LS 400 and SC 400 Starter Switch Repair (Special Service Campaign WL–1)

January 27, 1998 Lexus LS 400 & SC 400

Table of Contents

OVERVIEW 2

PREPARING FOR THE SSC

Determine Your Demand 3 Manpower and Facility Requirements 4 Tools and Equipment 5 Technical Training 5 Parts Availability/Ordering 6 TDN System 7 Planning Your Communication Strategy 9 Calls from the Media 13

IMPLEMENTING THE SSC

Car Rental and Service Loaners 15 Contacting Customers 16 Remote Area Service Plan 17 The Write–Up 19 Preparing for Delivery After SSC Completion 21 Delivery of the Vehicle After SSC Completion 21 Follow–Up 21 Work Order Closing/Claim Submission 21 Recap of Claim Submission and General Provisions of the SSC 22 Claiming Reimbursement for Special Services 23 TDN Claim Preparation Instructions 24 Invoicing 25 Paper Claim Submission 31 Customer Notification Letter 36

TECHNICAL INSTRUCTIONS 37

2 Special Service Campaign WL–1

PREPARING FOR THE SSC

Overview As a safety measure, Lexus will be initiating a voluntary Special Service Campaign (SSC) [WL–1] for selected 1995–97 LS 400s and SC 400s. Although this SSC is an unprecedented situation for Lexus, it’s also an opportunity to protect and strengthen the relationships we have estab- lished with our valued customers. This handbook provides all the details necessary to plan and implement the SSC at your dealership. Key points of this Special Service Campaign are summarized below.

Condition On certain 1995–1997 LS 400 and 1996–1997 SC 400 Lexus vehicles, there is a possibility that the starter motor may not operate and the engine will not start.

The cause of this condition is due to improper assembly of the battery cable terminal of the starter motor magnetic switch. An electrical short circuit may occur if electrically conductive liquid such as salt water moisture enters this area.

Repair This SSC involves replacing the starter switch assembly of the starter motor. For detailed information, refer to the attached technical instructions and the accompanying repair video.

Customer Notification Notification letters will be sent to selected vehicle owners in February, 1998 based upon the Lexus National Service History File. This letter will advise owners of the need to have the vehicle modification performed. The Lexus Web Site (www.lexus.com) will also feature a section dedicated to informing owners about this campaign.

SSC & Customer Satisfaction The Special Service Campaign provides us with an opportunity to demonstrate the Lexus commitment to safety and customer satisfaction. By

January 27, 1998 3 Lexus LS 400 & SC 400

implementing the SSC in an organized and efficient manner, we can protect our relationships with core customers and strengthen these associa- tions. Throughout the entire experience, we need to stay positive and let the customer know that we are genuinely interested in resolving the mat- ter in a timely fashion.

Determine Your Demand This Special Service Campaign only applies to 1995–97 LS 400s and SC 400s within the VIN range below. No other vehicles before or after this range are to be repaired under the provisions of this SSC.

Model Model Years VDS Involved VIN Range LS 400 1995–97 JT8UF22E*S 0024707–0094983 JT8BH22F*T 0024707–0094983 JT8BH28F*V 0024707–0094983 SC 400 1996–97 JT8CH32Y*T 0049511–1000658 JT8CH32Y*V 0049511–1000658

NOTE: CANADIAN vehicles falling within this VIN range qualify under the same guidelines.

The enclosed SSC summary report lists vehicles sold by your dealership. From this list, please determine the actual number of customers who should come back to your dealership for this SSC.

4 Special Service Campaign WL–1

Manpower and Facility Re- quirements It is the intent of Lexus to have 90% of SSC repairs completed by the end of March, 1998. This is an aggressive 45 day window that will require everyone’s full dedication. Adding to the challenge is the length of the repair. Given the length of the repair, it is our recommendation is that you will need to allocate at least 30% (and sometimes up to 50%) of your technicians to this SSC without negatively impacting your regular service customer business. In reviewing your dealership’s manpower and facility requirements for this Special Service Campaign, there are several items you need to consider and several questions to answer regarding your capacity:

• Investigate ways to increase your Service Departments production: – Extended service hours – Extended shop hours – Saturday/night service – Hire additional technicians – Team up technicians in a group dedicated to this repair

• Do you need to increase your pick–up and delivery staff?

• Can you increase your loaner fleet with off–lease Lexus vehicles. (Refer to the 1998 Lexus Customer Convenience System for information and monthly subsidy amounts.)

• Do you need to hire additional support staff for pick–up/delivery, car washes and fuel tank fill–ups?

• Has your local Enterprise Rent–A–Car Branch or Area Manager contacted you to arrange for extra loaner cars? (A special arrangement has been made with Enterprise. See page 15 for further details.)

January 27, 1998 5 Lexus LS 400 & SC 400

• You will need to hold a meeting with all associates to discuss: – Pick–up and delivery procedures – Remote repair questions and available options for the customer – Importance of Lexus customer care for each SSC customer – The importance of not only your valued SSC customers, but also your regular service customers. Make sure they also receive nothing less than “Lexus Cares” quality service due to the capacity is- sues.

⇒ Tools and Equipment Special service tools are required and will be provided at no charge with the initial dealership materials. These components are as follows:

SST # Description Qty. 09249–30100–ST Two wrench/handle set 1 09810–40000–ST Remote starter switch 1 N.P.N. Protective intake manifold covers 2 N.P.N. Coolant tube plug 1 00241–START–RR Technical video: Starter Switch 1 Repair

Additional special service tools and copies of the repair video are available from the Material Distribution Center.

Technical Training Included with this handbook, were video tapes describing the repair procedures. The number of copies enclosed was based upon the number of technicians at your dealership.

We recommend that all customer contact personnel view this video to better understand the nature of this SSC.

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⇒ We also suggest that all managers and staff who will be directly involved in completing the repairs or supporting the SSC should view the repair and administrative video and form group discussions to prepare for this SSC.

We also recommend that one person at your dealership be designated as the Campaign Coordinator. All inquiries about this SSC should be directed to this person to avoid dissemination of incorrect or inappropriate information.

Your District Service and Parts Manager or District Sales Manager will meet with you to answer your questions and monitor the progress of the SSC.

Parts Availability/Ordering

Part Number Part Name Qty. Per Ve- hicle 28226–50020 Repair Service Kit 1 04007–06350 Starter Gasket Kit 1

DEALER STOCKING GUIDE (D.S.G.). This will ensure automatic ordering to your facing Parts Distribution Center (P.D.C.) when you sell or obligate inventory. The quantities assigned will be based upon the number of vehicles at your dealership requiring the SSC.

There is sufficient inventory in the P.D.C. to complete this SSC. You are encouraged to order only those parts needed to repair the vehicles with service appointments. Individual dealer tracking will be made and irregularities in quantity ordering will be passed on to Lexus Area Of- fices for follow–up and correction.

January 27, 1998 7 Lexus LS 400 & SC 400

⇒ TDN System The following steps must be taken to prepare your TDN System for proc- essing SSC claims:

• The labor operation codes have been transmitted to your dealership. If you have not received these codes, call the TDN hotline (800–421–8154.)

• Create a menu code using the new labor operations code estab- lished for this SSC.

⇒ Menu Code: WL1 Labor Op. Code: 8514A2

Menu Option SC–2

MENU CODE CUSTOMIZATION LEXUS DEALERSHIP

1/23/98 Menu Code : WL1 Copy From: Start Date : 1/23/98 Stop Date : 0/00/00 Opcode and Combination : 8514A2 (Enter “?0” Or Press Cmd/F19) Use Flate Rate Hours : Y (Y/N) Description : R & R STARTER KIT Labor Hours : 4.3 (nnn.nn) Labor Level : (0–9, P,F or Blank) Override Labor Amount : (nnn.nn) Total Operation Estimate : (nnn.nn) Suppress Hours & Amount On Sub–Menu Codes (Y/N) MENU/OPCODE P MENU/OPCODE P MENU/OPCODE P MENU/OPCODE P MENU/OPCODE P Cmnd/F4: Reactivate 6: More Text 10: Return 19: View Flat Rate 5: Print 8: Attach Parts Enter: Process S#001AA

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⇒ Attach Part Numbers to Menu Code WL1

CMD SC–8

MENU CODE CUSTOMIZATION LEXUS DEALERSHIP

1/23/98 Page: 1 Of 1 Menu Code : WL1 R & R STARTER KIT PARTS PER MC PART NUMBER QTY DESCRIPTION QUP JOB DSG LX 2822650020 1 STARTER KIT 1 LX 0400706350 1 GASKET KIT 1 Roll: Up/Down 2: View MC (Mfg Code) 7: Exit Cmnd/F1: First Page 4: Delete 10: Return S#001BA

January 27, 1998 9 Lexus LS 400 & SC 400

⇒ Planning Your Communication Strategy It is important that you develop a strategy to communicate effectively. The following are some general statements that can be used when ex- plaining the SSC.

Q1: What is the condition?

A1: On certain 1995–1997 LS 400 and 1996–1997 SC 400 Lexus vehicles, there is a possibility that the starter motor may not operate and the engine will not start.

Q2: What is the cause of this condition?

A2: Due to improper assembly of the battery cable terminal of the starter motor magnetic switch, an electrical short circuit may occur if electrically conductive liquid such as salt water moisture enters this area.

Q3: What will happen if an electrical short circuit occurs?

A3: The starter motor will not operate correctly. In the worst and very rare case, it could result in an under–hood fire.

Q4: Which and how many vehicles are involved?

A4: ‘95, ‘96, and ’97 model year Lexus LS 400 and ’96 and ’97 model year Lexus SC 400 vehicles are involved. There are approximately 48,000 vehicles involved.

Q5: What is the production range of the involved vehicles?

A5: Lexus LS 400: From April 3, 1995 production to June 4, 1997. Lexus SC 400: From August 3, 1995 production to August 21, 1997.

Q6: How many cases have been reported? A6: 8 cases have been reported.

10 Special Service Campaign WL–1

Q7. Is there any prior indication to the vehicle owner that this condition might occur? A7: No.

Q8: Will all involved vehicles experience this condition? A8: No. Only very few vehicles may actually experience this condition.

Q9: What is the magnetic switch? A9: The magnetic switch is the electrical relay between the battery and the starter motor. It is activated when the ignition key is turned to the “START” position.

Q10: Where is the magnetic switch located? A10: It is part of the starter motor assembly.

Q11: What improvement has been made to current production vehicles? A11: The assembly process of the magnetic switch has been change d.

Q12: Who is the supplier of this magnetic switch? A12: Denso Corporation in Japan.

Q13: What is Lexus going to do?

A13: Owners of the involved vehicles will receive a campaign notification by first class mail in February 1998. Lexus dealers will replace the magnetic switch of the starter motor with an im- proved one. The replacement will be performed at no cost to the vehicle owners.

Q14. How long will the repair take? A14: It will take approximately 4 hours.

Q15: Has this condition occurred on other Toyota/Lexus models?

A15: No. The magnetic switch, which is the cause of this condition, is only installed on 1UZ–FE V8 engine. Therefore, the affected

January 27, 1998 11 Lexus LS 400 & SC 400

vehicles are limited to ’95, ’96, and ’97 model year Lexus LS 400 and’96 and ’97 model year Lexus SC 400 vehicles.

Q16: Will I experience this condition with my Lexus?

A16: To determine whether or not your vehicle is involved, please contact your Lexus dealers.

Q17: If my vehicle was previously repaired for this condition, is it necessary for me to contact my dealer again?

A17: Yes. Please contact your Lexus dealer to confirm your vehicle’s involvement and arrange for the magnetic switch replacement at your earliest convenience.

Q18: Was this the result of any government action? A18. No, this service campaign is entirely voluntary.

Q19. Have there been any deaths or injuries resulting from under– hood fires?

A19. We know of no deaths or injuries in the eight reported cases.

Calls to Your Customers

• LS 400 and SC 400 customers involved in the SSC

⇒ Use the list provided in this package to begin calling customers as soon as preparations are completed.

• LS 400 and SC 400 customers not involved

⇒ Assure any customers with vehicles outside of the involved VIN range that this repair is not needed.

⇒ Calls from Your Custom- ers

• It is important to institute a system to respond to customers calling your dealership for more information regarding the SSC. We rec-

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ommend designating an individual or individuals to answer these inquiries to ensure that callers get accurate, consistent information.

• The Lexus Website (www.lexus.com) also addresses customer con- cerns. Special sections help answer questions regarding customer safety and Campaign procedures.

• There is a separate Special Service Campaign hotline to respond to all customers inquiries: 1–888–333–9376. All Dealership questions should be directed to your DSPM.

⇒ Calls from the Media We ask that you refer any calls from the media or government agencies directly to Lexus headquarters in Torrance, California. The contacts at Lexus are:

Mike Michels, Lexus Public Relations Manager (310) 781–3282

and Holly Ferris, (310) 781–3279

The following is a copy of the press release sent to the media:

(Note, this is a draft. The following is a sample proposed Special Service Campaign news release, pre- pared to illustrate the type of information to be issued in a public statement. The details are preliminary and subject to change.)

Lexus Announces Voluntary Service Campaign

to Replace Starter Component

TORRANCE, Calif. (For release January 27, 1998) — Lexus Division of Toyota Motor Sales, USA, Inc. today announced a voluntary service campaign to modify starter relays on certain 1995, 1996 and 1997 LS 400 and SC 400 automobiles. The action was taken to maintain the highest degree of reliability and safety of the affected vehicles. In accordance with its commitment to complete satisfaction,

January 27, 1998 13 Lexus LS 400 & SC 400

Lexus and its dealers are making every effort to minimize inconvenience to Lexus customers, while as- suring that their vehicles will continue to provide reliable and safe service.

Lexus will replace starter solenoid assemblies in approximately 48,000 1995, 1996 and 1997 LS 400 and SC 400 models. The carmaker has determined that in certain conditions, deterioration of a battery connector post on the starter solenoid could cause an electrical short circuit and failure of the engine to start. In an extremely small number of cases, there is a potential for melted wiring and possible engine compartment fires. Only a small number of occurrences have been reported, amounting to less than 0.001 percent of the number of vehicles produced with this component.

Although the condition is quite rare, the company is voluntarily recalling all vehicles in which this component is installed to insure product reliability and safety.

“Lexus is totally committed to its customers,” said James E. Press, Lexus senior vice president and general manager. “We are contacting our customers to apologize, to assure them that their cars will be upgraded promptly and that Lexus dealers will do all they can to minimize inconvenience. While this is a highly unlikely situation, we are leaving nothing to chance and are replacing 100% of the potentially mal- functioning parts.”

The affected starter solenoids will be replaced with a redesigned component to prevent possible short circuits. Ample parts supplies will be available and Lexus dealers are dedicating technicians and facilities to service customer vehicles as quickly as possible. In addition to 1100 trained dealership technicians, an additional 50 factory technical specialists will be dispatched to assist dealerships.

Rather than wait for customers to call, Lexus dealers will begin contacting their customers to schedule the most convenient times for service. Owners of affected vehicles also will be notified by mail. Only some of the LS 400 and SC 400 models built in 1995, 1996 and 1997 are involved and vehicle owners are encouraged to make an appointment with their dealership as soon as possible.

Customers who have questions should contact their Lexus dealer or a Lexus customer satisfaction representative at 1–888–333–9376. All customers will be offered the use of a loaner vehicle while their LS 400 or SC 400 is being modified. As is customary when Lexus vehicles are serviced, customer’s cars will receive a complimentary wash and refueling.

14 Special Service Campaign WL–1

⇒ Implementing the SSC

Car Rental and Service Loaners

The affected customers of this Special Service Campaign are our core, highly–valued customers. We need to protect them and give them our best treatment. One of the ways we can demonstrate that Lexus cares is by honoring loaner car requests with the best loaner available.

{Preferred}

Lexus Customer Convenience System (LCCS) Officially enrolled LCCS vehicles may be claimed at a rate of $44.00 per day. (Lexus vehicles only.)

{Preferred}

Lexus Dealer Fleet (Lexus vehicles only) A rate of $44.00 per day may be claimed if using this option. Be sure to follow customer supplied insurance guidelines.

Enterprise Rent–A–Car Recognizing that loaner car capacity may become an issue, Lexus has made special arrangements with Enterprise Rent–A–Car to supple- ment the demand. The Branch or Area Manager of your nearest Enter- prise agency will be contacting you to discuss how they can facilitate this campaign. The specially negotiated price includes a $35.00 per day charge for premium cars and an $11.99 per day rate for full collision protection (C.D.W.) The total is $46.99 in all 48 contiguous states except for New York where the rate structure is different due to state laws gov- erning the sale of a Collision Damage Waiver.

An important feature to this preferred rental arrangement is that this rate entitles your customers to any available Enterprise vehicle including luxury vehicles. So please provide them with a selection of the best available vehicles. Also please employ the strategy (where practical) that

January 27, 1998 15 Lexus LS 400 & SC 400

SSC customers receive Lexus vehicles and Enterprise vehicles are reserved for regular service customers.

Lexus Dealer Fleet (non–Lexus vehicles) A rate of $35.00 per day may be claimed if using this option.

Other Car Rental Agencies (Other than Enterprise) In most cases, a rate of $35.00 per day may be claimed if using this option.

The motivating factor for any of these options is the customer’s convenience and consideration. Again please provide the best available vehicle. If extraordinary customer requests are made, please contact your DSPM. In addition, loaner car requests that exceed five days must carry proper DSPM authorization.

Contacting Customers When contacting customers, it is important to stress that this service campaign repair is a safety requirement and that the customer should have it done as soon as possible. Also let them know how valuable a customer they are and that this Special Service Campaign is being voluntarily undertaken by Lexus to keep their confidence in the Lexus brand.

Begin contacting the customers on your SSC list to schedule appointments and reserve parts using the TDN System. Make sure you schedule appointments to coincide with the receipt of all necessary parts and the completion of training by your technicians.

Also, reserve a LCCS or Enterprise vehicle to ensure a premium car for each customer.

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⇒ Remote Area Service Plan

“Remote” is defined as those distances where a customer is 100 or more miles from the nearest Lexus dealership.

Your DSPM will work with you to develop and authorize an action plan.

Guidelines to be used in performing remote repairs are:

• If the customer is within 100 miles of the nearest Lexus dealership, the closest Lexus dealership will perform the repair provided that prior authorization for related expenses has been approved by the DSPM.

• If the customer is more than 100 miles from the nearest Lexus dealership, Lexus area associates or, Lexus national associates may perform the repair. Dealerships may also make these repairs but only with the authorization of the Area Coordinator (most likely the F.T.S.) Remote Repairs plans must be coordinated and authorized by your A.S.P.M.

• Each situation will be handled on a case–by–case basis.

• Lexus will pay for authorized costs that have been approved by DSPM or area offices.

⇒ Alternatives include:

• Pick–up and re–delivery of remotely located vehicles

• Personnel performing repairs at remote locations

January 27, 1998 17 Lexus LS 400 & SC 400

⇒ Creating Appointments

SI–1 APPOINTMENT/WORK ORDER ENTRY LEXUS DEALERSHIP

DRIVER 1/23/98 Last Name : * SMITH Temp : (Press Help) First Name : * John Sal: * MR SSN : Prim Drvr: Address/PO : * 124 MAIN ST Hm Ph : Ext: Apartment Wrk Ph: Ext: City : * Torrance State : * CA Zip: * 90509 COMPANY Name : (Key Name and Press Enter) Address/PO : Temp : (Press Help) Suite : Phone : Ext: City : State : Zip: * VEHICLE VIN : * JT8BH28F5V0074042 Year : * 97 Make : * LEXUS Model : * LS400 Color: * BLACK Miles In : * 17342 License # : State: Miles Out: Stock # : HAT: DOFU : 12/06/96 Prod Date: APPOINTMENT Date : 2/03/98 Time : 10:00 A (A=AM, P=PM) SC : # 332 Status : Loaner: Hours: Confirmed : Prime Item : SSC WL1 Arrival Msg: Cmd/F1: Chg Drv/Co. 3: Clear Scrn 6: Company Note 9: Loaner Vehicle SI–1 2: Chg Vehicle 5: Driver Note 8: Vehicle Note 12: Conditions S#021FA CMD–12

APPOINTMENT/WORK ORDER ENTRY LEXUS DEALERSHIP

Consultant#: 332 Hat #: VIN: JT8BH28F5V0074042 Last Name : * SMITH Veh: LS400 Black Co Name : Stk: Miles: 17342 DRIVER VEHICLE Condition : 01 Type: 2 (1=Cust,2=War,3=Int,4=Ext) Dept: S SERVICE DEPT. LN MENU/OPCODE C INSTRUCTIONS/NOTES ESTIMATE 01 WL1 SSC WL1 .00 02 .00 Roll: Up/Down Cmd/F7: Exit Enter: Continue Help: Options SRVL21

Reserve Parts

SI–1 CMD–23

RESERVE PARTS ENTRY LEXUS DEALERSHIP 1/23/98 Page: 1 Of 1 CUSTOMER/VEHICLE SC# : 332 Hat: Driver : SMITH Mileage : 17342 Company : VIN : JT8BH28F5V0074042 Vehicle : 97 LEXUS LS400 BLACK PARTS RESERVED ON QTY QTY MENU CODE PART NUMBER MC QTY DESCRIPTION S Hand RSV AVAIL WL1 2822650020 LX 1 STARTER KIT 100 1 99 WL1 0400706350 LX 1 GASKET KIT 100 1 99 Roll: Up/Down 2: View MC (Mfg Code) 5: Print 10: Return Cmnd/F1: First Page 4: Delete 7: Exit S#027AA

The Write–Up Listed below are some general guidelines to use when the customer ar- rives at your dealership for the SSC:

• Explain that the actual service will take about four hours and that the special services (refueling, car wash) will require additional time at your dealership

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• Explain the type of repair involved

• If the customer does not have a SSC notice:

⇒ Check the VIN against the National Service History File to see if the vehicle has been previously repaired under this Cam- paign

⇒ Check the left front door hinge post for an SSC completion label

⇒ If there is no label, check the VIN against the SSC list⇒ vehicle does not require the Campaign repairs.

⇒ If the vehicle is eligible, explain the SSC to the customer, de- scribe the procedure and the amount of time needed for the repair

• If the customer has an appointment, pull the work order, otherwise, create a work order reflecting the need to complete the SSC WL–1 repair

• Issue the work order to the technician and include job instructions for the SSC.

January 27, 1998 19 Lexus LS 400 & SC 400

⇒ Preparing for the Deliv- ery After SSC Completion

• Wash/clean the vehicle inside and out

• Fill the gas tank with premium unleaded fuel (This actual fill–up cost will be charged as a SSC expense)

• Notify customer of completion

• Arrange for re–delivery or return of rental vehicle

⇒ Delivery of the Vehicle After SSC Completion The delivery of the vehicle is a very important part of ensuring a high level of customer satisfaction:

• Explain all SSC repairs to the customer

• Apologize for any inconveniences and emphasize desire to protect the relationship

• Thank the customer for his or her time and their continuing patron- age

⇒ Follow–Up Complete, 100% after–service follow–up is critical to ensure complete customer satisfaction with the repairs performed and the service provided.

Work Order Closing/ Claim Submission The following information explains the policies and procedures for preparation and submission of a warranty claim for reimbursement of a repair performed under the SSC WL–1.

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⇒

Repair Claim Opcode Combina- Labor Hours OPN T– CCR Sublet

tion Code Codes

Type

R & R Starter SC 8514A2 N/A 4.3 N/A N/A N/A GA (fuel),TW (tow), RT (loaner vehicle),

Kit DE (pick–up and delivery or remote repair),

or CW car wash)as required and substan-

tiated by invoices

R & R Starter RG 8514A3 N/A 4.3 hours for 28100 Required Required GA (fuel),TW (tow), RT (loaner vehicle),

Kit & Re- R & R starter – Condition: DE (pick–up and delivery or remote repair), placement of kit plus any 50060 T1 = 99 Additional time or CW (car wash)as required and substan-

Other Dam- additional T2 = 99 = x.x hours tiated by invoices aged Parts necessary Cause & Reme-

work (as sub- dy: Description

stantiated by of what addi-

time flags on tional repairs

the back of were made

the R.O.)

NOTE: Lexus warranty will only accept one claim per vehicle under the terms of the SSC. Please ensure that your dealership checks the National History File to see if the vehicle has been repaired under this SSC prior to servicing the vehicle.

Recap of Claims Submission and General Provisions of the SSC

• Lexus will pay for gas tank fill–up

• Lexus will provide a loaner vehicle

• Lexus will pay for costs associated with remote repairs

• Lexus will pay for remote pick–up and delivery (DSPM authorization only)

January 27, 1998 21 Lexus LS 400 & SC 400

⇒ Claiming Reimburse- ment for Special Services You must use sublet to claim any special services required in conjunction with the SSC repair.

• Issue “TW” (Tow Vehicle) –– Due to the safety aspects of this repair, expect a high incidence of tow/flat bed requests.

⇒ Applicable to every vehicle

⇒ Claim actual receipted amount as a sublet

⇒ You may utilize Amoco or any agency providing Lexus type service

• Issue “RT” (Rental Car) –– A high incidence of loaner car requests is possible.

⇒ Applicable to every vehicle

⇒ Special Service Campaign customers may also be given dealer owned Lexus or L.C.C.S. vehicles at the normal reimbursement rate of $44.00 per day

⇒ Lexus has negotiated a special day rate of $47.00 per day with Enterprise Rent–A–Car as an option (includes C.D.W., Colli- sion Damage Waiver insurance)

⇒ Dealer loaner vehicles or other car rental agencies will be re- imbursed at the rate of $35.00 per day

⇒ The loaner vehicle reimbursement rate cap is five days per repair unless otherwise authorized by DSPM.

• Issue “GA” (Gas Tank Fill–up)

⇒ Applicable to every vehicle

⇒ Claim actual fill–up amount

• Issue “CW” (Car Wash/Administrative Time)

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⇒ Applicable to every vehicle

⇒ Claim $20.00 per vehicle

• Issue “DE” (Pick–Up and Delivery/Remote Repairs)

⇒ Applicable only under special circumstances (e.g. more than 100 miles from the nearest Lexus dealership)

⇒ Claim actual dealer cost

⇒ F.T.S./A.S.P.M. authorization is required for this expense

• Issue “DE” (Pick–Up and Delivery/Non–Remote Repairs)

⇒ Applicable at dealer discretion

⇒ Claim actual dealer cost

⇒ TDN Claim Preparation Instructions NOTE: Each sublet must be a separate entry with:

• Unique invoice number

• Description

• Sublet Type

• Dollar Amount

• In Repair Order Management, select claim type “SC” (Special Ser- vice Campaign)

January 27, 1998 23 Lexus LS 400 & SC 400

⇒ Invoicing

Create Invoice

SI–3

INVOICING ENTRY LEXUS DEALERSHIP R/O 0006833 S/C: 332 HAT#: VIN: JT8BH28F5V0074042 Driver Name: SMITH Veh: LS 400 BLACK Co. Name : Stk: Miles: 17342 DRIVER VEHICLE Condition : 01 Type: 2 (1=Cust,2=War,3=Int,4=Ext) Dept: S SERVICE DEPT. LN MENU/OPCODE C L TEC ACT TM FLG TM INSTRUCTIONS/NOTES LABOR 01 WL1 354 4.30 4.30 SSC WL1 232.20 02 .00 Roll: Up/Down Cmd/F12 Total Enter: Process Help: Options SRVL23C

Condition Total

SI–3 CMD–12

SERVICE INVOICE CONDITION TOTAL LEXUS DEALERSHIP 2/23/98 R/O #: 0006833 Condition: 01 Type: Warranty Department: SERV Prime Item: SSC WL1 TOTAL AMOUNTS ! WARRANTY INFORMATION COST SALE ACCT DESCRIPTION CLAIMS DESCRIPTION 64.50 232.20 4420 WARR MECH LBR–T WARRANTY CLAIMS–TOY 55.79 78.10 PARTS 76.36 76.36 4460 SUBLET REPAIR M .00 .00 7193 SUPPLY&SM TOOLS .00 .00 7185 FREIGHT–P&A .00 .00 4770 TIRES GAS OIL & .00 4400 NEW CAR SLS–TOY .00 .00 MISCELLANEOUS .00 .00 MISCELLANEOUS 386.66 Condition Total Cmd/F10: Return 23: View Parts 12: Total (Continue) Enter: Process Claim Information

SI–3 CMD–12

SERVICE INVOICE CONDITION TOTAL LEXUS DEALERSHIP 1/23/98 R/O #: 0006833 Condition: 01 Type: Warranty Dept : SERV Prime Item: SSC WL1 Claim : # 0265553 WARRANTY CLAIM INFORMATION Operation Code : * 8514A2 Comb: Claim Type : SC (Help: Claim Types) RO Mileage : * 17342 Repair Date : * 1/23/98 DOFU : * 12/06/96 Original Part # : (Help) T1: T2: T3: Condition : Cause : Remedy : AUTHORIZATION PARTIAL/REQUEST AMTS ORIGINAL REPAIR ORDER Ath # : (CMD 16) Labor : RO Number : Ath. Type : Sublet : RO Date : 24 A/C Compressor: Parts : RO Mileage: Totals : .00 ADDITIONAL T3 CODES: Cmd/F10: Return 13: Warranty Help 23: View Parts 12: Total (Continue) 16: Auth Info. Enter: Process S#L23WB Special Service Campaign WL–1

Sublet Information Example of Transportation Costs to Make Remote Repairs

Condition Total

SI–3 CMD–22 (From Condition screen)

SI–3 CMD–12

SERVICE INVOICE CONDITION TOTAL LEXUS DEALERSHIP 1/23/98 R/O #: 0006833 Condition: 01 Type: Warranty Department: SERV Prime Item: SSC WL1 TOTAL AMOUNTS ! WARRANTY INFORMATION COST SALE ACCT DESCRIPTION CLAIMS DESCRIPTION 64.50 232.20 4420 WARR MECH LBR–T WARRANTY CLAIMS–TOY 55.79 78.10 PARTS 232.00 232.00 4460 SUBLET REPAIR M .00 .00 7193 SUPPLY&SM TOOLS .00 .00 7185 FREIGHT–P&A .00 .00 4770 TIRES GAS OIL & .00 4400 CUST MECH LBR–T .00 .00 MISCELLANEOUS .00 .00 MISCELLANEOUS 542.30 Condition Totals ======Cmd/F10: Return 23: View Parts 12: Total (Continue) Enter: Process

January 27, 1998 25 Lexus LS 400 & SC 400

Sublet Information Example of Remote Area Ser- vice

SI–3

CMD–22 (From Condition screen)

INVOICING ENTRY LEXUS DEALERSHIP R/O ...... : 0006833 S/C: 332 Hat# VIN: JT8BH28F5V0074042 FLUIDS DESCRIPTION UNITS COST SALE 5/30 CASTROL .00 .00 .00 DEXTRON II .00 .00 .00 PENNZ GEAR OIL .00 .00 .00 TIRE TAX .00 .00 .00 ENVIRONMENTAL .00 .00 .00 SUBLET REPAIRS FOR R/O# 0006833 – CONDITION 01 P.O. # INVOICE # TYPE VENDOR/DESCRIPTION COST % SALE 1234 1234 GA FUEL FILL UP 12.36 12.36 1234A 1234A RT LEXUS LOANER VEHICLE 44.00 44.00 1234B 1234B CW CAR WASH 20.00 20.00 1234C 1234C TW SMITH TOWING 37.00 37.00 .00 .00 Cmnd/F2: View Sublet Types 6: Move Fluid 8: Move Sublet 10: Return S0023BA

Condition Total

SI–3 CMD–12

SERVICE INVOICE CONDITION TOTAL LEXUS DEALERSHIP 1/23/98 R/O #: 0006833 Condition: 01 Type: Warranty Dept: SERV Prime Item: SSC WL1 TOTAL AMOUNTS ! WARRANTY INFORMATION COST SALE ACCT DESCRIPTION CLAIM# DESCRIPTION 64.50 232.20 4420 WARR MECH LBR–T WARRANTY CLAIMS–TOY 55.79 78.10 PARTS 113.36 113.36 4460 SUBLET REPAIR M .00 .00 7193 SUPPLY&SM TOOLS .00 .00 7185 FREIGHT–P&A .00 .00 4770 TIRES GAS OIL & .00 4200 NEW CAR SLS–TOY .00 .00 MISCELLANEOUS .00 .00 MISCELLANEOUS 423.66 Condition Totals ======Cmd/F10: Return 23: View Parts 12: Total (Continue) Enter: Process

26 Special Service Campaign WL–1

Warranty Information Screen

SERVICE INVOICE CONDITION TOTAL LEXUS DEALERSHIP 1/23/98 R/O #: 0006833 Condition: 01 Type: Warranty Dept : SERV Prime Item: SSC WL1 Claim : # 026553 WARRANTY CLAIM INFORMATION Operation Code : * 8514A2 Comb: Claim Type : SC (Help: Claim Types) RO Mileage : * 17342 Repair Date : * 1/23/98 DOFU : * 12/06/96 Original Part # : (Help) T1: T2: T3: Condition : Cause : Remedy : AUTHORIZATION PARTIAL/REQUEST AMTS ORIGINAL REPAIR ORDER Ath # : 300000 (CMD16) Labor : RO Number : Ath. Type : G Sublet : RO Date : A/C Compressor: Parts : RO Mileage: Totals : .00 ADDITIONAL T3 CODES: Cmd/F10: Return 13: Warranty Help 23: View Parts 12: Total (Continue) 16: Auth Info. Enter: Process S#L23WB

NOTE: Authorization is required for expense incurred for remote service or for pick–up and delivery in remote locations.

SERVICE INVOICE CONDITION TOTAL LEXUS DEALERSHIP 1/23/98 REPAIR AUTHORIZATION INFORMATION Last Name : SMITH First Name : JOHN Company Name : Warranty : * Y (Y/N) Goodwill : * N (Y/N) Reason For Expense :* SSC WL1 R&R STARTER KIT REMOTE REPAIR REQ DSPM AUTH CR Case # : TA Case # : BBB Case # : Legal Case # : PARTIAL ADJUST AMOUNTS TOTAL CLAIM DEALER AMOUNT CUSTOMER AMOUNT REQUESTED AMOUNT Labor 232.20 .00 .00 232.20 Parts + Markup 78.10 .00 .00 78.10 Sublet 232.00 .00 .00 232.00 Total 542.30 .00 .00 542.30 Must Be ‘Y’ Or ‘N’ Cmd/F10: Return Enter: Process S#L23WF 12: Total (Continue) 16: Auth Info. Enter: Process S#L23WB

January 27, 1998 27 Lexus LS 400 & SC 400

Repair Order Management Adding Fuel Costs

CW–1 CMD–22

INVOICING ENTRY LEXUS DEALERSHIP R/O ...... : 0006833 S/C: 332 Hat# VIN: JT8BH28F5V0074042 FLUIDS DESCRIPTION UNITS COST SALE 5/30 CASTROL .00 .00 .00 DEXTRON II .00 .00 .00 PENNZ GEAR OIL .00 .00 .00 TIRE TAX .00 .00 .00 ENVIRONMENTAL .00 .00 .00 SUBLET REPAIRS FOR R/O# 0006833 – CONDITION 01 P.O. # INVOICE # TYPE VENDOR/DESCRIPTION COST % SALE 1234 1234 GA FUEL FILL UP 12.36 12.36 1234A 1234A CW CAR WASH 20.00 20.00 .00 .00 .00 .00 .00 .00 Cmnd/F2: View Sublet Types 6: Move Fluid 8: Move Sublet 10: Return S0023BA Paper Claim Submission Please use the following instructions in the event that a paper claim must be submitted. The following claim instructions list information, field by field, corresponding to the format of the Lexus Warranty Paper Claim Form. If information is not required for SSC claim submission, it will be noted.

1. Dealer Code: Enter the 5–digit number assigned to your dealership by Lexus.

2. Claim Number: Enter the 6–digit claim number that your dealership has assigned to the claim. The claim number must be unique. It must begin with the letter “A” followed by numeric characters.

3. Repair Order Number: Enter the repair order number from the invoice created at the time of the repair.

4. In–Service Date: Enter the date the vehicle was first placed into service. (Enter MM–DD–YY format)

5. Vehicle Identification Number: Enter the complete 17–digit VIN from the vehicle that was repaired.

6. Repair Date: Enter the date the vehicle was repaired. (Enter MM– DD–YY format)

7. Repair Miles: Enter the vehicle mileage at the time of repair. (Do not enter tenths of a mile.)

8. Original Part Number: Not required on a SSC claim.

28 Special Service Campaign WL–1

9. Operation Codes: Enter one of two operation codes (8514A2 or 8514A3) for this SSC.

10. Combination Code: Not allowed for this SSC.

11. Total Hours: Enter the total labor hours allowed for this SSC. (Total hours allowed are 4.3.)

12. Sublet Invoice Number: Enter only if a special service was provided to the customer as per the guidelines of this manual.

13. Sublet Type: Enter the 2–digit sublet–type code only if a special service was provided to the customer as per the guidelines of this manual.

14. Sublet Description: Enter a brief description of the sublet only if a special service was provided to the customer as per the guidelines of this manual.

15. T–1 Code: Not required for an SSC claim.

16. T–2 Code: Not required for an SSC claim.

17. T–3 Code: Not required for an SSC claim.

18. Replacement Part Number: Enter the part number for the starter switch repair. (28226–50020 and 04007–06350)

19. Replacement Parts Quantity: Enter appropriate number in this field.

20. Original R.O./Installed Date/Installed Miles: Not required for an SSC claim.

21. Authorization Number: Enter a D.S.P.M. authorization number if authorization is required as per the guidelines of this manual. (Note:

January 27, 1998 29 Lexus LS 400 & SC 400

Service Manager self–authorization numbers are not allowed in this SSC.)

22. Authorization Type: Enter authorization type “G” only if an authorization number has been entered and is required as per the guidelines of this manual.

23. Labor Amount: Enter the total dollar amount to be claimed for the labor portion of the repair. This figure is calculated as the dealer’s authorized warranty labor rate multiplied by the allowable labor hours for the repair performed.

24. Sublet Amount: Enter the total dollar amount to be claimed for the sublet. Enter notation “Car Wash” separately at $20.00, “Gas” at the actual amount and any other applicable sublet codes.

25. Parts Amount: Enter the total dollar amount to be claimed for the replacement part. This figure is calculated as the dealer cost of the part replaced.

26. Parts Mark–Up: Enter the total dollar amount to be claimed for parts mark–up. This figure is calculated as the total parts amount claimed multiplied by 45%.

27. Claim Total: Enter the total amount to be claimed for the repair. This figure is calculated as the total of labor, sublet, parts and parts mark–up.

28. Battery Ship Code/Cell Readings: Not used at this time. Partial Adj. Labor/Sublet/Parts: not required for an SSC claim.

29. Condition/Cause/Remedy: Enter a description of the repair and the conditions requiring use of the “Pick–Up and Delivery” or “Remote Repair” special services. If a C/C/R is entered, something must be written in all three lines of the field.

30 Special Service Campaign WL–1

January 27, 1998 31 Lexus LS 400 & SC 400

SAFETY RECALL NOTICE – WL1 Lexus LS 400 and SC 400 – USA DRAFT Dear Lexus Owner: This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Lexus has decided that a defect which relates to motor vehicle safety exists in certain 1995 through 1997 model year LS 400 and 1996 through 1997 model year SC 400 vehicles. WHAT IS THE PROBLEM? Due to improper assembly of the terminal for the starter motor magnetic switch, an electrical short circuit may occur if electrically conductive liquid enters this area. Consequently, the starter motor may result in a no–start condition or, in the worst case, it could result in an under–hood fire. WHAT WILL LEXUS DO? Any Lexus Dealer will replace the starter motor magnetic switch to prevent this condition at NO COST to you. WHAT SHOULD YOU DO? Contact any authorized Lexus dealer and make an appointment to replace the starter motor magnetic switch as soon as possible. The labor time for replacement of the starter motor magnetic switch is approximately 4 hours. However, depending upon the dealer’s work schedule, it may be necessary to make your vehicle available for a longer period of time. Please present this notice to the dealer when you bring the vehicle in for the repair. If you no longer own the vehicle, please indicate so on the enclosed postage–paid form, providing us with the name and address of the new owner. WHAT IF YOU HAVE OTHER QUESTIONS? Please contact any Lexus dealer or call the Lexus Customer Satisfaction Department at toll free: 1–888–333–9376. If you believe that the dealer or Lexus has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the administrator, National Highway Traffic Safety Administration, 400 Seventh Street S.W., Washington, D.C. 20590, or call the toll free Auto Safety Hot Line at 800–424–9393 (Washington, D.C. area residents may call 366–0123). We have sent this notice in the interest of your continued satisfaction with our products and we sincerely re- gret any inconvenience this condition may have caused you. Thank you for driving a Lexus. Sincerely, LEXUS DIVISION Toyota Motor Sales, U.S.A., Inc.

32 Special Service Campaign WL–1

Technical Instructions

Table of Contents 37

Repair Procedures Flow Chart 38

VIN Location 39

Starter Switch Replacement Procedure 40

SSC Completion Label Installation 60

Repair Procedures Flow Chart

No Check whether this is an involved vehicle. Is the vehicle’s VIN included in the attached vehicle listing?

Yes

Yes Check National Service History File. Check for an SSC No action required. completion label at the specified location

Replace starter relay per the provided instructions.

Affix the SSC completion label (from the owner notification letter) at the specified location.

January 27, 1998 33 Lexus LS 400 & SC 400

⇒ VIN Location 1.Check the Vehicle Identification Number (VIN) a. Locate one of the Vehicle Identification Number (VIN) plates b. Check to make sure the eight digit number is within the following ranges:

⇒ 0024707–0094983 (For LS 400 models.)

⇒ 0049511–1000658 (For SC 400 models.)

⇒ YES: Check for an SSC–WL–1 Completion Label affixed to the left door hinge post near the door check.

NO: Assure the customer that their vehicle is not part of the SSC and that no further action is necessary.

2. Is an SSC–WL–1 Completion Label present?

⇒ YES: The Special Service Campaign has already been performed on the vehicle. No further action is necessary.

⇒ NO: Continue with SSC–WL–1 as outline in the following pages.

34 Special Service Campaign WL–1

TECHNICAL INSTRUCTIONS

FOR

SPECIAL SERVICE CAMPAIGN WL–1

January 27, 1998 35 Lexus LS 400 & SC 400

III. WORK PROCEDURE PRELIMINARY PREPARATION 1. Record the customer’s preset radio stations for AM, FM1 and FM2. 2. Position the driver’s seat in the No. 1 seat memory position. 3. Using the scan tool, retrieve and note any problem codes in ECM. NOTE: If there are any OBDII codes, also print or copy Freeze Frame Data. MAINTAINING CORRECT COOLANT LEVEL It is important to collect and return to the cooling system exactly the same amount of coolant that the system contained at the beginning of the work. Doing so will ensure that there are no air pockets trapped in the engine cooling system. 1. Before starting work, note the level of the engine coolant in the coolant reservoir. 2. Be careful to collect all coolant removed from the engine in a clean container. Do not mix coolant from different vehicles. 3. When refilling cooling system at the completion of the work, be sure that all removed coolant is reinstalled. Observe that the level of the coolant in the coolant reservoir is the same as before the work. If the level is below specification, top up with ”Toyota Long Life Antifreeze Coolant”.

STARTER REMOVAL 1. (a) Raise vehicle on the hoist. (b) Attach plastic hose to passenger side engine block drain fitting. Drain coolant into a clean container by loosening the petcock 1 full turn counterclockwise. NOTE: In order to prevent any damage, DO NOT loosen more than 1 full turn.

(c) After coolant is drained from block, tighten the petcock and lower vehicle. (d) Pull fuel door release and loosen fuel cap to release fuel pressure in tank. (e) Remove battery clamp cover and the air cleaner inlet. (f) Disconnect the negative battery terminal.

(g) Remove the bolt, 2 cap nuts and the V–bank cover. (h) Remove the hose retaining clamp and disconnect P/S air control hoses, IAC valve air supply hose, and EVAP hose from canister. (i) Remove the No. 1 air cleaner hose.

36 Special Service Campaign WL–1

(j) Remove one bolt and the intake air connector assembly.

2. Remove Air Intake Chamber Assembly (a) Disconnect the following cables: • Accelerator cable. • A/T throttle control cable. • Cruise control actuator cable.

(b) Remove the 2 bolts and the accelerator bracket. (c) Disconnect following connectors: • Throttle position sensor connector. • w/TRAC: Sub–throttle position sensor connector and Sub–throttle actuator connector. • IAC valve connector. • EGR valve connector. • VSV connector for fuel pressure control. • VSV connector for EVAP. (d) Disconnect the following hoses: (1) Brake booster vacuum hose from union on air intake chamber.

(2) PCV hose from PCV valve on LH cylinder head. (3) Disconnect vacuum hose for the fuel pressure VSV at the rear of the air intake chamber. (4) Water bypass hose from the rear water bypass to EGR valve. (disconnect from EGR valve). (5) Disconnect the EVAP hose from the VSV for the EVAP. (6) Water bypass hose to the IAC valve at the thermostat housing. NOTE: Use compressed air to blow off any dirt on top of engine before continuing with disassembly. Always wear eye protection when using the compressed air. (e) Remove the 2 bolts connecting the No. 2 EGR pipe to the rear of the air intake chamber.

January 27, 1998 37 Lexus LS 400 & SC 400

(f) Remove the 4 bolts and 8 nuts on the air intake chamber assembly. (g) Position the mounting bracket with the fuel pressure VSV on the right side of the intake manifold. (h) Raise air intake chamber and disconnect the EGR gas temperature sensor connector.

(i) Lift up the air intake chamber assembly and turn over to the right hand side of the engine. Disconnect the following hoses and remove the air intake chamber assembly and the 4 gaskets. • Disconnect the water bypass hose to the rear water bypass from the throttle body. • Disconnect the PCV hose to RH cylinder head from the throttle body. (j) Cover up intake manifold ports to prevent any dirt from entering. (k) Remove 2 nuts connecting the No. 2 EGR pipe to rear water bypass and lift off No. 2 EGR pipe with the 2 gaskets. (l) Cover the hole of the No. 2 EGR pipe to prevent any dirt from entering.

3. Disconnect Fuel Return Hose (a) Disconnect the fuel return hose from the fuel pressure regulator.

38 Special Service Campaign WL–1

4. Remove Heater Hoses (a) Disconnect the heater water hose from the water bypass pipe. (b) Disconnect the other heater water hose from the heater water valve assembly.

5. Disconnect Engine Wire Harness from Fuel Rails and Rear Water bypass (a) Disconnect the A/T throttle cable from the clamps on the engine hanger and engine wire protector. (b) Remove the 2 bolts and disconnect the engine wire harness from the rear water bypass. (c) Remove the 2 bolts, and disconnect the engine wire harness from the RH fuel rail. (d) Loosen, but do not remove the fuel return pipe mounting bolt from the rear of LH cylinder head. (e) Remove the fuel return pipe mounting bolt from the rear water bypass under engine wire harness. (f) Disconnect the following:

• DLC1 from bracket on LH fuel rail. • 2 engine wire connectors (EA1 & EA2 for LS400 and EC1 & EC2 for SC400) from connector mounting bracket on LH fuel rail. • Engine wire clamp from wire bracket on LH fuel rail. 6. Remove Intake Manifold Assembly (a) Disconnect the 8 injector connectors. (b) Remove the 6 bolts, 4 nuts, the intake manifold assembly and 2 gaskets. NOTE: When removing the intake manifold, first clear the wire bridge at left front corner, second, clear the wire harness at right front corner, then lift the rear of the manifold up and forward to clear the fuel return pipe and wire

January 27, 1998 39 Lexus LS 400 & SC 400

har ness at the rear of the engine.

(c) Carefully turn the intake manifold over on top of the LH strut tower with fuel hose still connected. NOTE: Place cardboard over LH strut

tower and battery (On SC400, also cover the ignitor) prior to placing the manifold.

(d) Place SST protective covers over intake ports and reinstall the nuts to keep the covers in place while you are working in the engine valley. NOTE: DO NOT disconnect knock sensor connectors from knock sensors.

7. Remove Water Bypass Pipe (a) Disconnect the wire clamp from the bracket on the water bypass pipe. (b) Remove the water bypass pipe mounting bolt. (c) Pull out the water bypass pipe from the back of the water pump.

(d) Position water bypass pipe to the right side with the rear end behind passenger side valve cover.

40 Special Service Campaign WL–1

8. Remove Rear Water Bypass (a) From the new SST set, select the phased six point box wrench that provides the best positioning of the tool for loosening the lower bolt for the top end of No. 1 EGR pipe. (b) Position SST under the rear water bypass (between starter and loosened water bypass pipe) and onto the lower bolt for the upper end of the No. 1 EGR pipe, slide the adjustable handle over the end of the wrench. Reach over the rear water bypass and use your finger tip to ensure that the wrench remains securely seated on the bolt head as you apply torque. NOTE: To take advantage of this SST, it is necessary to alternate use after each partial turn of the bolts.

(c) Remove upper bolt of No. 1 EGR pipe by accessing with SST behind rear water bypass. (d) Remove the 4 nuts holding the rear water bypass to the cylinder heads. (e) Remove the rear water bypass and 3 gaskets from under the engine harness. (No. 1 EGR pipe top gasket and 2 water bypass gaskets). NOTE: Lift the rear water bypass and then roll the bottom towards the front of engine for easier removal. Be careful not to bend the No. 1 EGR pipe as it will become difficult to reinstall.

January 27, 1998 41 Lexus LS 400 & SC 400

9. Starter Removal (a) Carefully pry open plastic cover on starter cable mounting stud. (b) Remove the starter cable mounting nut.

(c) Disconnect the starter connector. NOTE: Make sure the connector is released before pulling it out. (d) Remove the bolt, and disconnect the wire clamp from the starter. (e) Remove the 2 starter mounting bolts from top rear of the engine. NOTE: Use a 3/8 inch drive flex–head ratchet and a shallow 14 mm socket to break the bolts loose. Then use a 1/4 inch drive flex–head ratchet to back the bolts out as far as possible without trapping the ratchet between the bolt and the firewall.

While removing the starter mounting bolts, be careful not to bend the No. 1 EGR pipe as it will become difficult to reinstall. (f) Remove the starter from the cylinder block. (g) Remove water bypass pipe. NOTE: First install supplied cap on rear end of pipe to prevent coolant spillage. Pour coolant from pipe into the container of coolant drained from the engine block. COMPONENTS FOR DISASSEMBLY AND AS- SEMBLY

42 Special Service Campaign WL–1

MAGNETIC SWITCH ASSEMBLY REPLACEMENT 1. Disconnect the Lead Wire (a) Move the dust protector aside, remove the nut and disconnect the lead wire from the magnetic switch terminal.

2. Remove the Field Frame with the End Cover and the Armature (a) Remove the 2 through bolts and the field frame with the end cover and the armature.

(b) Hold the magnetic switch assembly as shown and pull the field frame down carefully. NOTE: Do not separate the armature from the field frame and brush holder in the end cover. If the field frame is not pulled down carefully, the armature drive end bearing may stick in the gear reduction housing. Do not damage the O–ring and the front bearing.

3. Remove the Magnetic Switch Assembly from the Gear Reduction Housing (a) Hold the magnetic switch assembly in a bench vise and remove the 2 screws. NOTE: Use protective vise jaws or shop towels in the vise to avoid any damage to the housing.

January 27, 1998 43 Lexus LS 400 & SC 400

(b) Use an impact screw driver with No. 3 Phillips bit to remove the 2 screws.

(c) To separate the magnetic switch assembly from the gear reduction housing, hold them as shown with the gear reduction housing down, If sticking, hit lightly with a plastic hammer. NOTE: Don’t let the roller bearings, gear s, or clutch assembly fall out. Leave the steel ball and spring in the starter clutch assembly.

44 Special Service Campaign WL–1

STARTER REASSEMBLY 1. Cleaning (a) Clean the field frame, gear reduction housing, etc. using compressed air to blow off any dirt and particles. NOTE: Always wear eye protection when using the compressed air.

2. Apply Grease (a) Apply the supplied grease onto the idler gear and on the gear reduction housing surface where the new magnetic switch assembly contacts. NOTE: Do not apply grease in the area of the fastener holes in the gear reduction housing.

3. Assemble the Gear Reduction Housing and the New Magnetic Switch Assembly as Shown (a) Assemble the new magnetic switch assembly onto the gear reduction housing assembly straight down. NOTE: Don’t let the roller bearings, idler gear, or clutch assembly fall out. Confirm the steel ball and spring remains in the starter clutch assembly. Be careful not to damage plastic connector on new magnetic switch assembly. 4. Tighten the Housing with 2 New T30 Torx Bolts (a) Install the new Torx bolts supplied with the magnetic switch assembly and tighten bolts as shown. Torque: 9.3 N–m (95 kg–cm, 82 in–lb) NOTE: Use protective vise jaws or shop towels in the vise to avoid damaging the magnetic switch housing. Do not damage the magnetic switch assembly by overtightening the vise.

January 27, 1998 45 Lexus LS 400 & SC 400

5. Assemble the Field Frame with the Armature (a) Align the protrusion of the field frame with the groove of the magnetic switch, and assemble the field frame with the armature to the magnetic switch and gear reduction housing.

NOTE: Be sure the O–ring is in good condition and is in place on the field frame.

(b) Tighten the 2 through bolts evenly. Torque: 12.7 N–m (130 kg–cm, 10 ft–lb)

6. Reconnect the Lead Wire (a) Pull dust protector away from the nut to prevent pinching, reconnect the lead wire to the magnetic switch terminal and secure the dust protector. Torque: 5.9 N–m (60 kg–cm, 52 in–lb)

7. Starter Performance Test. (a) Perform a no–load performance test using a fully charged battery, the starter switch SST and your VAT. (b) Connect a battery cable from the positive battery terminal to the battery cable terminal on the starter. Use the wing nut provided with the starter switch SST to attach the cable to the starter. (c) Connect a ground cable from the negative battery terminal to the starter housing.

46 Special Service Campaign WL–1

(d) Connect the VAT positive and negative clamps onto the battery, and the inductive power test pick–up to the negative battery cable close to battery terminal with the arrow facing towards the battery.

(e) Connect the starter switch SST from the positive battery terminal to the plug–in terminal on the starter magnetic switch. (f) Check that the starter rotates smoothly and steadily with the pinion gear moving out. Confirm that the ammeter shows the specified current: 100Amps or less at approximately 11.5 Volts. NOTE: Replace the starter If it does not spin or draws more than 100 A.

January 27, 1998 47 Lexus LS 400 & SC 400

STARTER REINSTALLATION 1. Install Starter (a) Install a new O–ring to the water bypass pipe, lightly coat O–ring with O–ring lubricant and place the pipe onto the shelf at the right front corner of the engine valley. The rear end of the water bypass pipe must be positioned behind the passenger side valve cover.

(b) Place the nose of the starter gear partially into the starter hole on cylinder block, connect the starter cable with the nut, tighten the nut until finger tight. (c) Install the wire clamp to the starter housing with the bolt.

Torque: 8.83 N–m (90 kg–cm, 78 in–lb) (d) Torque the starter cable nut and close plastic cover over starter cable mounting stud. Torque: 8.83 N–m (90 kg–cm, 78 in–lb) (e) Connect the starter connector. NOTE: Be careful not to damage the connector and be sure the lock tab is engaged.

(f) Reinstall the starter with the 2 bolts. Torque: 39 N–m (400 kg–cm, 29 ft–lb)

NOTE: Upon tightening the starter bolts, the torque wrench may contact the No. 1 EGR pipe, be careful not to deform the pipe as it will become difficult to reinstall. (g) Install a new gasket on the No. 1 EGR pipe. (h) Install 2 new rear water bypass gaskets to the cylinder heads and install the rear water bypass to the heads with 4 nuts. Torque: 18 N–m (185 kg–cm, 13 ft–lb) (i) Using the SST wrench set, reinstall the No. 1 EGR pipe to the rear water bypass with the 2 bolts.

48 Special Service Campaign WL–1

(j) Push the water bypass pipe into the pipe hole at the back of the water pump. (k) Install the water bypass pipe mounting bolt. Torque: 18 N–m (185 kg–cm, 13 ft–lb) NOTE: Be sure the correct length bolt is used (13 mm). If the bolt is too long it will not secure the water bypass pipe mounting bracket properly. (l) Connect the wire clamp to the bracket on the water bypass pipe.

2. Reinstall Intake Manifold Assembly (a) Remove protective covers from the intake ports, visually inspect all intake ports for any foreign material and clean up prior to reinstallation. (b) Place 2 new intake gaskets on the cylinder heads with the white painted mark facing upwards. NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction.

(c) Place the intake manifold on the cylinder heads with the arrow mark facing forward. NOTE: First, lower the rear of the intake manifold onto the rear studs being sure to clear the engine wire harness and fuel return pipe. Second, lower the front of the manifold being sure to clear the wire harness at the right front and the wire bridge at the left front. Be careful not to pinch any portion of harness or connectors under the manifold. (d) Be sure that the intake manifold ports are still covered to prevent any dirt from entering. (e) Install and uniformly tighten the 6 bolts and 4 nuts in several passes.

January 27, 1998 49 Lexus LS 400 & SC 400

Start from center and work outward. Torque: 18 N–m (185 kg–cm, 13 ft–lb) (f) Connect the 8 injector connectors.

3. Reinstall Fuel Return Pipe (a) Apply loc–tite to the first fuel return pipe mounting bolt and reinstall the fuel return pipe onto the rear water bypass under the wire harness. (b) Apply loc–tite to the thread of the second fuel return pipe mounting bolt between the bracket and the cylinder head, then tighten the bolt. 4. Reconnect fuel return hose (a) Reconnect the fuel return hose to the fuel pressure regulator.

5. Reconnect the Heater Hoses

(a) Reconnect the heater water hose to the water bypass pipe. (b) Reconnect the heater water hose from the rear water bypass to the heater water valve assembly.

6. Reinstall Engine Wire harness to Fuel Rail and Rear Water Bypass (a) Reinstall the following: • 2 engine wire connectors (EA1 & EA2 for LS400, EC1 & EC2 for SC400) to connector bracket on LH fuel rail. • DLC1 to bracket on LH fuel rail. • Engine wire clamp to wire bracket on LH fuel rail. (b) Reinstall the left hand side of the engine wire harness to the rear

50 Special Service Campaign WL–1

water bypass with one bolt. (c) Reinstall the A/T throttle cable to the clamps on the engine wire protector and engine hanger. (d) Reinstall the right hand side of the engine wire harness to the rear water bypass with one bolt. (e) Reinstall the engine wire harness to the RH fuel rail with the 2 bolts.

(f) Using new gaskets, place No. 2 EGR pipe on rear water bypass with nuts threaded at top of studs. NOTE: When placing the EGR pipe on the rear water bypass, the convoluted part of the EGR pipe is on top.

(g) Move the No. 2 EGR pipe toward the firewall and tie it back to provide clearance for the air intake chamber during reinstallation.

7. Reinstall Air Intake Chamber Assembly (a) Remove intake manifold port covers, place 4 new gaskets on the intake manifold. (b) Reconnect the following hoses: • PCV hose from RH cylinder head to throttle body. • Water bypass hose to throttle body from rear water bypass. (c) Place the air intake chamber assembly on the intake manifold, install forward end first, guide the

January 27, 1998 51 Lexus LS 400 & SC 400

IAC coolant hose onto thermostat housing and reinstall the clamp. (d) Reconnect the EGR gas temperature sensor connector. (e) Reinstall the air intake chamber fasteners along with the mounting brackets for the VSV for fuel pressure control and VSV for EVAP. Uniformly tighten the 4 bolts and 8 nuts using several passes. Torque: 18 N–m (185 kg–cm, 13 ft–lb)

(f) Install No. 2 EGR pipe to rear of air intake chamber with the 2 bolts. Tighten the 2 nuts and 2 bolts. Torque: 22.5 N–m (230 kg–cm, 17 ft–lb)

8. Reconnect Hoses and Connectors

(a) Reconnect the following hoses: • Brake booster vacuum hose to union on the air intake chamber. • Vacuum hose for the fuel pressure VSV to the rear of the air intake chamber. • PCV hose to PCV valve on LH cylinder head. • Hose from the rear water bypass to EGR valve. • EVAP hose to the VSV for the EVAP. (b) Reconnect these connectors: • EGR valve connector. • VSV connector for fuel pressure control. • VSV connector for EVAP • Throttle position sensor connector. • w/TRAC: Sub–throttle position sensor connector and Sub–throttle actuator connector. • IAC valve connector. (c) Install the accelerator bracket with the 2 bolts. (d) Reconnect these cables.

52 Special Service Campaign WL–1

• Accelerator cable. • A/T throttle control cable. • Cruise control actuator cable. (e) Reinstall intake air connector assembly. (f) Reconnect P/S air control hoses, the IAC valve air supply hose, the EVAP hose for canister, and the hose retaining clamp.

(g) Reinstall V–bank cover with the bolt and 2 cap nuts. (h) Reinstall air cleaner inlet and the battery clamp cover. (I) Reconnect the negative battery terminal. (j) With the ignition key ”ON” and the shift lever in the ”PARK” position, press the ”SET” and seat memory ”No. 1” buttons to reestablish the ”No. 1” seating position memory. (k) Tighten fuel tank fuel cap and close fuel door.

9. Refill Coolant into Engine (a) Remove the water filler plug from the water inlet housing. (b) Slowly pour coolant into the water inlet housing until it is full. (c) Reinstall the water filler plug to the water inlet housing. Torque: 44 N–m (450 kg–cm, 33 ft–lb)

(d) Remove radiator reservoir cap and slowly pour coolant into the radiator reservoir until it is full. Then reinstall the cap. (e) Bleed the cooling system. • Start the engine and turn on the heater to open the heater water valve. • Maintain the engine speed between 2,000 to 2,500 rpm until the engine is warm.

January 27, 1998 53 Lexus LS 400 & SC 400

(f) Monitor the coolant level, temperature gauge and check for any leaks. (g) Test drive vehicle to check for leaks and make sure the low coolant level warning light does not turn on. (h) Upon returning, stop the engine and let it cool down. Then check the coolant level and add additional coolant until the reservoir is full. If the level is below specification, top up with ”Toyota Long Life Antifreeze Coolant”.

10. Reset Clock and Radio (a) Reset the clock and radio stations as originally preset by customer.

11. Scan for Trouble Codes (a) Using the scan tool, check for any diagnostic trouble codes which may be set. If any codes are found, correct as necessary.

12. SSC Completion Label Installation (a) After completing repair and before returning vehicle to the owner, a SSC completion label that is enclosed in the owner’s notification must be affixed to the left front door hinge post near the check strap.

(b) The label is to be filled out as follows:

Write in SSC WL1 Write in date of repair Write in your Dealer Code

(c) Additional SSC completion labels, in sheets of 50 (P/N 00410–01917), may be ordered through the non–parts system on a 1450 order form or through the TDN system.