LEXUS SC400 1991 Service Repair Manual

35. INSTALL HEATER WATER VALVE(a) Install the water valve and bracket assembly with thetwo bolts.
(b) Install the engine wire clamp with the bolt.
(c) Connect the VSV connector.
36. INSTALL ISC VALVE (a) Install a new gasket and the ISC valve with the two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Connect the water by±pass hose (from throttle body) to
the ISC valve.
(c) Connect the ISC valve connector.
37. INSTALL EGR VALVE ADAPTOR (a) Install a new gasket, the adaptor and connector bracket(USA spec. only) with the two bolts and two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 20 mm (1.79 in.) in length.
NOTICE: Do not touch the air intake chamber and adap-
tor surfaces of the gasket with your hand.
(b) Connect the PCV hose to cylinder head.
(c) (USA Spec. only)
Connect the EGR gas temperature sensor connector.
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38. (USA Spec.)INSTALL EGR VALVE
(a) Place a new gasket on the EGR valve adaptor.
NOTICE:
w Do not touch the adapter and EGR valve surfaces of the
gasket with your hand.
w Align the port holes of the gasket and adaptor. Be careful
of the installation direction.
(b) Install the EGR valve with the two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(c) Connect the following hoses:
(1) Water by±pass pipe hose to ISC valve
(2) Water by±pass pipe hose to water by±pass pipe (from rear water by±pass joint)
(d) Connect the EGR valve connector.
39. (Exc. USA Spec.) INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Place a new gasket on the EGR valve adaptor.
NOTICE:
w Do not touch the adapter and EGR valve surfaces of the
gasket with your hand.
w Align the port holes of the gasket and adaptor. Be careful
of the installation direction.
(b) Install the EGR valve and vacuum and m odulator
assembly with the two nuts and bolt.
Torque (Nut): 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
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(c) Connect the following hoses:(1) Water by±pass pipe hose to ISC valve
(2) Water by±pass pipe hose to water by±pass pipe (from rear water by±pass joint)
(3) Two vacuum hoses to VSV for EGR system
40. INSTALL VACUUM PIPE (a) Install the vacuum pipe, vacuum hoses assembly andEGR water by±pass pipe (USA spec. only) with the two
bolts.
(b) Connect the following hoses: (1) (USA Spec.) Vacuum hose to throttle body
(2) (Exc. USA Spec.) Three vacuum hoses to throttle body
(3) Vacuum hose to fuel pressure regulator
(4) Two vacuum hoses to VSV for fuel pressure control system
(5) (Exc. USA Spec.) Two vacuum hoses to EGR vacuum modulator
(6) Two vacuum hoses (from VSV for EVAP system) to vacuum pipe
(7) Vacuum hose (from VSV for fuel pressure control system) to air intake chamber
(8) Vacuum hose (from charcoal canister) to vacuum pipe
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41. INSTALL TIMING BELT REAR PLATESInstall the rear plate with the two bolts. Install the two rear
plates.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
42. INSTALL WATER INLET AND INLET HOUSING
(a) Remove any old packing (FIPG) material.w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) materials from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose materials.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the sealing groove of the water inlet housing as shown in the illustration.
Seal packing: Part No.08826±00100 or equivalent
w Install a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Install a new O±ring to the water inlet housing.
(d) Apply soapy water to the O±ring.
(e) Push the water inlet housing end into the water pump hole.
(f) Install the water inlet and housing assembly with the two
bolts. Alternately tighten the bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 25 mm (0.98 in.) in length.
(g) Connect the water by±pass hose to the ISC valve.
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43. INSTALL RH IGNITION COILInstall the ignition coil with the two bolts.
44. CONNECT CONTROL CABLES TO THROTTLE BODY Connect the following cables:(1) Accelerator cable
(2) A/T throttle cable
(3) (w/ Cruise Control System)
Cruise control actuator cable
45. INSTALL THROTTLE BODY COVER Install the throttle body cover and hose clamp with the two
bolts and cap nut.
46. INSTALL CATALYTIC CONVERTERS (MAIN) (a) Install a new gasket and the catalytic converter to theexhaust manifold with the three new bolts. Install the two
catalytic converters.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
(b) Install a new gasket to each front end of the front
exhaust pipe.
(c) C onnect the front exhaust pipe to the catalytic
converters.
(d) Te mp o ra rily in sta ll th e fo u r bo lts ho ld in g th e pip e support bracket to the transmission.
(e) Install the four bolts and nuts holding the catalytic
converters to the front exhaust pipe.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(f) Tighten the four bolts holding the pipe support bracket
to the transmission.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
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47. INSTALL PS PUMP(a) In sta ll th e PS pu mp with th e th re e bo lts an d nu t.Alternately tighten the bolts and nut.
Torque:
Bolt 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
Nut 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(b) Connect the vacuum hose to the vacuum pipe.
48. INSTALL HYDRAULIC PUMP AND CAMSHAFT TIMING PULLEYS
(See steps 8, 10 and 11 on pages EM±48 to 49)
49. INSTALL HYDRAULIC PUMP AND CAMSHAFT TIMING PULLEYS
(See steps 12 to 43 on pages EM±49 to 57)
50. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
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CYLINDER BLOCK
COMPONENTS FOR REMOVAL AND
INSTALLATION OF ENGINE WITH
TRANSMISSION
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COMPONENTS FOR REMOVAL AND
INSTALLATION OF ENGINE WITH
TRANSMISSION (Cont'd)
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COMPONENTS FOR REMOVAL AND
INSTALLATION OF ENGINE WITH
TRANSMISSION (Cont'd)
REMOVAL OF ENGINE WITH
TRANSMISSION
1. REMOVE BATTERYCAUTION: Turn the ignition switch to ºLOCKº. Discon-
nect the cable from the negative (±) terminal of the bat-
tery. Wait at least 20 seconds before proceeding with
work.
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. DISCONNECT CONTROL CABLES FROM THROTTLE BODY
Disconnect the following cables:(1) Accelerator cable
(2) (A/T)Throttle control cable
(3) Cruise control actuator cable
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5. REMOVE AIR CLEANER ASSEMBLY(a) Disconnect the high±tension cord from the ignition coil.
(b) Disconnect the volume air flow meter connector.
(c) Disconnect the following hose:(1) PS air hose from No. 4 timing belt cover
(2) PCV hose from No. 2 cylinder head cover
(d) Loosen the hose clamp holding the air cleaner hose to the throttle body.
(e) Remove the three mounting bolts and air cleaner.
6. REMOVE DRIVE BELT, FAN WITH FLUID COUPLING AND
WATER PUMP PULLEY
(a) Loosen the four nuts holding the fluid coupling to the water pump.
(b) Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt.
(c) Remove the four nuts, fluid coupling and water pump
pulley.
7. REMOVE RADIATOR (a) Disconnect the following hoses:(1) Reservior hose from radiator
(2) Upper radiator hose from water inlet
(3) Lower radiator hose from water outlet
(4) (A/T)Two oil cooler hoses from radiator
Plug the hose ends.
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