LEXUS UCF20R service bulletin

LEXUS SERVICE BULLETIN

MODEL LEXUS LS400 - UCF20

SUBJECT SAFETY RECALL - STARTER MAGNETIC

SWITCH (SOLENOID)

Please direct the second copy of this service bulletin to your Service Manager for immediate
attention.

Investigations by Toyota Motor Corporation Japan have determined that a requirement
exists for the initiation of a safety related recall campaign to be conducted in accordance
with the FCAI Code of Practice for safety related recalls affecting a range of Lexus LS400
models.

DESCRIPTION OF CONCERN:

Due to improper assembly of the terminal of the starter magnetic switch (solenoid), an
electrical short circuit may occur if electrically conductive liquid enters this area.
Consequently the starter motor will not operate and a no-start condition will result, or in the
worst case, an under-hood fire.

AFFECTED VEHICLES:

Lexus LS400 vehicles produced from April 10th 1995 through to May 21st 1997
production within the vehicle identification range below are being recalled.

A total of 278 vehicles are involved.

VEHICLE IDENTIFICATION:

VIN RANGE

MODEL VDS VIS

UCF20R 53UF20 00025919 - 00093925

PLEASE NOTE: Not all vehicles within this range are affected.

Please refer to engine number range on pages 2 and 3 of the attached
Technical Instruction.

...2/

Toyota Motor Corporation Australia Limited

E

A.B.N. 64 009 686 097

Date: February 1998

Section: General

No: 12

- 2 -

CAMPAIGN ACTION:

All vehicles in this campaign will have the starter magnetic switch replaced, refer to the
Technical and Warranty Instructions attached.

PARTS SUPPLY:

Necessary parts required to carry out this exercise are:

PART NAME PART NUMBER QTY / VEH.

Repair Service Kit 28226 - 50040 1

Gasket Service Kit 04007 - 06350 1

NOTE: A detailed breakdown of all the components contained in the two kits is

included in the Technical Instructions attached.

PARTS ALLOCATION:

In order to ensure that sufficient parts are available at dealers to commence this
campaign, initial quantities will be distributed to each dealer as per allocation table below.

DEALER INITIAL QUANTITIES

MELBOURNE CITY LEXUS 15
SYDNEY CITY LEXUS 15
LEXUS OF WAITARA 15
LEXUS OF CANBERRA 5
LEXUS OF PERTH 5
LEXUS OF KEDRON 15
LEXUS OF CAIRNS 1
LEXUS OF SOUTHPORT 5
LEXUS OF ADELAIDE 5
TMCA NT 2

Additional quantities required should be sourced through normal parts channels.

DEALER ACTION:

Lexus Australia wishes to minimise customer inconvenience in this exercise and therefore
requests each dealer to contact each owner personally by telephone to make necessary
arrangements to have this campaign carried out.
Dealers will be provided with a complete customer and vehicle details list of all known
current owners of affected vehicles sold by the dealership.

Dealers are requested to contact owners by telephone no sooner than February 9th 1998
to make necessary arrangements to have this campaign carried out.

...3/

- 3 -

TIMING - OWNER NOTIFICATION:

All owners will be notified by:-

• Direct telephone contact from Lexus Division commencing February 2nd, 1998.

• Certified letter mailed to owners February 6th, 1998.

• Direct telephone contact by Lexus Dealers from February 9th, 1998 onwards.

• Newspaper advertisement February 14th, 1998 (subject to review of direct contacts

made by Lexus Division).

A copy of the owner letter is included herewith.

HANDLING OF ENQUIRES:

Customer enquires will be handled through the Lexus Helpline on 1800 023 009.

Lexus Australia requests the utmost co-operation of all dealers in this safety related recall
and particularly requests diligent telephone contact and follow-up of all owners to ensure
quick completion of this exercise with minimum inconvenience to Lexus owners.

Yours faithfully
Toyota Motor Corporation Australia Limited

C. Di Pietro
National Technical Operations Manager

att.

TECHNICAL AND WARRANTY INSTRUCTIONS

LEXUS LS400 - STARTER MAGNETIC SWITCH

CONTENTS:

1. OPERATIONAL FLOW CHART

2. VEHICLE AND ENGINE SERIAL NO. IDENTIFICATION / LOCATION

3. PREPARATION
A) NECESSARY PARTS

B) NECESSARY TOOLS / MANUALS
C) PRELIMINARY INSPECTION
D) PREPARATION FOR WO RK
E) STARTER MOTOR REMOVAL / INSTALLATION PROCEDURE
F) ENGINE COOLANT - FILL PROCEDURE
G) COMPLETION INSPECTION

4. STARTER MAGNETIC SWITCH REPLACEMENT PROCEDURE

5. COMPLETION IDENTIFICATION LABEL

6. WA RRANTY REIMBURSEMENT INSTRUCTIONS

- 1 -

1. OPERATIONAL FLOW CHART

IS VEHICLE WITHIN

AFFECTED VIN RANGE?

53UF20 00025919 - 00093925

YES

IS ENGINE SERIAL NO.

WITHIN AFFECTED

RANGE?

1UZ-FE 0529327-0672850

YES

CARRY OUT

REPLACEMENT OF

STARTER MAGNETIC

SWITCH

AFTER COMPLETION,

AFFIX LABEL TO RH A

PILLAR.

CODE NO. 8514A

NO

NO

NO FURTHER ACTION

REQUIRED AND RETURN

VEHICLE TO CUSTOMER

SUBMIT WARRANTY

CLAIM

END

- 2 -

2. VEHICLE AND ENGINE SERIAL NO. IDENTIFICATION / LOCATION

LEXUS LS400

VIN RANGE

MODEL VDS VIS

UCF20R 53UF20 00025919 - 00093925

The vehicle identification number is located on the firewall (1) and on the manufacturers
plate (2), refer diagram below.

1UZ-FE

ENGINE TYPE SERIAL NUMBER RANGE

1UZ-FE 0529327 - 0672850

The engine serial number is stamped on the engine block top surface as shown in
diagram below.

- 3 -

3. PREPARATION

A) NECESSARY PARTS

PART NO. PART NAME QTY / VEHICLE

28226 - 50040 Repair Service Kit 1
04007 - 06350 Starter Gasket Kit 1

REPAIR KIT - DETAILS

REPAIR KIT P/NO. INCLUDED

COMPONENTS

PART NO.

28226 - 50040 28150 - 54054 Switch Assy, Magnetic 1
Repair Service Kit 28227 - 50010 Grease 1

17176 - 50021 Air surge tank to intake manifold

gasket

17171 - 50011 No.1 intake manifold to head

gasket
04007 - 06350 96761 - 24019 O ring (for water bypass pipe) 1
Starter Gasket Kit 16341 - 50010 Water outlet gasket 2

22271 - 50010 Throttle body gasket 1
90430 - 20004 Gasket (for water inlet housing) 1
25628 - 50010 EGR inlet gasket 3
23231 - 41081 Gasket (for pulsation damper hose) 1
90430 - 12026 Gasket (for pulsation damper hose) 1

B) NECESSARY TOOLS / MANUALS

• Lexus Repair Manual, Pub No. RM425E1, Vol 1

• Torque wrench

• Standard tools

• Ammeter

• Seal lock adhesive 08833-00080 (supplied with initial quantity of parts)

• SST 09612-24014 (09617-24011). (Used for fuel pressure pulsation damper.)

PART NAME QTY / KIT

4
2

C) PRELIMINARY INSPECTION

1. Record customer s radio preset station for AM, FM1 & FM2 and radio security PIN No.

2. Check and note approximate seat positions set in memory 1 and 2.

3. Using Scan Tool, retrieve and note any problem code in ECU.
NOTE: If there are any OBD-II codes or DTC, also print or copy Freeze Frame Data.

- 4 -

D) PREPARATION FOR WORK

1. Pull fuel door release lever located at lower dash board.

2. With all electrical components off, disconnect negative battery terminal and bend cable
down by side of battery to avoid terminal contact.

3. Loosen fuel cap to release pressure in tank.

4. Raise vehicle and attach plastic hose to coolant drain cock located on the passenger
side of engine block.

5. Loosen coolant drain cock 1 full turn counterclockwise and drain coolant into clean
container.

6. When completed, tighten drain cock and lower vehicle to the ground - drain cock torque

12.7 Nm (130 kgf.cm, 9ft.Ibf).

CAUTION: To prevent damage, do not remove 10 mm head bolt from centre of drain

cock.

E) STARTER MOTOR REMOVAL / INSTALLATION PROCEDURES

The removal and installation procedures for 1UZ-FE engine starter motor has not changed
for this exercise. Please follow the summarised sequence listed below in conjunction with
Lexus Repair Manual, Volume No.1, Pub No. RM425E1.

NO. ITEM PAGE NO. DIAGRAM / STEP

1 Engine block drain cock location (LH) Engine 126 N/A
2 Remove air cleaner box, flex hose and

intake connector
3 Remove timing belt covers E/G 24 4 to 11
4 Remove throttle body E/G 185 / 186 Diag. - 1 to 5
5 Remove intake chamber E/G 48 9 to 21
6 Remove starter motor (refer to magnetic

switch replacement procedure attached)
7 Reassemble in reverse order Refer reassembly steps of page

NOTE: 1: At reassembly of intake chamber, the fuel pressure pulsation damper

gaskets must be replaced - refer page E/G 177 and E/G 178.

NOTE: 2: When installing fuel return pipe, apply seal lock adhesive

P/No. 08833-00080 to the two attaching bolts, refer page E/G 85,
step 19.

E/G 181 & 191 Diag.

ST 7 7B to 8D

sections mentioned above

- 5 -

F) ENGINE COOLANT - FILL PROCEDURE

1. Pour original coolant into engine through thermostat housing port (plug (for water inlet
housing)) and reservoir (refer Repair Manual page EM 218 - step 2 (a)).

2. Torque plug (for water inlet housing) with new gasket and check for visible leaks under
vehicle. Torque: 44 Nm (450kgf.cm, 33ft.Ibf)

3. Tighten fuel tank cap and close fuel filler opening lid.

4. Reconnect negative battery terminal.

5. Start engine and watch for initial drop in coolant level.

6. After initial adjustment of level, install reservoir cap and frequently hold engine at 2,000
RPM.

7. Constantly monitor for coolant level change, temperature gauge overshoot, radiator fan
air temperature and possible leaks.

8. Add coolant into reservoir as needed until stable level after thermostat opens.
CAUTION: Do not remove radiator cap if engine is overheating or if coolant is boiling in

reservoir. If cap needs to be removed on warm engine, open slowly with a
shop towel to avoid gushing of coolant or steam.

9. Test drive vehicle and inspect for additional drop in coolant level. NOTE: If possible,
check coolant level again after vehicle has cooled down before customer takes delivery.
It is imperative that customers do not experience a low coolant level and/or overheating
situation.

G) COMPLETION INSPECTION

Upon completion of repair, please ensure the following:-

1. Inspect the fuel lines and connections for leakage.

2. Connect scan tool and check for diagnostic trouble codes.

3. Reset radio station on AM, FM1 and FM2 and radio security PIN No. as previously
recorded.

4. Reset approximate seat positions as previously noted.

5. Look over engine compartment and interior for dirt or fingerprints.

NOTE: There should be no evidence on vehicle (visible to customer) of repairs other

than recall completion label.

- 6 -

4. STARTER MAGNETIC SWITCH REPLACEMENT PROCEDURE

SECTIONS:

1. Magnetic switch assembly replacement.

2. Magnetic switch reassembly procedure.

3. No-Load performance test.

4. Additional procedures (to be used for unintentional disassembly).

(a) Armature to field frame installation.
(b) Starter housing assembly.

STARTER MOTOR COMPONENTS (BREAKDOWN)

- 7 -

SECTION 1.:

MAGNETIC SWITCH ASSEMBLY
REPLACEMENT

1. DISCONNECT THE LEAD WIRE

Remove the rubber cap and the nut from
the magnetic switch.

2. REMOVE THE FIELD FRAME WITH THE

COVER AND THE ARMATURE

Remove the two through bolts and the field
frame with the end cover and the armature.

HINT: Hold the magnetic switch assembly as per

the illustration and pull the field frame down
slowly.

NOTICE:

a) Do not separate the armature from the brush
holder (the end cover).
b) If the field frame is pulled down too forcefully,
the armature may remain on the magnetic
switch assembly side.
c) If the armature is separated from the brush
holder, refer Section 4, item (A).
d) Do not damage the O ring and the front
bearing as it is to be reused.

3. REMOVE THE MAGNETIC SWITCH ASSEMBLY

FROM THE STARTER HOUSING ASSEMBLY

a) Hold the magnetic switch assembly carefully
in a vice using soft jaws or equivalent.
b) Remove the two bolts.

- 8 -

c) Hold the magnetic switch assembly with the
starter housing assembly as shown in the
illustration and by using a plastic hammer,
hit lightly to separate them.

NOTICE:

a) Take care not to allow the bearings and
gears to fall out when separating these two
parts.
b) If bearings and gears do fall out, refer to
Section 4, item (B).

HINT: Lift magnetic switch assembly upwards

as shown in the illustration.

- 9 -

SECTION 2.:

REASSEMBLY

1. CLEANING

Clean the field frame, the starter housing and
other associated parts by using compressed
air to blow dust or dirt particles off.

2. APPLY GREASE

Apply grease supplied in the repair kit to the
idle gear and on the starter housing surface
which contacts the magnetic switch assembly
as per illustration.

Do not apply grease at circled area (bolt holes).

3. ASSEMBLE THE STARTER HOUSING

ASSEMBLY AND THE NEW MAGNETIC
SWITCH ASSEMBLY AS PER ILLUSTRATION

a) Confirm the steel ball in the starter clutch
assembly.

b) Install the return spring into the new magnetic
switch assembly.

c) Bring the two assemblies together taking care
not to incline the magnetic switch assembly
to the starter housing assembly which may
cause the bearings and gear to fall off.

d) Install the starter housing to magnetic switch
with the 2 bolts.
Torque: 5.9 Nm (60 kgf.cm, 52 in.Ibf)

HINT:

Hold magnetic switch assembly carefully in a
vice using soft jaws when torquing the 2 bolts.

- 10 -

4. INSTALL FIELD FRAME AND ARMATURE

ASSEMBLY

a) Install the O ring to the groove of the field
frame.

b) Align the protrusion of the field frame with
the groove of the magnetic switch.

c) Install the field frame and armature assembly
with the 2 through bolts.
Torque: 5.9 Nm (60 kgf.cm, 52 in.Ibf)

NOTICE:

Tighten the 2 through bolts evenly.

d) Connect the lead wire to terminal C with the
nut.
Torque: 7.8 Nm (80 kgf.cm, 69 in.Ibf)
Install the dust protector.

- 11 -

SECTION 3.:

PERFORMANCE TEST

1. CARRY OUT NO-LOAD PERFORMANCE

TEST

a) Connect the battery and ammeter to the
starter as shown.

b) Check that the starter rotates smoothly and
steadily with the pinion gear moving out.

c) Check that the ammeter shows the specified
current.
Specified current: At 11.5 V 90 A or less

NOTICE:

Confirm the pinion gear moves outward and
rotates smoothly.
Confirm the pinion gear returns smoothly
when the power cuts off.

- 12 -

SECTION 4.:

ADDITIONAL PROCEDURES

(A) ARMATURE TO FIELD FRAME INSTALLATION
(WITH BRUSH HOLDER FITTED)

1. REMOVE END CASE

(a) Remove 2 screws and end cover from
field frame.
(b) Remove any grease that may have been
deposited on the brushes by the
unintentional displacement of the armature.

2. INSTALL ARMATURE

HINT: To avoid interference by the brushes

when installing the armature, pull the
brush springs away from the brushes and
rest them on brush holder, then retract the
brush by pulling the lead wire.

(a) Insert the armature into the field frame
and brush holder.
NOTICE: Take care not to place any

grease on the commutator portion.
(b) Press all 4 brushes into position and relocate
brush springs into position.
NOTICE: Ensure that the brush springs

contact the brushes correctly and

operate smoothly when depressed.

(c) Install the end cover to the field frame with
2 screws.
Torque: 3.8 Nm (39 kgf.cm, 34 in. Ibf)

(B) STARTER HOUSING ASSEMBLY

(a) Place these parts in position on the
starter housing:

1. Bearing

2. Idler gear
(b) Apply grease to the gear and the bearing.
HINT: To aid with installation of these parts,

install according to the order of 1,2,3
as shown in the illustration.

- 13 -

5. COMPLETION IDENTIFICATION LABEL

On completion of repair, a completed identification label is to be affixed to the right hand
side A pillar post between the upper and lower door hinges.

• The diagrams below show the type of label and completion method.

##/##/##

8514A

DLR CODE: XXXX

This label is designed so that the completion information can be impressed into the label
rather than being marked with ink, therefore the following applies:

1. Prior to affixing label, using a ball point pen, impress the date and campaign

code number 8514A and dealer code onto the label.

2. Ensure the right hand A pillar post between the upper and lower door hinges

is free of grease and oil in the area where the label is to be affixed.

3. Peel label from backing and affix to the A pillar.

- 14 -

6. WARRANTY REIMBURSEMENT INSTRUCTIONS

Dealers are requested to process all claims covered by this recall campaign on a daily
basis.

All claims must be submitted via the normal Telus claim input facility, and parts used must
also be included.

Please ensure the following information is used:

MODEL NAME MODEL CODE VIN RANGE PRODUCTION PERIOD

VDS VIS

LS400 UCF20R 53UF20 00025919 - 00093925 APRIL 10TH 1995 TO

MAY 21ST 1997

STARTER MAGNETIC SWITCH REPLACEMENT

WA RRANTY TYPE: WV E
ORIGINAL FAILED PART NO.: NOT REQUIRED
T1 & T2 CODES: 99 & 99
OPERATION NO.: 8514A2B
FLAT RATE TIME: 4.3 HRS / VEHICLE
CONDITION: STARTER
CAUSE: SWITCH
REMEDY: RECALL

- 15 -