oil type LEXUS SC400 1991 Service Repair Manual

12. Observe the following precautions to avoid damage to theparts:
(a) Do not open the cover or case of the ECU unless
absolutely necessary (If the IC terminals are touched, the
IC may be destroyed by static electricity.).
(b) To pull apart electrical connectors, pull on the connectoritself, not the wires (See page BE±2).
(c) Be careful not to drop electrical components, such as sensors or relays. It they are dropped on a hard floor,
they should be replaced and not reused.
(d) When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from
bending.
(e) To disconnect vacuum hoses, pull on the end, not the middle of the hose.
(f) When steam cleaning an engine, protect the distributor,
coil and air filter from water.
(g) Ne ve r use an imp a ct wre n ch to re mo ve or in sta ll temperature switches or temperature sensors.
(h) When using a vacuum gauge, never force the hose onto
a connector that is too large. Use a step±down adapter
instead. Once the hose has been stretched, it may leak.
13. Tag hoses before disconnecting them: (a) When disconnecting vacuum hoses, use tags to identify
how they should be reconnected.
(b) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood
shows the proper layout.
14. Installation of wheels The wheel assemblies are of the uni±directional type and
must be rotated only between the front and rear as illustrated.
Wheels are marked with turning direction indicators.
When installing the wheels, check the marks carefully and
install the wheel correctly.
15. Bleeding of traction control system When repairing the brake master cylinder or TRAC system,
bleed the air out of the TRAC system (See page BR±7).
CAUTION: Since the fluid is under high pressure, it could
spray out with great force, so be careful.
IN±6
±
INTRODUCTION General Repair Instructions
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
WhereEverybodyKnowsYourName

R±12 AIR CONDITIONER SYSTEM RETROFIT ± AC001±98 April 3, 1998
Page 4 of 4
E. Replace Receiver
1. Remove original R±12 Receiverand discard.
2. Measure oil and pour 1/2 of specified amount of oil into the
ªOUTº side of new Receiver (see
table on page 1 for amount).
3. Black out the sight glass on block ± joint ± type Receiver with black
paint.
4. Lubricate and install the O±rings on the Receiver connections.
5. Install Receiver.
F. Using R134a Recovery equipment,
evacuate, charge, and leak test the
system (Use equipment
manufacturer 's recommended
procedure).
1. Evacuate for 45 minutes.
2. Vacuum check.
3. If vacuum check is OK, add remaining 1/2 compressor oil using
the recovery equipment.
Using recovery / recycling /
recharging equipment charge
the system with the remaining
½ of the specified amount of oil
from step E2.
4. Charge system with specified amount of R134a. (reference table
on page 1).
5. Perform a gas leak check.
G. Confirm cooling performance of Air Conditioning system.
H. Install retrofit labels:
1. Choose R134a ªUSE ONLYº label
for proper oil type ( ND±OIL 8).
2. Using a ball point pen, enter the proper retrofit refrigerant and oil
charges on the caution label.
3. Cross out unused type of compressor oil on caution label.
4. Affix labels in a prominent location such as radiator support, underside
of hood, or suspension tower area.
5. Remove any R±12 labels.Repair
Procedure
(continued)FF Type
Black out
Replace O±Rings
Retrofit Receiver
BAG type
Replace O±Ring
Retrofit Receiver
WhereEverybodyKnowsYourName

Handling Precautions for Gas±Cylinder
Type Gas Leak Tester
1. BEFORE USING TESTER MAKE SURE THAT THEREARE NO FLAMMABLE SUBSTANCES NEARBY
2. BE CAREFUL NOT TO INHALE POISONOUS GAS If refrigerant gas comes in contact with flame, a poisonous
gas is prodused. During leak tests, do not inhale any gas.
Precautions When Replacing Parts in
Refrigerant Line
1. RECOVER REFRIGERANT IN SYSTEM BEFOREREMOVING PARTS
Using a recovery machine, recover refrigerant in system be-
fore removing the parts.
NOTICE: Do not release refrigerant to atmosphere.
2. INSERT PLUG IMMEDIATELY IN DISCONNECTED PARTS
Insert a plug immediately in the disconnected parts to pre-
vent the entry of moisture and dust.
3. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL
IMMEDIATELY BEFORE INSTALLATION
4. DO NOT USE BURNER FOR BENDING OR LENGTHENING OPERATIONS ON TUBE
If the tubes are heated with a burner, a layer of oxidation
forms inside the tube, causing the same kind of trouble as an
accumulation of dust.
5. DISCHARGE GAS IN NEW COMPRESSOR FROM
CHARGING VALVE BEFORE INSTALLING IT
If the gas in new compressor is not discharged first, compres-
sor oil will spray out with gas when the plug is removed.
6. TIGHTEN CONNECTING PARTS SECURELY Securely tighten the connecting parts to prevent leaking of
refrigerant gas.
wApply a few drops of compressor oil to O±ring fittings for
easy tightening and to prevent leaking of refrigerant
gas.
w Tighten the nuts using two wrenches to avoid twisting
the tube.
AC±4
±
AIR CONDITIONING SYSTEM General Description
WhereEverybodyKnowsYourName

wTighten the O±ring fittings or the bolted type fittings to
the specified torque.
Precautions When Charging Refrigerant
1. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH
REFRIGERANT IN REFRIGERANT CYCLE
If there is not enough refrigerant in the refrigerant cycle, oil
lubrication will be insufficient and compressor burnout may
occur, so take care to avoid this.
2. DO NOT OPEN HIGH PRESSURE VALVE OF MANIFOLD GAUGE WITH COMPRESSOR OPERATING
If the high pressure valve is opened, refrigerant flows in the
reverse direction and could cause the charging cylinder to
rupture, so open and close the low pressure valve only.
3. BE CAREFUL NOT TO OVERCHARGE WITH REFRIGERANT IN SYSTEM
If refrigerant is overcharged, it causes trouble such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.
Electrical Parts
Before removing and inspecting the electrical parts, set the
ignition switch to the LOCK position and disconnect the neg-
ative (±) terminal cable from the battery.
CAUTION: Work must not be started until after at least 20
seconds or longer from the time the negative (±) terminal
cable is disconnected.
SRS Airbag System
Failure to carry out service operations in the correct se-
quence could cause the airbag system to deploy, possibly
leading to a serious accident.
When removal or installation of the parts and the yellow wire
harness and connector for the airbag is necessary, refer to
the precautionary notices in the AB section before perform-
ing the operation.
±
AIR CONDITIONING SYSTEM General DescriptionAC±5
WhereEverybodyKnowsYourName

AT00S±01
PRELIMINARY CHECK
1. CHECK FLUID LEVELHINT:
wDrive the vehicle so that the engine and transmission
are at normal operating temperature.
Fluid temp.: 70±80 5C (158±176 5F)
w Only use the COOL range on the dipstick as a rough
reference when the fluid is replaced or the engine does
not run.
(a) Park the vehicle on a level surface and set the parking brake.
(b) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return
to P position.
(c) Pull out the transmission dipstick and wipe it clean.
(d) Push it back fully into the tube.
(e) Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add fluid.
Fluid type:
ATF TYPE T±II or Equivalent
NOTICE: Do not overfill.
2. CHECK FLUID CONDITION If the fluid smells burnt or is black, replace it.
3. REPLACE TRANSMISSION FLUID
(a) Remove the drain plug and drain the fluid.
(b) Reinstall the drain plug securely.
(c) With the engine OFF, add new fluid through the oil filler tube.
Fluid type:
ATF TYPE T±II or Equivalent
Capacity:
Total: 8.2 liters (8.7 US qts, 7.2 lmp. qts)
Drain and refill: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
(d) Start the engine and shift the shift lever into all positions fromP to L position and then shift into P position.
(e) With the engine idling, check the fluid level. Add fluid up to the
COOL level on the dipstick.
±
A304E (1UZ±FE) AUTOMATIC TRANSMISSION TROUBLESHOOTINGAT±47
WhereEverybodyKnowsYourName

EQUIPMENT
AT06V±05\
 \
Feeler gauge Check major clearance\
 
\

\
Vernier calipers
 

Check length of second coast brake
piston rod.
\
 
\

\
Dial indicator or dial indicator with magnetic baseCheck piston stroke and end play of
the output shaft.
\
 
\

\
Dial indicator with magnetic baseCheck inside diameter of major
bushing.
\
 \
Straight edgeCheck side clearance of oil pump.
\
 \
Torque wrench
\
 
\

\
Cylinder gaugeCheck inside diameter of the trans-
mission case rear bushing.
\
 \
Voltmeter
\
 \
Ammeter(A)
\
 \
Ohmmeter
LUBRICANT
AT0GW±03
 Item Capacity Classification
 Automatic transmission fluid
 Dry fill 8.2 liters (8.7 US qts, 7.2 lmp. qts) ATF Type T±II or equivalent
 Drain and refill 1.9 liters (2.0 US qts, 1.7 lmp. qts) 
SSM (SPECIAL SERVICE MATERIALS)
AT06X±03
\
 \
08826±00090 Seal Packing 1281, Transmission case X Oil pan
\
 
\

\

THREE BOND 128\
1 or equivalentTransmission case X Extension
housing
±
A304E (1UZ±FE) AUTOMATIC TRANSMISSION PREPARATIONAT±13
WhereEverybodyKnowsYourName

VALVE BODY
VALVE BODY REMOVAL
AT0GG±02
1. DRAIN ATF
2. REMOVE FRONT EXHAUST PIPE(See pages EG±204)
3. REMOVE OIL PAN
(a) Remove the 19 bolts.
(b) Install the blade of SST between the transmission case and oil pan, cut off applied sealer.
SST 09032±00100
NOTICE: Be careful not to damage the oil pan flange.
4. EXAMINE PARTICLES IN PANRemove the magnets and use them to collect steel particles.
Carefully look at the foreign matter and particles in the pan
and on the magnets to anticipate the type of wear you will find
in the transmission:
Steel (magnetic) 0 bearing, gear and clutch plate wear
Brass (non±magnetic) 0 bushing wear
5. REMOVE OIL STRAINER Remove the 3 bolts holding the oil strainer to the valve body.
6. REMOVE SOLENOID WIRING
(a) Remove the 2 bolts and the clamp.
(b) Disconnect the 4 connectors from the solenoid valves.
±
A304E (1UZ±FE) AUTOMATIC TRANSMISSION VALVE BODYAT±19
WhereEverybodyKnowsYourName

MAINTENANCE OF TAPE PLAYER
Head Cleaning
Using a moist±type cleaning tape, clean the head surface, pinch rolle\
rs and capstans.
COMPACT DISC PLAYER
Compact Disc (hereafter called ºCDº) players use a laser beam pick±up\
to read the digital signals recorded
on the CD and reproduce analog signals of the music, etc. There are 4.7 in\
. (12 cm) and 3.2 in. (8 cm) CD
available, but it is recommended that you do not use 3.2 in. (8 cm) discs in the\
CD auto changer.
HINT: Never attempt to disassemble or oil any part of the player unit. Do not\
insert any object other than
a disc into the magagine.
NOTICE: CD players use on invisible laser laser beam which could cause hazardou\
s radiation expo-
sure. Be sure to operate the player correctly as instructed.
±
BODY ELECTRICAL SYSTEM Audio SystemBE±197
WhereEverybodyKnowsYourName

ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the re-
quirements of your country.
HINT: For further details, see the description given in Section AR of this m\
anual.
ANTI-RUST AGENT (WAX)Apply anti-rust agent to
following sections.

Inside of the hems of the
doors and hood.

Around the hinges of the
doors and hood.

Inside of the welded parts
with boxed cross-section.
BODY SEALER
Apply body sealer to the
required areas.
Cartridge
Type
Tube
Type
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
Spray Gun
Undercoating
(Water base)
Undercoating
(Oil base)
INTRODUCTIONIN-14
WhereEverybodyKnowsYourName