LEXUS SC400 1991 Service Repair Manual

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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CodeMaterial
name Heat *
resistant
temperature
limit
°C (°F) Resistance to
alcohol or gasoline Notes
AAS Acrylonitrile
Acrylic Styrene 80
(176) Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease). Avoid gasoline and or-
ganic or aromatic sol-
vents.
ABS Acrylonitrile
Butadiene Styrene 80
(176) Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).
Avoid gasoline and or-
ganic or aromatic sol-
vents.
AES Acrylonitrile
Ethylene Styrene 80
(176) Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease). Avoid gasoline and or-
ganic or aromatic sol-
vents.
BMC Bulk
Moulding
Compound
150
(302) Alcohol and gasoline are
harmless. Most solvents are
harmless.
CAB Cellulose
Acetate 80
(176) Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease). Avoid gasoline and or-
ganic or aromatic sol-
vents.
EPDM Ethylene
Propylene 100
(212) Alcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts. Most solvents are harm-
less but avoid dipping in
gasoline, solvents, etc.
PA Polyamide
(Nylon) 80
(176) Alcohol and gasoline are
harmless.
Avoid battery acid.
PBT Polybutylene
Terephthalate 160
(320) Alcohol and gasoline are
harmless. Most solvents are
harmless.
PC Polycarbonate 120
(248) Alcohol is harmless. Avoid gasoline, brake
fluid, wax, wax removers
and organic solvents.
PE Polyethylene 80
(176) Alcohol and gasoline are
harmless. Most solvents are
harmless.
PET Polyethylene
Terephthalate 75
(167) Alcohol and gasoline are
harmless.
Avoid dipping in water.
HANDLING PRECAUTIONS
1. The repair procedure for plastic body parts must conform with the type o\
f plastic material.
2. Plastic body parts are identified by the codes in the following chart.
3. When repairing metal body parts adjoining plastic body parts (by brazin\
g, frame cutting, welding, paint-
ing, etc.), consideration must given to the property of the plastic.
*Temperatures higher than those listed here may result in material deforma\
tion during repair.
PLASTIC BODY PARTSPP-2
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CodeMaterial
name Heat*
resistant
temperature
limit
°C (°F) Resistance to
alcohol or gasoline Notes
PMMA Polymethyl
Methacrylate 80
(176) Alcohol is harmless if applied only
for short time in small amounts.
Avoid dipping or immers-
ing in alcohol, gasoline,
solvents, etc.
POM Polyoxymethylene
(Polyacetal) 100
(212) Alcohol and gasoline are
harmless.
Most solvents are
harmless.
PP Polypropylene 80
(176) Alcohol and gasoline are
harmless.
Most solvents are
harmless.
PPO Modified
Polyphenylene
Oxide
100
(212) Alcohol is harmless. Gasoline is harmless if
applied only for quick
wiping to remove
grease.
PS Polystyrene 60
(140) Alcohol and gasoline are harm-
less if applied only for short time
in small amounts. Avoid dipping or immers-
ing in alcohol, gasoline,
solvents, etc.
PUR Polyurethane 80
(176) Alcohol is harmless if applied only for
very short time in small amounts (e.g.,
quick wiping to remove grease).
Avoid dipping or immers-
ing in alcohol, gasoline,
solvents, etc.
PVC Polyvinylchloride
(Vinyl) 80
(176) Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease). Avoid dipping or immers-
ing in alcohol, gasoline,
solvents, etc.
SAN Styrene
Acrylonitrile 80
(176) Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease).
Avoid dipping or immers-
ing in alcohol, gasoline,
solvents, etc.
SMC Sheet
Moulding
Compound
180
(356) Alcohol and gasoline are
harmless.
Avoid alkali
TPO Thermoplastic
Olefine 80
(176) Alcohol is harmless.
Gasoline is harmless if applied only
for short time in small amounts.
Most solvents are harm-
less but avoid dipping in
gasoline, solvents, etc.
TPU Thermoplastic
Polyurethane 80
(176) Alcohol is harmless if applied only for
very short time in small amounts (e.g.,
quick wiping to remove grease).
Avoid dipping or immers-
ing in alcohol, gasoline,
solvents, etc.
UP Unsaturated
Polyester 11 0
(233) Alcohol and gasoline are
harmless.
Avoid alkali
* Temperatures higher than those listed here may result in material deforma\
tion during repair.
PLASTIC BODY PARTSPP-3
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LOCATION OF PLASTIC BODY PARTS
Outside Rear View Mirror (ABS)
Instrument Panel Safety Pad (PVC/PUR) Rear Spoiler (SMC)
Front Turn Signal Light (PC/PP)
Center Stop Light (PC)
Mead Light (PC/PP)
Head Light (PC/PP)
Front Bumper Extension
Mounting Bracket (PP)
Quarter Panel
Mud Guard (TPO)
Outside Moulding
Front Fender Mud Guard (TPO)
Front Spoiler (PUR) Cowl Top Ventilation Louver (PP)
Front Bumper Cover (PUR) Side Turn Signal Light (PMMA/ABS)
Cornering Light (PC)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-4
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Front Door Trim Upper Panel (ABS/PVC)
Battery Insulator (PE) Roof Side Inner Garnish (ABS/PVC)
Front Pillar Garnish (ABS/PVC)
Speed Control Actuator Cover (PP)
Radiator Reserver Tank (PP)
Radiator Cover Plate (PP) Cool Air Intake
Duct (PP)
Spare Wheel Cover (PP)
Washer Jar (PP)
Junction Block Cover (PP)
Front Fender Liner (PE)
Front Fender Splash Shield (PE)
Engine Under Cover (PE) Engine Under Cover (PE)
Engine Under Cover (PP/PE)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-5
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Steering Wheel Pad (PUR)A/C and Blower Unit (PP) Luggage Compartment Door
Striker Cover (PP)
Fuel Filler Opening
Lid (PBT)Rear Combination
Light (PMMA/PC/PP)
Door Scuff Outside Plate (PP) Door Scuff Inside Plate (PP)
Quarter Ventilation Duct (PP) License Plate
Light (PC/PP)
Rear Under Side Cover (PUR)
Rear Bumper Cover (PUR)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-6
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RADIATOR UPPER SUPPORT (ASSY)
REMOVAL
BODY PANEL REPLACEMENTRE-2
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INSTALLATION
1. Temporarily install the new parts and measureeach part in accordance with the body dimen-
sion diagram.
HINT: First install the hood lock support.
BODY PANEL REPLACEMENTRE-3
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