clock LEXUS SC400 1991 Service Owners Manual

Brush Springs
INSPECT BRUSH SPRING LOADTake the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard installed load:
26±32 N (2.7±3.3 kgf, 6.0±7.3 lbf)
If the installed load is not as specified, replace the brush
springs.
Brush Holder
INSPECT BRUSH HOLDER INSULATIONUsing an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
If there is continuity, repair or replace the brush holder.
Clutch and Gears
1. INSPECT GEAR TEETHCheck the gear teeth on the pinion gear, idler gear and the
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel ring gear for wear or
damage.
2. INSPECT CLUTCH PINION GEAR Rotate the pinion gear counterclockwise and check that it
turns freely. Try to rotate the pinion gear clockwise and check
that it locks.
If necessary, replace the clutch assembly.
Bearings
1. INSPECT FRONT BEARING Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
±
STARTING SYSTEM StarterST±19
WhereEverybodyKnowsYourName

DIAGNOSTIC CODE CLEARANCE
1. After repair of the trouble areas, the diagnostic code retainedin the ECU memory must be cleared out by removing the EFI
fuse (30A) from R/B No. 2 for 10 seconds or more, with the
ignition switch OFF.
HINT:
wCancellation can also be done by removing the battery
negative (±) terminal, but in this case, other memory
systems (clock, etc.) will also be cancelled out.
w If it is necessary to work on engine components
requiring removal of the battery terminal, a check must
first be made to see if a diagnostic code has been
recorded.
2. After cancellation, road test the vehicle to check that a normal
code is now read on the ºCHECKº engine warning light.
If the same diagnostic code appears, it indicates that the
trouble area has not been repaired thoroughly.
±
ENGINE TROUBLESHOOTING Diagnosis SystemTR±13
WhereEverybodyKnowsYourName

ON±VEHICLE INSPECTION
1. INSPECT BATTERY SPECIFIC GRAVITY ANDELECTROLYTE LEVEL
(a) Check the specific gravity of each cell.
Standard specific gravity:
1.27±1.29 when fully charged at 20 5C (68 5F)
If gravity is less than specification, charge the battery.
(b) Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
HINT: Check the indicator as shown in the illustration.
2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND FUSES
(a) Check that the battery terminals are not loose orcorroded.
(b) Check the fusible links and fuses for continuity.
H±fuse: ALT 150A AM1 100A
AM2 30A
M±fuse: IG SW 40A
Fuse: IGN 7.5A ENGINE 7.5A
INJ 30A
3. INSPECT DRIVE BELTHINT: A belt tensioner is used, so checking the belt tension
is not necessary.
(a) Visually check the drive belt for excessive wear, frayedcords, etc.
If necessary, replace the drive belt.
HINT:
w Cracks on rib side of a drive belt are considered
acceptable. If the drive belt has chunks missing from the
ribs, it should be replaced.
w The drive belt tension can be released by turning the
belt tensioner counterclockwise. The pulley bolt for the
belt tensioner has a left±hand thread.
±
CHARGING SYSTEM On±Vehicle InspectionCH±5
WhereEverybodyKnowsYourName

ALTERNATOR
COMPONENTS FOR REMOVAL AND
INSTALLATION
REMOVAL OF ALTERNATOR
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OFBATTERY
CAUTION: Work must be started after approx. 20 se-
conds or longer from the time the ignition switch is
turned to the ºLOCKº position and the negative (±) termi-
nal cable is disconnected from the battery.
2. REMOVE ENGINE UNDER COVER
3. REMOVE DRIVE BELT
Loosen the belt tension by turning the drive belt tensioner
counterclockwise, and remove the drive belt.
HINT: The pulley bolt for the belt tensioner has a left±hand
thread.
±
CHARGING SYSTEM AlternatorCH±9
WhereEverybodyKnowsYourName

(c) Remove the seal plate.
4. REMOVE PULLEY (a) 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)
(b) Check that SST (A) is secured to the rotor shaft.
(c) As shown in the illustration, mount SST (C) in a vise, and
install the alternator to SST (C).
(d) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE: To prevent damage to the rotor shaft, do not
loosen the pulley nut more than one±half of a turn.
(e) Remove the alternator from SST (C).
(f) Turn SST (B) and remove SST (A and B).
(g) Remove the pulley nut and pulley.
5. REMOVE RECTIFIER END FRAME (a) Remove the four mounting nuts.
(b) Using SST, remove the rectifier end frame.
SST 09286±46011
CH±12
±
CHARGING SYSTEM Alternator
WhereEverybodyKnowsYourName

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
WhereEverybodyKnowsYourName

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
WhereEverybodyKnowsYourName

REMOVAL OF HYDRAULIC PUMP
(See Components on page CO±26)
1. REMOVE BATTERY CAUTION: Work must be started after approx. 20 se-
conds or longer from the time the ignition switch is
turned to the ºLOCKº position and the negative (±) termi-
nal cable is disconnected from the battery.
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT (See page CO±6)
4. REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tension-
er counterclockwise, and remove the drive belt.
HINT: The pulley bolt for the belt tensioner has a left±hand
thread.
5. DISCONNECT A/C COMPRESSOR (a) Disconnect the A/C compressor connector.
(b) Remove the nut, and disconnect the ground cable.
(c) Remove the bolt and A/C compressor stay.
(d) R e m o v e t h e t w o b o l t s , a n d d i s c onnect the A/C
compressor from the engine.
6. REMOVE LH IGNITION COIL (a) Disconnect the following connectors and cord:(1) Ignition coil connector
(2) Noise filter connector
(3) High±tension cord
±
COOLIING SYSTEM Electronically Controlled Hydraulic
Cooling Fan (Hydraulic Pump)CO±27
WhereEverybodyKnowsYourName

3. MOUNT REAR HOUSINGHINT: Mount the parts in a vise as shown in the illustration.
4. REMOVE SOLENOID VALVE (a) Remove the solenoid valve.
(b) Remove the O±ring from the solenoid valve.
(c) Remove the O±ring from the rear housing.
5. REMOVE PUMP PULLEY (a) Using SST, remove the pulley nut by turning it clockwise.
SST 09278±54012
(b) Using SST, remove the pulley.
SST 09286±46011
6. REMOVE FRONT HOUSING (a) Remove the five mounting bolts.
CO±32
±
COOLIING SYSTEM Electronically Controlled Hydraulic
Cooling Fan (Hydraulic Pump)
WhereEverybodyKnowsYourName

(c) Using SST, install the pulley with the nut. Tighten the nut
by turning it counterclockwise.
SST 09278±54012
Torque: 59 N Vm (600 kgf Vcm, 43 ft Vlbf)
12. INSTALL SOLENOID VALVE
(a) Install a new O±ring to the solenoid valve.
(b) Install a new O±ring to the rear housing groove.
(c) Apply fluid to the two O±rings.
(d) Install the solenoid valve.
Torque: 39 N Vm (400 kgf Vcm, 28 ft Vlbf)
13. INSTALL WIRE CLAMP
(a) Install the wire clamp to the read wire.
(b) Install the wire clamp to the rear housing.
14. INSTALL SUCTION PORT UNION (a) Install the O±ring to the port union.
(b) Apply fluid to the O±ring.
(c) Install the port union with the bolt.
Torque: 13 N Vm (135 kgf Vcm, 10 ft Vlbf)
±
COOLIING SYSTEM Electronically Controlled Hydraulic Cooling Fan
(Hydraulic Pump)CO±41
WhereEverybodyKnowsYourName