LEXUS SC400 1991 Service Repair Manual

REMOVAL OF STARTER
(See Components on page ST±5)
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
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 the negative (±) termi-
nal cable is disconnected from the battery.
2. DRAIN ENGINE COOLANT
3. REMOVE THROTTLE BODY COVER (a) Remove the mounting cap nut.
(b) Loosen the two bolts, and remove the throttle bodycover.
4. DISCONNECT CONTROL CABLES FROM THROTTLE BODY
Disconnect the following cables:(1) Accelerator cable
(2) A/T throttle control cable
(3) (w/ Cruise Control System) Cruise control actuator cable
5. REMOVE INTAKE AIR CONNECTOR (a) Disconnect the following hoses:(1) Air hose from ISC valve
(2) Air hose (from PS air control valve) from intake air
connector
(b) Remove the bolt holding the intake air connector to the cylinder head cover.
(c) Loosen the two hose clamps.
(d) Disconnect the intake air connector from the throttle
body and air cleaner hose, and remove the intake air
connector.
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6. REMOVE UPPER HIGH±TENSION CORD COVER(a) Remove the two mounting bolts.
(b) Disconnect the front side claw groove of the cord coverfrom the claw of the lower cover, and remove the cord
cover.
7. REMOVE RH ENGINE WIRE COVER Remove the bolt and engine wire cover.
8. REMOVE LH ENGINE WIRE COVER Remove the two bolts and engine wire cover.
9. REMOVE VSV FOR EVAP SYSTEM Remove the two bolts, and disconnect the VSV from cylinder
head and timing belt cover.
10. REMOVE RH NO.3 TIMING BELT COVER Remove the three bolts and timing belt cover.
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11. REMOVE LH NO.3 TIMING BELT COVER(a) Remove the four mounting bolts.
(b) Disconnect the cord grommet from the timing belt cover,
and remove the timing belt cover.
(c) Remove the cord grommet from the high±tension cord.
12. REMOVE LOWER HIGH±TENSION CORD COVER (a) Disconnect the high±tension cord from the RH ignitioncoil.
(b) D i s c onnect the high±tension cords from the
high±tension cord cover.
(c) Remove the bolt and cord cover.
13. REMOVE THROTTLE BODY (a) Disconnect the following connectors:(1) Throttle position sensor connector
(2) (w/ TRAC)
Sub±throttle position sensor connector
(3) (w/ TRAC) Sub±throttle actuator connector
(b) Disconnect the following hoses: (1) Heat water hose from heater water valve
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(2) Water by±pass hose from ISC valve
(3) (USA Spec.)Vacuum hose from throttle body
(4) (Exc. USA Spec.)
Three vacuum hoses from throttle body
(c) Remove the two bolts and two nuts, disconnect the throttle body from the air intake chamber.
(d) Disconnect the following hoses, and remove the throttle body:
(1) PCV hose from throttle body
(2) Water by±pass hose from throttle body
(e) Remove the throttle body gasket.
14. DISCONNECT CONNECTORS Disconnect the following connectors:
wCold start injector connector
w ISC valve connector
w (USA Spec.)
EGR Valve connector
w (Exc. USA Spec.)
VSV connector for EGR system
w VSV connector for fuel pressure control system
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15. DISCONNECT HOSESDisconnect the following hoses:(1) Water by±pass hose (from water inlet housing) from ISC valve
(2) Vacuum hose (from PS air control valve) from air in-
take chamber
(3) Vacuum sensing hose (from fuel pressure regula- tor) from vacuum pipe
(4) Two vacuum hoses (from VSV for EVAP system) from vacuum pipe
(5) Vacuum hose (from charcoal canister) from vacu- um pipe.
(6) Water by±pass hose (from EGR valve) from water by±pass pipe
(7) Vacuum hose (from brake booster) from air intake chamber
(8) Vacuum hose (from VSV for heater water valve)
from air intake chamber
(9) PCV hose from LH cylinder head cover
16. REMOVE AIR INTAKE CHAMBER (a) Remove the bolt, stud bolt and accelerator bracket.
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(b) Remove the union bolt and two gaskets, and disconnectthe cold start injector tube from the RH delivery pipe.
(c) Remove the two bolts and gasket, and disconnect the EGR pipe from the air intake chamber.
(d) Remove the four bolts, eight nuts and A/T throttle cable bracket.
(e) (USA Spec.)
Disconnect the check (ºDIAGNOSISº) connector brack-
et from the air intake chamber.
(f) (Exc. USA Spec.) Remove the connector bracket from the check
(ºDIAGNOSISº) connector.
(g) Remove the air intake chamber assembly and four gaskets.
17. DISCONNECT FUEL INLET HOSE FROM LH DELIVERY PIPE
Remove the pulsation damper and two gaskets, and discon-
nect the inlet hose.
18. D I S C O N N E C T F U E L R E T U R N H O S E F R O M F U E L RETURN PIPE
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19. DISCONNECT EGR PIPE FROM RH CYLINDER HEADRemove the bolt holding the EGR pipe to the cylinder head,
and disconnect the EGR pipe.
20. DISCONNECT ENGINE WIRE FROM INTAKE MANIFOLD Remove the two bolts, and disconnect the engine wire.
21. DISCONNECT ENGINE WIRE FROM DELIVERY PIPES, REAR WATER BY±PASS JOINT AND RH CYLINDER
HEAD
(a) Remove the four bolts holding the engine wire to thedelivery pipes, and disconnect the engine wire from the
delivery pipe.
(b) Remove the two bolts holding the engine wire to the rear
water by±pass joint, and disconnect the engine wire
from the rear water by±pass joint.
(c) Remove the two bolts holding the engine wire to the rear
side of the RH cylinder head, and disconnect the engine
wire from the RH cylinder head.
(d) Disconnect the two engine wire connectors from the connector bracket on the front side of the LH delivery
pipe.
(e) Disconnect the eight injector connectors.
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22. REMOVE FUEL RETURN PIPE(a) Remove the bolt holding the return pipe to the LHcylinder head.
(b) Remove the union bolt, two gaskets and return pipe.
23. REMOVE DELIVERY PIPES AND INTAKE MANIFOLD ASSEMBLY
(a) Remove the six bolts and four nuts holding the intakemanifold to the cylinder heads.
(b) Remove the two delivery pipe and intake manifold assembly.
(c) Remove the two intake manifold gaskets.
24. DISCONNECT HEATER WATER HOSES FROM WATER BY±PASS PIPE AND REAR WATER BY±PASS JOINT
25. REMOVE WATER BY±PASS PIPE (a) Remove the two mounting bolts.
(b) Pull out the water by±pass pipe from the water pump.
(c) Remove the O±ring from the water by±pass pipe.
26. REMOVE REAR WATER BY±PASS JOINT Remove the four nuts, water by±pass joint and two gaskets.
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27. REMOVE STARTER(a) Remove the two bolts holding the starter to the cylinderblock.
(b) Disconnect the starter connector.
(c) Remove the nut, and disconnect the starter wire.
(d) Disconnect the wire clamp from the wire bracket, and remove the starter.
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COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
DISASSEMBLY OF STARTER
1. REMOVE FIELD FRAME AND ARMATURE(a) Remove the nut, and disconnect the lead wire from themagnetic switch terminal.
(b) Remove the two through bolts, spring washer, wire bracket and two O±rings.
(c) Pull out the field frame together with the armature.
(d) Remove the O±ring from the field frame.
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