LEXUS SC400 1991 Service Repair Manual

(e) Place 8 new insulators and the 4 spacers in position on theintake manifold.
(f) Place the 8 injectors and 2 delivery pipes assembly in position on the intake manifold.
(g) Temporarily install the connector bracket and 4 nuts.
(h) Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable cause
is incorrect installation of O±rings. Replace the O±rings.
(i) Position the injector connector upward.
(j) Tighten the 4 nuts holding the delivery pipes to the intake manifold.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
21. INSTALL FUEL RETURN PIPE
(a) Temporarily install the fuel return pipe with the bolt, 2 new
gaskets and union bolt.
(b) Tighten the union bolt holding the return pipe to the fuel pressure regulator.
Torque: 35 N Vm (360 kgf Vcm, 26 ft Vlbf)
(c) Tighten the bolt holding the return pipe to the LH cylinder
head.
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22. INSTALL ENGINE WIRE TO DELIVERY PIPES, REARWATER BYPASS JOINT AND RH CYLINDER HEAD
(a) Connect the 8 injector connector.
(b) Install the 2 engine wire connectors to the connector on the
LH delivery pipe.
(c) Install the engine wire protector to the RH cylinder head with the 2 bolts.
(d) Install the engine wire protector to the rear water bypass joint
with the 2 bolts.
(e) Install the engine wire protector to the delivery pipes with the 4 bolts.
23. INSTALL ENGINE WIRE TO INTAKE MANIFOLD Install the engine wire protector with the 2 bolts.
24. TEMPORARILY INSTALL EGR PIPE TO RH CYLINDER HEAD
Temporarily install the EGR pipe with the bolt.
HINT: Use bolt 25 mm (0.98 in.) in length.
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25. CONNECT FUEL RETURN HOSE TO FUEL RETURN PIPE
26. CONNECT FUEL INLET HOSE TO LH DELIVERY PIPE
(a) Temporarily connect the fuel inlet hose to the delivery pipe with 2 new gaskets and pulsation damper.
(b) Install the bolt holding the fuel inlet hose to the delivery pipe.
(c) Using SST tighten the pulsation damper. SST 09631±22020
Torque:
39 NVm (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.).
27. INSTALL HEATER WATER HOSES Connect the following noses:
(1) Water hose to water bypass pipe
(2) Water hose to rear water bypass joint
28. INSTALL AIR INTAKE CHAMBER
(a) Install the cold start injector, tube and lead wire assembly with
the 3 bolts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
(b) Place 4 new gaskets on the intake manifold.
HINT: Gaskets can only be used twice before being replaced.
(c) Place the air intake chamber on the intake manifold.
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(d) Install a new gasket to the EGR pipe.
(e) Temporarily connect the EGR pipe to the air intake chamberwith the 2 bolts.
HINT: Use bolt 20 mm (0.79 in.) in length.
(f) Temporarily install the air intake and and following parts with the 4 bolts and 8 nuts:
(1) VSV for fuel pressure control
(2) Except California:VSV for EGR
(3) Transmission throttle cable bracket
(4) DLC1
(g) Uniformly tighten the bolts and nuts several passes.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolt 40 mm (1.57 in.) in length.
(h) Tighten the 2 bolts holding the EGR pipe to the air intake chamber.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(i) Tighten the bolt holding the EGR pipe to the RH cylinder
head.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(j) Connect the cold start injector tube to the RH delivery pipe
with 2 new gaskets and the union bolt.
Torque: 15 N Vm (150 kgf Vcm, 11 ft Vlbf)
(k) Connect the following connectors:
wCold start injector connector
w VSV connector for fuel pressure control
w Except California:
VSV connector for EGR
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(l) Install the accelerator bracket with the bolt and stud bolt.
(m) Install 2 new gaskets and union with the union bolt.
Torque: 29 NVm (300 kgf Vcm, 22 ft Vlbf)
(n) Connect the following hoses:
(1) Brake booster vacuum hose to union on air intake cham-
ber
(2) Vacuum hose (from VSV for heater water valve to air in-
take chamber
29. INSTALL THROTTLE BODY
(a) Disconnect the following hoses: (1) PCV hose to throttle body
(2) Water bypass hose to throttle body
(b) Install a new gasket and throttle body with the 2 bolts and 2 nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolt 40 mm (1.57 in.) in length.
(c) Install the water bypass pipe (from the rear bypass joint) to the clamp on the engine wire cover.
(d) Connect the following connectors: (1) Throttle position sensor connector
(2) w/ TRAC: Sub±throttle position sensor connector
(3) w/ TRAC: Sub±throttle actuator connector
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30. INSTALL HEATER WATER VALVE
(a) Install the water valve and bracket assembly with the 2 bolts.
(b) Install the engine wire with the bolt.
(c) Connect the VSV connector.
31. INSTALL IAC VALVE
(a) Install a new gasket and IAC valve with the 2 nuts.
Torque: 18 NVm (185 kgf Vcm, 13 ft Vlbf)
(b) Connect the water bypass hose (from the throttle body) to the
IAC valve.
(c) Connect the IAC valve connector.
32. INSTALL EGR VALVE ADAPTOR
(a) Install a new gasket, the EGR valve adaptor and EGR gas temperature sensor connector bracket with the 2 bolts and 2
nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolt 20 mm (0.78 in.) in length.
NOTICE: Do not touch the air intake chamber and adaptor sur-
faces of the gasket with your hand.
(b) Connect the PCV hose to the cylinder head.
(c) Connect the EGR gas temperature sensor connector.
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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)
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(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
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36. INSTALL TIMING BELT REAR PLATESInstall the rear plate with the 2 bolts. Install the 2 rear plates.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
37. INSTALL WATER INLET AND INLET HOUSING
(a) Remove any old packing (FIPG) material and be careful not
to drop any oil on the contact surfaces of the water inlet
housing and water pump.
wUsing a razor blade and gasket scraper, remove all the
old packing (FIPG) material from the gasket surfaces
and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the sealing groove of water inlet
housing as shown in the illustration.
Seal packing:
Part No. 08826±00100 or equivalent
wInstall a nozzle that has been cut to a 2±3 mm (0.08±0
12 in.) opening.
w Parts must be assembled within 5 minutes of
application. Otherwise the material must be removed
and reapplied.
w Immediately remove nozzle from the tube and reinstall
cap.
(c) Install a new O±ring to the water inlet housing.
(d) Apply soapy water on the O±ring.
(e) Push the water inlet housing end into the water pump hole.
(f) Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 25 mm (0.98 in.) in length.
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(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
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