1991 LEXUS SC400 length

Handling Precautions for Gas±Cylinder
Type Gas Leak Tester
1. BEFORE USING TESTER MAKE SURE THAT THEREARE NO FLAMMABLE SUBSTANCES NEARBY
2. BE CAREFUL NOT TO INHALE POISONOUS GAS If refrigerant gas comes in contact with flame, a poisonous
gas is prodused. During leak tests, do not inhale any gas.
Precautions When Replacing Parts in
Refrigerant Line
1. RECOVER REFRIGERANT IN SYSTEM BEFOREREMOVING PARTS
Using a recovery machine, recover refrigerant in system be-
fore removing the parts.
NOTICE: Do not release refrigerant to atmosphere.
2. INSERT PLUG IMMEDIATELY IN DISCONNECTED PARTS
Insert a plug immediately in the disconnected parts to pre-
vent the entry of moisture and dust.
3. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL
IMMEDIATELY BEFORE INSTALLATION
4. DO NOT USE BURNER FOR BENDING OR LENGTHENING OPERATIONS ON TUBE
If the tubes are heated with a burner, a layer of oxidation
forms inside the tube, causing the same kind of trouble as an
accumulation of dust.
5. DISCHARGE GAS IN NEW COMPRESSOR FROM
CHARGING VALVE BEFORE INSTALLING IT
If the gas in new compressor is not discharged first, compres-
sor oil will spray out with gas when the plug is removed.
6. TIGHTEN CONNECTING PARTS SECURELY Securely tighten the connecting parts to prevent leaking of
refrigerant gas.
wApply a few drops of compressor oil to O±ring fittings for
easy tightening and to prevent leaking of refrigerant
gas.
w Tighten the nuts using two wrenches to avoid twisting
the tube.
AC±4
±
AIR CONDITIONING SYSTEM General Description
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EQUIPMENT
AT06V±05\
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Feeler gauge Check major clearance\
 
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Vernier calipers
 

Check length of second coast brake
piston rod.
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Dial indicator or dial indicator with magnetic baseCheck piston stroke and end play of
the output shaft.
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Dial indicator with magnetic baseCheck inside diameter of major
bushing.
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Straight edgeCheck side clearance of oil pump.
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Torque wrench
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Cylinder gaugeCheck inside diameter of the trans-
mission case rear bushing.
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Voltmeter
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Ammeter(A)
\
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Ohmmeter
LUBRICANT
AT0GW±03
 Item Capacity Classification
 Automatic transmission fluid
 Dry fill 8.2 liters (8.7 US qts, 7.2 lmp. qts) ATF Type T±II or equivalent
 Drain and refill 1.9 liters (2.0 US qts, 1.7 lmp. qts) 
SSM (SPECIAL SERVICE MATERIALS)
AT06X±03
\
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08826±00090 Seal Packing 1281, Transmission case X Oil pan
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THREE BOND 128\
1 or equivalentTransmission case X Extension
housing
±
A304E (1UZ±FE) AUTOMATIC TRANSMISSION PREPARATIONAT±13
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If the clearance is not as wide, slide the retainer part to adjust
the length of retainer.
(d) Install the retainers.
6. POSITION GLASS (a) Place glass in correct position.
(b) Check that all contacting parts of the glass rim areperfectly even and do not make contact with the
fasteners.
(c) Place reference marks between the glass and body.
(d) Remove the glass.
7. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface black±colored
area around the entire glass rim.
NOTICE: Do not touch the glass face after cleaning it.
8. INSTALL DAM (a) Apply double±stick tape at a point as shown.
(b) Place the dam on the double±stick tape.
NOTICE: Do not touch the glass face after cleaning it.
BO±48
±
BODY Windshield
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8. INSTALL MASTER CYLINDER BOOTWith the UP mark on the master cylinder boot facing up-
wards, install the cylinder boot on the master cylinder.
MASTER CYLINDER INSTALLATION
BR0EJ±05
1. ADJUST LENGTH OF BRAKE BOOSTER PUSH RODBEFORE INSTALLING MASTER CYLINDER
(See page
BR±19)
2. INSTALL MASTER CYLINDER Install the master cylinder and a new gasket on the brake
booster with 3 nuts.
Torque: 13 N Vm (130 kgf Vcm, 9 ft Vlbf)
3. CONNECT BRAKE LINES
Using SST, connect the brake lines to the master cylinder.
Torque the union nuts.
SST 09023±00100
Torque: 12 N Vm (125 kgf Vcm, 9 ft Vlbf)
4. CONNECT LEVEL WARNING SWITCH CONNECTOR
5. FILL BRAKE R ESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±8)
6. w/ TRAC:
BLEED TRAC SYSTEM
(See page BR±10)
7. CHECK FOR FLUID LEAKAGE
8. CHECK AND ADJUST BRAKE PEDAL (See page BR±7 )
±
BRAKE SYSTEM MASTER CYLINDERBR±17
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3. REMOVE BRAKE BOOSTER
(a) Remove the booster installation nuts.
(b) Remove the booster and gasket.
BRAKE BOOSTER INSTALLATION
BR03Z±08
1. INSTALL BRAKE BOOSTER
(a) Install the booster and gasket.
(b) Install and torque the booster installation nuts.
Torque: 12 NVm (125 kgf Vcm, 9 ft Vlbf)
(c) Insert the clevis pin into the clevis and brake pedal, and install
the clip to the clevis pin.
(d) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston.
SST 09737±00010
(c) Turn the SST upside down, and set it on the booster. SST 09737±00010
(d) Measure the clearance between the booster push rod and
pin head (SST).
Clearance:
0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod lightlytouches the pin head.
HINT: When adjusting the push rod, depress the brake pedal
enough so that the push rod sticks out.
3. INSTALL FOLLOWING PARTS: wVacuum hose
w Master cylinder
(See page BR±12)
w w/ TRAC:
TRAC pump assembly
(See page BR±162)
±
BRAKE SYSTEM BRAKE BOOSTERBR±19
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SERVICE SPECIFICATIONS
SERVICE DATA
BatterySpecific gravity1.27±1.29
(when fully charged at 205C (68 5F))
AlternatorRated output12 V±100 A
Rotor coil resistance2.8±3.0

Slip ring diameterSTD 14.2±14.4 mm0.559±0567 in.
Limit 12.8 mm0.504 in.
Brush exposed lengthSTD 10.5 mm0.413 in.
Limit 1.5 mm0.059 in.
AlternatorRegulating voltageat 255C (77 5F)13.9±15.1 V
regulatorat 115 5C (239 5F)13.5±14.3 V
TORQUE SPECIFICATIONS
Part tightenedN Vmkgf Vcmft Vlbf
Alternator pulley X Rotor11 01,12581
Alternator X Alternator bracket37380 27
Alternator X Cylinder block3738027
±
CHARGING SYSTEM Service SpecificationsCH±21
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Stator (Drive End Frame)
1. INSPECT STATOR FOR OPEN CIRCUITUsing an ohmmeter, check that there is continuity between
the coil leads.
If there is no continuity, replace the drive end frame assem-
bly.
2. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity be-
tween the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.
Brushes
INSPECT EXPOSED BRUSH LENGTHUsing a vernier caliper, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush
holder.
Rectifiers (Rectifier Holder)
1. INSPECT POSITIVE RECTIFIER(a) Using an ohmmeter, connect one tester probe to thepositive (+) terminal and the other to each rectifier
terminal.
(b) Reverse the polarity of the tester and repeat (a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.
2. INSPECT NEGATIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to each
negative (±) terminal and the other to each rectifier
terminal.
(b) Reverse the polarity of the tester probes and repeat (a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.
CH±14
±
CHARGING SYSTEM Alternator
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INSTALLATION OF WATER PUMP
(See Components on page CO±8)
1. INSTALL WATER PUMP (a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump and cylinder block.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the sealing groove of the water pump as shown in the illustration.
Seal packing: Part No. 08826±00100 or equivalent
w Install a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
HINT: Avoid applying an excessive amount to the surface. w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Install a new O±ring to the water by±pass pipe end.
(d) Apply soapy water to the O±ring.
(e) Connect the water by±pass pipe end to water pump.
(f) Install the water pump with the five bolts, two stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 30 mm (1.18 in.) in length.
2. INSTALL WATER INLET AND INLET HOUSING (a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
inlet housing and water pump.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
CO±10
±
COOLIING SYSTEM Water Pump
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