ect LEXUS SC300 1991 Service Repair Manual

HINT: Avoid applying an excessive amount to the surface.
(b) Remove grease from the surface of the inboard joint facing the cover.
(c) Align the bolt holes of the cover with those of the inboard joint,
then insert the hexagon bolts.
(d) Use a pl astic±faced hammer to tap the rim of the inboard joint
cover into place. Do this in the order shown, and repeat
several times.
4. INSTALL INBOARD JOINT
(a) Align the matchmarks placed before removal.
(b) Using a brass bar and hammer, tap the inboard joint onto the drive shaft.
NOTICE: Check that the brass bar is touching the inner race,
and not the cage.
(c) Using a snap ring expander, install a new snap ring.
5. ASSEMBLE BOOT TO OUTBOARD JOINTBefore assembling the boot, pack with only the same amount
of grease that was wiped off.
Grease capacity:
100 ± 105 g (0.22 ± 0.23 lb, 3.5 ± 3.7 oz.)
HINT: Use the grease supplied in the boot kit.
NOTICE:
wKeep grease off the joint connection groove of the boot.
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SUSPENSION AND AXLE REAR DRIVE SHAFTSA±71
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wPack with grease all over the ball contact surface inside
the joint.
6. ASSEMBLE BOOT TO INBOARD JOINT
Before assembling the boot, pack with grease.
Grease capacity:
100±105 g (0.22±0.23 lb, 3.5±3.7 oz.)
HINT: Use the grease supplied in the boot kit.
NOTICE:
wKeep grease off the joint connection groove of the boot.
w Pack with grease all over the ball contact surface inside
the joint.
7. INSTALL NEW BOOT CLAMPS TO BOTH BOOTS
(a) Position the clamp onto the boot. HINT: Pinch the inboard side of the boot clamp, as shown in
the illustration.
(b) Place SST onto the clamp. SST 09521±24010
(c) Tighten SST so that the clamp is pinched.
NOTICE: Do not overtighten the SST.
(d) Using SST, adjust the clearance of the clamp. SST 09240±00020
Clearance:
0.8 mm (0.031 in.) or less
SA±72±
SUSPENSION AND AXLE REAR DRIVE SHAFT
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(e) The drive shaft is designed to move + 20 mm from the normalposition.
Drive shaft standard length:
RH 598.5 mm (23.563 in.)
LH 553.5 mm (21.791 in.)
8. INSTALL NEW END COVER
(a) Pack grease into the end cover.
Grease capacity:50±55 g (0.11±0.12 lb, 1.8±1.9 oz.)
(b) Remove grease from the surface of the inboard joint facingthe cover.
(c) Glue on a new gasket, with the side with adhesive on it facing
toward the outer race side of the inboard joint.
(d) Align the bolt holes of the cover with those of the inboard joint.
(e) Install the 6 hexagon bolts and washer from the end cover side.
(f) Install the 6 nuts to the boot side.
(g) Using a 10 mm hexagon wrench, tighten the bolts. Do this in
the order shown, and repeat several times.
(h) Check that the claw of the end cover touches the inboard joint.
9. CHECK DRIVE SHAFT Check that operation of the joint is smooth within the sliding
region in the axial direction.
HINT: If a large angle is used for the cross±groove type joint,
the joint will feel like it is catching, but this does not indicate
an abnormality.
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SUSPENSION AND AXLE REAR DRIVE SHAFTSA±73
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5. INSTALL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.SST 09608±32010, 09608±35014 (09608±06020)
(b) Apply MP grease to the oil seal lip.
6. INSTALL SIDE GEAR SHAFT
(a) Install a new snap ring to the side gear shaft.
(b) Using a hammer and brass bar, tap in the side gear shaft to
the differential.
NOTICE: Be careful not damage the side gear shaft and oil
seal.
7. CHECK INSTALLATION OF SIDE GEAR SHAFT
(a) Check that there is 2±3 mm (0.08±0.12 in.) of play in axialdirection.
(b) Check that the side gear shaft will not come out by trying to pull it out by hand.
8. INSTALL REAR DRIVE SHAFT
(See page SA±65)
9. CHECK DIFFERENTIAL OIL LEVEL Fill with hypoid gear oil if necessary.
Oil grade:
API GL±5 Hypoid Gear Oil
Viscosity: Above±18
C (0
F) SAE 90
Below±18
C (0
F) SAE 80W±90 or 80W
Capacity: 1.35 liters (1.43 US qts, 1.19 lmp. qts)
SA±80±
SUSPENSION AND AXLE REAR DIFFERENTIAL
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ECU Power Source Circuit
CIRCUIT DESCRIPTION
When the ignition switch is turned on, battery voltage
is applied to the terminal IG SW of the ECU, and the
main relay control circuit in the ECU sends a signal to
the terminal M±REL of the ECU, switching on the
main relay. This signal causes current to flow to the
coil, closing the contacts of the main relay and supply-
ing power to the terminals +B and +B1 of the ECU.
If the ignition switch is turned off, the ECU continues
to switch on the main relay for a maximum of 2 se-
conds for the initial setting of the ISC valve.
DIAGNOSTIC CHARTDIAGNOSTIC CHART
See next page for the DIAGNOSTIC CHART.
WIRING DIAGRAM
TR±124±
ENGINE TROUBLESHOOTING Circuit Inspection
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DIAGNOSTIC CHART
DIAGNOSTIC
CHART
Check for short in all the harness and
components connected to IGN fuse.
Check voltage of terminal M±REL.
Check for open in harness and connector
between battery and ECU.
Check and replace ECU.
Replace ignition switch.
Repair or replace harness or
connector.
Repair or replace harness or
connector.
Check for open and short in harness and
connector between terminal M REL and body
ground.
Replace EFT main relay.
Check voltage of terminal IGSW.
Check IGN fuse.
Check continuity between terminals E1 and
body ground.
Check voltage of ECU power source.
Proceed to next circuit inspection
shown on matrix chart (See page
TR±35
).
Check ignition switch.
Check EFT fuse.
Check EFT main relay.
Check and repair or harness or connector
between EFI fuse and battery.
Check for short in all the harness and
components connected to EFI fuse.
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ENGINE TROUBLESHOOTING Circuit InspectionTR±125
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NGOK
OKNG
NGOK
INSPECTION PROCEDURE
1Check voltage between terminals + B, + B1 and E1 of engine & ECT ECU connecto\
r.
C
OK
P(2) Connect the Check Harness A.(See page TR±30)
(2) Turn ignition switch on.
Measure voltage between terminals + B, + B1 and E1
of engine & ECT ECU connector.
Voltage: 10 ± 14 V
Proceed to next circuit inspection shown on matrix chart
2Check for open in harness and connector between terminals E1 of engine &\
ECT ECU and body
ground (See page IN±27).
Repair or replace harness or connector.
3Check voltage between terminal IG SW of engine & ECT ECU connector and b\
ody ground.
C
OK
PTurn ignition switch on.
Measure voltage between terminal IG SW of engine &
ECT ECU connector and body ground.
Voltage: 10 ± 14 V
Go to step 6.
TR±126
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ENGINE TROUBLESHOOTING Circuit Inspection
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OKNG
OKNG
4Check IGN Fuse.
C
OK
PRemove IGN fuse from J/B No.1.
Check continuity of IGN fuse.
Continuity.
Check for short in all the harness and components con-
nected to IGN fuse (See attached wiring diagram).
5Check ignition switch.
C
OK
PRemove under cover and finish panel.
Check continuity between terminals.
continuity
Replace ignition switch.
Check and repair harness and connector between
battery and ignition switch, ignition switch and en-
gine & ECT ECU.
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ENGINE TROUBLESHOOTING Circuit InspectionTR±127
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OKNG
OKNG
6Check voltage between terminal M±REL of engine & ECT ECU connector and bod\
y ground.
C
OK
PTurn ignition switch on.
Measure voltage between terminal M±REL of engine &
ECT ECU connection and body ground.
Voltage: 10 ± 14 V
Check and replace engine & ECT ECU.
7Check EFI
C
OK
PRemove EFI fuse R/B No.2.
Check continuity of EFI fuse.
Continuity
Rep
TR±128
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ENGINE TROUBLESHOOTING Circuit Inspection
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OKNG
OKNG
8Check EFI main relay.
C
OK
P
C
OK
Remove EFI main relay.
Check continuity between terminals of EFI main relay
shown below.
(2) Apply battery voltage between terminals 1 and 3.
(2) Check continuity between terminals 2 and 4.
Replace EFI main relay.
9Check for open and short in harness and connector between terminal M±REL o\
f engine & ECT
ECU and body ground (See page IN±27).
Repair or replace harness or connector.
Check and repair harness or connector between
EFI fuse and battery.
±
ENGINE TROUBLESHOOTING Circuit InspectionTR±129
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