LEXUS SC400 1991 Service Repair Manual

38. (USA Spec.)INSTALL EGR VALVE
(a) Place a new gasket on the EGR valve adaptor.
NOTICE:
w Do not touch the adapter 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) Connect the following hoses:
(1) Water by±pass pipe hose to ISC valve
(2) Water by±pass pipe hose to water by±pass pipe (from rear water by±pass joint)
(d) Connect the EGR valve connector.
39. (Exc. USA Spec.) INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Place a new gasket on the EGR valve adaptor.
NOTICE:
w Do not touch the adapter 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 and m odulator
assembly with the two nuts and bolt.
Torque (Nut): 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
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(c) Connect the following hoses:(1) Water by±pass pipe hose to ISC valve
(2) Water by±pass pipe hose to water by±pass pipe (from rear water by±pass joint)
(3) Two vacuum hoses to VSV for EGR system
40. INSTALL VACUUM PIPE (a) Install the vacuum pipe, vacuum hoses assembly andEGR water by±pass pipe (USA spec. only) with the two
bolts.
(b) Connect the following hoses: (1) (USA Spec.) Vacuum hose to throttle body
(2) (Exc. USA Spec.) Three vacuum hoses to throttle body
(3) Vacuum hose to fuel pressure regulator
(4) Two vacuum hoses to VSV for fuel pressure control system
(5) (Exc. USA Spec.) Two vacuum hoses to EGR vacuum modulator
(6) Two vacuum hoses (from VSV for EVAP system) to vacuum pipe
(7) Vacuum hose (from VSV for fuel pressure control system) to air intake chamber
(8) Vacuum hose (from charcoal canister) to vacuum pipe
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41. INSTALL TIMING BELT REAR PLATESInstall the rear plate with the two bolts. Install the two rear
plates.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
42. INSTALL WATER INLET AND INLET HOUSING
(a) Remove any old packing (FIPG) material.w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) materials from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose materials.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the sealing groove of the water inlet housing as shown in the illustration.
Seal packing: Part No.08826±00100 or equivalent
w Install 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 to 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 two
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.
(g) Connect the water by±pass hose to the ISC valve.
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43. INSTALL RH IGNITION COILInstall the ignition coil with the two bolts.
44. CONNECT CONTROL CABLES TO THROTTLE BODY Connect the following cables:(1) Accelerator cable
(2) A/T throttle cable
(3) (w/ Cruise Control System)
Cruise control actuator cable
45. INSTALL THROTTLE BODY COVER Install the throttle body cover and hose clamp with the two
bolts and cap nut.
46. INSTALL CATALYTIC CONVERTERS (MAIN) (a) Install a new gasket and the catalytic converter to theexhaust manifold with the three new bolts. Install the two
catalytic converters.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
(b) Install a new gasket to each front end of the front
exhaust pipe.
(c) C onnect the front exhaust pipe to the catalytic
converters.
(d) Te mp o ra rily in sta ll th e fo u r bo lts ho ld in g th e pip e support bracket to the transmission.
(e) Install the four bolts and nuts holding the catalytic
converters to the front exhaust pipe.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(f) Tighten the four bolts holding the pipe support bracket
to the transmission.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
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47. INSTALL PS PUMP(a) In sta ll th e PS pu mp with th e th re e bo lts an d nu t.Alternately tighten the bolts and nut.
Torque:
Bolt 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
Nut 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(b) Connect the vacuum hose to the vacuum pipe.
48. INSTALL HYDRAULIC PUMP AND CAMSHAFT TIMING PULLEYS
(See steps 8, 10 and 11 on pages EM±48 to 49)
49. INSTALL HYDRAULIC PUMP AND CAMSHAFT TIMING PULLEYS
(See steps 12 to 43 on pages EM±49 to 57)
50. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
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CYLINDER BLOCK
COMPONENTS FOR REMOVAL AND
INSTALLATION OF ENGINE WITH
TRANSMISSION
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COMPONENTS FOR REMOVAL AND
INSTALLATION OF ENGINE WITH
TRANSMISSION (Cont'd)
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COMPONENTS FOR REMOVAL AND
INSTALLATION OF ENGINE WITH
TRANSMISSION (Cont'd)
REMOVAL OF ENGINE WITH
TRANSMISSION
1. REMOVE BATTERYCAUTION: 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. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT (See page CO±6)
4. DRAIN ENGINE OIL
5. REMOVE HOOD
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 belt tensioner has a left±hand
thread.
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7. REMOVE THROTTLE BODY COVER(a) Remove the mounting cap nut.
(b) Loosen the two bolts, and remove the throttle bodycover.
8. DISCONNECT CONTROL CABLES FROM THROTTLE BODY
Disconnect the following cables:(1) Accelerator cable
(2) A/T throttle cable
(3) (w/ Cruise Control System) Cruise control actuator cable
9. REMOVE AIR CLEANER AND AIR FLOW METER (a) Disconnect the air flow meter connector.
(b) Loosen the hose clamp holding the air cleaner hose tothe intake air connector.
(c) Remove the four mounting 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 and air flow meter assembly.
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 hose:(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 hose clamp.
(d) Disconnect the intake air connector from the throttle
body, and remove the intake air connector.
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12. REMOVE RADIATOR RESERVOIR TANK(a) Disconnect the coolant level sensor connector.
(b) Disconnect the following hoses:(1) Reservoir hose to water inlet housing
(2) Reservoir hose to radiator
(c) Remove the two bolts and reservoir tank bracket.
(d) Disconnect the reservoir tank from the reservoir tank bracket, and remove the reservoir tank.
13. REMOVE RADIATOR (a) Disconnect the water temperature sensor connector.
(b) Disc onnect the wire clamp (for water temperature
sensor) from the radiator fan shrould.
(c) Disconnect the following hoses: (1) Two oil cooler hoses (for cooling fan) from pipes
(2) Two radiator hoses
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