lock LEXUS SC400 1991 Service Repair Manual

(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
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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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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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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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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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mm in.150
200
300 5.91
7.87
11.81
Replacement parts
QUARTER PANEL
HOW TO USE THIS MANUAL
Each repair method description provided in Section RE of this manual com\
prises two pages, divided into
2 blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair.
BODY PANEL REPLACEMENT-Rear Body Components
RE-40
QUARTER PANEL (CUT)REMOVAL Cut and Join Location
200 - 300 mm
150 - 200 mm
[Cut and Join Location]
Cut and Join Location
(Cut Location for Supply Parts)
1. Cut and join the parts at the location shown above.
HINT: Make incision and bend the roof drip channel at the upper part of the cur and join location.
REPLACEMENT PARTS AND METHOD
(CUT)
Replacement method(ASSY) Assembly replacement . . . . .
(CUT) Major cutting (less than 1/2 of parts used) . . . . . .
(CUT-H) Half cutting (about 1/2 of parts used) . . . .
(CUT-P) Partial cutting (most of parts used) . . . .
PARTS LOCATION
REMOVAL DIAGRAM
Describes in detail removal of the damaged parts involving repair by cut\
ting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
INTRODUCTIONIN-2
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Steering Wheel Pad (Airbag and Inflator)
Junction Block No. 1 Center Airbag
Front Airbag Sensor
Front Airbag Sensor
Warning Light Spiral Cable (in Combination Switch)
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. SRS AIRBAG
Locations of Airbag Components
This vehicle has an SRS AIRBAG (referred to as the airbag in the remain\
der of this manual).
When handling airbag components (removal, installation or inspection, e\
tc.), always follow the directions
given in the repair manual for the relevant model year to prevent the oc\
currence of accidents and airbag
malfunction.
Also take the following precautions when repairing the body:

Work must be started after 20 seconds or longer from the time the ignitio\
n switch is set to the LOCK
position and the negative (-) terminal cable is disconnected from the \
battery.
(The airbag system is equipped with a back-up power source so that if w\
ork is started within 20 seconds
of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the\
contents memorized by each
memory system. Then when work is finished, reset the clock and audio sys\
tems as before.
When the vehicle has tilt and telescopic steering, power seat, and outsi\
de rear view mirror, which are all
equipped with memory function, it is not possible to make a record of th\
e memory contents.
So when the operation is finished, it will be necessary to explain this \
fact to the customer, and request
the customer to adjust the features and reset the memory.
To avoid erasing the memory of each memory system, never use back-up powe\
r supply from outside
the vehicle.

When using electric welding, first disconnect the airbag connector (yel\
low color and 2 pins) under the
steering column near the combination switch connector before starting wo\
rk.
Sensor Assembly
INTRODUCTIONIN-6
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Front
Fender Area
Area from the Front Fender Apron
to the Cowl Side Member


Before repairing the body, remove the airbag sensors if, during repair, shocks are likely to, be applied
to the sensors due to vibrations of the body or direct tapping with tool\
s or other parts.

Do not expose the airbag sensors or the steering wheel pad directly to h\
ot air or flames.
NOTICE:
1) The maximum ambient temperature tolerance is 120
°C (248°F) for the front airbag sensor, 105°C
(221
°F) for the center airbag sensor assembly and 93°C (200°F) for the steering wheel pad. If it is
possible that the ambient temperature may reach or exceed the temperatur\
e limit, remove the sen- sors and the steering wheel pad from the vehicle or protect them with a \
hot insulation material be-fore starting work.
2) Prior to welding, remove adjacent airbag sensors or the steering wheel p\
ad from the vehicle or protect them with fire-proof covers.

If the front fender or periphery of the vehicle is damaged, visually ins\
pect for damage to the front air-
bag sensor using the inspection procedures described in section AB of th\
e repair manual for the rele-
vant model year.
Also check that the dimensions of the body where the front airbag sensor\
is installed match those in
the body dimension drawings.
(The airbag may malfunction; or may not work, if the mounting angle or \
dimensions of the sensor
mount are not correct.)

If the vehicle is damaged, visually inspect for damage to the steering w\
heel pad using the inspection
procedures described in section AB of the repair manual for the relevant\
model year.

When removing the steering wheel pad or handling a new steering wheel pa\
d, keep the pad upper
surface facing upward. Also, lock the lock lever of the twin lock type c\
onnector at the rear of the pad
and take care not to damage the connector.
(Storing the pad with its metallic surface up may lead to a serious acc\
ident if the airbag inflates for
some reason.)

Store the steering wheel pad where the ambient temperature remains below\
93 °C (200 °F), without
high humidity and away from electrical noise.

Be careful not to let painting materials contact the airbag sensors.

Information labels are attached to the periphery of the airbag component\
s. Follow the NOTICES.
INTRODUCTIONIN-7
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Shift Lock ECU
Tilt and Power
Telescopic ECU
Airbag ECU
Cruise Control ECU Engine ECUABS and Traction ECU
(w/ Traction System) or
ABS ECU
(w/o Traction System)
Theft Deterrent and
Door Lock ECU
(w/ Traction System)
Traction ECU
Remote Control Mirror ECU A/C Control Amplifier
PPS ECU
Engine Cooling Fan ECU
Component to be aligned
Section of repair manual
for relevant model year
Front Wheels Suspension and Axle (SA) section
Rear Wheels Suspension and Axle (SA) section
Propeller Shaft Propeller Shaft (PR) section
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always \
follow the directions and
notes given in section BR of the repair manual for the relevant model ye\
ar when handling brake sys-
tem parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed t\
he air out of the TRAC
system.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in \
the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. P\
articularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Alway\
s follow the directionsgiven in the repair manual for the relevant model year during alignment \
and section DI of this manual.
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
INTRODUCTIONIN-8
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