ignition switch LEXUS SC400 1991 Service Repair Manual

HIGH±TENSION CORDS AND CORD
CLAMPS
COMPONENTS FOR REMOVAL AND
INSTALLATION
REMOVAL OF HIGH±TENSION CORDS
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.
±
IGNITION SYSTEM High±Tension Cords and Cord ClampsIG±11
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REMOVAL OF RH IGNITION COIL
(See Components on page IG±20)
1. REMOVE RH ENGINE WIRE COVER (See steps 1, 3 and 4 on pages IG±11 and 12)
2. DISCONNECT HIGH±TENSION CORD (See step 9 on pages IG±13 and 14)
3. DISCONNECT IGNITION COIL CONNECTOR
4. REMOVE IGNITION COIL (a) Remove the three bolts, and disconnect the ignition coil.
(b) Disconnect the cam position sensor connector, and
remove the ignition coil.
REMOVAL OF LH IGNITION COIL
(See Components on page IG±20)
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. DISCONNECT IGNITION COIL CONNECTOR
3. DISCONNECT HIGH±TENSION CORD (See step 9 on pages IG±13 and 14)
4. DISCONNECT NOISE FILTER FROM IGNITION COIL Remove the bolt, and disconnect the noise filter.
5. REMOVE IGNITION COIL Remove the two bolts and ignition coil.
±
IGNITION SYSTEM Ignition CoilsIG±21
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INSPECTION AND ADJUSTMENT OF
VALVE CLEARANCE
HINT: Inspect and adjust the valve clearance when the
engine is cold.
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 (See page CO±6)
3. REMOVE THROTTLE BODY COVER (a) Remove the mounting cap nut.
(b) Loosen the two bolts, and remove the throttle body
cover.
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 throttle body.
±
ENGINE MECHANICAL Engine Tune±UpEM±11
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REMOVAL OF TIMING BELT
(See Components on pages EM±33 and 34)
1. REMOVE 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. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT (See page CO±6)
4. 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.
5. REMOVE RESERVOIR TANK RADIATOR (See steps 12 and 13 on pages EM±120 and 121)
6. REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES
(a) Disconnect the compressor connector.
(b) Remove the mounting nut, and disconnect the groundcable.
(c) Remove the mounting bolt and compressor stay.
(d) R e m o v e t h e t w o b o l t s , a n d d i s c onnect the A/C
compressor from the engine.
HINT: Put aside the compressor, and suspend it.
±
ENGINE MECHANICAL Timing BeltEM±35
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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.
EM±118
±
ENGINE MECHANICAL Cylinder Block
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PRECAUTIONS
1. Before working on the fuel system, disconnect the cablefrom negative (±) terminal of the battery.
HINT: Any diagnostic code retained by the computer will be
erased when the battery terminal is removed. Therefore, if
necessary, read the diagnosis before removing the battery
terminal.
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 negative (±) terminal
cable is disconnected from the battery.
2. Do not smoke or work on open flame when working on the fuel system.
3. Keep gasoline away from rubber or leather parts.
INSPECTION PRECAUTIONS
MAINTENANCE PRECAUTIONS
1. CHECK CORRECT ENGINE TUNE±UP (See page EM±8)
2. PRECAUTIONS WHEN CONNECTING GAUGE (a) Use the battery as the power source for the timing light,tachometer, etc.
(b) Connect the test probe of a tachometer to the terminal IG of the check connector.
3. IN EVENT OF ENGINE MISFIRE, FOLLOWING PRECAUTIONS SHOULD BE TAKEN
(a) Check proper connection of battery terminals, etc.
(b) Handle high±tension cords carefully.
(c) After repair work, check that the ignition coil terminalsand all other ignition system lines are reconnected
securely.
(d) When cleaning the engine compartment, be especially careful to protect the electrical system from water.
4. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR (a) Do not allow oxygen sensor to drop or hit against anobject.
(b) Do not allow the sensor to come into contact with water.
FI±12
± Precautions, Inspection PrecautionsEFI SYSTEM
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FUEL SYSTEM
Fuel Pump
ON±VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION(a) Using SST, connect terminals +B and FP of the check
(ºDIAGNOSISº) connector.
SST 09843±18020
(b) Turn the ignition switch ON.
NOTICE: Do not start the engine.
(c) Check that there is pressure in the fuel inlet hose from the fuel filter.
HINT: At this time, you will hear fuel return noise.
(d) Turn the ignition switch OFF.
(e) Remove SST from the check connector.
SST 09843±18020 FI±17
± Fuel System (Fuel Pump)EFI SYSTEM
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If there is no pressure, check the following parts:w Fuses
w EFI main relay
w Fuel pump ECU
w Fuel pump
w Engine & ECT ECU
w Wiring connections
2. CHECK FUEL PRESSURE (a) Check the battery voltage above 12 volts.
(b) Disconnect the cable from the negative (±) terminal ofthe 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 negative (±) terminal
cable is disconnected from the battery.
(c) (Exc. USA Spec.) Remove the filter from the VSV (for EGR system).
(d) Remove the union bolt holding the LH deliver pipe to the
rear fuel pipe. Remove the two gaskets.
HINT:
w Put a suitable container or shop towel under the cold
start injector pipe.
w Slowly loosen the union bolt.
(e) Install the rear fuel pipe and SST (pressure gauge) to the LH delivery pipe with three new gaskets and the
union bolt.
SST 09268±45012
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
(f) Wipe off any splattered gasoline.
(g) (Exc. USA Spec.)
Reinstall the filter to the VSV.
(h) Using SST, connect terminals B and FP of the check (ºDIAGNOSISº) connector.
SST 09843±18020
(i) Reconnect the cable to the negative (±) terminal of the
battery.
FI±18
EFI SYSTEM
± Fuel System (Fuel Pump)
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(j) Turn the ignition switch ON.
(k) Measure the fuel pressure.
Fuel pressure: 265±304 kPa(2.7±3.1 kgf/cm
2, 38±44 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the following parts:w Fuel hoses and connections
w Fuel pump
w Fuel filter
w Fuel pressure regulator
(l) Remove SST from the check connector.
SST 09843±18020
(m) Start the engine.
(n) Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end.
(o) Measure the fuel pressure at idling.
Fuel pressure: 265±304 kPa
(2.7±3.1 kgf/cm
2, 38±44 psi)
(p) Re connect the vacuum sensing hose to the fuel
pressure regulator.
(q) Measure the fuel pressure at idling.
Fuel pressure: 196±235 kPa
(2.0±2.4 kgf/cm
2, 28±34 psi)
If pressure is not as specified, check the vacuum sensing
hose and fuel pressure regulator.
(r) Stop the engine. Check that the fuel pressure remains147 kPa (1.5 kgf/cm
2, 21 psi) or more for 5 minutes after
the engine is turned off.
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(s) After checking fuel pressure, disconnect the battery negative (±) cable and carefully remove the SST to
prevent gasoline from splashing.
SST 09268±45012
(t) Connect the rear fuel pipe to the delivery pipe with two new gaskets and the union bolt.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
(u) (Exc. USA spec.)
Reinstall the filter to the VSV.
(v) Reconnect the cable to the negative (±) terminal of the
battery.
(w) Check for fuel leaks. (See page FI±16) FI±19
EFI SYSTEM
± Fuel System (Fuel Pump)
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REMOVAL OF FUEL PUMP
(See Components on page FI±20)
CAUTION: Do not smoke or work near an open flame
when working on the fuel pump.
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 negative (±) terminal
cable is disconnected from the battery.
2. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
3. REMOVE SPARE TIRE
4. REMOVE LUGGAGE COMPARTMENT TRIM COVER
5. DISCONNECT FUEL PUMP CONNECTOR
6. REMOVE SEAT CUSHION AND BACK
7. REMOVE PARTITION COVER Using a scraper, pry out the partition cover.
8. REMOVE FUEL PUMP (a) Remove the eight bolts, and disconnect the fuel pumpset plate from the fuel tank.
(b) Remove the three nuts, and disconnect the fuel pump bracket from the fuel tank.
(c) Disconnect the fuel hose from the fuel pump bracket, and remove the fuel pump, bracket and set plate
assembly. FI±21
EFI SYSTEM
± Fuel System (Fuel Pump)
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