ect LEXUS SC300 1991 Service Repair Manual

4. INSTALL PULLEY(a) Install the pulley to the rotor shaft by tightening thepulley nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820±63010
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) As shown in the illustration, mount SST (C) in a vise, and
install the alternator to SST (C).
(e) To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 110 N Vm (1,125 kgf Vcm, 81 ft Vlbf)
(f) Remove the alternator from SST (C).
(g) Turn SST (B) and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER (a) Place the seal plate on the rectifier end frame.
(b) Install the four rubber insulators on the lead wires.
(c) Install the rectifier holder with the four screws.
CH±18
±
CHARGING SYSTEM Alternator
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6. INSTALL IC REGULATOR AND BRUSH HOLDER(a) Place the IC regulator together and brush holder on therectifier end frame.
NOTICE: Be careful of the holder installation direction.
(b) Install the five mounting screws until there is a clearance
of approx. 1 mm (0.04 in.) between the brush holder and
connector.
(c) Place the brush holder cover on the brush holder.
7. INSTALL REAR END COVER (a) Install the end cover with the three nuts.
(b) Install the terminal insulator with the nut.
8. CHECK THAT ROTOR ROTATES SMOOTHLY
±
CHARGING SYSTEM AlternatorCH±19
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INSTALLATION OF ALTERNATOR
(See Components on page CH±9)
1. INSTALL ALTERNATOR (a) Install the alternator and A/T oil cooler bracket with the
bolt and nut.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
(b) Connect the alternator connector.
(c) Connect the alternator wire with the nut and cap.
2. INSTALL DRIVE BELT Install the drive belt by turning the drive belt tensioner coun-
terclockwise.
HINT: The pulley bolt for the belt tensioner has a left±hand
thread.
3. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
4. PERFORM ON±VEHICLE INSPECTION (See steps 6 to 8 on pages CH±6 to 8)
5. INSTALL ENGINE UNDER COVER
CH±20
±
CHARGING SYSTEM Alternator
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ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
ABS Antilock Brake System
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempi Gratia (For Example)
Ex. Except
in. inch
LH Left-hand
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
w/ with
w/o without
INTRODUCTIONIN-16
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INSTALLATION
2. Temporarily install the front fender and thehood, and check the fit.
1. Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.
NOTICE: Make sure each measurement is correct,
as this parts affects the front wheel alignment.
BODY PANEL REPLACEMENTRE-11
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INSTALLATION
Front Side
MemberFront Side Member
No. 3 Reinforcement
Front Side Member
Plate
1. Before temporarily installing the new front side member, weld the front side member
No. 3 reinforcement with standard points. 2. Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.
NOTICE: Make sure each measurement is correct,
as this part affects the front wheel alignment.
BODY PANEL REPLACEMENTRE-18
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INSTALLATION
Body Sealer
Body Sealer Braze
(both sides)
2. Braze the quarter panel connection.
NOTICE: Before performing these operations,place a wet rag on the roof panel to protect it fromdamage.
1. Before temporarily installing the new parts, apply body sealer to the windshield header
panel and the back window upper frame.
HINT: Apply just enough sealer for the new parts
to make contact.
BODY PANEL REPLACEMENTRE-35
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INSTALLATION
Body Sealer
Body Sealer Braze (both sides)
2. Braze the quarter panel connection.
NOTICE: Before performing these operations,place a wet rag on the roof panel to protect it fromdamage.
1. Before temporarily installing the new parts, apply body sealer to the windshield header
panel and back window upper frame.
HINT: Apply just enough sealer for the new parts
to make contact.
BODY PANEL REPLACEMENTRE-37
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INSTALLATION
Butt WeldButt Weld
Body Sealer
Body Sealer
about 10 mmDo not close the
drain hole.
Body Sealer
Cloth Tape
30
°
Hemming Tool
1. Before temporarily installing the new parts, apply body sealer to the back side of the new
parts.
HINT: 1) Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diame-
ter.
2) For other sealing-points, refer to section AR.
2. Bend the flange hem about 30 ° with a ham-
mer and dolly, then fasten tightly with a hem-
ming tool.
HINT:
1) Perform hemm ing in three steps, being care-
ful not to warp the panel.
2) If a hemming tool cannot be used, hem with
a hammer and dolly.
BODY PANEL REPLACEMENTRE-39
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mm in.5 0.20
INSTALLATION
Butt Weld
Body Sealer
Butt Weld
Body Sealer
about 5 mm
1. Before temporarily installing the new parts, apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16 in.) in diameter.
3) For other sealing points, refer to section AR.
2. Temporarily install the new parts and check the fit of the front door, luggage compartment
door and rear combination light.
3. Apply foamed material to the pillar section.
HINT: For the foamed material application areas, refer to page AP-4.
BODY PANEL REPLACEMENTRE-42
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