Lexus Car ES, IS, LS 1998-06

Solenoid or Relay

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  1. Disconnect and isolate the battery negative cable.
  2.  
  3. Remove the cover from the Power Distribution Center (PDC).
  4.  
  5. See the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location.
  6.  
  7. Remove the starter relay from the PDC.
  8.  

To install:

  1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location.
  2.  
  3. Position the starter relay in the proper receptacle in the PDC.
  4.  
  5. Align the starter relay terminals with the terminal cavities in the PDC receptacle.
  6.  
  7. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle.
  8.  
  9. Install the cover onto the PDC.
  10.  
  11. Reconnect the battery negative cable.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  4.  
  5. Remove the starter motor from the vehicle.

    Click image to see an enlarged view

    Fig. Disconnect the lead wire from the starter solenoid (repair service starter kit).



    Click image to see an enlarged view

    Fig. Remove the 2 screws holding the starter solenoid (repair service sterter kit) to the starter housing.

  6.  
  7. Remove the nut, and disconnect the lead wire from the starter solenoid (repair service starter kit or magnetic switch).
  8.  
  9. Remove the 2 screws holding the starter solenoid to the starter housing.
  10.  
  11. Remove the starter solenoid.
  12.  
  13. Remove the return spring and plunger.
  14.  

To install:

  1. Apply grease to the plunger and hook.
  2.  
  3. Hang the plunger hook of the starter solenoid to the drive lever.
  4.  
  5. Install the plunger and return spring.
  6.  
  7. Install the starter solenoid with the 2 screws and tighten to 66 inch lbs. (7.5 Nm).
  8.  
  9. Apply grease to the nut of the lead wire.
  10.  
  11. Connect the lead wire to the terminal with the nut and tighten to 7 ft. lbs. (10 Nm).
  12.  
  13. Install the starter motor into the vehicle.
  14.  
  15. Connect the negative battery cable.
  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  4.  
  5. Remove the starter motor from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the 2 long screws holding the dust protector.

  6.  
  7. Remove the dust protector.
  8.  
  9. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
  10.  
  11. Remove the 2 through bolts.

    Click image to see an enlarged view

    Fig. Pull out the field frame together with the armature.

  12.  
  13. Remove the field frame together with the armature.
  14.  
  15. Remove the O-ring from the field frame.

    Click image to see an enlarged view

    Fig. Remove the 2 screws holding the starter housing, idler gear, bearing, clutch assembly and return spring to the starter solenoid (magnetic switch).

  16.  
  17. Remove the 2 bolts.
  18.  
  19. Remove the starter housing, idler gear, bearing, clutch assembly and return spring from the starter solenoid (magnetic switch).
  20.  

To install:


NOTE
Before reassembly, use high-temperature grease to lubricate the bearings and gears.

  1. Install the return spring, clutch assembly, bearing, idler gear and starter housing to the solenoid (magnetic switch).
  2.  
  3. Install the 2 bolts and tighten to 52 inch lbs. (6 Nm).
  4.  
  5. Install a new O-ring onto the field frame.
  6.  
  7. Install the field frame together with the armature. Align the protrusion of the field frame with the cutout of the magnetic switch.
  8.  
  9. Install the 2 through bolts and tighten to 52 inch lbs. (6 Nm).
  10.  
  11. Connect the lead wire to the magnetic switch terminal and tighten the nut to 52 inch lbs. (6 Nm).
  12.  
  13. Install the dust protector.
  14.  
  15. Install the starter motor.
  16.  
  17. Connect the negative battery cable.
  18.  

Testing



Starter Relay


Click image to see an enlarged view

Fig. Inspecting startert relay continuity.

  1. Inspect the relay continuity as follows:


    1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay.
    2.  
    3. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay.

      Click image to see an enlarged view

      Fig. Inspecting starter relay operation.

    4.  

  2.  
  3. Inspect the relay operation as follows:


    1. Apply battery positive voltage across terminals 1 and 2.
    2.  
    3. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay.
    4.  

  4.  

  1. Inspect the resistance using an ohmmeter.
  2.  
  3. Measure the resistance between terminals 3 and 5 of the relay.
  4.  
  5. The resistance should measure 10 k--or higher
  6.  
  7. If the resistance measures below 1-, apply battery voltage to terminals 1 and 2.
  8.  
  9. If the result is not as specified, replace the starter relay.
  10.  

 
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