LEXUS ES300 2005 Repair Manual

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.

A76677
Length
A88418
Ohmmeter
A81655
FreeLock
A81656
Apply Grease
A82440
Snap Ring
Pliers
19-12
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2344 Author
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:
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.

A58810
Length
A81178
A73991
keyway
Key
A79727
Rubber
Cutout
A79728Key Keyway
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
19-13
2345 Author
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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.

A79720
A79729
A79719
A79718
19-14
- STARTING & CHARGINGSTARTER ASSY (3MZ-FE)
2346 Author
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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)

190SI-01
- STARTING & CHARGINGCHARGING SYSTEM (3MZ-FE)
19-15
2347 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
CHARGING SYSTEM (3MZ-FE)
PRECAUTION
1. SYSTEM INITIALIZATION
NOTICE:
When disconnecting the negative (-) battery terminal, initialize the following systems after the termi-
nal is reconnected.
System NameSee Page
Power Window Control System05-1470
Sliding Roof System74-8
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.

190SJ-01
A01260
A82941
White Red Blue 19-16
- STARTING & CHARGINGCHARGING SYSTEM (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.
(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: OK

White: Charging Necessary

Red: Insufficient Water
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.

A01259
A01260
A82941
White Red Blue
B00543
- STARTING & CHARGINGCHARGING SYSTEM (3MZ-FE)
19-17
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
(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.
(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: OK

White: Charging Necessary

Red: Insufficient Water
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.

B00540
A88419
Disconnect Wire
from Terminal B
Generator Voltmeter
BatteryAmmeter 19-18
- STARTING & CHARGINGCHARGING SYSTEM (3MZ-FE)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(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.
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.
8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(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
ammeter.
(2) Connect the positive (+) lead of the ammeter to ter-
minal B of the generator.
(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 ºHIº 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.

190SK-01
A87596N´m (kgf´cm, ft´lbf) : Specified torqueGenerator
Connector
Generator Assy
V-ribbed Belt No. 1
18 (184, 13)
Plate Washer
9.8 (100, 7)
58 (591, 43)
8.4 (86, 74 in.Vlbf)
Wiring Harness Clamp Bracket
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-19
2351 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
GENERATOR ASSY (3MZ-FE)
COMPONENTS