evap LEXUS SC400 1991 Service Repair Manual

(5) Water by±pass hose (from water inlet housing) to ISC
valve
(6) Vacuum hose (from PS air control valve) to air intake chamber
(7) Vacuum sensing hose (from fuel pressure regulator) to vacuum pipe
(8) Two vacuum hoses (from VSV for EVAP system) to vacuum pipe
(9) Vacuum hose (from charcoal canister) to vacuum pipe.
14. CONNECT CONNECTORS Connect the following connectors:w Cold start injector connector
w ISC valve connector
w (USA Spec.)
EGR valve connector
w (Exc. USA Spec.)
VSV connector for EGR system
w VSV connector for fuel pressure control system
15. INSTALL THROTTLE BODY (a) Connect the following hoses:(1) PCV hose to throttle body
(2) Water by±pass hose to throttle body
(b) Install a new gasket and throttle body with the two bolts and two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 40 mm (1.57 in.) in length.
(c) Install the water by±pass pipe (from rear water bypass
joint) to the clamp on the engine wire cover.
ST±30
±
STARTING SYSTEM Starter
WhereEverybodyKnowsYourName

(c) Install the clamps on the high±tension cords to thehigh±tension cord cover.
(d) Connect the high±tension cord to the RH ignition coil.
17. INSTALL RH NO.3 TIMING BELT COVER (a) Install the three gaskets to the timing belt cover.
(b) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(c) Install the timing belt cover with the three bolts.
18. INSTALL VSV FOR EVAP SYSTEM Install the VSV with the two bolts.
19. INSTALL LH NO.3 TIMING BELT COVER (a) Install the three gaskets to the timing belt cover.
(b) Install the cord grommet to the high±tension cord.
(c) Install the cord grommet to the timing belt cover.
(d) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(e) Install the timing belt cover with the four bolts.
20. INSTALL RH ENGINE WIRE COVER (a) Fit portions A and B of the engine wire cover, matchingthem with the lower high±tension cord cover and No.3
timing belt cover.
(d) Install the engine wire cover with the bolt.
ST±32
±
STARTING SYSTEM Starter
WhereEverybodyKnowsYourName

(b) Stake the differential case.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and thethreads of the ring gear and differential case.
(b) Heat the ring gear in boiling water.
(c) A f t e r t h e m o i s t u r e o n t h e r i n g g e a r h a s c o m p l e t e l y evaporated, quickly install the ring gear to the differential
case.
HINT: Align the matchmarks on the ring gear and the dif feren-
tial case.
(d) Tighten 2 of the bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned.
NOTICE: The ring gear set bolts should not be tightened until
the ring gear has cooled sufficiently.
4. INSTALL RING GEAR SET BOLTS
(a) After the ring gear has cooled sufficiently, install 10 new ringgear set bolts to which thread lock has been applied.
Thread lock:
Part No. 08833±00100, THREE BOND 1360 K or
equivalent.
NOTICE: New ring gear set bolts should be used in every case.
(b) Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 N Vm (650 kgf Vcm, 47 ft Vlbf)
(c) Tighten the bolts an additional 60±90
.
NOTICE: Tighten the bolts in diagonally opposite pairs.
SA±94±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

TSIB
IntroductionA musty odor may be emitted from the air conditioning system of some vehicles which are
usually operated in areas with high temperature and humidity. It is most noticeable when
the air conditioner is first turned ªONº after the vehicle has bee\
n parked for several hours.
The odor could result from one or more of the following conditions:
1. Blockage of the evaporator housing drain pipe, resulting in the build up of cond\
ensation.
2. Microbial growth in the evaporator, arising from dampness in the evaporator housing
where the cooling air flow is dehumidified.
To address excessive air conditioning evaporator odor, check the evaporator housing drain
pipe for blockage. If no problems are found, the evaporator and housing\
should be cleaned
and disinfected using the general procedure given on page 2, and the model \
specific
procedure on the pages indicated in the Table of Contents at the bottom of this page.
Affected While this procedure may be used on any Lexus vehicle, this bulletin giv\
es details
Vehicles specifically for the '92±'96 ES 300, all GS 300, '93±'94 LS 400, all SC 300/400 and the\
LX 450.
Tools &
PART NUMBER DESCRIPTION OF TOOLS & MATERIALS QUANTITY SOURCE
Materials08821±00810±01 Spray Gun Kit 1 OTC 08821±00811±01 Spray Gun (replacement) (1) OTC
08821±00812±01 Spray Gun Nozzle (replacement) (1) OTC
08821±00813±01 Freshener Mixing Container (replacement) (1) OTC
08821±00801±DS Air Conditioning Freshener 1 per vehicle TMS
CAUTION:
Wear safety glasses, protective mask, and gloves while working with the
freshener.
Warranty
OPCODE DESCRIPTION TIME OPN T1 T2
Information
N/A No applicable warranty information ± ± ± ±
Table ofMODEL PAGE MODEL PAGE MODEL PAGE MODEL PAGE
Contents
ES 300 3 GS 300 5 LS 400 7
GENERAL 2
SC 300 9 SC 400 9 LX 450 11
General Procedure applies to all models and model years.
The Specific Model Sections cover only the listed ªaffected models.º
HEATING & AIR CONDITIONING
September 12, 1997
Title:
AIR CONDITIONING EVAPORATOR ODOR
Models:
'92±96 ES 300, '93±'94 LS 400,
All GS 300, SC 300/400, LX 450.
Page 1 of 11
AC001±97
WhereEverybodyKnowsYourName

AIR CONDITIONING EVAPORATOR ODOR ± AC001±97 September 12, 1997
General1. Preparation of freshener solution:
Procedure (a) Invert freshener container and shake vigorously for 30 seconds.
(b) Mix 3.4 fl. oz. of freshener (1 container) with 30 fl. oz. to make 1 q\
t. of solution.
2. Drying the evaporator: Dry the evaporator for 10 minutes with the following settings:
A/C: Off
. . . . . . . . . . .
Air Outlet: Foot
. . . . . .
Mode: Recirc.
. . . . . . . . . .
Blower: High
. . . . . . . .
Te m p : Max Warm
. . . . . . . . . .
3. Evaporator Treatment Preparation: (a) Ensure availability of 30±45 psi compressed air to be used with spray\
gun for application of freshener.
(b) Place a tray under the evaporator housing drain hose to collect used cle\
aning solution.
(c) Place shop cloth under the evaporator housing in the vehicle to prevent \
cleaning solution from dripping onto the floor mat.
4. Vehicle Preparation: See specific model section.
5. Evaporator treatment: (a) Set HVAC mode as follows: A/C: Off
. . . . . . . . . . .
Air Outlet: Face
. . . . . .
Mode: Fresh
. . . . . . . . . .
Blower: High
. . . . . . . .
Te m p : Max Warm
. . . . . . . . . .
Windows: Open
. . . . . .
(b) Insert spray nozzle into the filter inlet and spray the entire quantity (1 qt.) of
freshener solution into the evaporator
while moving the nozzle around to
cover the complete evaporator surface.
(c) Turn the blower OFF.
6. Reinstallation of Parts.
7. Completion of Treatment. (a) Dry the evaporator for 30 minutes with the following settings:
A/C: Off
. . . . . . . . . . .
Air Outlet: Foot
. . . . . .
Mode: Recirc.
. . . . . . . . . .
Blower: High
. . . . . . . .
Te m p : Max Warm
. . . . . . . . . .
Windows: Closed
. . . . . .
(b) If the vehicle still has alcohol smell, open windows for ventilation. Do not turn on
the AC switch until the evaporator is
completely dry as this can reduce the
effectiveness of the solution.
Page 2 of 11
CAUTION
Do not get into the vehicle during
this drying operation.
WhereEverybodyKnowsYourName

Page 3 of 11
AIR CONDITIONING EVAPORATOR ODOR ± AC001±97 September 12, 1997
ES 3001. Removal of parts.
('92±'96) (a) Pull down the carpet from the center
console as indicated by red arrow in the
illustration.
(b) Remove the plate on the side of the heater unit using steps and
,
indicated with red arrows to show
direction, in the illustration.
CAUTION:
Do not bend the cable.
NOTE:
The Plate will be reused.
(c) Remove the filter.
(d) Remove the blower controller.
2. Clean the Evaporator. Follow the general procedures given
on page 2.
NOTE:
Location for insertion of spray nozzle
is indicated by the red arrow in the
illustration.
WhereEverybodyKnowsYourName

AIR CONDITIONING EVAPORATOR ± AC001±97 September 12, 1997
ES 3003. Reinstallation of parts.
('92±'96)
(Continued) (a) Insert the filter (up side) into the
heater unit following the numbered
steps shown in the illustration.
(b) Insert the filter (down side) into the heater unit.
(c) Reinstall the plate on the side of the heater unit using steps and
,
indicated with red arrows to show
direction, in the illustration.
CAUTION:
Confirm that the plate is secure.
(d) Restore the carpet to its original position taking care not to bend
the cable.
Page 4 of 11
WhereEverybodyKnowsYourName

Page 5 of 11
AIR CONDITIONING EVAPORATOR ODOR ± AC001±97 September 12, 1997
GS 3001. Removal of parts.
(a) Remove the undercover.
NOTE:
Pull down the clip areas (3 places) of
the Undercover to remove.
(b) Remove the lamp.
(c) Remove the (2) wing nuts and the plate on the bottom of the cooling
unit.
CAUTION:
The plate and wing nuts will be reused.
(d) Remove the (2) filters from the cooling unit.
2. Clean the Evaporator. Follow the general procedures given on
page 2.
NOTE:
Location for insertion of spray nozzle is
indicated by the red arrow in the
illustration.
WhereEverybodyKnowsYourName

AIR CONDITIONING EVAPORATOR ODOR ± AC001±97 September 12, 1997
GS 3003. Reinstallation of parts.
(Continued) (a) Insert the (2) filters into the cooling
unit as shown in the illustration.
NOTE:
Insert a clean air filter with it's knob
facing downwards, then slide it forward
and install the second filter in the same
manner.
(b) Assemble the rubber insulator on the plate.
CAUTION:
To prevent the cooling unit from leaking
water, pull the three rubber projections
from the other side of the plate to make
sure that the rubber insulator seals
properly against the plate.
(c) Install the plate on the cooling unit and secure with the (2) wing nuts.
CAUTION:
To prevent water leaks, verify that the
cooling unit and plate are fully secure
before tightening the wing nuts.
NOTE:
Before installing the plate on the cooling
unit, coat the rubber insulator with water
for easier assembly.
(d) Reinstall the lamp.
(e) Reassemble the Undercover.
Page 6 of 11
WhereEverybodyKnowsYourName

Page 7 of 11
AIR CONDITIONING EVAPORATOR ODOR ± AC001±97 September 12, 1997
LS 4001. Removal of parts.
('93±'94) (a) Remove the undercover.
NOTE:
Remove the front of ªAº clips.
Pull down the three ªBº clip areas
of the Undercover to remove.
(b) Remove the lamp.
(c) Remove the (2) wing nuts and the plate on the bottom of the cooling unit.
CAUTION:
The plate and wing nuts will be reused.
(d) Remove the (2) filters from the cooling unit.
2. Clean the Evaporator Follow the general procedures given on
page 2.
NOTE:
Location for the insertion of spray
nozzle is indicated by the red arrow
in the illustration.
WhereEverybodyKnowsYourName