
x2
Starter Armature Assy

Starter Commutator End Frame Assy
Washer
Snap Ring
Drive Housing
Starter Bearing Cover
x2
Starter Magnetic Switch Assy

6.0 (61, 53 in.lbf)
10 (102, 7)
7.5 (76, 66 in.lbf) x2
Starter Drive Housing Assy

(w/ Clutch & Drive Lever Planetary Gear
& Center Bearing)
Starter Armature Plate
Starter Field Frame

Assy
Non-reusable part A86243
Author: Date: 2336

19-5
190SG-01
REPLACEMENT
1. REMOVE RADIATOR SIDE DEFLECTOR RH

(a) Remove the 8 clips, then remove the radiator lower air de-
flector.
A86308
2. REMOVE AIR CLEANER INLET ASSY

(a)
(a) Remove the wire harness clamp.
(b) Remove the 2 vacuum hoses from the hose clamp.
(c) (b) (c) Remove the 2 bolts, then remove the air cleaner inlet.
(b)
(c)
A86245
3. REMOVE BATTERY
4. REMOVE BATTERY TRAY
(b) 5. REMOVE AIR CLEANER ASSY

(d) (a)
(a) Disconnect the mass air flow meter connector.
(b) (b) Disconnect the 4 vacuum hoses.
(b) (b) (c) (c) Loosen the 2 air cleaner cap bolts.
(d) Loosen the air cleaner hose clamp bolt, then remove the
air cleaner cap.
(c)
(e) Remove the air cleaner filter element.
A81652
Author: Date: 2337

19-6
(f) Disconnect the VSV connector.

(i) (i) (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.
(g)
(f) (h)
(h)
(h)
A86307
6. REMOVE AIR CLEANER BRACKET

(a) Remove the 2 bolts, then remove the air cleaner bracket.
A78525
7. REMOVE AIR CLEANER INLET NO.1

(a) Remove the bolt, then remove the air cleaner inlet No. 1.
A78526
Terminal Cap 8. REMOVE STARTER ASSY

(c) (a) Disconnect the starter connector.
(b) Open the terminal cap.
(c) Remove the nut, then disconnect the starter wire.
(a)
A78527
Author: Date: 2338

19-7
(d) Remove the 2 bolts, then remove the starter.

(d)
(d)
A78528
9. INSTALL STARTER ASSY

Torque:
37 Nm (380 kgfcm, 26 ftlbf) for bolt
9.8 Nm (100 kgfcm, 7 ftlbf) for nut
10. INSTALL AIR CLEANER INLET NO.1
Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
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.
1 Torque: 7.5 Nm (76 kgfcm, 66 in.lbf)
A78525
12. INSTALL AIR CLEANER ASSY

(a) Install the air cleaner case to the air cleaner inlet No. 1 as
(b) (b)
(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.
(d) Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
(d) Connect the vacuum hose.
(e)
1 (e) Connect the VSV connector.
(f) Install the air cleaner filter element.
(g) Install the air cleaner cap, then tighten the air cleaner
3 hose clamp bolt.
2
(h) Tighten the 2 air cleaner cap bolts.
Air Cleaner
(i) Connect the 4 vacuum hoses.
Air Cleaner (j) Connect the mass air flow meter connector.
Case
Inlet No. 1
A86248
Author: Date: 2339

19-8
13. INSTALL BATTERY TRAY

14. INSTALL BATTERY
Torque:
9.0 Nm (92 kgfcm, 79 in.lbf) for bolt
3.5 Nm (36 kgfcm, 31 in.lbf) for nut
5.4 Nm (55 kgfcm, 48 in.lbf) for terminal
15. INSTALL AIR CLEANER INLET ASSY
16. CHECK CONNECTION OF VACUUM HOSE (See page 14-29 )
17. INSTALL RADIATOR SIDE DEFLECTOR RH
18. SYSTEM INITIALIZATION (See page 19-15 )
Author: Date: 2340

19-9
190SH-01
OVERHAUL
1. REMOVE STARTER MAGNETIC SWITCH ASSY

(a) Remove the nut, then disconnect the lead wire from termi-
nal C.
A79718
(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.
A79719
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.
A79720
(b) Remove the starter field frame from the starter commuta-
tor end frame.
A79721
Author: Date: 2341

19-10
3. REMOVE STARTER ARMATURE PLATE

(a) Remove the starter armature plate from the starter field
frame.
A79722
4. REMOVE STARTER COMMUTATOR END FRAME

COVER
(a) Using a screwdriver, remove the starter commutator end
frame cover.
A79723
5. REMOVE STARTER ARMATURE ASSY

Snap Ring (a) Using snap ring pliers, remove the snap ring and plate
Pliers washer.
(b) Remove the starter armature from the commutator end
frame.
A82440
6. REMOVE PLANETARY GEAR

(a) Remove the 3 planetary gears from the starter drive hous-
ing.
A81167
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.
A58586
Author: Date: 2342

19-1 1
(b) Check the continuity.

(1) Using an ohmmeter, check that there is continuity
Terminal C between terminals 50 and C.
Ohmmeter
If there is no continuity, replace the starter magnetic switch.
Terminal 50
A88413
Body (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.
Ohmmeter
Terminal 50
A88414
8. INSPECT STARTER ARMATURE ASSY

(a) Check the continuity.
Ohmmeter (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.
Segment A88416
(2) Using an ohmmeter, check that there is no continu-

ity between the commutator and armature coil core.
Ohmmeter 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.
Commutator Coil Core

A88417
(c) Inspect the depth.

(1) Using vernier calipers, measure the commutator
depth.
Standard depth: 3.1 mm (0.122 in.)
Depth Maximum depth: 3.8 mm (0.150 in.)
If the depth is greater than maximum, replace the starter arma-
ture.
A58584
Author: Date: 2343

19-12
9. INSPECT STARTER COMMUTATOR END FRAME

ASSY
(a) Inspect the length.
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.
A76677
(b) Check the continuity.

ity between the positive (+) and negative (- )
Ohmmeter
brushes.
If there is continuity, repair or replace the starter commutator
end frame.
A88418
10. INSPECT STARTER DRIVE HOUSING ASSY (W/

Lock 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.
Free
A81655
11. INSTALL PLANETARY GEAR

(a) Apply grease to the planetary gears and pin parts of the
Apply Grease
planetary shaft.
(b) Install the 3 planetary gears to the starter drive housing.
A81656
12. INSTALL STARTER ARMATURE ASSY

Snap Ring (a) Apply grease to the plate washer and armature shaft.
Pliers (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.
A82440
Author: Date: 2344

19-13
(d) Inspect the length.

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.
A58810
13. INSTALL STARTER COMMUTATOR END FRAME

COVER
(a) Install the starter commutator end frame cover to the
starter commutator end frame.
A81178
Key 14. INSTALL STARTER ARMATURE PLATE

(a) Insert the starter armature plate to the starter field frame.
keyway (b) Align the keyway of the starter plate with the key inside the
starter yoke, then install the starter plate.
A73991
Rubber 15. INSTALL STARTER COMMUTATOR END FRAME

Cutout 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.
A79727
16. INSTALL STARTER FIELD FRAME ASSY

(a) Align the key of the starter field frame with the keyway of
the starter drive housing.
Keyway Key
A79728
Author: Date: 2345

19-14
(b) Install the starter field frame with the 2 through bolts.
A79720
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.
A79729
(d) Install the starter magnetic switch with the 2 screws.

A79719
(e) Connect the lead wire to terminal C with the nut.

A79718
Author: Date: 2346

19-15
STARTING & CHARGING - CHARGING SYSTEM (3MZ-FE)
CHARGING SYSTEM (3MZ-FE)

190SI-01
PRECAUTION
1. SYSTEM INITIALIZATION
NOTICE:
When disconnecting the negative (-) battery terminal, initialize the following systems after the termi-
nal is reconnected.
System Name See Page
Power Window Control System 05-1470
Sliding Roof System 74-8
2. Check that the battery cables are connected to the correct terminals.
3. Disconnect the battery cables if a quick charge is given to the battery.
4. Do not perform tests with a high voltage insulation resistance tester.
5. Never disconnect the battery while the engine is running.
6. Check that the charging cable is tightened on terminal B of the generator and the fuse box.
7. Do not check whether the alternator generates current or not with terminal F connected to the
other terminals.
Author: Date: 2347

19-16
190SJ-01
ON-VEHICLE INSPECTION
1. INSPECT BATTERY (MAINTENANCE- FREE BAT-
TERY)
(a) Check the battery electrolyte level.
(1) Check the electrolyte quantity of each cell.
If the electrolyte quantity is below the recommended amount,
replace the battery.
(b) Check the battery voltage.

(1) If it has been less than 20 minutes since you
stopped driving the vehicle or since the engine was
stopped, turn the ignition switch and electrical sys-
tems (headlight, blower motor, rear defogger etc.)
to the ON position for 60 seconds. This will remove
the surface charge on the battery.
(2) Turn the ignition switch and electrical systems OFF.
A01260 (3) Using a voltmeter, measure the battery voltage be-
tween the negative (-) and positive (+) terminals of
the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
If the voltage is less than the specification, charge the battery.
(c) Check the indicator as shown in the illustration.

HINT:
Blue White Red
Blue: OK
White: Charging Necessary
Red: Insufficient Water
A82941
2. INSPECT BATTERY (EXCEPT MAINTENANCE-FREE

BATTERY)
(a) Check the battery electrolyte level.
(1) Check the electrolyte quantity of each cell.
If the electrolyte quantity is below the recommended amount,
add distilled water.
Author: Date: 2348

19-17
(b) Check the battery specific gravity.

(1) Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
If the specific gravity is less than specification, charge the bat-
tery.
A01259
(c) Check the battery voltage.

(1) If it has been less than 20 minutes since you
stopped driving the vehicle or since the engine was
stopped, turn the ignition switch and electrical sys-
tems (headlight, blower motor, rear defogger etc.)
to the ON position for 60 seconds. This will remove
the surface charge on the battery.
(2) Turn the ignition switch and electrical systems OFF.
A01260 (3) Using a voltmeter, measure the battery voltage be-
tween the negative (-) and positive (+) terminals of
the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
If the voltage is less than the specification, charge the battery.
(d) Check the indicator as shown in the illustration.

HINT:
Blue White Red
Blue: OK
White: Charging Necessary
Red: Insufficient Water
A82941
3. INSPECT BATTERY TERMINALS, FUSIBLE LINK AND FUSES

(a) Visually check the battery terminals.
(1) Check that the battery terminals are not loosened or corroded.
(b) Visually check the fusible link and fuses.
(1) Check that there is continuity of the fusible links, high current fuses and regular fuses.
4. INSPECT V-RIBBED BELT
(a) Visually check the belt for excessive wear, frayed cords,
etc.
If any defects are found, replace the v-ribbed belt.
Cracks on the rib side of the belt are considered ac-
ceptable.
If the belt has chunks missing from the ribs, it should
be replaced.
B00543
Author: Date: 2349

19-18
(b) Check that the belt fits properly in the ribbed grooves.
Confirm that the belt has not slipped out of the groove on the
bottom of the pulley by hand.
B00540
5. INSPECT GENERATOR WIRING

(a) Visually check the generator wiring.
(1) Check that the wiring is in good condition.
6. INSPECT ABNORMAL NOISES
(a) Listen to abnormal noises from generator.
(1) Check that no abnormal noise is heard from the generator while the engine is running.
7. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine, then check that the light goes off.
If the light does not operate as specified, troubleshoot the charge warning light circuit.
Ammeter 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
Disconnect Wire
from Terminal B (a) If a tester is not available, connect a voltmeter to the
charging circuit as follows.
(1) Disconnect the wire from terminal B of the genera-
tor, then connect it to the negative (-) lead of the
Voltmeter
ammeter.
Battery (2) Connect the positive (+) lead of the ammeter to ter-
Generator
minal B of the generator.
A88419 (3) Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
(4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm, then check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 to 14.8 V
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn the high beam headlights ON and turn the heater blower
switch to the HI position.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, repair the generator.
If the battery is fully charged, the indication will sometimes be less than the standard amperage.
Author: Date: 2350

19-19
STARTING & CHARGING - GENERATOR ASSY (3MZ-FE)
GENERATOR ASSY (3MZ-FE)

190SK-01
COMPONENTS
9.8 (100, 7)
Plate Washer
58 (591, 43)
Generator
Connector
18 (184, 13)
Generator Assy
8.4 (86, 74 in.lbf)
Wiring Harness Clamp Bracket
V-ribbed Belt No. 1

A87596
Author: Date: 2351

19-20
Generator Washer
Generator Pulley
Generator Rotor Assy
111 (1,125, 81) Drive End Frame Assy

Generator
Terminal Insulator 4.6 (47, 41 in.lbf)

Generator
Brush Holder Assy
5.8 (59, 51 in.lbf)
x3
x4 x2
1.8 (18, 16 in.lbf)

Generator
Rear End Cover
Generator Coil Assy

Non-reusable part A86392
Author: Date: 2352

19-21
190SL-01
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
(a) 2. REMOVE GENERATOR ASSY

Terminal Cap (a) Remove the 2 wire harness clamps.
(b) Disconnect the generator connector.
(c)
(c) Open the terminal cap.
(d) Remove the nut, then disconnect the generator wire.
(b)
(a)
A86379
(e) Loosen bolts A and B.

(f) Loosen bolt C to lessen the tension of the V-ribbed belt
No.1.
B
A C
A87594
(g) Remove bolts A and B, then remove the generator.
A
A87593
(h) Remove the bolt, then remove the wiring harness clamp
bracket.
(h)
A87595
Author: Date: 2353

19-22
3. INSTALL GENERATOR ASSY

(a) Install the wiring harness clamp bracket with the bolt.
B (b) Temporarily install the generator with bolts A and B.
A
A87593
(c) Adjust the V-ribbed belt No. 1 tension by tightening bolt

C (see page 14-1 ).
(d) Tighten bolts A and B.
B Torque:
18 Nm (180 kgfcm, 13 ftlbf) for bolt A
58 Nm (591 kgfcm, 43 ftlbf) for bolt B
(e) Install the generator wire with the nut.
Torque: 9.8 Nm (100 kgfcm, 7 ftlbf)
C
A A87594 (f) Connect the generator connector.
(g) Install the wire harness clamp.
4. INSPECT DRIVE BELT (See page 14-1 )
5. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
6. SYSTEM INITIALIZATION (See page 19-15 )
Author: Date: 2354

19-23
190SM-01
OVERHAUL
SST 1-A 1. REMOVE GENERATOR PULLEY

SST 09820-6301 1 (09820-06010, 09820-06020)
SST 1-B
HINT:
Turn SST 1-A and B 09820 - 06010
SST 2 09820 - 06020
(a) Hold SST 1-A with a torque wrench, then tighten SST
Hold
1-B clockwise with the specified torque.
A81658 NOTICE:
Check that SST is secured to the rotor shaft.
(b) Clamp SST 2 in a vise.

(c) Insert SST 1-A and B into SST 2, then attach the pulley
nut to SST 2.
SST 2
Insert
SST 1
A81659
(d) To loosen the pulley nut, turn SST 1-A in the direction
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than a half turn.
(e) Remove the generator from SST 2.
SST1-A
Turn
A81660
(f) Turn SST 1-B, then remove SST 1-A and B.

SST 1-A
(g) Remove the pulley nut, then remove the generator pulley.
SST 1-B
Turn
Hold
A81661
Author: Date: 2355

19-24
2. REMOVE GENERATOR BRUSH HOLDER ASSY

(a) Place the generator on the generator pulley.
(b) Remove the 3 nuts, then remove the generator rear end
Pulley
cover.
A81662
(c) Remove the terminal insulator from the generator coil.
A81146
(d) Remove the 2 screws, then remove the generator brush

holder.
A81147
3. REMOVE GENERATOR COIL ASSY

(a) Remove the 4 bolts.
A81148
(b) Using SST, remove the generator coil.

Turn SST 09950- 40011 (09951- 04020, 09952- 04010,
SST
09953- 04020, 09954- 04010, 09955- 04071,
09957-04010, 09958-04011)
Hold
A81663
Author: Date: 2356

19-25
Generator Washer 4. REMOVE GENERATOR ROTOR ASSY

(a) Remove the generator washer and generator rotor.
A81664
5. INSPECT GENERATOR BRUSH HOLDER ASSY

(a) Inspect the length.
(1) Using vernier calipers, measure the exposed brush
Length
length.
Standard exposed brush length: 10.5 mm (0.413 in.)
Minimum exposed brush length: 4.5 mm (0.177 in.)
If the exposed brush length is less than minimum, replace the
generator brush holder.
A79305
6. INSPECT GENERATOR ROTOR ASSY

(a) Check that the bearing is not rough or worn.
If necessary, replace the generator rotor.
A79306
(b) Inspect the resistance.

Slip Ring
(1) Using an ohmmeter, measure the resistance be-
tween the slip rings.
Ohmmeter Resistance: 2.3 to 2.7 at 20C (68F)
If the resistance is not as specified, replace the generator rotor.
A88420
(c) Check the continuity.

Slip Ring Rotor Core
ity between the slip ring and rotor core.
Ohmmeter If there is continuity, replace the generator rotor.
(d) Check the appearance.
(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor.
A88421
Author: Date: 2357

19-26
(e) Inspect the diameter.

(1) Using vernier calipers, measure the slip ring diame-
Diameter ter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than minimum, replace the generator ro-
tor.
A75676
Generator Washer 7. INSTALL GENERATOR ROTOR ASSY

(a) Place the generator drive end frame on the generator
Generator pulley.
Pulley (b) Install the generator rotor and generator washer.
A81670
8. INSTALL GENERATOR COIL ASSY

Deep Socket
Wrench 21 (a) Using a deep socket wrench 21 and press, press in the
generator coil carefully.
A81671
(b) Tighten the 4 bolts.

A81148
9. INSTALL GENERATOR BRUSH HOLDER ASSY

Pin (1.0 mm (0.039 in.)) (a) While pushing the 2 brushes to inside the brush holder,
insert a pin (1.0 mm (0.039 in.)) into the brush holder
hole.
A79315
Author: Date: 2358

19-27
Pin (1.0 mm (0.039 in.)

(b) Install the generator brush holder with the 2 screws.
(c) Pull out the pin (1.0 mm (0.039 in.)) from the generator
brush holder.
A81672
(d) Install the terminal insulator.

NOTICE:
Pay attention to the mounting orientation of the terminal in-
sulator.
A81146
(e) Install the generator rear end cover with the 3 nuts.
A81164
SST 1-A 10. INSTALL GENERATOR PULLEY

SST 09820-6301 1 (09820-06010, 09820-06020)
SST 1-B
HINT:
Turn SST 1-A and B 09820 - 06010
SST 2 09820 - 06020
(a) Install the generator pulley to the rotor shaft by tightening
Hold
the generator pulley nut by hand.
(b) Hold SST 1-A with a torque wrench, then tighten SST
A81658 1-B clockwise with the specified torque.
NOTICE:
Check that SST is secured to the rotor shaft.
Author: Date: 2359

19-28
(c) Clamp SST 2 in a vise.

(d) Insert SST 1-A and B into SST 2, then attach the genera-
tor pulley nut to SST 2.
SST 2
Insert
SST 1
A81659
(e) Tighten the generator pulley nut by turning SST 1-A in the
direction shown in the illustration.
Torque: 111 Nm (1,125 kgfcm, 81 ftlbf)
(f) Remove the generator from SST 2.
SST1-A
Turn
A81673
(g) Turn SST 1-B, then remove SST 1-A and B.

SST 1-A
(h) Turn the generator pulley, then check that the generator
SST 1-B pulley moves smoothly.
Turn
Hold
A81661
Author: Date: 2360

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19-1

STARTING & CHARGING - STARTING SYSTEM (3MZ-FE)

STARTING SYSTEM (3MZ-FE)

1. INSPECT STARTER ASSY

(2) Connect the battery to the repair service starter kit

(b) Perform the hold-in test.

(c) Check the operation.

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2333

(d) Perform the no-load performance test.

(2) Clamp the starter in a vise.

2. INSPECT STARTER RELAY ASSY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2334

STARTER ASSY (3MZ-FE)

Radiator Lower Air Deflector

5.0 (51, 44 in.lbf)

x2 7.5 (76, 66 in.lbf)

Air Cleaner Bracket

Nm (kgfcm, ftlbf) : Specified torque

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2335

Starter Armature Assy

Starter Magnetic Switch Assy

7.5 (76, 66 in.lbf) x2

Starter Drive Housing Assy

Starter Field Frame

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2336

1. REMOVE RADIATOR SIDE DEFLECTOR RH

2. REMOVE AIR CLEANER INLET ASSY

(b) 5. REMOVE AIR CLEANER ASSY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2337

(f) Disconnect the VSV connector.

6. REMOVE AIR CLEANER BRACKET

7. REMOVE AIR CLEANER INLET NO.1

Terminal Cap 8. REMOVE STARTER ASSY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2338

(d) Remove the 2 bolts, then remove the starter.

9. INSTALL STARTER ASSY

11. INSTALL AIR CLEANER BRACKET

12. INSTALL AIR CLEANER ASSY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2339

13. INSTALL BATTERY TRAY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2340

1. REMOVE STARTER MAGNETIC SWITCH ASSY

(b) Remove the 2 screws which secure the starter magnetic

2. REMOVE STARTER FIELD FRAME ASSY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2341

3. REMOVE STARTER ARMATURE PLATE

4. REMOVE STARTER COMMUTATOR END FRAME

5. REMOVE STARTER ARMATURE ASSY

6. REMOVE PLANETARY GEAR

7. INSPECT STARTER MAGNETIC SWITCH ASSY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2342

(b) Check the continuity.

Body (2) Using an ohmmeter, check that there is continuity