LEXUS GS400 2000 Service Repair Manual

B01894
No.1 Fuel Filter Cushion
Fuel Filter
No.2 Fuel Filter Cushion

O±Ring
Fuel Pump
Connector
Fuel Pump
No.1 Fuel Suction Support
Fuel Suction
Filter
Fuel Pressure
Regulator and Fuel
Return Jet Tube
Assembly Rubber Cushion
Clip Fuel Suction Plate
with Sender Gauge
No.2 Fuel Suction Support

O±Ring

Non±reusable part
SF±10
± SFI (2JZ±GE)FUEL PUMP
1476 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

ST04X±01
± STARTING (2JZ±GE)STARTING SYSTEM
ST±1
1619 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
STARTING SYSTEM
ON±VEHICLE INSPECTION
NOTICE:

Before changing the starter, check the following items again:

Connector connection

Accessory installation, e.g.: theft deterrent system

ST052±01
P10595
SST
P10596
Upward
DownwardSST
P10593
SST
P10594
B01971
ST±10
± STARTING (2JZ±GE)STARTER
1628 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820±00030
2. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using a press, press in a new rear bearing.
3. REPLACE MAGNETIC SWITCH TERMINAL PARTS
(a) Remove the 3 bolts, end cover, gasket and plunger.

P25785
Wear
B01973
SST
P25787
Long
Short
(3)
Indentation
Protrusion (4)
(5) (1)
(2)
(8) (7) (6)
P25788
Long
Short
(3) (4) (5)
(1)(2) (7)
(6)
Lead Terminal
± STARTING (2JZ±GE)STARTER
ST±11
1629 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(b) Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove the terminal kit parts.
(1) Using SST, loosen the terminal nuts.
SST 09810±38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O±ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O±ring, terminal bolt,
contact plate, terminal insulator (inside) and insula-
tion paper.
(d) Temporarily install these new terminal 30 kit parts:
(1) Insulation paper
(2) Terminal insulator (inside)
(3) Contact plate
(4) Terminal bolt
(5) O±ring
(6) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nut
NOTICE:
Be careful to install the terminal insulators in the correct
direction.
(e) Temporarily install these new terminal C kit parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O±ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulators in the correct
direction.

B01974
40 mm
Contact
Plate
20 mm37 mmWooden
Block
(kgf/cm2) =Ram diameter (cm)
100 kgf
2x 3.14 (p)
2
(psi) =Ram diameter (in.)
221 lbf
2x 3.14 (p)
2
(kPa) = (kgf/cm2) x 98.1
(kPa) = (psi) x 6.9
B01975
SST
ST±12
± STARTING (2JZ±GE)STARTER
1630 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(f) Temporarily tighten the terminal nuts.
(g) Tighten the terminal nut
(1) Put a wooden block on the contact plate and press
it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then
calculate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nuts to the specified torque.
SST 09810±38140
Torque: 17 N´m (173 kgf´cm, 13 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.

B01972
± STARTING (2JZ±GE)STARTER
ST±13
1631 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(h) Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the plunger, new gasket, end cover and lead
clamp with the 3 bolts.
Torque: 2.5 N´m (26 kgf´cm, 22 in.´lbf)

ST053±01
ST±14
± STARTING (2JZ±GE)STARTER
1632 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST±5).
HINT:
Use high±temperature grease to lubricate the bearings and gears when assembling the starter.

ST054±01
B01964
Terminal 50
Battery
Terminal C
B01965
Battery
Terminal CDisconnect
B01966
Disconnect
Battery
B01967
Battery Terminal 30
Terminal 50
Ammeter
± STARTING (2JZ±GE)STARTER
ST±15
1633 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL±IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the pinion gear moves outward.
2. DO HOLD±IN TEST
While connected as above with the pinion gear out, disconnect
the negative (±) lead from terminal C.
Check that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (±) lead from the starter body.
Check that the pinion gear returns inward.
4. DO 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. Check that the ammeter
shows the specified current.
Specified current: 90 A or less at 11.5 V

ST055±01
ST±16
± STARTING (2JZ±GE)STARTER
1634 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
Installation is in the reverse order of removal. (See page ST±4)

B00923
Starter
RelayST056±01
P07170
OhmmeterContinuity
No Continuity1
3
25
Ohmmeter
P07171
Ohmmeter
Continuity1
3
25
Battery
± STARTING (2JZ±GE)STARTER RELAY
ST±17
1635 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
STARTER RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE STARTER RELAY
3. INSPECT STARTER RELAY
(a) Inspect the relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
3 and 5.
If there is continuity, replace the relay.
(b) Inspect the relay operation.
(1) Apply battery positive voltage across terminals 1
and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY
5. REINSTALL RELAY BOX COVER