lock LEXUS SC400 1991 Service Repair Manual

INSPECTION AND REPAIR OF STARTER
Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUITUsing an ohmmeter, check that there is continuity between
the segments of the commutator.
If there is no continuity, replace the armature.
2. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNTSURFACE
If the surface is dirty or burnt, correct with sandpaper
(No.400) or on a lathe.
2. INSPECT COMMUTATOR FOR RUNOUT (a) Place the commutator on V±blocks.
(b) Using a dial indicator, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a
lathe.
3. INSPECT COMMUTATOR DIAMETER Using a vernier caliper, measure the diameter.
Standard diameter: 35.0 mm (1.378 in.)
Minimum diameter: 34.0 mm (1.339 in.)
If the diameter is less than minimum, replace the armature.
±
STARTING SYSTEM StarterST±17
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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
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SERVICE SPECIFICATIONS
SERVICE DATA
StarterRated voltage and output power12 V 1.4 kW
No±load characteristicCurrent 90 A or less at 11.5 V
rpm 3,500 rpm or more
Brush lengthSTD 15.5 mm0.610 in.
Limit 10.0 mm0.394 in.
CommutatorOuter diameter STD 30 mm1.18 in.
Limit 29 mm1.14 in.
Undercut depth STD 0.6 mm0.024 in.
Limit 0.2 mm0.008 in.
Circle runout Limit 0.05 mm0.0020 in.
Spring installed loadSTD 18±24 N
(1.79 ± 2.41 kgf, 3.9 ± 5.3 lbf)
Limit12 N1.2 kgf2.6 lbf
TORQUE SPECIFICATIONS
Part tightenedNVmkgf Vcmft Vlbf
Starter x Cylinder block3940029
±
STARTING SYSTEM Service SpecificationsST±15
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STARTER RELAY
INSPECTION OF STARTER RELAY
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OFBATTERY
CAUTION: Work must be started after approx. 20 seconds or
longer from the time the ignition switch is turned to the
ºLOCKº position and the negative (±) terminal cable is dis-
connected from the battery.
2. REMOVE STATER RELAY LOCATION: In the engine compartment relay box.
3. INSPECT STARTER RELAY
A. Inspect relay continuity
(a) Using an ohmmeter, check that there is continuitybetween terminals 1 and 2.
(b) Check that there is no continuity between terminals 3 and 5.
If continuity is not as specified, replace the relay.
B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuitybetween terminals 3 and 5.
If operation is not as specified, replace the relay.
4. REINSTALL STARTER RELAY
5. RECONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
NEUTRAL START SWITCH
(See AT section)
THEFT DETERRENT SYSTEM
(See BE section)
±
STARTING SYSTEM Starter Relay, Neutral Start Switch, Theft Deterrent
SystemST±35
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SR±52 ).
IN±33 ).
WIRING DIAGRAM
Telescopic Motor Circuit
CIRCUIT DESCRIPTION
The ECU provides both + B and ground for the telescopic motor.
Reversing polarity of the applied voltage reverses the motor.
 Te M+ Te M± Rotation Telescopic
 

+ 

± 

Clockwise 

Contracted
 ± + Counterclockwise Extended
DIAGNOSTIC CHARTDIAGNOSTIC CHART
SR±78±
STEERING STEERING COLUMN
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SR±52).
IN±33 ).
Unlock Warning Switch Circuit
CIRCUIT DESCRIPTION
Whether or not the key is inserted in the key cylinder is detected and a signal\
is sent to the ECU.
(The switch is ON (closed) when the ignition key is inserted.)
 Ignition key Unlock Warning Switch UWSW Voltage
 

Out 

Opened 

10±14 V
 In Closed Below 1 V
DIAGNOSTIC CHARTDIAGNOSTIC CHART
SR±100±
STEERING STEERING COLUMN
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NGOK
OKNG
OKNG
INSPECTION PROCEDURE
1Check voltage between terminal UWSW of ECU connector and body ground
C
OK
PRemove ECU with connectors still connected.
Measure voltage between terminal UWSW of ECU con-
nector and body ground with the ignition key inserted,
or removed.
Proceed to next circuit inspection shown on matrix chart
(See page SR±52).
2Check unlock warning switch.
C
OK
PDisconnect unlock warning switch connector.
Measure resistance between terminals 9 and 10 of un-
lock warning switch connector with the ignition key in-
serted or removed.
Replace unlock warning switch.
3Check harness and connector between ECU and unlock warning switch (See \
page IN±33).
Repair or replace harness or connector.
Check and replace ECU.
±
STEERING STEERING COLUMNSR±101
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RECOMMENDED TOOLS
SR0FW±03
LUBRICANT
SR015±05
 Item Capacity Classification
 
Power steering fluid
1 0 liters (1 1 US qts 0 9 lmpqts)ATF DEXRON[II 

Total1.0 liters (1.1 US qts, 0.9 lmp.qts)AT F DEXRON[ II
EQUIPMENT
SR0FX±01\
 
\

\
Caliper gauge
 

Power steering pump
\
 \
Dial indicatorSteering rack
\
 
\

\
MicrometerPower steering pump
\
 
\

\

Oil pressure gauge
\
 \
Torque wrench
\
 
\

\

Vacuum gaugeGear housing
SSM (SPECIAL SERVICE MATERIALS)
SR0FY±01 08833±00080 Adhesive 1344, Rack housing cap  THREE BOND 1344, Rack guide spring cap
 


 


LOCTITE 242 or equivalent 


Rack guide spring cap lock nut
SR±112±
STEERING POWER STEERING
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ON±VEHICLE INSPECTION
CHECK IDLE±UP
SR0FZ±04
1. WARM UP ENGINE
2. TURN AIR CONDITIONER SWITCH OFF
3. CHECK IDLE±UP
(a) Fully turn the steering wheel.
(b) Check that the engine rpm decreases when the air controlvalve hose is pinched.
(c) Check that the engine rpm increases when the air control valve hose is released.
FLUID LEVEL CHECK
SR0G0±03
1. KEEP VEHICLE LEVEL
2. BOOST FLUID TEMPERATUREWith the engine idling at 1,000 rpm or less, turn the steering
wheel from lock to lock several times to boost fluid tempera-
ture.
Fluid temperature:
805C (176 5F)
3. STOP ENGINE
4. CHECK FOR FOAMING OR EMULSIFICATION
HINT: Foaming and emulsification indicate either the exis-
tence of air in the system or that the fluid level is too low.
5. CHECK FLUID LEVEL IN OIL RESERVOIR Check the fluid level and add fluid if necessary.
Fluid:
ATF DEXRON
[ II
HINT: Check that the fluid level is within the HOT LEVEL of
the dipstick of the reservoir cap. If the fluid is cold, check that
it is within the COLD LEVEL of the dipstick.
±
STEERING POWER STEERINGSR±113
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POWER STEERING FLUID
REPLACEMENT
SR0G1±04
1. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITHSTANDS
2. REMOVE FLUID RETURN HOSE FROM OIL RESERVOIR AND DRAIN FLUID INTO CONTAINER
NOTICE: Take care not to spill fluid on the drive belt.
3. TURN STEERING WHEEL FROM LOCK TO LOCK WHILEDRAINING FLUID
4. FILL OIL RESERVOIR WITH FRESH FLUID
Fluid: ATF DEXRON
[ II
5. START ENGINE AND RUN IT AT 1,000 RPMAfter 1 or 2 seconds, fluid will begin to discharge from the re-
turn hose. Stop the engine immediately at this time.
NOTICE: Take care that some fluid remains left in the oil reser-
voir.
6. REPEAT STEPS 4 AND 5 FOUR OR FIVE TIMES UNTIL THERE IS NO MORE AIR IN FLUID
7. CONNECT RETURN HOSE TO OIL RESERVOIR
8. BLEED POWER STEERING SYSTEM (See page SR±115)
SR±114
±
STEERING POWER STEERING
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