check engine LEXUS SC400 1991 Service Repair Manual

(b) Turn the camshaft, and align the timing marks of thecamshaft timing pulleys and No. 4 timing belt cover.
SST 09278±54012
9. INSTALL TIMING BELT HINT (When re±using timing belt): Align the matchmarks of
the timing belt and camshaft timing pulleys.
(a) Remove any oil or water on the camshaft timing pulley,and keep it clean.
(b) Install the timing belt, checking the tension between the
crankshaft timing pulley and exhaust camshaft timing
pulley.
10. SET TIMING BELT TENSIONER (a) Using a press, slowly press in the push rod using981±9,807N (100±1,000 kgf, 220±2,205 lbf) of
pressure.
(b) Align the holes of the push rod and housing, pass a 1.50
mm hexagon wrench through the holes to keep the push
rod retracted.
(c) Release the press.
(d) Install the dust boot onto the tensioner.
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ENGINE MECHANICAL Timing BeltEM±31
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11. INSTALL TIMING BELT TENSIONER(a) Temporarily install the tensioner with the two bolts.
(b) Alternately tighten the two bolts.
Torque: 26 N Vm (270 kgf Vcm, 20 ft Vlbf)
(c) R e m o v e t h e 1 . 5 0 m m h e x agon wrench from the
tensioner with pliers.
12. CHECK VALVE TIMING (a) Turn the crankshaft pulley two revolutions from TDC toTDC.
NOTICE: Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as shown in the figure.
If the marks do not align, remove the timing belt and reinstall
it.
13. INSTALL DRIVE BELT TENSIONER Install the tensioner with the three bolts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
NOTICE: Be careful not to drop the bolts inside the timing
belt cover.
EM±32
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ENGINE MECHANICAL REPAIR INSTRUCTIONS
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14. INSTALL NO. 2 AND NO. 3 TIMING BELT COVERS(a) Install the gasket on the timing belt cover.
(b) Using a 5 mm hexagon wrench, install the belt coverswith the nine bolts.
(c) Install the oil filler cap.
15. INSTALL RADIATOR AND WATER PUMP PULLEY (See steps 15, 16, 19 and 24 on pages EM±110 to 112)
16. FILL ENGINE WITH COOLANT (See page CO±5)
Capacity (w/ Heater):
M/T 8.5 liters (9.0 US qts, 7.5 Imp. qts)
A/T 8.4 liters (8.9 US qts, 7.4 Imp. qts)
17. (A/T)CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
(See page MA±11)
NOTICE: Do not overfill.
18. START ENGINE AND CHECK FOR LEAKS
19. CHECK IGNITION TIMING (See page IG±14)
Ignition timing:
105 BTDC @ idle
(w/ Terminals TE1 and E1 connected)
20. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
21. RECHECK ENGINE COOLANT LEVEL
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IDLE AND/OR 2,500 RPM HC/CO
CONCENTRATION CHECK METHOD
HINT: This check is used only to determine whether or not the
idle HC/CO complies with regulations.
1. INTIAL CONDITIONS (a) Engine at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT: All vacuum hoses for EGR systems, etc. should be
properly connected.
(f) EFI system wiring connectors fully plugged.
(g) Transmission in neutral range.
(h) Tachometer and HC/CO meter calibrated at hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 PRM FOR APPROX. 120 SECONDS
4. INSERT HC/CO METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm (1.3 ft)
5. CHECK HC/CO CONCENTRATION AT IDLE AND/OR 2,500 PRM
Complete the measuring within three times.
HINT: When performing the 2 mode (2,500 rpm and idle) test,
follow the measurement order prescribed by the regulations.
If the HC/CO concentration at 2,500 rpm does not comply
with regulations, try the following procedure.
Race the engine again at 2,500 rpm for approx. 1 minute and
quickly repeat steps 4 and 5 above.
This may correct the problem.
EM±28
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ENGINE MECHANICAL Idle and/or 2,500 rpm HC/CO
Concentration Check Method
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Troubleshooting
If the HC/CO concentration does not comply with regulations,
perform troubleshooting in the order given below.
(a) Check oxygen sensor operation.(See page FI±113)
(b) See the table below for possible cause, and then inspect
and correct the applicable causes if necessary.
 

HC 

CO 

Symptoms\
 

\
Cause
 High Normal Rough idle\
 \
1. Faulty ignitions:
   \
 \

Incorrect timing
   \
 \

Fouled, shorted or improperly gapped plugs
   \
 \

Open or crossed high±tension cords
Ckddiib\

Cracked distributor cap
Ill   \
 \
2. Incorrect valve clearance
3 L k EGR l   \
 \
3. Leaky EGR valve
4L k i k d h l   \
 \
4. Leaky intake and exhaust valves
L k li d   \
 \
5. Leaky cylinders
 High Low Rough idle\
 \
1. Vacuum leaks:
   (Fluctuating HC reading)\
 \

PCV hoses
   \
 \

EGR valve
   \
 \

Intake manifold
Ai i k h b   \
 \

Air intake chamber
Th l b d   \
 \

Throttle body
ISC l\

ISC valve
Bkb li   \
 \

Brake booster line
2L i i ifi   \
 \
2. Lean mixture causing misfire
 High High Rough idle\
 \
1. Clogged air filter g g g
(Black smoke from exhaust)\
 \
gg
2. Faulty EFI systems:   ()\
 \
yy

Faulty pressure regulator
   \
 \

yg

Clogged fuel return line
   \
 \

gg

Defective water temp. sensor
   \
 \

Defective air temp. sensor
   \
 \

Faulty ECU
   \
 \

y

Faulty injectors
\

yj

Faulty cold start injector   \
 \
yj

Faulty throttle position sensor   \
 \

Faulty air flow meter
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ENGINE MECHANICAL Idle and/or 2,500 rpm HC/CO
Concentration Check MethodEM±29
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COMPRESSION CHECK
HINT: If there is lack of power, excessive oil consumption or
poor fuel economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating tempera-
ture.
2. REMOVE NO.3 TIMING BELT COVERS (See steps 1, 5 to 10 and 14 on pages EM±11 to 13)
3. DISCONNECT COLD START INJECTOR CONNECTOR
4. DISCONNECT RH CAM POSITION SENSOR CONNECTOR
(a) Disconnect the connector from the ignition coil bracket.
(b) Disconnect the sensor connector.
5. DISCONNECT LH CAM POSITION SENSOR CONNECTOR
6. REMOVE SPARK PLUGS (a) Disconnect the eight high±tension cords from the sparkplugs.
Disconnect the high±tension cords at rubber boot. Do
not pull on the cords.
NOTICE: Pulling on or bending the cords may damage
the conductor inside.
EM±30
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ENGINE MECHANICAL Compression Check
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(b) Using a 16 mm spark plug wrench, remove the eightspark plugs.
7. CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a compression tester into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compressionpressure.
HINT: Always use a fully charged battery to obtain engine rev-
olution of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE: This measurement must be done in as short
time as possible.
Compression pressure:
1,226 kPa (12.5 kgf/cm, 178 psi) or more
Minimum pressure: 981 kPa (10.0 kgf/cm, 142 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm, 14 psi) or less
(e) If the cylinder compression in one or more cylinders islow, pour a small amount of engine oil into the cylinder
through the spark plug hole and repeat steps (a) through
(c) for the cylinder with low compression.
w If adding oil helps the compression the piston rings
and/or cylinder bore are probably worn or
damaged.
w If pressure stays low, a valve may be sticking or
seating improper, or there may be leakage past the
gasket.
8. REINSTALL SPARK PLUGS (a) Using a 16 mm plug wrench, install the eight sparkplugs.
Torque: 18 N Vm (180 kgf Vcm, 13 ft Vlbf)
(b) C onnect the eight high±tension cords to the spark
plugs.
(c) Fit the high±tension cords to the cord clamps.
(See page IG±16)
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ENGINE MECHANICAL Compression CheckEM±31
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9. RECONNECT RH CAM POSITION SENSOR CONNECTOR
(a) Connect the sensor connector.
(b) Connect the connector to the ignition coil bracket.
10. RECONNECT LH CAM POSITION SENSOR CONNECTOR
11. RECONNECT COLD START INJECTOR CONNECTOR
12. REINSTALL NO.3 TIMING BELT COVERS (See steps 28 to 30, 34 to 37, 40 and 41 on pages EM±25
to 27)
EM±32
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ENGINE MECHANICAL Compression Check
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22. REMOVE ALTERNATOR(a) Disconnect the alternator connector.
(b) Remove the cap and nut, and disconnect the alternatorwire.
(c) Remove the bolt, and disconnect the A/T oil cooler pipe bracket.
(d) Remove the nut and alternator.
23. REMOVE DRIVE BELT TENSIONER Remove the bolt, two nuts and tensioner.
24. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the eight spark plugs.
25. IF RE±USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT
Check that there are four installation marks on the timing belt
by turning the crankshaft pulley as shown in the illustration.
If the installation marks have disappeared, place a new
installation mark on the timing belt before removing each
part.
26. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with thetiming mark ºOº of the No.1 timing belt cover.
EM±40
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ENGINE MECHANICAL Timing Belt
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(b) Check that the timing marks of the camshaft timingpulleys and timing belt rear plates aligned.
If not, turn the crankshaft one revolution (360 5).
27. REMOVE TIMING BELT TENSIONER HINT:
w(Re±using timing belt)
If the installation marks have disappeared, before re-
moving the timing belt, place new installation marks on
the timing belt to match the timing marks of the camshaft
timing pulleys, and place a new installation mark on the
timing belt to match the end of the hydraulic pump.
w (When replacing timing belt tensioner only)
To avoid meshing of the timing pulley and timing belt, se-
cure one of them with string. And place matchmarks on
the timing belt and RH camshaft timing pulley.
Alternately loosen the two bolts, and remove them, the ten-
sioner and dust boot.
28. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS
(a) Using SST, loosen the tension between the LH and RHcamshaft timing pulleys by slightly turning the LH
camshaft timing pulley clockwise.
SST 09278±54012
±
ENGINE MECHANICAL Timing BeltEM±41
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