torque LEXUS SC400 1991 Service Repair Manual

(e) Tighten the bolt holding the EGR pipe to the air intakechamber.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(f) Tighten the bolt holding the EGR pipe to the RH cylinder
head.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(g) Connect the cold start injector tube to the RH delivery
pipe with two new gaskets and union bolt.
Torque: 15 N Vm (150 kgf Vcm, 11 ft Vlbf)
(h) Install the accelerator bracket with the bolt and stud bolt.
13. CONNECT HOSES Connect the following hoses:(1) Water by±pass (from EGR valve) to water bypass
pipe
(2) Vacuum hose (from brake booster) to air intake chamber
(3) Vacuum hose (from VSV for heater water valve) to
air intake chamber
(4) PCV hose to LH cylinder head cover
±
STARTING SYSTEM StarterST±29
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(5) Water by±pass hose (from water inlet housing) to ISC
valve
(6) Vacuum hose (from PS air control valve) to air intake chamber
(7) Vacuum sensing hose (from fuel pressure regulator) to vacuum pipe
(8) Two vacuum hoses (from VSV for EVAP system) to vacuum pipe
(9) Vacuum hose (from charcoal canister) to vacuum pipe.
14. CONNECT CONNECTORS Connect the following connectors:w Cold start injector connector
w ISC valve connector
w (USA Spec.)
EGR valve connector
w (Exc. USA Spec.)
VSV connector for EGR system
w VSV connector for fuel pressure control system
15. INSTALL THROTTLE BODY (a) Connect the following hoses:(1) PCV hose to throttle body
(2) Water by±pass hose to throttle body
(b) Install a new gasket and throttle body with the two bolts and two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 40 mm (1.57 in.) in length.
(c) Install the water by±pass pipe (from rear water bypass
joint) to the clamp on the engine wire cover.
ST±30
±
STARTING SYSTEM Starter
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SERVICE SPECIFICATIONS
SERVICE DATA
StarterRated voltage and output power12 V 2.0 kW
No±load characteristicCurrent 120 A or less at 11.5 V
rpm 3,300 rpm or more at 11.5 V
Brush lengthSTD 15.0±15.5 mm0.591±0.610 in.
Limit 9.5 mm0.374 in.
CommutatorOuter diameter STD 35.0 mm1.378 in.
Limit 34.0 mm1.339 in.
Undercut depth STD 0.7±0.9 mm0.028±0.035 in.
Limit 0.2 mm0.008 in.
Circle runout Limit 0.05 mm0.0020 in.
Spring installed load26±32 N
(2.7±3.3 kgf, 6.0±7.3 lbf)
TORQUE SPECIFICATIONS
Part tightenedNVmkgf Vcmft Vlbf
Starter X Cylinder block3940029
Rear water by±pass joint X Cylinder head18185 13
Water by±pass pipe X Cylinder block18185 13
Intake manifold X Cylinder head18185 13
Fuel return pipe X Fuel pressure regulator35360 26
Fuel inlet hose X LH delivery pipe39400 29
for SST 33340 24
Air intake chamber X Intake manifold18185 13
EGR pipe X Air intake chamber18185 13
EGR pipe X RH cylinder head18185 13
Cold start injector tube X RH delivery pipe15150 11
Throttle body X Air intake chamber1818513
ST±36±
STARTING SYSTEM Service Specifications
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FAIL±SAFE CHART
If any of the following codes is recorded, the ECU enters fail±
safe mode.
Code No.Fail±Safe OperationFail±Safe Deactivation Conditions
14Fuel cut1 IGF1 detected in consecutive 8 ignitions.
15Fuel cut1 IGF2 detected in consecutive 8 ignitions.
16Torque control prohibited.Returned to normal condition.
22THW is fixed at 805C (176 5F).Returned to normal condition.
24THA is fixed at 20 5C (68 5F).Returned to normal condition.
31
Ignition timing controlled between 10 5 ~ 30 5
BTDC,
Injection time controlled between 3 msec. ~ 30 m
sec., in relation to:
w Engine rpm
w Throttle angle
w ISC step value
KS input 15 times/sec. or more.
35Atmospheric pressure is fixed at 760 mmHg.Returned to normal condition.
The following 1 or 2 must be repeated at least 2
times consecutively.
41VTA1 is fixed at 051 When IDL is ON41VTA1 is fixed at 051 When IDL is ON
0.25 V
VTA1
0.95 V
2 When IDL is OFF2 When IDL is OFF
0.25 V
VTA1
4.9 V
The following 1 or 2 must be repeated at least 2
times consecutively.
47Value of VTA1 is used1 When IDL2 is ON47Value of VTA1 is used.1 When IDL2 is ON
0.25 V
VTA2
0.95 V
2 When IDL2 is OFF2 When IDL2 is OFF
0.25 V
VTA2
4.9 V
52Max. timeing retardation.IG switch OFF.
53Max. timeing retardation.Returned to normal condition.
55Max. timeing retardation.IG switch OFF.
Back±Up Function
If there is trouble with the program in the ECU and the ignition signals\
(IGT) are not output, the ECU controls
fuel injection and ignition timing at predetermined levels as a back±up f\
unction to make it possible to continue
to operate the vehicle.
Furthermore, the injection duration is calculated from the satrting sign\
al (STA) and the throttle position signal
(IDL). Also, the ignition timing is fixed at the initial ignition timing, 5 5 BTDC, without relation to the engine speed.
HINT: If the engine is controlled by the back±up function, the CHECK ENGIN\
E light lights up to warn the driver
of the malfunction but the diagnostic code is not output. TR±22
±
ENGINE TROUBLESHOOTING Fail±Safe Chart
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Diag. Code 16ECT Control Signal Malfunction
CIRCUIT DESCRIPTION
The signal from the ECT CPU retards the ignition timeing of the engine duri\
ng ECT gear shifting, thus mo-
mentarily reducing torque output of the engine for smooth clutch operati\
on inside the transmission and re-
duced shift shock.
Code No.Diagnostic Code Detecting ConditionTrouble Area
16Fault in communications between the engine
CPU and ECT CPU in the ECU.
ECU
If the ECU records the diagnostic code ª16º in memory, it prohibits the torque control of the ECT which per-
forms smooth gear shifting.
DIAGNOSTIC CHARTDIAGNOSTIC CHART
Are there any other codes (besides Code 16)
being output?
Replace engine & ECT ECU. Go to relevant diag. code chart.
±
ENGINE TROUBLESHOOTING Circuit InspectionTR±61
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PREPARATION
SST (SPECIAL SERVICE TOOLS)
09285±76010
Injection Pump
Camshaft Bearing
Cone ReplacerRotor rear bearing
09286±46011Injection Pump
Spline Shaft PullerRectifier end frame
09608±20012
Front Hub & Drive
Pinion Bearing Tool
Set
(09608±00030)
(Replacer)
Rotor front bearing
09820±00021Alternator Rear
Bearing Puller
09820±00030Alternator Rear
Bearing Replacer
09820±63010Alternator Pulley Set
Nut Wrench Set
RECOMMENDED TOOLS
09082±00015TOYOTA
Electrical Tester
09200±00010Engine Adjust
Kit
EQUIPMENT Part Name\
 \
Note Battery specific gravity gauge\
 \
Battery Vernier caliper\
 \
Rotor (Slip ring) Torque wrench\
 \

CH±4±
CHARGING SYSTEM Preperation
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(c) Remove the seal plate.
4. REMOVE PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST (B)clockwise to the specified torque.
SST 09820±63010
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
(b) Check that SST (A) is secured to the rotor shaft.
(c) As shown in the illustration, mount SST (C) in a vise, and
install the alternator to SST (C).
(d) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE: To prevent damage to the rotor shaft, do not
loosen the pulley nut more than one±half of a turn.
(e) Remove the alternator from SST (C).
(f) Turn SST (B) and remove SST (A and B).
(g) Remove the pulley nut and pulley.
5. REMOVE RECTIFIER END FRAME (a) Remove the four mounting nuts.
(b) Using SST, remove the rectifier end frame.
SST 09286±46011
CH±12
±
CHARGING SYSTEM Alternator
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4. INSTALL PULLEY(a) Install the pulley to the rotor shaft by tightening thepulley nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820±63010
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) As shown in the illustration, mount SST (C) in a vise, and
install the alternator to SST (C).
(e) To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 110 N Vm (1,125 kgf Vcm, 81 ft Vlbf)
(f) Remove the alternator from SST (C).
(g) Turn SST (B) and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER (a) Place the seal plate on the rectifier end frame.
(b) Install the four rubber insulators on the lead wires.
(c) Install the rectifier holder with the four screws.
CH±18
±
CHARGING SYSTEM Alternator
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INSTALLATION OF ALTERNATOR
(See Components on page CH±9)
1. INSTALL ALTERNATOR (a) Install the alternator and A/T oil cooler bracket with the
bolt and nut.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
(b) Connect the alternator connector.
(c) Connect the alternator wire with the nut and cap.
2. INSTALL DRIVE BELT Install the drive belt by turning the drive belt tensioner coun-
terclockwise.
HINT: The pulley bolt for the belt tensioner has a left±hand
thread.
3. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
4. PERFORM ON±VEHICLE INSPECTION (See steps 6 to 8 on pages CH±6 to 8)
5. INSTALL ENGINE UNDER COVER
CH±20
±
CHARGING SYSTEM Alternator
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SERVICE SPECIFICATIONS
SERVICE DATA
BatterySpecific gravity1.27±1.29
(when fully charged at 205C (68 5F))
AlternatorRated output12 V±100 A
Rotor coil resistance2.8±3.0

Slip ring diameterSTD 14.2±14.4 mm0.559±0567 in.
Limit 12.8 mm0.504 in.
Brush exposed lengthSTD 10.5 mm0.413 in.
Limit 1.5 mm0.059 in.
AlternatorRegulating voltageat 255C (77 5F)13.9±15.1 V
regulatorat 115 5C (239 5F)13.5±14.3 V
TORQUE SPECIFICATIONS
Part tightenedN Vmkgf Vcmft Vlbf
Alternator pulley X Rotor11 01,12581
Alternator X Alternator bracket37380 27
Alternator X Cylinder block3738027
±
CHARGING SYSTEM Service SpecificationsCH±21
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