torque LEXUS SC400 1991 Service Repair Manual

STANDARD BOLT TORQUE SPECIFICATIONS
HOW TO DETERMINE BOLT STRENGTH
±
INTRODUCTION Standard Bolt Torque SpecificationsIN±35
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SPECIFIED TORQUE FOR STANDARD BOLTS
ClassDiameterPitchSpecified torqueClassmmmmHexagon head boltHexagon flange bolt
NVmkg Vcmft VlbN Vmkg Vcmft Vlb
6155548 in. Vlb66052 in. Vlb
81.2512.5130 9 14145 10
4T101.2526260 19 29290 21
121.2547480 35 53540 39
141.574760 55 84850 61
161.511 51,150 83 ±±±
616.56556 in. Vlb7.57565 in. Vlb
81.2515.5160 12 17.5175 13
5T101.2532330 24 36360 265T121.2559600 43 65670 48
141.591930 67 1001,050 76
161.51401,400 101 ±±±
6188069 in. Vlb99078 in. Vlb
81.2519195 14 21210 15
6T101.2539400 29 44440 326T121.2571730 53 80810 59
141.511 01,100 80 1251,250 90
161.51701,750 127 ±±±
6110.511 08121209
81.2525260 19 28290 21
7T101.2552530 38 58590 437T121.2595970 70 1051,050 76
141.51451,500 108 1651,700 123
161.52302,300 166 ±±±
81.2529300223333024
8T101.2561620 45 68690 50
121.2511 01,100 80 1201,250 90
81.2534340253738027
9T101.2570710 51 78790 57
121.251251,300 94 1401,450 105
81.2538390284243031
10T101.2578800 58 88890 64
121.251401,450 105 1551,600 116
81.2542430314748035
11 T101.2587890 64 97990 72
121.251551,60011 61751,800130
IN±36±
INTRODUCTION Standard Bolt Torque Specifications
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The procedures are presented in a step±by±step format:
wThe illustration shows what to do and where to do it.
w The task heading tells what to do.
w The detailed text tells how to perform the task and gives
other information such as specifications and warnings.
Example:
This format provides the experienced technician with a FAST
TRACK to the information needed. The upper case task
heading can be read at a glance when necessary, and the
text below it provides detailed information. Important specifi-
cations and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when
they are required you are given the page to refer to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text
where needed. You never have to leave the procedure to look
up your specifications. They are also found at the end of each
section, for quick reference.
CAUTIONS, NOTICES, HINTS:
w CAUTIONS are presented in bold type, and indicate
there is a possibility of injury to you or other people.
w NOTICES are also presented in bold type, and indicate
the possibility of damage to the com ponent being
repaired.
w HINTS are separated from the text but do not appear in
bold. They provide additional information to help you
efficiently perform the repair.
SI UNIT
The UNIT given in this manual are primarily expressed with
the SI UNIT (International System of Unit), and alternately ex-
pressed in the metric system and in the yard/pound system.
Example:
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
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INTRODUCTION How to Use This ManualIN±3
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5. Non±reusable parts(a) Always replace cotter pins, gaskets, O±rings and oilseals etc. with new ones.
(b) Non±reusable parts are indicated in the component
illustrations by the º º symbol.
6. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with
a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or causedto move in any way, it must be recoated with the
specified adhesive.
(b) Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut or threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the bolt or nut threads.
(c) P re co a te d pa rts are in d ica te d in th e co m ponent
illustrations by the º
º symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified
and follow the proper work procedure. A list of SST and SSM
can be found in the preparation part at the front of each
section in this manual.
10. When replacing fuses, be sure the new fuse has the correct
amperage rating. DO NOT exceed the rating or use one with
a lower rating.
11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper
locations (See page IN±33).
(a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in
order to ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on a
vehicle raised on a jack alone, even for a small job that
can be finished quickly.
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INTRODUCTION General Repair InstructionsIN±5
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SERVICE SPECIFICATIONS
SERVICE DATA
Idle speedMagnetic clutch no engagedApprox. 700 rpm
Magnetic clutch engaged Approx. 700 rpm
Magnetic clutch clearance0.5 + 0.15 mm0.020 + 0.006 in.
TORQUE SPECIFICATIONS
Part tightenedN Vmkgf Vcmft Vlbf
Suction hose X Compressor2525018
Discharge hose X Compressor25250 18
Compressor X EngineBolt 49500 36
Nut 29300 22
Liquid tube X Receiver10100 7
Liquid tube X Condenser10100 7
Discharge tube X Condenser10100 7
Expansion valve X Evaporator5.455 48 in. Vlbf
Suction tube X A/C Unit10100 7
Liquid tube X A/C Unit10100 7
Equalizer tube X EPR25250 18
Pressure switch X Liquid tube101007
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AIR CONDITIONING SYSTEM Service SpecificationsAC±141
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R±12 AIR CONDITIONER SYSTEM RETROFIT ± AC001±98 April 3, 1998
Page 2 of 4
A. Required Equipment:
1. R±12 recovery/recycling/recharging equipment
2. R134a recovery/recycling/recharging equipment
3. Measuring cylinder (for compressor oil)
4. Valve core remover for service valves
5. Air conditioner service tool set
6. Torque Wrench Set, P/N 00002±50284±01, includes the following*: 14 mm 00002±51410±01
17 mm 00002±51710±01
22 mm 00002±52216±01
27 mm 00002±52724±01
B. Required Parts & Materials: **
1. R134a Refrigerant
2. Service Fitting Adaptors
3. Caution Labels
4. ND±OIL 8 compressor oil (PAG type oil)
5. Receiver
6. O±Rings for compressor, line & hose connections ***
7. Loctite 262 or equivalent
* required size dependent upon model.
** see parts information section of this bulletin on page 1.
*** it is not necessary to replace any O±rings on ES 300, SC 300 and SC 400 models\
.
A. Refrigerant and Oil Charges
Oil and refrigerant charge amounts are different after the R±12 system has been
retrofitted to R134a. Refrigerant charge amounts are less, while oil ch\
arge
amounts are greater, compared to R±12 system requirements. Refer to the
ND OIL
8
and CHARGE columns in ªParts Informationº table on page 1 for proper amounts\
.
B. System Performance A slight decrease in system performance may be noticed on some vehicles \
under
certain operating conditions.
C. Refrigerant Pressures
R134a high side pressures are greater than that of R±12 above ambient\
temperatures of 68 °F.
D. Flushing Requirements There is no need to remove or flush R±12 mineral oil from the system.\
Simply
charge the system with the specified amount of ND±Oil 8 to provide pr\
oper
lubrication.
E. Use of Sight Glass Mineral based R±12 oil remains and circulates in the A/C system and d\
oes not
dissolve in R134a refrigerant. This results in a cloudy appearance at th\
e sight
glass making it impossible to judge the refrigerant charge amount by us\
ing the
sight glass method. To prevent misdiagnosis on retrofit vehicles, apply black
paint to the sight glass on block±joint (FF) type Receivers. Union\
±nut joint (BAG)
type retrofit Receivers are manufactured without a sight glass.
Required
Tools &
Materials
Retrofitting Overview
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R±12 AIR CONDITIONER SYSTEM RETROFIT ± AC001±98 April 3, 1998
Page 3 of 4
A. Refrigerant handling
1. Do not handle refrigerant in an enclosed area or near an open flame.
2. Always wear eye protection.
3. Avoid getting liquid refrigerant in your eyes or on your skin.
4. Never heat a container with an open flame.
5. Keep containers below 104 °F.
6. When heating a refrigerant can with water, keep the valve above water.
7. Never reuse empty service cans.
B. Replacing parts 1. Plug off any open connections to prevent the entry of moisture and dust.
2. Do not remove plugs from Receiver ports until it is ready for installati\
on.
C. Tightening connecting parts
1. Apply a few drops of ND±Oil 8 compressor oil to O±ring fittings be\
fore tightening.
2. Avoid twisting refrigerant piping when installing R134a service fitting a\
dapters.
3. Tighten all fittings to specified torque.
D. Recharging with A/C ªonº
1. Never open the high side valve with the engine running.
2. Never run the A/C system when low on refrigerant as compressor damage ma\
yoccur.
3. Never charge the system with liquid refrigerant with the engine running.\
4. Be careful not to overcharge the system.
NOTE:
Oil removed during R±12 evacuation should not be used with an R134a Syst\
em.
A. Vehicle Inspection:
Ensure the integrity of the A/C system before proceeding with retrofit.
B. Recover R±12 using R±12 recovery/recycling/recharging equipment: Follow Lexus recommended procedure.
C. Install R134a service fitting adapters: 1. Remove valve cores from R±12 service fittings and discard.
2. Clean external threads of the R±12 service fittings.
3. Apply adhesive to threads (Loctite 262 or equivalent), screw on R134a \
adapterfittings, and tighten to 13 ft±lb.
NOTE:
Vehicles with more than 2 service fittings will require the installation \
of additional
adaptors. All service fittings must have R134a adaptors installed.
D. Replace piping and hose O±rings:
1. Disconnect discharge hose from compressor.
2. Remove and discard old O±rings.
3. Lubricate with ND±Oil 8 and install new O±rings.
4. Disconnect discharge hose from condenser.
5. Lubricate and install retrofit O±rings with ND±Oil 8.
6. Reconnect hoses and torque to specification. (Specifications can be fou\
nd in applicable manuals/guides.)
Service
Precautions
Repair
Procedure
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wTighten the O±ring fittings or the bolted type fittings to
the specified torque.
Precautions When Charging Refrigerant
1. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH
REFRIGERANT IN REFRIGERANT CYCLE
If there is not enough refrigerant in the refrigerant cycle, oil
lubrication will be insufficient and compressor burnout may
occur, so take care to avoid this.
2. DO NOT OPEN HIGH PRESSURE VALVE OF MANIFOLD GAUGE WITH COMPRESSOR OPERATING
If the high pressure valve is opened, refrigerant flows in the
reverse direction and could cause the charging cylinder to
rupture, so open and close the low pressure valve only.
3. BE CAREFUL NOT TO OVERCHARGE WITH REFRIGERANT IN SYSTEM
If refrigerant is overcharged, it causes trouble such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.
Electrical Parts
Before removing and inspecting the electrical parts, set the
ignition switch to the LOCK position and disconnect the neg-
ative (±) terminal cable from the battery.
CAUTION: Work must not be started until after at least 20
seconds or longer from the time the negative (±) terminal
cable is disconnected.
SRS Airbag System
Failure to carry out service operations in the correct se-
quence could cause the airbag system to deploy, possibly
leading to a serious accident.
When removal or installation of the parts and the yellow wire
harness and connector for the airbag is necessary, refer to
the precautionary notices in the AB section before perform-
ing the operation.
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AIR CONDITIONING SYSTEM General DescriptionAC±5
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REFRIGERANT LINES
TIGHTENING TORQUE OF
REFRIGERANT LINES
ON±VEHICLE INSPECTION
1. INSPECT HOSES AND TUBES FOR LEAKAGEUse a gas leak tester. Replace if necessary.
2. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS
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AIR CONDITIONING SYSTEM Refrigerant LinesAC±105
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REPLACEMENT OF REFRIGERANT
LINES
1. RECOVER REFRIGERANT IN REFRIGERATION SYSTEMSee page AC±16
2. REPLACE FAULTY TUBE OR HOSE NOTICE: To prevent the intrusion of moisture or dirt, caps
should be placed on hose or tube ends immediately.
3. TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE: Connections should not be torque tighter than the
specified torque.
4. EVACUATE REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT
See page AC±17
Specified amount: 950 + 50 g (33.44 + 1.76 oz)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak tester, check for leakage of refrigerant.
6. INSPECT A/C OPERATION
AC±106
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AIR CONDITIONING SYSTEM Refrigerant Lines
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