service LEXUS SC400 1991 Service Manual PDF

EQUIPMENT
 Part Name\
 \
Note
 Caliper gauge\
 \
Hydraulic pump, Hydraulic motor
 Micrometer\
 \
Hydraulic pump, Hydraulic motor
 Precision straight edge\
 \
Hydraulic pump, Hydraulic motor Pressure gauge\
 \

 
Radiator cap tester\
 
\
 

Thermometer
\
 
\

\

 Torque wrench\
 \

 Vernier caliper\
 \
Hydraulic pump
COOLANT 

Item
 

Capacity
 

Classification
 
Item
 Liters US qts lmp. qts 
Classification
 Engine coolant 10.8 11.4 9.5 Ethylene±glycol base
LUBRICANT
 Item Capacity Classification
 Cooling fan fluid ± ATF DEXRON
[II
SSM (SPECIAL SERVICE MATERIALS) 

Part Name
 

Part No.
\
 

\
Use etc.
 


Seal packing 1282B,
Three bond 1282B or equivalent 


08826±00100\
 

\

Water pump, Water inlet housing
±
COOLIING SYSTEM PreparationCO±5
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(3) Upper radiator hose or radiator
(4) Reservoir hose to radiator
5. INSTALL BATTERY
6. 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)
7. (A/T)
CHECK AUTOMATIC TRANSMISSION FLUID LEVEL (See pageMA±11 )
NOTICE: Do not overfill.
8. START ENGINE AND CHECK FOR LEAKS
9. INSTALL ENGINE UNDER COVER
SERVICE SPECIFICATIONS
SERVICE DATA
ThermostatValve opening temperature80±84 5c176±183 5F
Valve liftat 95 5C (203 5F) 8.5 mm0.335 in.
Radiator capRelief valve opening pressureSTD74±103 kPa
(0 75 1 05 k f/ 10 7 14 9 i)(0.75±1.05 kgf/cm, 10.7±14.9 psi)
Limit59 kPa0.6 kgf/cm28.5 psi
TORQUE SPECIFICATIONS
Part tightenedN
mkgf
cmft
lbf
Engine drain plug X Cylinder block2930022
Water pump X Cylinder block2121015
Water pump X Water by±pass pipe2121015
Water by±pass outlet X Cylinder head 8.89078 in.
lbf
Water inlet X Water pump 8.89078 in.
lbf
Oil cooler X Radiator lower tank (A/T) 8.38574 in.
lbf
Oil cooler X Pipe (A/T)1515011
Radiator fan shroud X Radiator 4.95043 in.
lbf
Radiator X Body121209
±
COOLING SYSTEM Radiator, Service SpecificationsCO±21
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SERVICE SPECIFICATIONS
SPECIFICATIONS
VSV (For EVAP) Resistance30±34

VSV (For EGR)Resistance33±39

TORQUE SPECIFICATIONS
Part tightenedN mkgf cmftVlbf
VSV for EGR X Intake manifold18185 13
EGR valve X Intake manifold18185 13
EGR valve X EGR Pipe64650 47
Catalytic converter (Front) X Exhaust manifold62630 46
Catalytic converter (Front) X Front Exhaust pipe43440 32
Front exhaust pipe X Center exhaust pipe43440 32
Sub±oxygen sensor X Front exhaust pipe1818013
EC±20±
EMISSION CONTROL SYSTEMS Service Specifications
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SERVICE SPECIFICATIONS
SERVICE DATA
VSVResistance30±34

for EVAP
VSVResistance33±39

for EGR
EGR valveResistance19.9±23.4

(CALIF. only)
TORQUE SPECIFICATIONS
Part tightenedNVmkgf Vcmft Vlbf
VSV for EGR X Air intake chamber (Exc. USA Spec.)1818513
EGR valve X Air intake chamber18185 13
Catalytic converter (Main) X Exhaust manifold62630 46
Catalytic converter (Main) X Front exhaust pipe43440 32
Front exhaust pipe support bracket X Transmission43440 32
Front exhaust pipe X Center exhaust pipe43440 32
Main oxygen sensor X Front exhaust pipe4445033
EC±30±
EMISSION CONTROL SYSTEMS Servuce Specifications
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SCHEMATIC DRAWING
PREPARATION
SST (SPECIAL SERVICE TOOLS)
IllustrationPart No.Part NameNote
09843±18020Diagnosis Check Wire
for EGR system inspection
RECOMMENDED TOOLS
IllustrationPart No.Part NameNote
09082±00015TOYOTA Electrical
Tester
EQUIPMENT
Part NameNote
Vacuum gaugeEGR system
Engine tune±up testerEngine speed
SSM (SPECIAL SERVICE MATERIALS)
Part NamePart No.Note
08833±00070THREE
BOND 1324BVSV
±
EMISSION CONTROL SYSTEMS Description, PreparationEC±3
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PREPARATION
SST (SPECIAL SERVICE TOOL)
RECOMMENDED TOOLS
EQUIPMENT
Part NameNote
Engine tune±up testerEngine speed
±
EMISSION CONTROL SYSTEMS PreparationEC±5
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SERVICE SPECIFICATIONS
SERVICE DATA
EG065±0A Tune±up Battery specific gravity  1.27±1.29
    (when fully charged at 205C (68 5F))
  High±tension cord resistance Limit 25 k
per cord
  Valve clearance (Cold) Intake 0.15±0.25 mm (0.006±0.010 in.)
   Exhaust 0.25±0.35 mm (0.010±0.014 in.)
Valve clearance adjusting shimNo.012.500 mm (0.0984 in.)   No.62 2.525 mm (0.0994 in.)   No.63 2.550 mm (0.1004 in.)   No.64 2.575 mm (0.1014 in.)   No.06 2.600 mm (0.1024 in.)
   No.65 2.625 mm (0.1033 in.)
   No.66 2.650 mm (0.1043 in.)
   No.67 2.675 mm (0.1053 in.)
   No.13 2.700 mm (0.1063 in.)
   No.68 2.725 mm (0.1073 in.)
   No.18 2.750 mm (0.1083 in.)
No.192.775 mm (0.1093 in.)   No.23 2.800 mm (0.1102 in.)   No.70 2.825 mm (0.1112 in.)   No.28 2.850 mm (0.1122 in.)   No.71 2.875 mm (0.1132 in.)
   No.33 2.900 mm (0.1142 in.)
   No.72 2.925 mm (0.1152 in.)
   No.38 2.950 mm (0.1161 in.)
   No.73 2.975 mm (0.1171 in.)
   No.43 3.000 mm (0.1181 in.)
No.743.025 mm (0.1191 in.)   No.48 3.050 mm (0.1201 in.)   No.75 3.075 mm (0.1211 in.)   No.51 3.100 mm (0.1220 in.)   No.76 3.125 mm (0.1230 in.)   No.77 3.150 mm (0.1240 in.)
   No.78 3.175 mm (0.1250 in.)
   No.56 3.200 mm (0.1260 in.)
   No.79 3.225 mm (0.1270 in.)
   No.80 3.250 mm (0.1280 in.)
   No.81 3.275 mm (0.1289 in.)
No.613.300 mm (0.1299 in.)  Ignition timing  8 ± 12 5 BTDC @ idle 


 


 


 

(w/ Terminals TE1 and E1 connected
of DLC1)
  Idle speed  700
+ 50 rpm
 Intake at idle speed  60 kPa (450 mmHg. 17.7 in.Hg)
 manifold
 vacuum   
±
1UZ ± FE ENGINE ENGINE MECHANICALEG±205
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PREPARATION
EG0AY±0M
SST (SPECIAL SERVICE TOOLS)
±
1UZ±FE ENGINE ENGINE MECHANICALEG±5
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\
 \

Spring tester Valve spring
\
 
\

\
Steel square 

Valve spring
\
 
\

\

Thermometer 


\
 \
Torque wrench 
\
 
\

\
Valve seat cutter 


\
 
\

Vernier calipers 

EG0B1±0A
COOLANT
 Item Capacity Classification
 Engine coolant (w/ Heater) 10.8 liters (11.4 US qts, 9.5 lmp. qts) Ethylene±glycol base
EG0B1±10
LUBRICANT
 Item Capacity Classification
 Engine oil  API grade SG or SH, Energy±Conserving II
 Dry fill 6.0 liters (6.3 US qts, 5.3 lmp. qts) or ILSAC multigrade and recommended
 Drain and refill  viscosity oil with SAE 5W±30
 w/ Oil filter change 4.8 liters (5.1 US qts, 4.2 lmp. qts) being the preferred engine oil
 w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 lmp. qts) 
EG0B1±0J
SSM (SERVICE SPECIAL MATERIALS)
 08826±00080 Seal packing or equivalent Camshaft bearing cap
   Cylinder head semi±circular plug
   Cylinder head cover
   Rear oil sear retainer
 08826±00080 Seal packing or equivalent Oil pump
   
   
   
 08826±00100 Seal Packing 1282B, Water inlet housing
  THREE BOND 1282B or equivalent Water seal plate
   Water pump
   
 08833±00070 Adhesive 1311, Drive plate bolt
  THREE BOND 1311 or equivalent 
   
   
 08833±00080 Adhesive 1344 No.1 idler pulley bolt
  THREE BOND 1344. 
  LOCTITE 242 or equivalent 
   
EG±8±
1UZ±FE ENGINE ENGINE MECHANICAL
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35. REMOVE CYLINDER HEAD COVERSRemove the 8 bolts, seal washers, cylinder head cover and
gasket. Remove the 2 cylinder head covers.
36. IF NECESSARY, REMOVE SEMI±CIRCULAR PLUGS
37. REMOVE CAMSHAFTS
NOTICE: Since the thrust clearance of the camshaft is small,
the camshaft must be kept level while it is being removed. If the
camshaft is not kept camshaft is not kept level, the portion of
the cylinder head receiving the shaft thrust may crack or be
damaged, causing the camshaft to seize or break. To avoid
this, the following steps should be carried out.
A. Remove exhaust camshaft from RH cylinder head
(a) Boring the service bolt hole of the driven sub±gear upward by turning the hexagon wrench head portion of the exhaust
camshaft with a wrench.
(b) Secure the exhaust camshaft sub±gear to the drive gear with
a service bolt.
Recommended service bolt: 6 mm for thread diameter
1.0 mm for thread pitch
16 ± 20 mm (0.63 ± 0.79 in.) for bolt length
HINT: When removing the camshaft, make sure that the tor-
sional spring force of the sub±gear has been eliminated by
the above operation.
(c) Set the timing mark (1 dot mark) of the camshaft driven gear at approx. 10
angle by turning the hexagon wrench head
portion of the exhaust camshaft with a wrench.
EG±86
±
1UZ±FE ENGINE ENGINE MECHANICAL
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