steering LEXUS SC400 1991 Service Manual Online

PREPARATION
SST (SPECIAL SERVICE TOOLS)
IllustrationPart No.Part NameNote
09268±41045Injection Measuring
Tool Set
(09268±41090)(No. 7 Union)
Injector
(09268±52010)(Injection Measuring
Attachment)
Injector
(09405±09015)(No. 1 Union)
Injector
09268±45012EFI Fuel Pressure
Gauge
09612±24014
Steering Gear
Housing Overhaul
Tool Set
(09617±24011(Steering Rack Wrench)
Fuel pressure pulsation damper
09631±22020
Power Steering
Hose Nut 14 x 17 mm
Wrench SetFuel line flare nut
09816±30010Oil Pressure
Switch Socket
Knock sensor
09842±30070Wire ªFº
EFI Inspection
Injector
09843±18020Diagnosis Check
Wire
09990±01000
Engine Control
Computer Check
Harness ªAº
±
EFI SYSTEM PreparationFI±9
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Preparation
SST (SPECIAL SERVICE TOOLS)
IllustrationPart No.Part NameNote
09268±41045Injection Measuring
Tool Set
(90268±41070)No. 4 Union
Injector
(09268±41080)No. 6 Union
Cold start Injector
(09268±52010)Injection Measuring
Attachment
Injector
09268±45012EFI Fuel Pressure
Gauge
09612±24014
Steering Gear
Housing Overhaul
Tool Set
(09617±24011)Steering Rack Wrench
Fuel pressure pulsation damper
09631±22020
Power Steering
Hose Nut 14 X 17 mm
Wrench SetFuel line flare nut
09816±30010Oil Pressure
Switch SocketKnock sensor
09842±30055Wire ªGº
EFI Inspection
Cold start Injector
09842±30070Wire ªFº
EFI Inspection
Injector
09843±18020Diagnosis Check
Wire
0990±01000
Engine Control
Computer
Check Harness ªAº
FI±10 ± PreparationEFI SYSTEM
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SERVICE SPECIFICATIONS
SERVICE DATA
MA002±0B 








Engine 








Spark plug
Recommended spark plug
Correct electrode gap
Firing order
Valve clearance 








ND
NGK
Intake
Exhaust
\








\
PK20R11
BKR6EP11
1.1 mm (0.043 in.)
1 ± 8 ± 4 ± 3 ± 6 ± 5 ± 7 ± 2
0.15 ± 0.25 mm (0.006 ± 0.010 in.)
0.25 ± 0.35 mm (0.010 ± 0.014 in.)
 






BrakeFront and rear brakes
Pad thickness
Disc thickness
Limit
Limit (Front) (Rear)1.0 mm (0.039 in.)
30.0 mm (1.181 in.)
15.0 mm (0.591 in.)
 




Disc runout
Parking brake
Lining thickness
Drum inside diameter
()
Limit
Limit
Limit
()
0.05 mm (0.0020 in.)
1.0 mm (0.039 in.)
191 mm (7.520 in.)
 ChassisSteering linkage
Steering wheel freeplay
Limit30 mm (1.18 in.) 


gy
Ball joint
Vertical play
Limit
()
0.3 mm (0.012 in.)
MA002±0B
TORQUE SPECIFICATIONS
\
 \
Part tightened N
Vm kgf Vcm ft Vlbf
 Spark plug x Cylinder head1818013
 Front seat x Body3737527
 Front suspension crossmember x Body for nut1271,30094
  for bolt 201
,
2,050148
 Rear suspension member x Body1761,800130
 Rear suspension member rear cushion x Body3839028
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MAINTENANCE (1UZ ± FE)MA±21
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V04535
(4) Also applicable to drum lining for parking brake. For other usage condit\
ions, refer to SCHEDULE B.
(5) Check for leakage.
(6) Check for oil leaks from steering gear housing.
(7) Applicable only when operating mainly on rough, muddy roads. The applicable parts \
are listed below. Forother usage conditions, refer to SCHEDULE B.
Front and rear suspension member to cross body.
 Bolts for seat installation.
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MAINTENANCE (1UZ ± FE)MA±3
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MA033±0C
SCHEDULE B
CONDITIONS:
Conditions others than those listed for SCHEDULE A.Maintenance operation: A = Check and adjust if necessary. R = Replace, change or lubricate.
I = Inspect and correct or replace if necessary.
V04409

mark indicates maintenance which is part of the warranty conditions for\
the Emission Control Systems.
The warranty period is in accordance with the owner's guide or the warranty booklet.
(
: California and New York specification vehicles only)
(1) Includes inspection of fuel tank band and vaper vent system.
(2) Also applicable to drum lining for parking brake.
(3) Check for leakage.
(4) Check for oil leaks from steering gear housing.
(5) The applicable parts are listed below. Front and rear suspension member to cross body.
 Bolts for seat installation.
MA±4
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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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MAINTENANCE (1UZ ± FE)MA±13
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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.
MA±14
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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
MA±18
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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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MAINTENANCE (1UZ ± FE)MA±19
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19. BRAKE PEDAL
(a) Check that pedal for smooth operation.
(b) Check that the pedal has the proper reservedistance and freeplay.
(c) Check the brake booster function.
20. BRAKES At a safe place, check that the brakes do not
pull to one side when applied.
21. PARKING BRAKE
(a) Check that the pedal has the proper travel.
(b) On a safe incline, check that the vehicle is held securely with only the parking brake applied.
22. A U TO M AT I C T RANSMISSION PARK
MECHANISM
(a) Check the lock release button of the selector lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is held securely with the selector lever in the ªPº
position and all brakes released.
MA00T±0A
UNDER HOOD
23. WINDSHIELD WASHER FLUIDCheck that there is sufficient fluid in the tank.
24. ENGINE COOLANT LEVEL
Check that the coolant level is between the
LEVEL lines on the see±through reservoir at
normal temperature (20 5C (68 5F)).
25. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
26. BATTERY ELECTROLYTE LEVEL
Check the indicator.
When the indicator color is blue, the condition
is satisfactory. A red color indicates that dis-
tilled water must be added, and white indicates
that charging is necessary. 27. BRAKE FLUID LEVEL
Check that the brake fluid level is near the up-
per level line on the see±through reservoir.
28. ENGINE DRIVE BELT Check drive belt for fraying, cracks, wear or oili-
ness.
29. ENGINE OIL LEVEL
Check that level on the dipstick with the engine
turned off.
30. POWER STEERING FLUID LEVEL Check the level on the dipstick.
The level should be in the ªHOTº or ªCOLDº
range depending on the fluid temperature.
31. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking and foot brake applied, shift the selector into all
positions from ªPº to ªLº, and then shift into ªPº.
(c) Turn and pull out the dipstick and wipe off the fluid with a clean rag.
Re±insert the dipstick fully and check that the
fluid level is in the ªHOTº range.
(d) Perform this check with the fluid at normal driving temperature (70 ± 80
C (158 ± 176
F)).
If the level is at the low side, add fluid.
NOTICE: Do not overfill.
HINT: Wait about 30 minutes before checking
the fluid level after extended driving at high
speeds in hot weather, driving in heavy traffic
or with a trailer.
32. EXHAUST SYSTEM Visually inspect for cracks, holes or loose sup-
ports.
If any change in the sound of the exhaust or
smell of the exhaust fumes is noticed, have the
cause located and corrected.
MA±20
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