LEXUS SC400 1991 Service Repair Manual

2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLYAND GEARS
(a) Remove the two mounting screws.
(b) Remove the following parts from the magnetic switch:(1) Starter housing
(2) Return spring
(3) Pinion gear
(4) Bearing
(5) Idler gear
(6) Clutch assembly
3. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
4. REMOVE BRUSH HOLDER Using a screwdriver, hold the spring back and disconnect the
brush from the brush holder. Disconnect the four brushes,
and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME
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INSPECTION AND REPAIR OF STARTER
Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUITUsing an ohmmeter, check that there is continuity between
the segments of the commutator.
If there is no continuity, replace the armature.
2. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNTSURFACE
If the surface is dirty or burnt, correct with sandpaper
(No.400) or on a lathe.
2. INSPECT COMMUTATOR FOR RUNOUT (a) Place the commutator on V±blocks.
(b) Using a dial indicator, 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.
3. INSPECT COMMUTATOR DIAMETER Using a vernier caliper, measure the diameter.
Standard diameter: 35.0 mm (1.378 in.)
Minimum diameter: 34.0 mm (1.339 in.)
If the diameter is less than minimum, replace the armature.
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4. INSPECT UNDERCUT DEPTHCheck that the undercut depth is clean and free of foreign
material. Smooth out the edge.
Standard undercut depth: 0.7±0.9 mm
(0.028±0.035 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.
Field Coil (Field Frame)
1. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between
the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
2. INSPECT FIELD COIL FOR GROUND Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, replace the field frame.
Brushes
INSPECT BRUSH LENGTHUsing a vernier caliper, measure the brush length.
Standard length: 15.0±15.5 mm
(0.591±0.610 in.)
Minimum length: 9.5 mm (0.374 in.)
If the length is less than minimum, replace the brush holder
and field frame.
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Brush Springs
INSPECT BRUSH SPRING LOADTake the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard installed load:
26±32 N (2.7±3.3 kgf, 6.0±7.3 lbf)
If the installed load is not as specified, replace the brush
springs.
Brush Holder
INSPECT BRUSH HOLDER INSULATIONUsing an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
If there is continuity, repair or replace the brush holder.
Clutch and Gears
1. INSPECT GEAR TEETHCheck the gear teeth on the pinion gear, idler gear and the
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel ring gear for wear or
damage.
2. INSPECT CLUTCH PINION GEAR Rotate the pinion gear counterclockwise and check that it
turns freely. Try to rotate the pinion gear clockwise and check
that it locks.
If necessary, replace the clutch assembly.
Bearings
1. INSPECT FRONT BEARING Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
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2. IF NECESSARY, REPLACE FRONT BEARING(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using a 10 mm nut and press, press in a new frontbearing.
NOTICE: Be careful of the bearing installation direction.
(c) Using a punch, stake the armature shaft.
3. INSPECT REAR BEARING Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
4. IF NECESSARY, REPLACE REAR BEARING (a) Using SST and a press, press out the bearing.
SST 09950±00020
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(b) Using SST and a press, press in a new bearing.SST 09201±41020
Magnetic Switch
1. PERFORM PULL±IN COIL OPEN CIRCUIT TESTUsing an ohmmeter, check that there is continuity between
terminals 50 and C.
If there is no continuity, replace the magnetic switch.
2. PERFORM HOLD±IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between
terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
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ASSEMBLY OF STARTER
(See Components on page ST±15)
HINT: Use high±temperature grease to lubricate the bearings
and gears when assembling the starter.
1. PLACE ARMATURE INTO FIELD FRAME Apply grease to the armature bearings, and insert the arma-
ture into the field frame.
2. INSTALL BRUSH HOLDER (a) Align the claw of the brush holder with the claw grooveof the field frame.
(b) Place the brush holder on the field frame.
(c) Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the
four brushes.
NOTICE: Check that the positive (+) lead wires are not
grounded.
3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE (a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole.
4. INSTALL CLUTCH ASSEMBLY, GEARS AND STARTER HOUSING
(a) Apply grease to the return spring.
(b) Insert the return spring into the magnetic switch hole.
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(c) Place the following parts in position on the starterhousing:
(1) Clutch assembly
(2) Idler gear
(3) Bearing
(4) Pinion gear
(d) Install the starter housing to magnetic switch with the two screws.
5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY (a) Install a new O±ring to groove of the field frame.
(b) Align the claws of the brush holder with the grooves ofthe magnetic switch, and install the field frame and
armature shaft assembly.
(c) Align the punch mark of the field frame with the line of the magnet switch.
(d) Install a new O±ring to through bolt A.
(e) Install the spring washer, plate washer, wire bracket and
a new O±ring to through bolt B.
(f) Install the two through bolts.
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(g) Connect the lead wire to terminal C, and install the nut.
PERFORMANCE TEST OF STARTER
NOTICE: These tests must be performed within 3 to 5 se-
conds to avoid burning out the coil.
1. PERFORM PULL±IN TEST (a) Disconnect the field coil lead wire from terminal C.
(b) C onnect battery to the magnetic switch as shown.
Check that the pinion gear moves outward.
If the pinion gear does not move, replace the magnetic
switch.
2. PERFORM HOLD±IN TEST While connected as above with the pinion gear out, discon-
nect the negative (±) lead from terminal C.
Check that the pinion gear remains out.
If the pinion gear returns inward, replace the magnetic switch.
3. INSPECT PLUNGER RETURN Disconnect the negative (+) lead from the switch body. Check
that the pinion gear returns inward.
If the pinion gear does not return, replace the magnetic
switch.
4. PERFORM NO±LOAD PERFORMANCE TEST (a) Connect battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out.
Check the reading on the ammeter.
Standard amperage: 120 A or less at 11.5 V
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INSTALLATION OF STARTER
(See Components on page ST±5)
1. INSTALL STARTER (a) Connect the wire clamp to the wire bracket.
(b) Connect the starter wire with the nut.
(c) Connect the starter connector.
(d) Install the starter with the two bolts.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
2. INSTALL REAR WATER BY±PASS JOINT
(a) Install four new gaskets and the water by±pass joint with
the four nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Install the bolt holding the water by±pass pipe to the LH
engine hanger.
3. INSTALL WATER BY±PASS PIPE (a) Install a new O±ring to the water by±pass pipe.
(b) Apply soapy water to the O±ring.
(c) Push in the water by±pass pipe end into the pipe holeof the water pump.
(d) Install the water by±pass pipe with the two bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
4. CONNECT HEATER WATER HOSES TO WATER
BY±PASS PIPE AND REAR WATER BY±PASS JOINT
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