LEXUS SC400 1991 Service Repair Manual

5. INSTALL DELIVERY PIPES AND INTAKE MANIFOLDASSEMBLY
(a) Place two new gaskets on the cylinder heads with thewhite painted mark facing upward.
NOTICE: Align the port holes of the gasket and cylinder
head. Be careful of the installation direction.
(b) Place the delivery pipes and intake manifold assembly in position on the cylinder heads with the arrow mark on
the intake manifold facing forward.
NOTICE: Be careful of the installation direction.
(c) Install the six mounting bolts and four mounting nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 30 mm (1.18 in.) in length.
6. INSTALL FUEL RETURN PIPE Install the return pipe with two new gaskets, union bolt and
bolt.
Torque (Union bolt):
35 NVm (360 kgf Vcm, 26 ft Vlbf)
7. INSTALL ENGINE WIRE TO DELIVERY PIPES, REAR
WATER BY±PASS JOINT AND RH CYLINDER HEAD
(a) Connect the eight injector connectors.
(b) C onnect the two engine wire connectors to the
connector bracket on the LH delivery pipe.
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(c) Install the engine wire to the RH cylinder head with thetwo bolts.
(d) Install the engine wire to the rear water by±pass joint with the two bolts.
(e) Install the engine wire to the delivery pipes with the four bolts.
8. INSTALL ENGINE WIRE TO INTAKE MANIFOLD Install the engine wire with the two bolts.
9. TEMPORARILY INSTALL EGR PIPE TO RH CYLINDER HEAD
Temporarily install the EGR pipe with the bolt.
10. CONNECT FUEL RETURN HOSE TO FUEL RETURN PIPE
11. CONNECT FUEL INLET HOSE TO LH DELIVERY PIPE Using SST, connect the inlet hose with two new gaskets and
pulsation damper.
SST 09612±24014 (09617±24011)
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
33 N Vm (340 kgf Vcm, 24 ft Vlbf) for SST
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
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12. INSTALL AIR INTAKE CHAMBER(a) Place four new gaskets and the air intake chamber onthe intake manifold.
(b) Temporarily install a new gasket and the EGR pipe to air
intake chamber with the two bolts.
(c) (Exc. USA Spec.) Install the connector bracket to check (ºDIAGNOSISº)
connector.
(d) Install the air intake chamber and following parts with the four bolts and eight nuts:
(1) Check (ºDIAGNOSISº) connector
(2) A/T throttle cable bracket
(3) VSV for fuel pressure control system
(4) VSV for EGR system
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 40 mm (1.57 in.) of length.
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(e) Tighten the bolt holding the EGR pipe to the air intakechamber.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(f) Tighten the bolt holding the EGR pipe to the RH cylinder
head.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(g) Connect the cold start injector tube to the RH delivery
pipe with two new gaskets and union bolt.
Torque: 15 N Vm (150 kgf Vcm, 11 ft Vlbf)
(h) Install the accelerator bracket with the bolt and stud bolt.
13. CONNECT HOSES Connect the following hoses:(1) Water by±pass (from EGR valve) to water bypass
pipe
(2) Vacuum hose (from brake booster) to air intake chamber
(3) Vacuum hose (from VSV for heater water valve) to
air intake chamber
(4) PCV hose to LH cylinder head cover
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(5) Water by±pass hose (from water inlet housing) to ISC
valve
(6) Vacuum hose (from PS air control valve) to air intake chamber
(7) Vacuum sensing hose (from fuel pressure regulator) to vacuum pipe
(8) Two vacuum hoses (from VSV for EVAP system) to vacuum pipe
(9) Vacuum hose (from charcoal canister) to vacuum pipe.
14. CONNECT CONNECTORS Connect the following connectors:w Cold 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
15. INSTALL THROTTLE BODY (a) Connect the following hoses:(1) PCV hose to throttle body
(2) Water by±pass hose to throttle body
(b) Install a new gasket and throttle body with the two bolts and two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 40 mm (1.57 in.) in length.
(c) Install the water by±pass pipe (from rear water bypass
joint) to the clamp on the engine wire cover.
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(d) Connect the following hoses:(1) Water by±pass hose to the ISC valve
(2) (USA Spec.) Vacuum hose to throttle body
(3) (Exc. USA Spec.) Three vacuum hoses to throttle body
(4) Heater water hose to heater water valve
(e) Connect the following connectors: (1) Throttle position sensor connector
(2) (w/ TRAC) Sub±throttle position sensor connector
(3) (w/ TRAC) Sub±throttle actuator connector
16. INSTALL LOWER HIGH±TENSION CORD COVER (a) Connect the end portions of the high±tension cord to the
cord clamps
(b) Install the high±tension cord cover with the bolt.
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(c) Install the clamps on the high±tension cords to thehigh±tension cord cover.
(d) Connect the high±tension cord to the RH ignition coil.
17. INSTALL RH NO.3 TIMING BELT COVER (a) Install the three gaskets to the timing belt cover.
(b) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(c) Install the timing belt cover with the three bolts.
18. INSTALL VSV FOR EVAP SYSTEM Install the VSV with the two bolts.
19. INSTALL LH NO.3 TIMING BELT COVER (a) Install the three gaskets to the timing belt cover.
(b) Install the cord grommet to the high±tension cord.
(c) Install the cord grommet to the timing belt cover.
(d) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(e) Install the timing belt cover with the four bolts.
20. INSTALL RH ENGINE WIRE COVER (a) Fit portions A and B of the engine wire cover, matchingthem with the lower high±tension cord cover and No.3
timing belt cover.
(d) Install the engine wire cover with the bolt.
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21. INSTALL LH ENGINE WIRE COVER(a) Connect portions A and B engine wire cover to the wirebrackets.
(b) Set the VSV (for fuel pressure control system) wire in
original position.
(c) Fit portions C and D of the engine wire cover, matching them with the lower high±tension cord cover and No.3
timing belt cover.
(d) Install the engine wire cover with the two bolts.
22. INSTALL UPPER HIGH±TENSION CORD COVER (a) Fit portion A of the upper high±tension cover, matchingit with the top of the lower high±tension cord cover.
(b) Push the front side of the high±tension cord cover, and connect the front side claw groove of the upper
high±tension cord cover to the claw of the lower
high±tension cord cover.
(c) Install the upper high±tension cord cover with the two
bolts.
23. INSTALL INTAKE AIR CONNECTOR (a) Connect the end portions of the intake air connector tothe throttle body and air cleaner hose.
(b) Tighten the two hose clamps.
(c) Install the bolt holding the intake air connector to the cylinder head cover.
(d) Connect the following hoses: (1) Air hose to ISC valve
(2) Air hose (from PS air control valve) to intake air connector
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24. CONNECT CONTROL CABLES TO THROTTLE BODYConnect the following hoses:(1) Accelerator cable
(2) A/T throttle control cable
(3) (w/ Cruise Control System) Cruise control actuator cable
25. INSTALL THROTTLE BODY COVER Install the throttle body cover and hose clamp with the two
bolts and cap nut.
26. C O N N E C T C A B L E TO N E G AT I V E T E R M I N A L O F BATTERY
27. FILL WITH ENGINE COOLANT (See page CO±7)
28. CHECK THAT ENGINE STARTS
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STARTER RELAY
INSPECTION OF STARTER RELAY
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OFBATTERY
CAUTION: Work must be started after approx. 20 seconds or
longer from the time the ignition switch is turned to the
ºLOCKº position and the negative (±) terminal cable is dis-
connected from the battery.
2. REMOVE STATER RELAY LOCATION: In the engine compartment relay box.
3. INSPECT STARTER RELAY
A. Inspect relay continuity
(a) Using an ohmmeter, check that there is continuitybetween terminals 1 and 2.
(b) Check that there is no continuity between terminals 3 and 5.
If continuity is not as specified, replace the relay.
B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuitybetween terminals 3 and 5.
If operation is not as specified, replace the relay.
4. REINSTALL STARTER RELAY
5. RECONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
NEUTRAL START SWITCH
(See AT section)
THEFT DETERRENT SYSTEM
(See BE section)
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