height LEXUS SC400 1991 Service Repair Manual

9. COAT CONTACT SURFACE OF BODY WITH PRIMER ºMºUsing a brush, coat the contact surface on the body with
Primer M.
NOTICE:
wLet the Primer coating dry for 10 minutes or more. Make
sure that the installation of the glass is finished within 2
hours.
wTake care not to leave any part of the contact surface
uncoated or excessively coated, as Primer M and G serve
to boost he adhesive power of the adhesive to the glass
or body.
wDo not keep any of the opened Primer M and G for later
use.
10. COAT CONTACT SURFACE OF GLASS WITH PRIMER ºGº
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) Before the Primer dries, wipe it off with a clean shop rag.
NOTICE: Be sure that installation of the glass is finished
within 70 minutes.
11. MIX ADHESIVE COATING NOTICE:
wBe sure that installation of the moulding is finished
within usable time. (See step 3 on page BO±11)
wThe mixture should be made in 5 minutes or less.
(a) Thoroughly clean the glass plate and putty spatula with
solvent.
(b) Thoroughly mix 500 g (17.64 oz.) of the main agent and 75 g (2.65 oz.) of the hardening agent on a glass plate
or like object with a putty spatula.
12. APPLY ADHESIVE (a) Cut off the tip of the cartridge nozzle. Fill the cartridge
with adhesive.
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive on all contact surfaces as shown.
Adhesive height: If adhesive remains on body
3.5 ± 5.0 mm (0.138 ± 0.197 in.)
If no adhesive remains on body
8 ± 10 mm (0.31 ± 0.39 in.)
±
BODY WindshieldBO±49
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3. CLEAN REMOVED GLASS(a) Using a scraper, cut away any adhesive remaining onthe glass.
HINT: Do not damage the spacers.
(b) Clean the glass with a cleaner.
NOTICE: Do not touch the glass after cleaning it.
4. CLEAN CONTACT SURFACE OF GLASS Using cleaner, clean the contact surface and the glass rim.
5. INSTALL BACK WINDOW MOULDING (See page BO±99)
6. COAT CONTACT SURFACE OF BODY WITH PRIMER ºMº (See step 9 on page BO±49)
7. COAT CONTACT SURFACE OF GLASS WITH PRIMER ºGº
(See step 10 on page BO±49)
8. MIX ADHESIVE COATING (See step 11 on page BO±49)
9. APPLY ADHESIVE (a) Cut off the tip of the cartridge nozzle to make a hole 5
mm (0.20 in.) in diameter. Fill the cartridge with
adhesive.
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive on all contact surfaces as shown.
Adhesive height: If adhesive remains on body
3.5 ± 5.0 mm (0.138 ± 0.197 in.)
If no adhesive remains on body
8 ± 10 mm (0.31 ± 0.39 in.)
BO±56±
BODY Back Window Glass
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BODY DIMENSIONS
Description
1. BASIC DIMENSIONS(a) There are two types of dimensions in the diagram. (Three±dimensional distance)
wStraight±line distance between the centers of two
measuring points.
(Two±dimensional distance)
wHorizontal distance in forward/rearward between the centers of two measuring points.
wThe height from an imaginary standard line.
(b) In cases in which only one dimension is given, left and right are symmetrical.
(c) The dimensions in the following drawing indicate actual
distance. Therefore, please use the dimensions as a
reference.
2. MEASURING (a) Basically, all measurements are to be done with atracking gauge. For portions where it is not possible to
use a tracking gauge, a tape measure should be used.
(b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.
HINT:
1. The height of the left and right pointers must be equal.
2. Always calibrate the tracking gauge before measuring or after adjusting the pointer height.
3. Take care not to drop the tracking gauge or otherwise shock it.
4. Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and bends in
the tape.
(d) When tracking a diagonal measurement from the front
spring support inner hole to the suspension member
upper rear installation hole, measure along the front
spring support panel surface.
±
BODY Body Dimensions (Description)BO±127
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SERVICE SPECIFICATIONS
SERVICE DATA
BR03A±0G\
\
Brake pedal height from asphalt sheet (LHD)  150.4±160.4 mm (5.92±6.31 in.)
\


\
Brake pedal freeplay 




1±6 mm (0.04±0.24 in.)
\


\
Brake pedal reserve distance at 490 N (50 kgf, 110.2
lbf) 





More than 89 mm (3.50 in.)
\
\
Brake booster push rod to piston clearance (w/ SST)  0 mm (0 in.)
\
\
Front brake pad thickness STD 11.0 mm (0.433 in.)
\
\
Front brake pad thickness Limit 1.0 mm (0.039 in.)\


\
Front brake disc thickness (SC 300)
 


STD


28.0 mm (1.102 in.)
\
\
Front brake disc thickness (SC 300) Limit 26.0 mm (1.024 in.)
\
\
Front brake disc thickness (SC 400) STD 32.0 mm (1.260 in.)
\


\
Front brake disc thickness (SC 400) 


Limit

30.0 mm (1.181 in.)
\
\
Front brake disc runout Limit 0.05 mm (0.0020 in.)
\
\
Rear brake disc pad thickness STD 10.0 mm (0.394 in.)
\
\
Rear brake disc pad thickness Limit 1.0 mm (0.039 in.)\


\
Rear brake disc thickness
 


STD


16.0 mm (0.630 in.)
\
\
Rear brake disc thickness Limit 15.0 mm (0.591 in.)
\
\
Rear brake disc runout Limit 0.05 mm (0.0020 in.)
\


\
Rear brake disc inside diameter 


STD

190 mm (7.48 in.)
\
\
Rear brake disc inside diameter Limit 191 mm (7.52 in.)
\
\
Parking brake lining thickness STD 2.5 mm (0.098 in.)
\
\
Parking brake lining thickness Limit 1.0 mm (0.039 in.)\


\
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)
 




5±8 clicks
\
\
Parking brake clearance between rear shoe and lever  Less than 0.35 mm (0.012 in.)
\


\
Parking brake adjusting shim thickness for rear disc
brake 




0.3 mm (0.012 in.)
\
\
  0.6 mm (0.024 in.)
\


\
 




0.9 mm (0.035 in.)
±
BRAKE SYSTEM SERVICE SPECIFICATIONSBR±229
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CHECK AND ADJUSTMENT
BR0EC±07
BRAKE PEDAL CHECK AND
ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:150.4±160.4 mm (5.92±6.31 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N Vm (260 kgf Vcm, 19 ft Vlbf)
(f) Install the stop light switch and turn it until it lightly contacts
the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and pedal.
Clearance:
0.5±2.4 mm (0.02±0.09 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal isdepressed, and go off when the brake pedal is released.
(l) After adjusting the pedal height, check the pedal free±play.
HINT: If clearance (A) between the stop light switch and the
brake pedal stopper has been adjusted correctly, the pedal
freeplay will meet the specifications.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS SHOWN
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the second point of resistance is felt, then measure the distance, as
shown.
Pedal freeplay:
1±6 mm (0.04±0.24 in.)
If incorrect, check the stop light switch clearance. And if the
clearance is OK, then troubleshoot the brake system.
HINT: The freeplay to the first point of resistance is due to the
play between the clevis and pin. It is 1±3 mm (0.04±0.12 in.)
on the pedal.
±
BRAKE SYSTEM CHECK AND ADJUSTMENTBR±7
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GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left and right are symmetrical.
(c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimen-
sions as a reference.
2. MEASURING
(a) Basically, all measurements are to be done with atracking gauge. For portions where it is not possible
to use a tracking gauge, a tape measure should be
used.
(b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.
HINT:
1. The height of the left and right pointers must be equal.
2. Always calibrate the tracking gauge before measuring or after adjusting the pointer height.
3. Take care not to drop the tracking gauge or otherwise shock it.
4. Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and bends in the tape.
(d) When tracking a diagonal measurement from the front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.
Center-to-center
straight-line
distance
Three-dimensional
distance
Front Spring Support Inner HoleTape Measure
Along Body
Surface Front Suspension Member Rear Side
Upper Installation Hole Master Gauge
Pointer
Pointer LoosenessBody Looseness
Plate Looseness
Two-dimensional
distance
Center-to-center
Horizontal distance in
forward/rearward
Vertical distance
in lower surface
Vertical distance
in center
Imaginary Standard Line
Wrong Correct
Pointer
BODY DIMENSIONSDI-2
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Camshaft Thrust clearance STD 0.040±0.090 mm (0.0016±0.0035 in.)
   Limit 0.12 mm (0.0047 in.)
  Journal oil clearance  
  Exhaust camshaft thrust portion STD 0.025±0.061 mm (0.0010±0.0024 in.)  
Others
 
STD
 
0.030±0.067 mm (0.0012±0.0026 in.)   
Limit
 
0.10 mm (0.0039 in.)  Journal diameter  
  Exhaust camshaft thrust portion  23.959±23.975 mm (0.9433±0.9539 in.)  Others  26.954±26.970 mm (1.0612±1.0618 in.)  Circle runout Limit 0.08 mm (0.0031 in.)  Cam lobe height STD (Intake) 41.710±41.810 mm (1.6421±1.6461 in.)   (Exhaust) 41.910±42.010 mm (1.6500±1.6539 in.)   Limit (Intake) 41.56 mm (1.6362 in.)
   (Exhaust) 41.76 mm (1.6441 in.)
  Camshaft gear backslash STD 0.020±0.200 mm (0.0008±0.0079 in.)
   Limit 0.30 mm (0.0188 in.)
  Camshaft gear spring end free distance  18.2±18.8 mm (0.712±0.740 in.)
 Air intake Warpage Limit 0.15 mm (0.0059 in.)
 chamber
 Manifold Warpage Limit (Intake) 0.15 mm (0.0059 in.)
   (Exhaust) 1.00 mm (0.0394 in.)
 Cylinder block Cylinder head surface warpage Limit 0.07 mm (0.0028 in.)
  Cylinder bore±diameter Mark 1 87.500±87.510 mm (3.4449±3.4453 in.)
   Mark 2 87.510±87.520 mm (3.4453±3.4457 in.)
   Mark 3 87.520±87.530 mm (3.4457±3.4461 in.)
Limit87.73 mm (3.4539 in.)  
Main journal bore diameter (Reference)
 
Mark 00
 
72.000 mm (2.8346 in.)   Mark 01 72.001 mm (2.8347 in.)   Mark 02 72.002 mm (2.8347 in.)   Mark 03 72.003 mm (2.8348 in.)   Mark 04 72.004 mm (2.8348 in.)   Mark 05 72.005 mm (2.8348 in.)   Mark 06 72.006 mm (2.8349 in.)   Mark 07 72.007 mm (2.8349 in.)
   Mark 08 72.008 mm (2.8350 in.)
   Mark 09 72.009 mm (2.8350 in.)
   Mark 10 72.010 mm (2.8350 in.)
   Mark 11 72.011 mm (2.8351 in.)
   Mark 12 72.012 mm (2.8351 in.)
   Mark 13 72.013 mm (2.8352 in.)
   Mark 14 72.014 mm (2.8352 in.)
   Mark 15 72.015 mm (2.8352 in.)
   Mark 16 72.016 mm (2.8353 in.)
 Main bearing cap stud bolt tension portion diameter
   STD 7.500±7.600 mm (0.2953±0.2992 in.)
   Limit 7.40 mm (0.2913 in.)
±
1UZ ± FE ENGINE ENGINE MECHANICALEG±207
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10. INSPECT CAMSHAFTS AND BEARINGS
A. Inspect camshaft for runout
(a) Place the camshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout at the centerjournal.
Maximum circle runout:
0.08 mm (0.0031 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
B. Inspect cam lobes Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake41.710 ± 41.810 mm (1.6421 ± 1.6461 in.)
Exhaust 41.910 ± 42.010 mm (1.6500 ± 1.6539 in.)
Minimum cam lobe height: Intake41.56 mm (1.6362 in.)
Exhaust
41.76 mm (1.6441 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
C. Inspect camshaft journals Using a micrometer, measure the journal diameter.
Journal diameter:
Exhaust camshaft thrust portion (A)23.959 ± 23.975 mm (0.9433 ± 0.9439 in.)
Others 26.954 ± 26.970 mm (1.0612 ± 1.0618 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
EG±102
±
1UZ±FE ENGINE ENGINE MECHANICAL
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6. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS(a) Using SST and a hammer, tap out the guide bushing.
SST 09201±70010
(b) Using a caliper gauge, measure the bushing borediameter of the cylinder head.
(c) Select a new guide bushing (STD size or O/S 0.05).
Both intake and exhaust If the bushing bore diameter of the cylinder head is greater
than 11.044 mm (0.4348 in.), machine the bushing bore to
the following dimension:
11.035±11.056 mm (0.4344±0.4353 in.)
If the bushing bore diameter of the cylinder head is greater
than 11.056 mm (0.4353 in.), replace the cylinder head.
(d) Using SST and hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201±70010
Protrusion height:
Intake 12.3±12.7 mm (0.484±0.500 in.)
Exhaust 11.4±11.8 mm (0.449±0.465 in.)
HINT: Different bushings are used for the intake and exhaust.
±
ENGINE MECHANICAL Cylinder HeadEM±45
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B. Inspect cam lobesUsing a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.570±44.670 mm (1.7547±1.7587 in.)
Exhaust 44.250±44.350 mm (1.7421±1.7461 in.)
Maximum cam lobe height: Intake 44.42 mm (1.7488 in.)
Exhaust 44.10 mm (1.7362 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
C. Inspect camshaft journals Using a micrometer, measure the journal diameter.
Journal diameter: 28.949±28.965 mm
(1.1397±1.1404 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
D. Inspect camshaft bearings Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and
cylinder head as a set.
E. Inspect camshaft journal oil clearance (a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaftjournals.
(d) Install the bearing caps. (See step 2 on page EM±55)
Torque: 20 N Vm (200 kgf Vcm, 14 ft Vlbf)
HINT: Do not turn the camshaft.
±
ENGINE MECHANICAL Cylinder HeadEM±49
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