LEXUS SC400 1991 Service Repair Manual

2. When the components of the second system whichneed to be removed are few in number and can be
removed as a unit:
An abbreviated diagram of the parts and the name of the se-
cond system are included inside the larger component dia-
gram.
HINT: For more detail than is given in the abbreviated dia-
gram, refer to the component diagram on the page number
referred to by the ºSee pageº next to the diagram title.
Example:
±
BODY General InformationBO±7
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SRS AIRBAG
(See page AB±2)
The LEXUS SC300 is equipped with an SRS (Supplemental Restraint System)\
airbag.
Failure to carry out service operations in the correct sequence could cause the airbag system to deploy,
possibly leading to a serious accident.
When removal or installation of airbag parts and the yellow wire harness\
and connector for the airbag is
necessary, refer to the precautionary notices in the AB section before performing\
the operation.

Work must be started after 20 seconds or longer from the time the ignition switch is set to the LOCK
position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The airbag system is equipped with a back±up power source so that if wor\
k is started within 20 se-
conds of disconnecting the negative (±) terminal cable of the batte\
ry, the airbag may be deployed.

To avoid erasing the memory of each memory system, never use a back±up power supply from
outside the vehicle.

Before repairs, remove the airbag sensors if shocks are likely to be applied t\
o the sensors during
repaires.

The front airbag sensor set bolt has been anti±rust treated. When the\
sensor is removed, always
replace the set bolt with a new one.

If the front airbag sensors, center airbag sensor or steering wheel pad ha\
ve been dropped, or if there
are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.

Never use airbag parts from another vehicle. When replacing parts, repla\
ce them with new parts.

Do not expose the front airbag sensors, center airbag sensor or steering w\
heel pad directly to hot air
or flames.

The airbag system's wire harness is integrated with the cowl wire harness assembly. The wires for the
airbag wire harness are encased in a yellow corrugated tube. All the connector\
s for the system are
also a standard yellow color. If the airbag system wire harness becomes disconnected or the
connector becomes broken due to an accident, etc., repair or replace it as shown \
on page AB±20.

The steering wheel must be fitted correctly to the steering column with the\
spiral cable at the neutral
position; otherwise, cable disconnection and other troubles may result. \
Refer to page AB±14 of this
manual concerning correct steering wheel installation.

When removing the steering wheel pad or handling a new steering wheel pad, i\
t should be placed with
the pad top surface facing up. In this case, the twin±lock type connector lock lever should be in the
locked state and care should be taken to place it so the connector will not be damaged. (\
Storing the
pad with its metallic surface up may lead to a serious accident if the a\
irbag inflates for some reason.)

Grease should not be applied to the steering wheel pad and the pad should not \
be cleaned with
detergents of any kind.

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

Information labels are attached to the periphery of the airbag component\
s. Follow the notices.

When the ignition switch is at ACC or ON and the airbag warning light remains on, the cent\
er airbag
sensor assembly has detected a malfunction code. (See page AB±30).
BO±8
±
BODY General Information
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PREPARATION
EQUIPMENT
Part NameNote
Clip remover±
Torque wrench±
Hexagon wrench±
Torx driver±
Hog ring pliers±
TapeFor applying to the tip of the tools to avoid scratching parts or
painted surfaces of the body
Double±stick tape±
Adhesive tapeFor applying to the body surfaces around the parts to avoid
scratching painted surface
Instant adhesive±
Adhesive±
Cleaner±
Knife±
Shop rag±
Sealer gun±
Brush±
Putty spatula±
Glass plate or like objectFor mixing the adhesive on
Wooden block or like objectFor tying both piano wire ends
Plastic sheetFor placing between the piano wire and the safety pad to avoid
scratching the safety pad
LUBRICANT
ItemCapacityClassificationItemLitersUS qtslmp. qtsClassification
MP grease±±±±
±
BODY PreparationBO±9
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SSM (SPECIAL SERVICE MATERIALS)
Part NamePart No.Use etc.
Windshield glass adhesive set No. 1508850±00070
Contents of set:Main agent 500 g (17.64 oz.)
Hardening agent 75 g (2.65 oz.)
Windshield glass adhesive set No. 3508850±00080
Hardening agent 75 g (2.65 oz.)
Primer G [for glass] 20 g (0.71 oz.)
Primer M [for body] 20 g (0.71 oz.)
Sponge for applying primer
Windshield glass adhesive set No. 4508850±00090
S onge for a lying rimer
Piano wire 0.6 mm dia. X 1 m
(0.024 in. dia. X 39.37 in.)
Cartridge
Auto glass sealer08833±00030 or equivalent±
1. CHOOSE SUITABLE ADHESIVE SET Use an adhesive set suitable for the ambient temperature.
2. CHECK ADHESIVE USABLE TIME After mixing main and hardening agents, finish glass installa-
tion within the specified time as shown.
Example: For glass installation in an ambient temperature of
25 5C (77 5F), apply adhesive set No. 35 within 45 minutes.
3. CHECK ADHESIVE HARDENING TIME After main and hardening agents are mixed, leak tests should
be made only after the hardening time has elapsed.
Example: The hardening time for adhesive set No. 35 with an
ambient temperature of 25 5C (77 5F) is 2 1/2 hours.
NOTICE: Do not drive the vehicle until at least double
the hardening time has elapsed.
BO±10
±
BODY Preparation
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BUMPER
Front Bumper
COMPONENTS
±
BODY Bumper (Front Bumper)BO±11
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REMOVAL OF FRONT BUMPER
(See page BO±11)
1. REMOVE FENDER SPLASH SHIELD Remove fourteen screws, a bolt and the shield.
2. REMOVE NO. 2 ENGINE UNDER COVER Remove seven screws, five bolts and the cover.
3. REMOVE HEADLIGHT (Low Beam)
(a) Remove two nuts, a bolt and the headlight.
(b) Disconnect the connectors.
4. REMOVE UPPER BUMPER RETAINER (a) Remove the hood seal.
(b) Remove five screws and the retainer.
5. REMOVE BUMPER COVER ASSY (a) Remove six clips.
BO±12
±
BODY Bumper (Front Bumper)
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(b) Remove four clips.
(c) Remove the clip and ambient temperature sensor.
(d) Remove four nuts.
(e) Remove ten clips.
(f) Remove two bolts.
(g) Disconnect the connectors.
(h) Remove the bumper cover assy.
6. REMOVE REINFORCEMENT Remove six bolts and the reinforcement.
7. REMOVE UPPER REINFORCEMENT Remove eight bolts and the reinforcement.
8. REMOVE HEADLIGHT (High Beam)
(a) Remove two screws, a clip and the headlight.
(b) Disconnect the connector.
±
BODY Bumper (Front Bumper)BO±13
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INSTALLATION OF FRONT BUMPER
(See page BO±11)
INSTALL FRONT BUMPER PARTS BY FOLLOWING RE-
MOVAL SEQUENCE IN REVERSE HINT:
wWhen installing the bumper on the body, be careful
not to damage the serrated part of side bolts.
wAfter installing the headlight, adjust the light aiming.
(See page BE±38).
DISASSEMBLY AND ASSEMBLY OF
FRONT BUMPER
DISASSEMBLY AND ASSEMBLY BY
FOLLOWING PARTS:
(a) Cornering lights
(b) Side turn lights
(c) Bumper energy absorber
(d) Retainers
(e) License bracket
BO±14
±
BODY Bumper (Front Bumper)
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Rear Bumper
COMPONENTS
Trim (LUGGAGE COMPARTMENT)
±
BODY Bumper (Rear Bumper)BO±15
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REMOVAL OF REAR BUMPER
(See page BO±15)
1. REMOVE FOLLOWING PARTS:
(See steps 1 to 6 on pages BO±79 to 80)
(a) Floor mat
(b) Door striker cover
(c) Trim rear cover
(d) Trim front cover
(e) LH side cover
(f) RH side cover
2. REMOVE REAR COMBINATION LIGHT (a) Remove four nuts and disconnect the connectors.
(b) Remove the light.
3. REMOVE VENTILATION DUCT Remove three screws and the duct.
4. REMOVE REAR BUMPER COVER
(a) Remove sixteen clips and six nuts.
(b) Remove the cover.
BO±16±
BODY Bumper (Rear Bumper)
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