LEXUS SC400 1991 Service Repair Manual

(d) Clean the filter in the canister.Clean the filter by blowing 294 kPa (3 kgf/cm
2, 43 psi) of com-
pressed air into port A while holding port B closed.
NOTICE:
w Do not attempt to wash the canister.
w No activated carbon should come out.
(e) Reinstall the charcoal canister.
(See Emission Control System on page EG±222)
9. REPLACE GASKET IN FUEL TANK CAP
(a) Remove the old gasket from the tank cap. Do not damage the
cap.
(b) Install a new gasket by hand.
(c) Check the cap for damage or cracks.
(d) Install the cap and check the torque limiter.
10. INSPECT FUEL LINES AND CONNECTIONS Visually check the fuel lines for cracks, leakage, loose con-
nections, deformation or tank band looseness.
11. INSPECT EXHAUST PIPES AND MOUNTINGS Visually check the pipes, hangers and connections for se-
vere corrosion, leaks or damage.
12. ADJUST VALVE CLEARANCE (See Engine Mechanical on page EG±14)
Valve clearance (Cold):
Intake
.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust
.25 ± 0.35 mm (0.010 ± 0.014 in.)
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MA04N±01
BRAKES
13. INSPECT BRAKE LINE PIPES AND HOSESHINT: Check in a well lighted area. Check the entire circum-
ference and length of the brake hoses using a mirror as re-
quired. Turn the front whe els fully right or left before checking
the front brake.
(a) Check all brake lines and hoses for: wDamage
w Wear
w Deformation
w Cracks
w Corrosion
w Leaks
w Bends
w Twists
(b) Check all clamps for tightness and connections for leakage.
(c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through the center of the grommets.
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14. INSPECT BRAKE PADS AND DISCS FOR FRONT ANDREAR
(a) Check the thickness of the disc brake pads and check for irregular wear.
Minimum pad thickness:
1.0 mm (0.039 in.)
HINT: If a squealing or scraping noise comes from the brake
during driving, check the pad wear indicator to see if it is con-
tacting the disc rotor. If so, the disc pad should be replaced.
(b) Check the disc for wear or runout.
Minimum disc thickness: Front
30.0 mm (1.181 in.)
Rear
15.0 mm (0.591 in.)
(c) Check the disc for runout.
Maximum disc runout: 0.05 mm (0.0020 in.)
15. INSPECT BRAKE LININGS AND DRUMS FOR PARKINGBRAKE
(a) Check the lining±to±drum contact condition and lining wear.
Minimum lining thickness:
1.0 mm (0.039 in.)
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(b) Check the brake drums for scoring or wear.
Maximum drum inside diameter:191 mm (7.520 in.)
(c) Clean the brake parts with a damp cloth.NOTICE: Do not use compressed air to clean the brake
parts.
(d) Seat the parking brake shoes during the road test (item 25) in do the following:
wDrive the vehicle at approx. 50 km/h (30 mph) on a safe,
level and dry road.
w With the parking brake release buttom pushed in, pull on
the lever with 88 N (9 kgf, 20 lbf) of force.
w Drive the vehicle for approx. 400 meters (1/4 mile) in this
condition.
w Repeat this procedure 2 or 3 times.
w Check parking pedal travel.
If necessary, adjust the parking brake.
16. INSPECT AND CHANGE BRAKE FLUID
(a) Visually inspect the master cylinder for leaks.
(b) Change brake fluid (See BR section)
Fluid: SAE J1703 or FMVSS No.116 DOT3
MA04F±01
CHASSIS
17. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay.
Maximum freeplay:30 mm (1.18 in.)
With the vehicle stopped and pointed straight ahead, rock the
steering wheel gently back and forth with light finger pres-
sure.
(b) Check the steering linkage for looseness or damage. Check that:
wTie rod ends do not have excessive play.
w Dust seals and boots are not damaged.
w Boot clamps are not loose.
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18. INSPECT SRS AIRBAGDriver Airbag:
Visually inspect the steering wheel pad (airbag and inflater).
wUse the diagnosis check to check if there are
abnormalities.
w Check that there are no cuts, cracks or noticeable color
changes on the surface of the steering wheel pad or in
the center groove of the pad.
w Remove the steering wheel pad from the vehicle and
check the wiring and steering wheel for damage and
corrosion due to rusting, etc.
If necessary, replace the steering wheel pad.
Front Passenger Airbag:
Visually inspect the front passenger airbag assembly (airbag
and inflater).
w Use the diagnosis check to check if there are
abnormalities.
w Check that there are no cuts, cracks or noticeable color
changes in the front passenger airbag door.
w Remove the front passenger airbag assembly from the
vehicle and check the wiring and front passenger airbag
door for damage and corrosion due to rusting, etc.
If necessary, replace the front passenger airbag assembly.
CAUTION:
w For removal and replacement of the steering wheel pad
or front passenger airbag assembly, see page RS±28 and
be sure to perform the operation in the correct order.
w Before disposing of the steering wheel pad or front
passenger airbag assembly must first be deployed by
using SST and wiring harness connector (See page
RS±28 ).
19. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
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20. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.wJack up the front of the vehicle and support it with
stands.
w Make sure the front wheels are in a straight±ahead
position, and depress the brake pedal.
w Jack up the lower suspension arm until there is about
half a load on the front coil spring.
w Move the front wheel up and down and check that the
ball joint has no excessive play.
Maximum lower ball joint vertical play.
0.3 mm (0.012 in.)
If the play is greater than maximum, replace the ball joint.
(b) Visually check the dust covers for damage
21. C H E C K A U TO M AT I C T RANSMISSION AND
DIFFERENTIAL OIL (FLUID)
A. Inspect automatic transmission fluid
(a) Visually check the differential for fluid and leakage.
If leakage is found, check for the cause and repair.
(b) Check the fluid level with the engine idling and shift lever at ªPº.
If the level is low, add fluid.
Transmission fluid:
See item 22 (A)
B. Inspect differential oil
(a) Visually check the transmission for oil and leakage.If leakage is found, check for the cause and repair.
(b) Remove the filler plug, and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in) of the
bottom edge of the filler hole.
If the level is low, add oil until it begins to run out of the filler
hole.
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Differential oil:See item 22 (B)
(c) Reinstall the filler plug securely.
22. R E P L A C E A U TO M AT I C T RANSMISSION AND
DIFFERENTIAL OIL (FLUID)
A. Replace automatic transmission fluid
(a) Remove the drain plug, and drain the fluid.
(b) Clean the drain plug.
(c) Reinstall the drain plug securely.
(d) With the engine ªOFFº, add new fluid through the dipstick
tube.
Fluid type:
ATF Type T±II or equivalent
Drain and refill capacity: 1.9 liters (2.0 US qts. 1.7 lmp. qts)
(e) Start the engine and shift the selector into all positions fromªPº through ªLº, and then shift into ªPº position.
(f) With the engine idling, check the fluid level. Add fluid up the ªCOOLº level on the dipstick.
(g) Check that the fluid level is in the ªHOTº range at the normal
operating temperature (70 ± 80
C (158 ± 176
F)) and add
as necessary.
NOTICE: Do not overfill.
B. Replace differential oil
(a) Remove the filler and drain plugs, and drain the oil.
(b) Clean the drain plug.
(c) Reinstall the drain plug securely.
(d) Add new oil until it begins to run out of the filler hole.
Differential oil: Oil grade
API GL±5
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ViscosityAbove ± 185C (05F) SAE 90
Below ± 18 5C (0 5F) SAE 80W±90 or 80W
Capacity:
1.35 liters (1.43 US qts, 1.19 lmp. qts)
(e) Reinstall the filler plug securely.
23. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the following parts.
wFront seat±to±body mounting bolts
Torque: 37 N Vm (375 kgf Vcm, 27 ft Vlbf)
w Front suspension crossmembers - to - body mounting
nuts and bolts
Torque:
127 N Vm (1.300 kgf Vcm, 94 ft Vlbf) for nut
201 N Vm (2,050 kgf Vcm, 148 ft Vlbf) for bolt
w Rear suspension member - to - body mounting bolts
Torque: 176 NVm (1,800 kgfVcm, 130 ftVlbf)
wRear suspension member rear cushion - to - body
mounting bolts
Torque: 38 N Vm (390 kgf Vcm, 28 ft Vlbf)
24. BODY INSPECTION
(a) Check the body exterior for dents, scratches and rust
(b) Check the underbody for rust and damage.
If necessary, replace or repair.
25. ROAD TEST
(a) Check the engine and chassis for abnormal noises.
(b) Check that the vehicle does not wander or pull to one side.
(c) Check that the brakes work properly and do not drag.
(d) Perform setting of the parking brake shoes and drum.
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26. FINAL INSPECTION
(a) Check the operation of the body parts:wHood:
Auxiliary catch operates properly Hood locks securely
when closed
w Doors:
Door locks operate properly Doors close properly
w Luggage compartment door:
Door lock operates properly
w Seats:
Seat adjusts easily and locks securely in any position
Front seat back locks securely in any position Folding±
down rear seat backs lock securely
(b) Be sure to deliver a clean car. Especially check: wSteering wheel
w Shift lever knob
w All switch knobs
w Seats
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GENERAL MAINTENANCE
MA00M±03
There are the maintenance and inspection
items which are considered to be the owner's
responsibility. They can be performed by the
owner or be can have them done at a service
shop. These items include those which should
be checked on a daily basis, those which, in
most cases, do not require (special) tools and
those which are considered to be reasonable
for the owner to perform. Items and procedures
for general maintanance are as follows:
MA00P±04
OUTSIDE VEHICLE
1. TIRES
(a) Check the pressure with a gauge. Adjust ifnecessary.
(b) Check for cuts, damage or excessive wear.
2. WHEEL NUTS Wheel checking the tires, check the nuts for
looseness or for missing nuts. If necessary,
tighten them.
3. TIRE ROTATION It is recommended that tires be rotated every
12,000 km (7,500 miles).
4. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not
wipe clean. Replace if necessary.
5. FLUID LEAKS
(a) Check underneath for leaking fuel, oil, water or
other fluid.
(b) If you smell gasoline fumes or notice any leak, have the cause found and corrected.
6. DOORS AND ENGINE HOOD
(a) Check that all doors including the trunk lid operate smoothly, and that all latches lock
securely.
(b) Check that the engine hood secondary latch secures the hood from opening when the
primary latch is released.
MA00R±05
INSIDE VEHICLE
7. LIGHTS
(a) C h e c k t h a t t h e h eadlights, stop lights,
tail±lights, turn signal lights, and other lights
are all working. (b) Check the headlight aiming.
8. WARNING LIGHT AND BUZZERS
Check that all warning lights and buzzers func-
tion properly.
9. HORN Check that it is working.
10. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
11. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
12. WINDSHIELD DEFROSTER Check that the air comes out from the defroster
outlet when operating the heater air condition-
er at defroster mode.
13. REAR VIEW MIRROR
Check that it is mounted securely.
14. SUN VISORS Check that they move freely and are mounted
securely.
15. STEERING WHEEL Check that it has the specified freeplay. Be
alert for changes in steering condition, such as
hard steering, excessive freeplay or strange
noise.
16. SEATS
(a) Check that all front seat controls such as seat adjusters, seatback recliner, etc. operate
smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the locks hold securely in any latched position.
(d) Check that the head restraints move up and
down smoothly and that the locks hold securely
in ay latches position.
(e) For folding±down rear seat backs, check that the latches lock securely.
17. SEAT BELTS
(a) Ch e ck th a t th e se a t be lt syste m su ch as buckles, retractors and anchors operate
properly and smoothly.
(b) Check that the belt webbing is not cut, frayed,
worn or damaged.
18. ACCELERATOR PEDAL Check the pedal for smooth operation and un-
even pedal effort or catching.
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