ect LEXUS SC300 1991 Service Repair Manual

33. California:INSTALL EGR VALVE
(a) Place a new gasket on the EGR valve apaptor.
NOTICE:
w Do not touch the adaptor 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 2 nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(c) Connect the following hoses:
(1) Water bypass hose to IAC valve
(2) Water bypass hose to water bypass pipe (from rear wa-ter bypass joint)
(d) Connect the EGR valve connector.
34. Except California: INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Place a new gasket on the EGR valve adaptor.
NOTICE:
w Do not touch the adaptor 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 modulator assembly with
the bolt and 2 nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
±
1UZ±FE ENGINE ENGINE MECHANICALEG±131
WhereEverybodyKnowsYourName

(c) Connect the following hoses:(1) Water bypass hose to IAC valve
(2) Water bypass hose to water bypass pipe(from rear water bypass joint)
(3) 2 vacuum hoses to VSV for EGR
(d) Install the hose clamp to the PCV hose.
35. INSTALL VACUUM PIPE
(a) Install the vacuum pipe, vacuum hose assembly and EGR water bypass pipe (California) with the 2 bolts.
(b) Connect the following hoses: (1) California: Vacuum hose to throttle body
(2) Except California: 3 vacuum hoses to throttle body
(3) Vacuum hose to fuel pressure regulator
(4) 2 vacuum hoses to VSV for fuel pressure control
(5) Except California: 2 vacuum hoses to EGR vacuum modulator
(6) 2 vacuum hoses (from VSV for EVAP) to vacuum pipe
(7) Vacuum hose (from VSV for fuel pressure) to air intake chamber
(8) Vacuum hose (from charcoal canister) to vacuum pipe
EG±132
±
1UZ±FE ENGINE ENGINE MECHANICAL
WhereEverybodyKnowsYourName

(g) Connect the water bypass hose to the IAC valve.
38. INSTALL RH IGNITION COIL
(a) Install the ignition coil with the 2 bolts.
(b) Connect the ignition coil connector.
39. CONNECT CONTROL CABLES TO THROTTLE BODYConnect the following cables:
(1) Accelerator cable
(2) Transmission throttle control cable
(3) Cruise control actuator cable
40. INSTALL THROTTLE BODY COVER
(a) Install the thro ttle body cover and hose clamp with the cap nut
and 2 bolts.
(b) Install the EVAP hose to the hose clamp.
41. INSTALL POWER STEERING (PS) PUMP
(a) Install the PS pump with the nut and 3 bolts. Alternately tighten the bolts and nut.
Torque:
39 NVm (400 kgf Vcm, 29 ft Vlbf) for bolt
43 N Vm (440 kgf Vcm, 32 ft Vlbf) for nut
EG±134±
1UZ±FE ENGINE ENGINE MECHANICAL
WhereEverybodyKnowsYourName

(b) Connect the vacuum hose to the air intake chamber.
42. INSTALL TWC (FRONT)
(a) Using a 14 deep socket wrench, install a new gasket and theTWC with 3 new nuts. Install the 2 TWC.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
(b) Te m p o r a r i l y i n s t a l l t h e p i p e s upport bracket to the
transmission with the 4 bolts.
(c) Install a new gasket to each front end of the front exhaust
pipe.
(d) Connect the front exhaust pipe to the 2 TWC with the 4 bolts and 4 new nuts.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(e) Tighten the 4 bolts holding the pipe support bracket to the
transmission.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
43. INSTALL HYDRAULIC PUMP
Install the hydraulic pump with the 2 bolts and 2 nuts.
Torque:
16 NVm (160 kgf Vcm, 12 ft Vlbf) for 12 mm head
30 N Vm (310 kgf Vcm, 22 ft Vlbf) for 14 mm head
HINT: Each bolt length is indicated in the illustration.
Bolt length:
106 mm (4.17 in.) for A of 12 mm head
114 mm (4.49 in.) for B of 14 mm head
44. INSTALL RH CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of the
timing pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the ªRº mark forward.
(c) Using SST, install the pulley bolt. SST 09278±54012
Torque: 108 N Vm (1,100 kgf Vcm, 80 ft Vlbf)
±
1UZ±FE ENGINE ENGINE MECHANICALEG±135
WhereEverybodyKnowsYourName

45. INSTALL LH CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of the
timing pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the ªLº mark forward.
(c) Using SST, install the pulley bolt. SST 09278±54012
Torque: 108 N Vm (1,100 kgf Vcm, 80 ft Vlbf)
46. C O N N E C T T I M I N G B E LT TO C A M S H A F T T I M I N G
PULLEYS
(See steps 10 to 40 on pages EG±61 to 72)
47. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY
48. FILL WITH ENGINE COOLANT
49. START ENGINE AND CHECK FOR LEAKS
50. CHECK TRANSMISSION FLUID LEVEL
51. PERFORM ENGINE ADJUSTMENT (See Tune±Up on pages EG±9 to 34)
52. PERFORM ROAD TEST Check for abnormal noise, shock, slipage, correct shift points
and smooth operation.
53. INSTALL ENGINE UNDER COVER
EG±136
±
1UZ±FE ENGINE ENGINE MECHANICAL
WhereEverybodyKnowsYourName

ENGINE REMOVAL
EG24W±02
(See Components for Engine Removal and Installation)
1. REMOVE BATTERYCAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the ªLOCKº posi-
tion and the negative (±) terminal cable is disconnected
from the battery.
2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tension-
er counterclockwise, and remove the drive belt.
HINT: The pulley bolt for the drive belt tensioner has a left±
hand thread.
±
1UZ±FE ENGINE ENGINE MECHANICALEG±139
WhereEverybodyKnowsYourName

7. REMOVE THROTTLE BODY COVER
(a) Disconnect the EVAP hose from the hose clamp.
(b) Remove the cap nut.
(c) Loosen the 2 bolts, and remove the hose clamp and throttlebody cover.
8. DISCONNECT CONTROL CABLES TO THROTTLE BODY Disconnect the following cables:
(1) Accelerator cable
(2) Transmission throttle control cable
(3) Cruise control actuator cable
9. REMOVE AIR CLEANER
(a) Disconnect the VAF meter connector.
(b) Remove the hose clamp bolt holding the air cleaner hose to the intake air connector.
(c) Remove the 4 bolts.
(d) Disconnect the air cleaner hose from the intake air connector.
(e) Disconnect the air duct from the air cleaner case, and remove
the air cleaner.
10. D I S C O N N E C T VA CUUM HOSE (A) (FROM PS AIR
CONTROL VALVE) FROM AIR INTAKE CHAMBER
11. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the following hoses from the intake air connector:
(1) Air hose (from IAC valve)
(2) Air hose (from air control valve on PS pump)
(b) Remove the hose clamp bolt holding the intake air connector to the throttle body.
(c) Remove the bolt and intake air connector.
EG±140
±
1UZ±FE ENGINE ENGINE MECHANICAL
WhereEverybodyKnowsYourName

12. REMOVE RADIATOR RESERVOIR TANK
(a) Disconnect the coolant level sensor connector.
(b) Disconnect the following hoses:(1) Reservoir hose from water inlet housing
(2) Reservoir hose from radiator
(c) Remove the 2 bolts and reservoir tank bracket.
(d) Remove the bolt holding the reservoir tank to the radiator.
(e) Disconnect the reservoir tank from the reservoir tank bracket,
and remove the reservoir tank.
13. REMOVE RADIATOR ASSEMBLY
(a) Disconnect the ECT sensor connector (for cooling fan).
(b) Disconnect the ECT sensor wire clamp from the radiator fan shroud.
(c) Disconnect the following hoses: (1) 2 oil cooler hoses (for cooling fan) from pipes
(2) 2 radiator hoses
±
1UZ±FE ENGINE ENGINE MECHANICALEG±141
WhereEverybodyKnowsYourName

(3) 2 oil cooler hoses (for transmission) from radiator
HINT: Plug the hose ends.
(4) Suction hose from hydraulic pump
(5) Pressure hose from hydraulic pump
(d) Remove the 2 bolts, screw and upper radiator support. Remove the 2 upper radiator supports.
(e) Slightly lift the radiator, and disconnect the 2 oil cooler hoses (for cooling fan) from the hose clamp on the radiator fan
shroud.
(f) Remove the radiator assembly.
(g) Remove the 2 lower radiator supports from the radiator.
14. DISCONNECT IGNITER CONNECTORS
(a) Disconnect the 2 igniter connectors.
(b) Disconnect the wire clamp from the body.
EG±142
±
1UZ±FE ENGINE ENGINE MECHANICAL
WhereEverybodyKnowsYourName

15. DISCONNECT ENGINE WIRE CONNECTORS
16. DISCONNECT THEFT DETERRENT HORN CONNECTOR
17. DISCONNECT GROUND CABLE FROM BODY
18. DIS CO NNE CT PO WE R STE E RING (P S ) SO LE NO IDVALVE CONNECTOR
19. DISCONNECT WIRE CLAMP (FOR GENERATOR) FROM VSV (FOR EVAP)
(a) Remove the 2 bolts, and disconnect the VSV from the RH
cylinder head.
(b) Disconnect the wire clamp from the VSV bracket.
20. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the cap and nut, and disconnect the generator wire.
(c) Remove the bolt, and disconnect the transmission oil cooler pipe bracket from the generator.
(d) Remove the nut and generator.
21. DISCONNECT POWER STEERING (PS) TUBES FROM SUSPENSION CROSSMEMBER
Remove the clamp bolt, and disconnect the PS tubes.
±
1UZ±FE ENGINE ENGINE MECHANICALEG±143
WhereEverybodyKnowsYourName