ST-1

STARTING - STARTING SYSTEM

STARTING SYSTEM
ST04X-01

ON-VEHICLE INSPECTION
NOTICE:
Before changing the starter, check the following items again:

Connector connection

Accessory installation, e.g.: theft deterrent system

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1522

ST-2
STARTING - STARTER

STARTER
ST04Y-04

COMPONENTS

Engine Wire

Clamp Bracket

Starter

Starter Wire
Starter Connector

B11926

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1523

 ST-3
STARTING - STARTER

Starter Clutch Assembly

Starter Housing
Return Spring
Magnetic Switch Assembly

Idler Gear

Steel Ball

Bearing
O-Ring

Front Bearing

O-Ring
Armature
End Cover

Rear Bearing

Field Frame (Field Coil)

Brush Holder
Dust Protector

Non-reusable part
B01640

Magnetic Switch Assembly

Contact Plate
Terminal C Kit Part

Terminal Insulator Terminal
Bolt
17 (173, 13)
Wave Washer
Terminal Insulator
O-Ring

Plunger Lead

Gasket
Terminal

Terminal 30 Kit Part

O-Ring Packing

Terminal Bolt Terminal Insulator

Wave Washer
Contact Plate
End Cover Terminal Insulator
17 (173, 13)

N·m (kgf·cm, ft·lbf) : Specified torque

Non-reusable part B11947

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1524

ST-4
STARTING - STARTER
ST04Z-04

REMOVAL
REMOVE STARTER
(a) Remove the rubber cap and nut, and disconnect the start-
er wire.
(b) Disconnect the starter connector.

B01960

(c) Remove the 2 bolts and starter.

Clamp Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
Bracket HINT:
At time of the installation, when installing the upper bolt, tighten
it together with the clamp bracket.

B01981

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1525

 ST-5
STARTING - STARTER
ST050-05

DISASSEMBLY
1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(b) Remove the 2 through bolts.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
B02814

(c) Pull out the field frame together with the armature.
HINT:
At the time of reassembly, align the protrusion of the field frame
with the cutout of the magnetic switch.
(d) Remove the O-ring from the field frame.
HINT:
At the time of reassembly, use a new O-ring.

B01647

3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY

AND GEAR
(a) Remove the 2 bolts.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

B01959

Idler Gear Bearing (b) Remove the starter housing, idler gear, bearing, clutch
assembly and return spring from the magnetic switch.

Return Spring

Starter Housing
Clutch Assembly B01970

4. REMOVE STEEL BALL

Magnetic Finger Using a magnetic finger, remove the steel ball from the clutch
shaft hole.

ST0948

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1526

ST-6
STARTING - STARTER

5. REMOVE BRUSH HOLDER

(a) Remove the 2 screws and end cover from the field frame.
Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf)
(b) Remove the O-ring from the field frame.
HINT:
At the time of reassembly, use a new O-ring.

B01645

(c) Using a screwdriver, hold the spring back and disconnect

the brush from the brush holder. Disconnect the 4
brushes, and remove the brush holder.
NOTICE:
At the time of reassembly, check that the positive (+) lead
wires are not grounded.
6. REMOVE ARMATURE FROM FIELD FRAME

P10568

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1527

 ST-7
STARTING - STARTER
ST051-06

Ohmmeter INSPECTION
1. INSPECT ARMATURE COIL
Continuity
(a) Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.

P10584

Ohmmeter (b) Check the commutator for ground.

Using an ohmmeter, check that there is no continuity be-
No Continuity tween the commutator and armature coil core.
If there is no continuity, replace the armature.
2. INSPECT COMMUTATOR
(a) Check the commutator for the dirty and burnt surfaces.
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a table.
P10585

(b) Check for the commutator circle runout.

(1) Place the commutator on V-blocks.
(2) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.

P10586

(c) Using a vernier caliper, measure the commutator diame-

ter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.412 in.)
If the diameter is less than minimum, replace the armature.

P10587

(d) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

ST0040

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1528

ST-8
STARTING - STARTER

3. INSPECT FIELD COIL

Ohmmeter (a) Check the field coil for open circuit.
Continuity Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.

P10588

(b) Check the field coil for ground.

Ohmmeter
Using an ohmmeter, check that there is no continuity be-
No Continuity tween the field coil end and field frame.
If there is continuity, replace the field frame.

P10589

Brush Holder Side 4. INSPECT BRUSHES

Using a vernier caliper, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 10.0 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and
field frame.

Length
Field Frame Side

Length Z07019

5. INSPECT BRUSH SPRINGS

Check the brush spring load. Take the pull scale reading the
instant the brush spring separates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.8 - 2.4 kgf, 3.9 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is less than minimum, replace the brush
ST0019 springs.

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1529

 ST-9
STARTING - STARTER

6. INSPECT BRUSH HOLDER

Check the brush holder insulator. Using an ohmmeter, check
Ohmmeter
that there is no continuity between the positive (+) and negative
No Continuity (-) brush holders.
If there is continuity, repair or replace the brush holder.
7. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the pinion gear, idle gear and the
clutch assembly for wear or damage.
P10592 If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.

(b) Check the clutch pinion gear.

Rotate the pinion gear counterclockwise, and check that
Free it turns freely. Try to rotate the pinion gear clockwise and
check that it locks.
LOCK If necessary, replace the clutch assembly.

P10821

Ohmmeter 8. INSPECT MAGNETIC SWITCH

Continuity (a) Check the pull -in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.

Terminal 50
Terminal C B01968

Ohmmeter (b) Check the hold-in coil for open circuit.

Using an ohmmeter, check that there is continuity be-
Continuity
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
9. INSPECT BEARING
Turn the bearing by hand and while apply inward force.
If resistance is felt or bearing sticks, replace the bearing (See
Terminal 50 page ST-10 ).
B01969

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1530

ST-10
STARTING - STARTER
ST052-08

REPLACEMENT
SST
1. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1

P10595

Upward (b) Using SST and a press, press in a new bearing.

NOTICE:
SST Be careful of the bearing installation direction.
SST 09820-00031

Downward P10596

2. REPLACE REAR BEARING

SST
(a) Using SST, remove the bearing.
SST 09286-4601 1

P10593

(b) Using a press, press in a new rear bearing.

P10594

3. REPLACE MAGNETIC SWITCH TERMINAL PARTS

(a) Remove the 3 bolts, end cover, gasket and plunger.

B01971

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1531

 ST-1 1
STARTING - STARTER

(b) 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.

Wear
P25785

(c) Remove the terminal kit parts.

(1) Using SST, loosen the terminal nuts.
SST 09810-38140
SST
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O- ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
B01973 Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O-ring, terminal bolt,
contact plate and terminal insulator (inside).

Long (d) Temporarily install new terminal 30 kit parts:

Short
(1) Install a new terminal insulator (inside).
(3) (4) (2) Install a new contact plate.
(5)
(2) (3) Install a new terminal bolt.
(1) (4) Install a new O-ring.
(6) (5) Install a new packing and terminal insulator (out-
(7) side).
Install the packing to the terminal insulator, and
Indentation
Protrusion B11946 install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(6) Install a new wave washer.
(7) Install a new terminal nut.
NOTICE:
Be careful to install the terminal insulators in the correct
direction.

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1532

ST-12
STARTING - STARTER

(7) Long (e) Temporarily install new terminal C kit parts:

(6) (1) Install a new terminal insulator (inside).
Short
(5)
(2) (2) Install a new contact plate.
(4) (1) (3) (3) Install a new terminal bolt.
(4) Install a new O-ring.
(5) Install a new terminal insulator (outside).
(6) Install a new wave washer.
(7) Install a new terminal nut.
Lead Terminal NOTICE:
P25788

Be careful to install the terminal insulators in the correct

direction.
(f) Temporarily tighten the terminal nuts.

Wooden (g) Tighten the terminal nut

Block (1) Put a wooden block on the contact plate and press
it down with a hand press.
40 mm
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
37 mm 20 mm Press force:
981 N (100 kgf, 221 lbf)
Contact
Plate NOTICE:
B01974
Check the diameter of the hand press ram. Then
calculate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
100 kgf
(kgf/cm2) = Ram diameter (cm) 2
x 3.14 (π)
2
221 lbf
2
(psi) = Ram diameter (in.)
x 3.14 (π)
2
(kPa) = (kgf/cm2) x 98.1

(kPa) = (psi) x 6.9

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.

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1533

 ST-13
STARTING - STARTER

(2) Using SST, tighten the nuts to the specified torque.

SST 09810-38140
Torque: 17 N·m (173 kgf·cm, 13 ft·lbf)
SST NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.

B01975

(h) Clean the contact surfaces of the remaining contact plate

and plunger with a dry shop rag.
(i) Reinstall the plunger, new gasket, end cover and lead
clamp with the 3 bolts.
Torque: 2.5 N·m (26 kgf·cm, 22 in.·lbf)

B01972

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1534

ST-14
STARTING - STARTER
ST053-03

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST-5 ).
HINT:
Before reassembly, use high-temperature grease to lubricate the bearings and gears.

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1535

 ST-15
STARTING - STARTER
ST054-06

TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.

Terminal 50 1. DO PULL-IN TEST

(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the pinion gear moves outward.

Terminal C Battery

B01964

2. DO HOLD-IN TEST
While connected as above with the pinion gear out, disconnect
the negative (-) lead from terminal C. Check that the pinion gear
remains out.

Disconnect
Terminal C Battery

B01965

Disconnect 3. INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (-) lead from the starter body. Check
that the pinion gear returns inward.

Battery
B01966

Terminal 30 4. DO NO-LOAD PERFORMANCE TEST

Terminal 50 (a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
Battery
the pinion gear moving out. Check that the ammeter
shows the specified current.
Ammeter
Specified current: 90 A or less at 11.5 V

B01967

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1536

ST-16
STARTING - STARTER
ST055-03

INSTALLATION
Installation is in the reverse order of removal (See page ST-4 ).

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1537

 ST-17
STARTING - STARTER RELAY

STARTER RELAY ST0Q3-01

INSPECTION
1. REMOVE RELAY BOX COVER
Starter Relay
2. REMOVE STARTER RELAY

B07080

Ohmmeter
3. INSPECT STARTER RELAY
1 (1) Using an ohmmeter, measure the resistance be-
3 5
tween the terminals.
Standard:
Tester Connection Specified Condition
3-5 10 kΩ or higher
2 Below 1 Ω
3-5
(Apply battery voltage to terminals 1 and 2)
Battery Continuity B00223
If the resistance is not as specified, replace the relay.
4. REINSTALL STARTER RELAY
5. REINSTALL RELAY BOX COVER

2005 LEXUS IS300 (RM1140U)

Author
: Date
: 1538