LEXUS SC400 1991 Service Repair Manual

FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a largeamount of gasoline will spill out, so observe the following
procedures:
(a) Remove the luggage compartment trim cover.
(b) Disconnect the fuel pump connector.
(c) Start the engine, After the engine has stopped on itsown, turn off the ignition switch.
(d) Put a container under the connection.
(e) Slowly loosen the connection.
(f) Disconnect the connection.
(g) Plug the connection with a rubber plug.
(h) Reconnect the fuel pump connector.
(i) Reinstall the luggage compartment trim cover.
2. When connecting the flare nut or union bolt on the high pressure pipe union, observe the following procedures:
(Union Bolt Type)
(a) Always use a new gasket.
(b) Tighten the union bolt by hand.
(c) Tighten the union bolt to the specified torque.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
(Flare Nut Type)
(a) Apply a light coat of engine oil to the flare nut and tighten
the flare nut by hand.
(b) Using SST, tighten the flare nut to specified torque.
SST 09631±22020
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
3. Observe the following precautions when removing and installing the injectors.
(a) Never reuse the O±ring.
(b) When placing a new O±ring on the injector, take care not
to damage it in any way.
(c) Coat a new O±ring with spindle oil or gasoline before installing±never use engine, gear or brake oil.
FI±14
±
EFI SYSTEM Inspection Precautions
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4. Install the injector to delivery pipe and cylinder head asshown in the illustration.
5. Check that there are no fuel leaks after performing any maintenance on the fuel system.
(a) Using SST, connect terminals +B and FP of the check(ºDIAGNOSISº) connector.
SST 09843±18020
(b) With engine stopped, turn the ignition switch ON.
(c) When the fuel return hose is pinched, the pressure within high pressure line will rise to approx. 392 kPa (4
kgf/cm2, 57 psi). In this state, check to see that there are
no leaks from any part of the fuel system.
NOTICE: Always pinch the hose. Avoid bending as it may
cause the hose to crack.
(d) Turn the ignition switch OFF.
(e) Remove SST from the check connector.
SST 09843±18020
±
EFI SYSTEM Inspection PrecautionsFI±15
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PRECAUTIONS
1. Before working on the fuel system, disconnect the cablefrom negative (±) terminal of the battery.
HINT: Any diagnostic code retained by the computer will be
erased when the battery terminal is removed. Therefore, if
necessary, read the diagnosis before removing the battery
terminal.
CAUTION: Work must be started after approx. 20 se-
conds or longer from the time the ignition switch is
turned to the ºLOCKº position and negative (±) terminal
cable is disconnected from the battery.
2. Do not smoke or work on open flame when working on the fuel system.
3. Keep gasoline away from rubber or leather parts.
INSPECTION PRECAUTIONS
MAINTENANCE PRECAUTIONS
1. CHECK CORRECT ENGINE TUNE±UP (See page EM±8)
2. PRECAUTIONS WHEN CONNECTING GAUGE (a) Use the battery as the power source for the timing light,tachometer, etc.
(b) Connect the test probe of a tachometer to the terminal IG of the check connector.
3. IN EVENT OF ENGINE MISFIRE, FOLLOWING PRECAUTIONS SHOULD BE TAKEN
(a) Check proper connection of battery terminals, etc.
(b) Handle high±tension cords carefully.
(c) After repair work, check that the ignition coil terminalsand all other ignition system lines are reconnected
securely.
(d) When cleaning the engine compartment, be especially careful to protect the electrical system from water.
4. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR (a) Do not allow oxygen sensor to drop or hit against anobject.
(b) Do not allow the sensor to come into contact with water.
FI±12
± Precautions, Inspection PrecautionsEFI SYSTEM
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IF VEHICLE IS EQUIPPED WITH MOBILE
RADIO SYSTEM (HAM, CB, ETC.)
The ECU has been designed so that it will not be affected by out-
side interference. However, if your vehicle is equipped with a CB
radio transceiver, etc. (even one with about 10 W output), it may,
at times, have an effect upon ECU operation, especially if the an-
tenna and feeder are installed nearby.
Therefore, observe the following precautions:
1. Install the antenna as far away as possible from the ECU. The
ECU is located on the floor panel on the passenger side so
the antenna should be installed at the rear of the vehicle.
2. Keep the antenna feeder as far away as possible from the ECU wires±at least 20 cm (7.87 in.)±and, especially, do not
wind them together.
3. Check that the feeder and antenna are properly adjusted.
4. Do not equip your vehicle with a powerful mobile radio
system.
5. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC
may be destroyed by static electricity.)
AIR INDUCTION SYSTEM
1. Separation of the engine oil dipstick, oil filler cap, PCV hose,
etc. may cause the engine to run out of tune.
2. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder
head will cause air suction and cause the engine to run out
of tune.
ELECTRONIC CONTROL SYSTEM
1. Before removing EFI wiring connectors, terminals, etc., firstdisconnect the power by either turning the ignition switch
OFF or disconnecting the battery terminals.
HINT: Always check the diagnosis code before disconnecting
the battery terminals.
2. When installing the battery, be especially careful not to
incorrectly connect the positive (+) and negative (±) cables.
3. Do not permit parts to receive a severe impact during removal or installation. Handle all EFI parts carefully, especially the
ECU.
4. Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact
can cause further troubles.
5. Do not open the ECU cover.
6. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment,
prevent water from getting on the EFI parts and wiring
connectors.
7. Parts should be replaced as an assembly. FI±13
EFI SYSTEM
± Inspection Precautions
WhereEverybodyKnowsYourName

8. Care is required when pulling out and inserting wiring
connectors.
(a) Release the lock and pull out the connector, pulling on the connectors.
(b) Fully insert the connector and check that it is locked.
9. When inspecting a connector with a volt/ohmmeter. (a) Carefully take out the water±proofing rubber if it is a
water±proof type connector.
(b) Insert the test probe into the connector from wiring side when checking the continuity, amperage or voltage.
(c) Do not apply unnecessary force to the terminal.
(d) After checking, install the water±proofing rubber on the connector securely.
10. Use SST for inspection or test of the injector, cold start injector or its wiring connector.
SST 09842±30055 (A) and 09842±30070 (C)
FI±14
EFI SYSTEM
± Inspection Precautions
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FUEL SYSTEM
1. When disconnecting the high fuel pressure line, a largeamount of gasoline will spill out, so observe the following
procedures:
(a) Put a container under the connection.
(b) Slowly loosen the connection.
(c) Disconnect the connection.
(d) Plug the connection with a rubber plug.
2. When connecting the flare nut or union bolt on the high pressure pipe union, observe the following procedures:
(Union Bolt Type)
(a) Always use a new gasket.
(b) Tighten the union bolt by hand.
(c) Tighten the union bolt to the specified torque.
Torque: 15 N Vm (150 kgf Vcm, 11 ft Vlbf)
(Flare Nut Type)
(a) Apply a light coat of engine oil to the flare nut and tighten
the flare nut by hand.
(b) Using SST, tighten the flare nut to specified torque.
SST 09631±22020
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
3. Observe the following precautions when removing and installing the injectors.
(a) Never reuse the O±ring.
(b) When placing a new O±ring on the injector, take care not
to damage it in any way.
(c) Coat a new O±ring with spindle oil or gasoline before installing±never use engine, gear or brake oil.
4. Install the injector to delivery pipe and cylinder head as shown in the illustration. FI±15
EFI SYSTEM
± Inspection Precautions
WhereEverybodyKnowsYourName

5. Check that there are no fuel leaks after performing anymaintenance on the fuel system.
(a) Using SST, connect terminals +B and FP of the check(ºDIAGNOSISº) connector.
SST 09843±18020
(b) With engine stopped, turn the ignition switch ON.
(c) When the fuel return hose is pinched, the pressure within high pressure line will rise to approx. 392 kPa (4
kgf/cm2, 57 psi). In this state, check to see that there are
no leaks from any part of the fuel system.
NOTICE: Always pinch the hose. Avoid bending as it may
cause the hose to crack.
(d) Turn the ignition switch OFF.
(e) Remove the SST from the check connector.
SST 09843±18020
FI±16
EFI SYSTEM
± Inspection Precautions
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FUEL SYSTEM
Fuel Pump
ON±VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION(a) Using SST, connect terminals +B and FP of the check
(ºDIAGNOSISº) connector.
SST 09843±18020
(b) Turn the ignition switch ON.
NOTICE: Do not start the engine.
(c) Check that there is pressure in the fuel inlet hose from the fuel filter.
HINT: At this time, you will hear fuel return noise.
(d) Turn the ignition switch OFF.
(e) Remove SST from the check connector.
SST 09843±18020
FI±16
±
EFI SYSTEM Fuel System (Fuel Pump)
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If there is no pressure, check the following parts:
wFuses
w EFI main relay
w Fuel pump ECU
w Fuel pump
w Engine (& ECT) ECU
w Wiring connections
2. CHECK FUEL PRESSURE (a) Check the battery voltage above 12 volts.
(b) Disconnect the cable from the negative (±) terminal ofthe battery.
CAUTION: 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.
(c) Remove the union bolt holding the deliver pipe to the No. 1 fuel pipe. Remove the two gaskets.
HINT:
w Put a suitable container or shop towel under the delivery
pipe.
w Slowly loosen the union bolt.
(d) Install the No. 1 fuel pipe and SST (pressure gauge) to the delivery pipe with three new gaskets and the union
bolt.
SST 09268±45012
Torque: 42 N Vm (420 kgf Vcm, 30 ft Vlbf)
(e) Wipe off any splattered gasoline.
(f) Using SST, connect terminals +B and FP of the check
(ºDIAGNOSISº) connector.
SST 09843±18020
(g) Reconnect the cable to the negative (±) terminal of the battery.
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EFI SYSTEM Fuel System (Fuel Pump)FI±17
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(h) Turn the ignition switch ON.
(i) Measure the fuel pressure.
Fuel pressure: 265±304 kPa (2.7±3.1 kgf/cm, 38±44 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the following parts:w Fuel hoses and connections
w Fuel pump
w Fuel filter
w Fuel pressure regulator
(j) Remove SST from the check connector.
SST 09843±18020
(k) Start the engine.
(l) Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end.
(m) Measure the fuel pressure at idle.
Fuel pressure: 265±304 kPa
(2.7±3.1 kgf/cm, 38±44 psi)
(n) Re c onnect the vacuum sensing hose to the fuel
pressure regulator.
(o) Measure the fuel pressure at idle.
Fuel pressure: 196±235 kPa
(2.0±2.4 kgf/cm, 28±34 psi)
If pressure is not as specified, check the vacuum sensing
hose and fuel pressure regulator.
(p) Stop the engine. Check that the fuel pressure remains147 kPa (1.5 kgf/cm2, 21 psi) or more for 5 minutes after
the engine is turned off.
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(q) After checking fuel pressure, disconnect the battery
negative (±) cable and carefully remove SST to prevent
gasoline from splashing.
SST 09268±45012
(r) Connect the No. 1 fuel pipe to the delivery pipe with two new gaskets and the union bolt.
Torque: 42 N Vm (420 kgf Vcm, 30 ft Vlbf)
(s) Reconnect the cable to the negative (±) terminal of the
battery.
(t) Check for fuel leaks. (See page FI±15)
FI±18
±
EFI SYSTEM Fuel System (Fuel Pump)
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