LEXUS SC400 1991 Service Repair Manual

8. INSTALL VSV FOR EVAP SYSTEMInstall the VSV with the two bolts.
9. 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.
10. INSTALL RH ENGINE WIRE COVER (a) Fit portions A and B 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 bolt.
11. 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.
12. INSTALL UPPER HIGH±TENSION CORD COVER (a) Fit portion A of the upper high±tension cover, matching
it with the top of the lower high±tension cord cover.
FI±40
EFI SYSTEM
± Fuel System (Cold Start Injector)
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(b) Push the front side of the high±tension cord cover, andconnect 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.
13. 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 con- nector
14. CONNECT CONTROL CABLES TO THROTTLE BODY Connect the following cables:(1) Accelerator cable
(2) A/T throttle control cable
(3) (w/ Cruise Control System) Cruise control actuator cable
15. INSTALL THROTTLE BODY COVER Install the throttle body cover and hose clamp with the two
bolts and cap nut.
16. 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
17. FILL WITH ENGINE COOLANT (See page CO±7)
18. CHECK FOR FUEL LEAKS (See page FI±16) FI±41
EFI SYSTEM
± Fuel System (Cold Start Injector)
WhereEverybodyKnowsYourName

Injectors
ON±VEHICLE INSPECTION
1. INSPECT INJECTOR OPERATIONCheck operation sound from each injector.
(a) With the engine running or cranking, use a stethescopeto check that there is normal operating noise in
proportion to engine rpm.
(b) If you have no stethescope, you can check the injector transmission operation with your finger.
If no sound or an unusual sound is heard, check the wiring
connector, injector or injection signal from the ECU.
2. INSPECT INJECTOR RESISTANCE (a) Disconnect the injector connector.
(b) Using an ohmmeter, measure the resistance betweenthe terminals.
Resistance: 13.4±14.2
at 20 5C (68 5F)
If the resistance is not as specified, replace the injector.
(c) Reconnect the injector connector.
FI±26
±
EFI SYSTEM Fuel System (Injectors)
WhereEverybodyKnowsYourName

COMPONENTS FOR REMOVAL AND
INSTALLATION
±
EFI SYSTEM Fuel System (Injectors)FI±27
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REMOVAL OF INJECTORS
(See Components on page FI±27 )
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF
BATTERY
CAUTION: Turn the ignition switch to ºLOCKº.
Disconnect the cable from the negative (±) terminal of the
battery. Wait at least 20 seconds before proceeding with
work.
2. DRAIN ENGINE COOLANT
3. REMOVE THROTTLE BODY WITH INTAKE AIR CONNECTOR
(See steps 2 to 6 on pages EM±10 and 11)
4. DISCONNECT NO.1 FUEL PIPE FROM DELIVERY PIPE Remove the union bolt and two gaskets, and disconnect the
fuel pipe.
HINT:
wPut a suitable container or shop towel under the delivery
pipe.
w Slowly loosen the union bolt.
5. DISCONNECT NO. 2 FUEL PIPE FROM FUEL PRESSURE
REGULATOR
Remove the union bolt and two gaskets, and disconnect the
fuel pipe from the pressure regulator.
HINT:
w Put a suitable container or shop towel under the
pressure regulator.
w Slowly loosen the union bolt.
6. REMOVE AIR INTAKE CHAMBER STAYS Remove the bolt, nut and intake chamber stay.
Remove the No. 1 and No. 2 stays.
FI±28
±
EFI SYSTEM Fuel System (Injectors)
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7. DISCONNECT VACUUM SENSING HOSE FROMPRESSURE REGULATOR
8. DISCONNECT INJECTOR CONNECTORS
9. DISCONNECT CONTROL VALVE ACTUATOR
Remove the two bolts and turn the actuator sideways.
HINT: Wrap the actuator with adhesive tape and attach it to
the intake chamber.
NOTICE: Do not apply any force on the actuator rod and
prevent the rod clip from detaching.
10. REMOVE DELIVERY PIPE AND INJECTORS (a) Remove the three bolts and delivery pipe together with
the six injectors.
NOTICE: Be careful not to drop the injectors when re-
moving the delivery pipe.
(b) Pull out the six injectors from the delivery pipe.
(c) Remove the O±ring and grommet from each injector.
(d) Remove the six insulators and three spacers from the cylinder head.
±
EFI SYSTEM Fuel System (Injectors)FI±29
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INSPECTION OF INJECTORS
1. INSPECT INJECTOR INJECTIONCAUTION: Keep injector clear of sparks during the test.
(a) Remove the two bolts and fuel hose clamp.
(b) Disconnect the fuel inlet hose from the fuel tube.
(c) Connect SST (hose) to the fuel inlet tube with SST(union). Tighten the flare nut on the fuel tube.
SST 09268±41045 (90405±52010)
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Use SST. (See page FI±14)
SST 09631±22020
(d) Install a new O±ring to the fuel inlet of the pressure regulator.
(e) Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the two bolts.
SST 09268±41045 (09268±41090)
(f) Connect the fuel return hose to the fuel outlet of the pressure regulator with SST (union), two new gaskets
and union bolt.
SST 09268±41045 (90405±09015)
FI±30
±
EFI SYSTEM Fuel System (Injectors)
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(g) Install the grommet and a new O±ring to the injector.
(h) Connect SST (hose) to the injector with SST (union),and hold the injector and union with SST (clamp).
SST 09268±41045
(i) Put the injector into the graduated cylinder.
HINT: Install a suitable vinyl hose onto the injector to prevent
gasoline from splashing out.
(j) Using SST, connect terminals +B and FP of the check (ºDIAGNOSISº) connector.
SST 09843±18020
(k) Reconnect the cable to negative (±) terminal of battery.
(l) Turn the ignition switch ON.
NOTICE: Do not start the engine.
(m) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a
graduated cylinder. Test each injector two or three
times.
SST 09842±30070
Volume: 70±88 cm3 (4.3±5.4 cu in.) per 15 sec.
Difference between each injector:
9 cm
3 (0.5 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE (a) In the condition above, disconnect the test probes ofSST (wire) from the battery and check the fuel leakage
from the injector.
SST 09842±30070
Fuel drop: One drop or less per minute
(b) Disconnect the battery negative (±) cable.
(c) Remove SST.
SST 09268±41045 and 09843±18020
(d) Reconnect the fuel inlet hose to the fuel tube.
SST 09631±22020
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
±
EFI SYSTEM Fuel System (Injectors)FI±31
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(e) Install the fuel hose clamp with the two bolts.
INSTALLATION OF INJECTORS
(See Components on page FI±27)
1. INSTALL INJECTORS AND DELIVERY PIPE (a) Install the grommet to each injector.
(b) Apply a light coat of gasoline to a new O±ring and install
it to each injector.
(c) W h i l e t u r n i n g t h e i n j e c t o r c l o c k w i s e a n d counterclockwise, push it to the delivery pipe. Install the
six injectors.
(d) Position the injector connector outward.
(e) Place the six insulators and three spacers in position on
the intake manifold.
(f) Place the six injectors together with the delivery pipe in position on the cylinder head.
FI±32
±
EFI SYSTEM Fuel System (Injectors)
WhereEverybodyKnowsYourName

(g) Temporarily install the three bolts holding the deliverypipe to the cylinder head.
(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 three bolts holding the delivery pipes to the intake manifold.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
2. INSTALL CONTROL VALVE ACTUATOR
(a) Install the actuator with the two bolts.
Torque: 6.8 N Vm (70 kgf Vcm, 61 in. Vlbf)
(b) Inspect the IACV. (See page FI±59)
3. CONNECT INJECTOR CONNECTORS HINT: The No. 1, No. 3 and No. 5 injector connectors are gray,
and the No. 2, No. 4 and No. 6 injector connectors are dark
gray.
4. CONNECT VACUUM SENSING HOSE
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EFI SYSTEM Fuel System (Injectors)FI±33
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