engine coolant LEXUS SC400 1991 Service Repair Manual

INSPECTION OF EGR SYSTEM
(Exc. USA Spec.)
1. CHECK AND CLEAN FILTERS IN EGR VACUUMMODULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filters.
(d) Reinstall the filter and cap.
HINT: Install the filter with the coarser surface facing the at-
mospheric side (outward).
2. INSPECT SYSTEM OPERATION (a) Using SST, connect terminals TE1 and E1 of the check
(ºDIAGNOSISº) connector.
SST 09843±18020
(b) Keep the engine at 3,500 rpm.
(c) Set the transmission shift lever to the ºNº position.
(d) Remove the SST from the check connector.
SST 09843±18020
(e) Check whether the engine rpm increases 100±300 rpm under the following conditions:
Coolant temp.
Below 53 5C (127 5F) No increase
Above 55 5C (131 5F) Increases
EC±18
±
EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) System
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INSPECTION OF EGR VALVE
(USA Spec.)
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OFBATTERY
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. DISCONNECT EGR VALVE CONNECTOR
3. INSPECT EGR VALVE RESISTANCE Using an ohmmeter, measure the resistance between termi-
nal B1 (or B2) and other terminals (S1, S2, S3 and S4).
Resistance (Cold): 19.9±23.4

4. DRAIN ENGINE COOLANT (See page CO±6)
5. REMOVE EGR VALVE (a) Disconnect the following hoses:(1) Water by±pass hose (from ISC valve) from the EGR
valve
(2) Water by±pass hose (from rear water by±pass joint) from the EGR valve
(b) Remove the two nuts, EGR valve and gasket.
6. INSPECT EGR VALVE
A. Visually inspect EGR valve Check for sticking and heavy carbon deposits.
If a problem is found, replace the EGR valve assembly.
EC±22
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EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) System
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(b) Install the EGR valve with the two nuts.
Torque: 18 NVm (185 kgf Vcm, 13 ft Vlbf)
(c) Connect the following hoses:
(1) Water by±pass hose (from ISC valve) to the EGR valve
(2) Water by±pass hose (from rear water by±pass joint) to the EGR valve
8. RECONNECT EGR VALVE CONNECTOR
9. RECONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
10. REFILL WITH ENGINE COOLANT (See page CO±7)
INSPECTION OF EGR VALVE
(Exc. USA Spec.)
1. DRAIN ENGINE COOLANT (See page CO±6)
2. REMOVE EGR VALVE (a) Disconnect the following hoses:(1) Vacuum hose (from VSV) from EGR valve
(2) Vacuum hose (from VSV) from EGR vacuum
modulator
(3) Vacuum hose (from EGR vacuum modulator) f rom EGR valve
(4) Water by±pass hose (from ISC valve) from the
EGR valve
(5) Water by±pass hose (from rear water by±pass joint) from the EGR valve
(b) Disconnect the vacuum modulator bracket from the
EGR valve.
(c) Remove the two nuts, EGR valve and gasket.
EC±24
±
EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) System
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3. INSPECT EGR VALVECheck for sticking and heavy carbon deposits.
If a problem is found, replace the EGR valve assembly.
4. REINSTALL EGR VALVE (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 with the two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(c) Install the vacuum modulator bracket to the EGR valve.
(d) Connect the following hoses:
(1) Vacuum hose (from VSV) to EGR valve
(2) Vacuum hose (from VSV) to EGR vacuum modula- tor
(3) Vacuum hose (from EGR vacuum modulator) to EGR valve
(4) Water by±pass hose (from ISC valve) to the EGR
valve
(5) Water by±pass hose (from rear water by±pass joint) to the EGR valve
5. REFILL WITH ENGINE COOLANT (See page CO±7)
±
EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) SystemEC±25
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The 1 UZ±FE engine has 8±cylinders in a V±arrangement at a bank an\
gle of 905. From the front of the RH
bank cylinders are numbered 2±4±6±8, and from the front of the LH b\
ank cylinders are numbered 1 ±3±5±7.
The crankshaft is supported by 5 bearings specified by the inside of the cr\
ankcase. These bearings are made
of a copper and lead alloy. The crankshaft is integrated with 8 weights which are cast along with it\
for balancing. Oil holes are built
into the center of the crankshaft for supplying oil to the connecting ro\
ds, pistons and other components. The ignition order is 1±8±4±3±6±5±7±2. The cylinder\
head is made of aluminum alloy, with a cross flow
type intake and exhaust layout and with pent±roof type combustion chambers. The spark plugs are loca\
ted in
the center of the combustion chambers.
At the front and rear of the intake manifold, a water passage has been p\
rovided which connects the RH
and LH cylinder heads. Exhaust and intake valves are equipped with irregular pitch springs made\
of special valve spring carbon
steel which are capable of following no matter what the engine speed.
The RH and LH intake camshafts are driven by a single timing belt, and a ge\
ar on the intake camshaft en-
gages with a gear on the exhaust camshaft to drive it. The camshaft jour\
nal is supported at 5 (intake) or 4 (ex-
haust) places between the valve lifters of each cylinder and on the front end of the cylinder \
head. Lubrication
of the cam journal gear is accomplished by oil being supplied through the \
oiler port in the center of the camshaft. Adjustment of the valve clearance is done by means of an outer shim type\
system, in which valve adjusting
shims are located above the valve lifters. This permits replacement of the sh\
ims without removal of the cam-
shafts. Pistons are made of high temperature±resistant aluminum alloy, and a depression is built into the piston
head to prevent interference with valves.
Piston pins are the full±floating type, with the pins fastened to neither the piston boss nor the connecting
rods. Instead, snap rings are fitted on both ends of the pins, preventing the\
pins from falling out. The No.1 compression ring is made of steel and the No.2 compression ring\
is made of cast iron. The oil
ring is m ade of a combination of steel and stainless steel. The outer diameter of\
each piston ring is slightly larger
than the diameter of the piston and the flexibility of the rings allows them\
to hug the cylinder walls when they
are mounted on the piston. Compression rings No.1 and No.2 work to prevent \
the leakage of gas from the cylin-
der and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combustion chamber. The cylinder block is made of aluminum alloy with a bank angle of 90 5. Cast iron cylinders are installed
inside the cylinder block. It has 8 cylinders which are approximately twice the length of th\
e piston stroke. The
top of each cylinder is closed off by the cylinder heads and the lower end of the cylinders becomes the crank-
case, in which the crankshaft is installed. In addition, the cylinder bl\
ock contains a water jacket, through which
coolant is pumped to cool the cylinders. The No.1 and No.2 oil pans are bolted onto the bottom of the cylinder block\
. The No.1 oil pan is made of
aluminum alloy. The No.2 oil pan is an oil reservoir made of pressed steel sheet. An o\
il level sensor is installed
in the No.1 oil pan (If the oil level drops below a set level, a warnin\
g light lights up.). A oil pan baffle plate keeps
sufficient oil in the bottom of the No.2 oil pan even when the vehicle is tilted. \
This dividing plate also prevents
the oil from making waves when the vehicle is stopped suddenly and the oil \
shifts away from the oil pump suction
pipe. Plastic region tightening bolts are used for the cylinder head, main bearing ca\
p and connecting rod.
EM±4
±
ENGINE MECHANICAL Operation
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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.
ST±6
±
STARTING SYSTEM Starter
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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
ST±34
±
STARTING SYSTEM Starter
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Cold Start Injector Circuit
CIRCUIT DESCRIPTION
The cold start injector is used to maintain the engine startability when it\
is cold. The injection volume, i,e, the
length of time the injector is energized, is controlled by the ECU and t\
he cold start injector time switch.
During a cold start, when the starter turns the contacts in the cold start inj\
ector time switch close. Thus current
flows to the cold start injector coil, injecting fuel. At the same time, a bi\
metal in the heat coil is energized and
heats up. This soon causes the contacts to open, cutting off the current flow to the injector coil and stopping
fuel injection.
The injection duration of the cold start injector is determined by the cool\
ant temperature and the length of time
current flows to the heat coil. When the engine is warm, the contacts are opened by the bimetal and the cold
start injector does not operate.
When the engine is hard to start and the starter is operated continuously, heat coil (2) heats up the bimetal keep-
ing the contacts open to prevent spark plugs from becoming fouled, which is\
caused by the cold start injector
operation when the open contacts close again.
When the engine is started at a coolant temperature of 225C (72 5F) or lower, the cold start injector operation
time is controlled by the cold start injector time switch.
When the coolant temperature is in the normal temperature range 22 5C (72 5F) or higher, the contacts of the cold
start injector time switch are open and the time switch is off, instead, the ECU controls the operating time of the
cold start injector.
In this way, the CO and HC levels can be reduced while the engine is being started \
and the engine startability
is maintained. Control by the ECU ends when the coolant temperature reac\
hes 60 5C (140 5F).
TR±136±
ENGINE TROUBLESHOOTING Circuit Inspection
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Fuel Pressure Control VSV Circuit
CIRCUIT DESCRIPTION
The ECU turns on a VSV (Vacuum Switching Valve)
to draw the air into the diaphragm chamber of the
pressure regulator if it detects that the temperature of
the coolant is too high during engine starting.
The air drawn into the chamber increases the fuel
pressure to prevent fuel vapor lock at high engine
temperature in order to help the engine start when it
is warm.
Fuel pressure control ends approx. 100 secs. after
the engine is started.
DIAGNOSTIC CHARTDIAGNOSTIC CHART
Check operation for fuel pressure control
VSV.Replace fuel pressure control VSV.
Repair or replace harness or
connector.
Proceed to next circuit inspection
shown on matrix chart (See page
TR±35).
Check for open and short in harness and
connector between main relay and ECU.
Check voltage of VSV power source.
Check and replace ECU.
WIRING DIAGRAM
TR±142±
ENGINE TROUBLESHOOTING Circuit Inspection
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Diag. Code 21, 28Main Oxygen Sensor Circuit
CIRCUIT DESCRIPTION
To obtain a high purification rate for the CO, HC and NOx components of th\
e exhaust gas, a three±way catalyst
is used, but for most efficient use of the three±way catalyst, the air±fuel ratio must be \
precisely controlled so
that it is always close to the stoichiometric air±fuel ratio.
The oxygen sensor has the characteristic whereby its output voltage changes\
suddenly in the vicinity of the stoi-
chiometric air±fuel ratio. This characteristic is used to detect the oxygen con\
centration in the exhaust gas and
provide feedback to the computer for control of the air±fuel ratio.
When the air±fuel ratio becomes LEAN, the oxygen concentration in the exh\
aust increases and the oxygen sen-
sor informs the ECU of the LEAN condition (small electromotive force: 0 V)\
.
When the air±fuel ratio is RICHER than the stoichiometric air±fuel rat\
io the oxygen concentration in the exhaust
gas is reduced and the oxygen sensor informs the ECU of the RICH condition \
(large electromotive force: 1V).
The ECU judges by the electromotive force from the oxygen sensor whether th\
e air±fuel ratio is RICH or LEAN
and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of ab-
normal electromotive force, the ECU is unable to perform accurate air±fuel \
ratio control.
DTC No.DTC Detecting ConditionTrouble Area
21.
28
(1) Main oxygen sensor signal voltage is reduced to tbetween 0.35 V and 0.70 V for 60 sec. under
conditions (a)
(d). (2 trip detection logic)*
(a) Coolant temp.: Between 805C (176 5F) and
95 5C (203 5F).
(b) Engine speed: 1,500 rpm or more
(c) Load driving (EX. ECT in 4th (5th for M/T) speed, A/C ON, Flat road, 50 mph
(80km/h)).
(d) Main oxygen sensor signal voltage: Alternating above and below 0.45 V.

Main oxygen sensor circuit

Main oxygen sensor
(2) Main oxygen sensor signal voltage exceeds
0.70 V for 3 sec. or more during fuel cut.
*: See page TR±25..
HINT: Diag. trouble code 21 is for the front side main oxygen sensor circuit.\
Diag. trouble code 28 is for the rear side main oxygen sensor circuit.
TR±60
±
ENGINE TROUBLESHOOTING Circuit Inspection
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