light LEXUS SC400 1991 Service Repair Manual

ABBREVIATIONS USED IN THIS
MANUAL
ABS Anti±Lock Brake System J/B Junction Block
A/C Air Conditioner LED Light Emitting Diode
ALR Automatic Locking Retractor LH Left±Hand
APPROX. Approximation LHD Left±Hand Drive
A/T, ATM Automatic Transmission LLC Long Life Coolant (Year Around Coolant)
ATF Automatic Transmission Fluid Max. Maximum
BTDC Before Top Dead Center Min. Minimum
BVSV Bimetal Vacuum Switching Valve MP Multipurpose
CALIF. Vehicles Sold in California N Neutral
CB Circuit Breaker OD, O/D Overdrive
DOHC Double Over Head Cam O/S Oversize
DP Dash Pot P & BV Proportioning and Bypass Valve
ECT Electronic Controlled Transmission PCV Positive Crankcase Ventilation
ECU Electronic Controlled Unit PS Power Steering
EFI Electronic Fuel Injection RH Right±Hand
EGR Exhaust Gas Recirculation RL Rear Left
ELR Emergency Locking Retractor RR Rear Right
EPR Evaporator Pressure Regulator RR, Rr Rear
ESA Electronic Spark Advance SRS Supplemental Restraint System
EVAP Evaporative (Emission Control) SSM Special Service Materials
EX Exhaust (manifold, valve) SST Special Service Tools
Ex. Except STD Standard
FIPG Formed in Place Gasket SW Switch
FL Front Left TDC Top Dead Center
FL Fusible Link TDCL Total Diagnostic Communication Link
FPU Fuel Pressure Up Temp. Temperature
FR Front Right TRAC Traction Control System
FR, Fr Front TWC Three±Way Catalyst
HAC High Altitude Compensation VSV Vacuum Switching Valve
IG Ignition VTV Vacuum Transmitting Valve
IN Intake (manifold, valve) w/ With
INT Intermittent w/o Without
ISC Idle Speed Control
IN±34±
INTRODUCTION Abbreviations Used in This Manual
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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 con-
tents memorized by each memory system. Then when work
is finished, reset the clock and audio systems as before.
When the vehicle has power tilt and power telescopic steer-
ing, power seat, power outside rear view mirror and power
shoulder belt anchorage, which are all equipped with
memory function, it is not possible to make a record of the
memory contents. So when the operation is finished, it will be
necessary to explain this fact to the customer, and ask the
customer to adjust the features and reset the memory.
To avoid erasing the memory of each memory system, never
use a back±up power supply from outside the vehicle.
3. Even in cases of a minor collision where the airbag does not deploy, the front airbag sensors and the steering wheel pad
should be inspected. (See page AB±9)
4. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
5. Before repairs, remove the airbag sensors if shocks are likely
to be applied to the sensors during repairs.
6. The center airbag sensor assembly contains mercury. After
performing replacement, do not destroy the old part. When
scrapping the vehicle or replacing the center airbag sensor
assembly itself, remove the center airbag sensor assembly
and dispose of it as toxic waste.
7. Never disassemble and repair the front airbag sensors, center airbag sensor assembly or steering wheel pad in order
to reuse it.
8. If the front airbag sensors, center airbag sensor assembly or steering wheel pad have been dropped, or if there are cracks,
dents or other defects in the case, bracket or connector,
replace them with new ones.
9. Do not expose the front airbag sensors, center airbag sensor assembly or steering wheel pad directly to hot air or flames.
10. U s e a v o l t / o h m m e t e r w i t h h i g h i m pedance (10 kW/V
minimum) for troubleshooting of the electrical circuit.
11. Information labels are attached to the periphery of the airbag components. Follow the notices.
12. After work on the airbag system is completed, perform the
airbag warning light check (See page AB±30).
±
INTRODUCTION Precautions for Vehicles Equipped with SRS AirbagIN±9
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PRECAUTIONS FOR VEHICLES
EQUIPPED WITH TRACTION
CONTROL (TRAC) SYSTEM
When using a rear wheel two±wheel drum tester such as a
speedometer tester or chassis dynamometer, etc., or jacking up
the rear wheels and driving the wheels, always push in the TRAC
cut (ºTRAC OFFº) switch and turn the TRAC system OFF.
CONFIRM TRAC SYSTEM IS OFF
1. Press the TRAC cut (ºTRAC OFFº) switch.
2. Check that the TRAC OFF indicator light comes on when the
TRAC system is turned off by the TRAC cut switch.
HINT: The TRAC indicator light should always operate right after
the engine is restarted.
3. Begin measurements.
4. Press the TRAC cut switch again to change the TRAC to operative and check that the TRAC OFF indicator light goes
off.
HINT: The TRAC indicator light blinks when the TRAC system is
operative.
±
INTRODUCTION Precautions for V
ehicles Equipped with Traction Cotnrol
(TRAC)SystemIN±13
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[3] SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In s\
uch cases, a
thorough customer problem analysis must be carried out, then simulate the same or similar conditions and envi-
ronment in which the problem occurred in the customer's vehicle. No matter now much experience a technician
has, or how skilled he may be, if he proceeds to troubleshoot without confir\
ming the problem symptoms he will
tend to overlook something important in the repair operation and make a wron\
g guess somewhere, which will
only lead to a standstill. For example, for a problem which only occurs when\
the engine is cold, or for a problem
which occurs due to vibration caused by the road during driving, etc., the pr\
oblem can never be determined so
long as the symptoms are confirmed with the engine hot condition or the \
vehicle at a standstill. Since vibration,
heat or water penetration (moisture) are likely causes for problems which are \
difficult to reproduce, the symptom
simulation tests introduced here are effective measures in that the external causes are applied to the vehicle
in a stopped condition.
Important Points in the Symptom Simulation Test
In the symptom simulation test, the problem symptoms should of course be co\
nfirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the sym\
ptoms
before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judg-
ing whether the circuit being tested is defective or normal and also confir\
ming the problem symptoms at the
same time. Refer to the matrix chart of problem symptoms for each system to \
narrow down the possible causes
of the symptom.
[1] VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
Slightly shake the connector vertically and horizon-
tally.
WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thor-
oughly.
PARTS AND SENSORS
Apply slight vibration with a finger to the part of the
sensor considered to be the problem cause and
check if the malfunction occurs.
HINT: Applying strong vibration to relays may result
in open relays. IN±20
±
INTRODUCTION How to Troubleshoot ECU Controlled Systems
WhereEverybodyKnowsYourName

[2] HEAT METHOD: When the problem seems to occur when the suspect area is heated.
Heat the component that is the likely cause of the malfunc-
tion with a hair dryer or similar object. Check to see if the
malfunction occurs.
NOTICE:
(1) Do not heat to more than 60°C (140 °F).
(Temperature limit that no damage is done to the
component).
(2) Do not apply heat directly to parts in the ECU.
[3] WATER SPRINKLING METHOD: When the malfunction seems to occur on a
rainy\
day or in a high±humidity condition.
Sprinkle w ater onto the vehicle and check to see if the mal-
function occurs.
NOTICE:
(1) Never sprinkle water directly into the engine compartment, but indirectly change the tempera-
ture and humidity by applying water spray onto
the radiator front surface.
(2) Never apply water directly onto the electronic components.
(Service hint)
If a vehicle is subject to water leakage, the leaked water
may contaminate the ECU. When testing a vehicle with a
water leakage problem, special caution must be used.
[4] OTHER: When the malfunction seems to occur when electrical load is excessive.
Turn on all electrical loads including the heater blower,
head lights, rear window defogger, etc. and check to see
if the malfunction occurs.
±
INTRODUCTION TITLE±NAMEIN±21
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1. CONTINUITY CHECK (OPEN CIRCUIT CHECK)(1) Disconnect the connectors at both ECU and sensor sides.
(2) Measure the resistance between the applicable terminalsof the connectors.
Resistance: 1
or less
HINT:
w Measure the resistance while lightly shaking the wire
harness vertically and horizontally.
w When tester probes are inserted into a connector, insert
the probes from the back. For waterproof connectors in
which the probes cannot be inserted from the back, be
careful not to bend the terminals when inserting the
tester probes.
2. RESISTANCE CHECK (SHORT CIRCUIT CHECK) (1) Disconnect the connectors at both ends.
(2) Measure the resistance between the applicable terminalsof the connectors and body ground. Be sure to carry out
this check on the connectors on both ends.
Resistance: 1 M
or higher
HINT: Measure the resistance while lightly shaking the wire
harness vertically and horizontally.
3. VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends.
(b) Check for rust or foreign material, etc. on the terminalsof the connectors.
(c) Check crimped portions for looseness or damage and check if the terminals are secured in the lock position.
HINT: The terminals should not come out when pulled lightly.
(d) Prepare a test male terminal and insert it in the female
terminal, then pull it out.
HINT: When the test terminal is pulled out more easily than
others, there may be poor contact in that section.
IN±28
±
INTRODUCTION How to Troubleshoot ECU Controlled Systems
WhereEverybodyKnowsYourName

R±12 AIR CONDITIONER SYSTEM RETROFIT ± AC001±98 April 3, 1998
Page 2 of 4
A. Required Equipment:
1. R±12 recovery/recycling/recharging equipment
2. R134a recovery/recycling/recharging equipment
3. Measuring cylinder (for compressor oil)
4. Valve core remover for service valves
5. Air conditioner service tool set
6. Torque Wrench Set, P/N 00002±50284±01, includes the following*: 14 mm 00002±51410±01
17 mm 00002±51710±01
22 mm 00002±52216±01
27 mm 00002±52724±01
B. Required Parts & Materials: **
1. R134a Refrigerant
2. Service Fitting Adaptors
3. Caution Labels
4. ND±OIL 8 compressor oil (PAG type oil)
5. Receiver
6. O±Rings for compressor, line & hose connections ***
7. Loctite 262 or equivalent
* required size dependent upon model.
** see parts information section of this bulletin on page 1.
*** it is not necessary to replace any O±rings on ES 300, SC 300 and SC 400 models\
.
A. Refrigerant and Oil Charges
Oil and refrigerant charge amounts are different after the R±12 system has been
retrofitted to R134a. Refrigerant charge amounts are less, while oil ch\
arge
amounts are greater, compared to R±12 system requirements. Refer to the
ND OIL
8
and CHARGE columns in ªParts Informationº table on page 1 for proper amounts\
.
B. System Performance A slight decrease in system performance may be noticed on some vehicles \
under
certain operating conditions.
C. Refrigerant Pressures
R134a high side pressures are greater than that of R±12 above ambient\
temperatures of 68 °F.
D. Flushing Requirements There is no need to remove or flush R±12 mineral oil from the system.\
Simply
charge the system with the specified amount of ND±Oil 8 to provide pr\
oper
lubrication.
E. Use of Sight Glass Mineral based R±12 oil remains and circulates in the A/C system and d\
oes not
dissolve in R134a refrigerant. This results in a cloudy appearance at th\
e sight
glass making it impossible to judge the refrigerant charge amount by us\
ing the
sight glass method. To prevent misdiagnosis on retrofit vehicles, apply black
paint to the sight glass on block±joint (FF) type Receivers. Union\
±nut joint (BAG)
type retrofit Receivers are manufactured without a sight glass.
Required
Tools &
Materials
Retrofitting Overview
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DESCRIPTION
FEATURES
The microprocessor controlled automatic air conditioner is a system whic\
h controls the the cabin air conditioning
automatically using a microcomputer.
The microcomputer senses the air temperature outside and inside the cabin, \
the amount of sunlight, the com-
pressor operating condition and temperature setting, etc. and maintains the optimum blower\
air temperature
and air flow at the intakes and outlets automatically.
PARTS LOCATION
AC±6±
AIR CONDITIONING SYSTEM Description
WhereEverybodyKnowsYourName

INDICATOR
1. Turn the ignition switch on while pressing the ari conditioner control
switch and REC swich
simultaneously.
2. Check that all the indicators light up and go off at 1 second intervals 4 times in succession.
3. Check that the buzzer sounds when the indicators light up in 2.
HINT:
wAfter the indicator check is ended, the diagnostic code
check begins automatically.
w Press the OFF switch when desiring to cancel the check
mode.
DIAGNOSTIC CODE CHECK (SENSOR
CHECK)
1. Perform an indicator check. After the indicator check is completed, the system enters the diagnostic code check
mode automatically.
2. Read the code displayed on the panel. Refer to the list of
codes on page AC±28 when reading the codes. (Codes are
output at the temperature display.)
If the slower display ped is desired, press the FRS
switch and change it to stepped operation. Each time the
FRS
switch is pressed, the display changes by 1 step.
HINT:
w If the buzzer sounds when a code is being read, it means
the trouble indicated by that code continues to occur.
w If the buzzer does not sound when a code is being read,
it means the trouble indicated by that code occurred ear-
lier (such as poor connector contacts, etc.)
CLEARING DIAGNOSTIC CODES
1. Pull out the DOME fuse in Relay Block No. 2 for 10 sec. or
longer to clear the memory of diagnostic codes.
2. After reinserting the fuse, check that the normal code is output.
±
AIR CONDITIONING SYSTEM TroubleshootingAC±27
WhereEverybodyKnowsYourName

DIAGNOSTIC CODE CHART
If a malfunction code is displayed during the diagnostic code check (sens\
or check), check the circuit listed for
that code in the table below (Proceed to the page given for that circuit.)\
Code No.Diag. Code Detecting Condition
00 Normal
11 *1 Open or short in room temperature sensor circuit.
12 Open or short in ambient temperature sensor circuit.
13 Open or short in evaporator temperature sensor circuit.
14*2 Open or short in water temperature sensor circuit.
21*3 Open in solar sensor circuit.
21*3
 Short in solar sensor circuit.
22*4
 All conditions below are detected for 3 secs. or more.
 (a) Engine rpm : 450 rpm or more.
 (b) Ratio between engine and compressor rpm deviates 20% or more in c\
omparison to normal
operation.
23
 Open in pressure sensor circuit.
 Abnormal refrigerant pressure below 206 kPa (2.1 kgf/cm, 30 psi)
over 2,650 kPa (27 kgf/cm, 385 ps\
i)
31 Short to ground or power source circuit in Air Mix Damper position sens\
or circuit.
32 Short to ground or power source circuit in Air Inlet Damper position se\
nsor circuit.
33 Short to ground or power source circuit in Air Outlet Damper position s\
ensor circuit.
41 Air mix damper position sensor value does not change even if ECU operat\
es air mix servomotor.
42 Air inlet damper position sensor value does not change even if ECU oper\
ates air inlet servomotor.
43 Air outlet damper position sensor value does not change even if ECU ope\
rates air outlet
servomotor.
HINT: *1 If the room temp. is approx. ±20 °C (±4 °F) or lower, code 11 may be output even though the system
is normal.
*2 If the ambient temperature is approx. ±50 °C (±58 °F) or lower, a malfunction code may be output
even though the system is normal.
*3 If the check is being performed in a dark place, diagnostic code 21 (so\
lar sensor circuit abnormal) could be displayed.
In this case, perform diagnostic code check again while shining a light,\
such as an inspection light,
on the solar sensor.
If code 21 is still displayed, there could be trouble in the solar senso\
r circuit
AC±28
±
AIR CONDITIONING SYSTEM Troubleshooting
WhereEverybodyKnowsYourName