Starter LEXUS SC400 1991 Service Repair Manual

TORQUE CONVERTER CLUTCH
CLEANING
AT079±04
If the transmission is contaminated, the torque converter
clutch and transmission cooler should be thoroughly flushed
with ATF.
TORQUE CONVERTER CLUTCH AND
DRIVE PLATE INSPECTION
AT00J±01
1. INSPECT ONE±WAY CLUTCH
(a) Install SST so that it fits in the notch of the converter hub and
outer race of the one±way clutch.
SST 09350±30020 (09350±32020)
(b) Press on the serrations of starter with a finger and rotate it. Check if it rotates smoothly when turned clockwise and locks
up when turned counterclockwise.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR
Set up a dial indicator and measure the drive plate runout.
If runout exceeds 0.20 mm (0.0079 in.) or if the ring gear is
damaged, replace the drive plate. If installing a new drive
plate, note the orientation of spacers and tighten the bolts.
Torque: 98 N Vm (1,000 kgf Vcm, 72 ft Vlbf)
±
A304E (1UZ±FE) AUTOMATIC TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATIONAT±25
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Description
The power source supplies power to each of the vehicle's electrical devices. It is composed of the battery, fuses
and relays, which are located centrally at relay block No. 2 and relay block No. 6 i\
n the engine compartment
and junction block No. 1 relay block No. 4 and relay block No. 5 in the \
cabin near the driver's feet.
Related systems for each Fuse
No.Part NameRelated Systems or Parts
1IGN
Charging System
AIR±BAG System1IGN
Engine
2ST
Starter
3WIPER
Wiper and Washer System
4HTR
Defogger System
A/C System
5ENGINE
Charging System
6RADIO NO. 2
Audio System
Power Mirror System

Cigarette Lighter
A/C System
7CIG
Combination Meter System
AIR±BAG System7CIG
Shift Lock System
Theft Deterrent System

TEL System
8STOP
Stop Light System
Cruise Control System
9TURN
Turn Signal and Hazard
Warning Light System
Cornnering Light System
10MIR HTR
Mirror Heater System
11PANEL
Illumination Light System
12ECU±B
Combination Meter System
AIR±BAG System

Combination Meter System
ECT System
13GAUGE
Back±Up Light
Transmission Indicator

Light Failare Sensor
ABS and TRAC

Power Seat System
Door Lock Control System

TEL System
Shift Lock System
14ECU±IG
Radiator Fan
Auto Antenna

Electric Tension Reducer System
Power Steering

Auto±Tilt away Steering
Cruise Control System
15TAIL
Taillight System
Side Marker15TAIL
Clearance Light
16DOOR
Power Seat System
Luggage Door Opener16DOOR
Door Lock Control System
Fuel Lid Opener System
17IG SWUpstream of ECU±IG, ENGINE, WIP, HTR, TURN, GAUGE, and ST Fuse
18PWR
Power Window System
Sliding Roof System
19ABS NO. 1
ABS and TRAC
20AM1Upstream of MIR HTR, TAIL, PANEL, STOP, ECUA±B, DOOR and PWR Fuse
21ALTUpstream of DEF, HTR, AM1, and ABS No. 1 Fuse
BE±18±
BODY ELECTRICAL SYSTEM Power Source
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Front water bypass joint x Cylinder head  18 185 13
 Intake manifold x Cylinder head1818513
Delivery pipe x Intake manifold1818513 
Fuel return pipe x Fuel pressure regulator
  
35
 
360
 
26 Fuel inlet hose x Delivery pipe  39 400 29  for SST 33 340 24 Cold start injector x Air intake chamber  7.8 80 69 in.Vlbf Air intake chamber x Intake manifold  18 185 13 EGR pipe x Air intake chamber  18 185 13
 EGR pipe x RH cylinder head  18 185 13
 Cold start injector tube x Air intake chamber  15 150 11
 Union (for brake booster) x Air intake chamber  29 300 22
 Throttle body x Air intake chamber  18 185 13
 IAC valve x Air intake chamber  18 185 13
 EGR valve adaptor x Air intake chamber  18 185 13
 EGR valve x EGR valve adaptor  18 185 13
Timing belt rear plate x Cylinder head7.88069 in. Vlbf 
Water outlet housing x Water pump
  
18
 
185
 
13 Main bearing stud bolt x Cylinder block  15 150 11 Main bearing cap x Cylinder block for nut (1st) 27 275 20  (2nd) Turn 90 5  
  for bolt 49 500 36 Connecting rod cap x Connecting rod 1st 25 250 18
  2nd Turn 905  
 Rear oil seal retainer x Cylinder block  7.8 80 69 in.Vlbf
 Water seal plate x Cylinder block  14 145 10
 Generator bracket x Cylinder block  18 185 13
 Oil pump x Cylinder block 12 mm head 16 160 12
  14 mm head 30 310 22
 No.1 oil pan x Cylinder block 10 mm head 7.8 80 69 in. Vlbf
12 mm head1818513 
No.1 oil pan x Oil pump
  
7.8
 
80
 
69 in. Vlbf No.1 oil pan x Rear oil seal retainer  7.8 80 69 in. Vlbf Oil strainer x Cylinder block  7.8 80 69 in. Vlbf Oil strainer x Oil pump  7.8 80 69 in. Vlbf Oil pan baffle plate x No.1 oil pan  7.8 80 69 in. Vlbf No.1 oil pan x No.2 oil pan  7.8 80 69 in. Vlbf
 Water pump x Cylinder block  18 185 13
 Water bypass pipe x Cylinder Block  18 185 13
 Knock sensor x Cylinder block  44 450 33
 Starter x Cylinder block  39 400 29
 Engine mounting bracket x Cylinder block  37 380 27
 Drive plate x Crankshaft  98 1,000 72
 Transmission x Cylinder block  57 580 42
 Transmission x No.1 oil pan  39 400 29
Drive plate x Torque converter3334025 Transmission oil cooler pipe x Transmission for union nut 34 350 25 Rear engine mounting member x Body  25 250 19\
 \
Rear engine mounting member x Rear engine mounting insulator1313510
EG±210±
1UZ ± FE ENGINE ENGINE MECHANICAL
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PREPARATION FOR DISASSEMBLY
EG34Y±01
(See Components for Cylinder Block Disassembly and As-sembly)
1. REMOVE DRIVE PLATE Remove the 8 bolts, front spacer drive plate and rear spacer.
2. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
3. REMOVE TIMING BELT AND PULLEYS (See pages EG±49 to 57)
4. REMOVE CYLINDER HEAD (See pages EG±75 to 93)
5. REMOVE RH ENGINE MOUNTING BRACKET Remove the 4 bolts and mounting bracket.
6. REMOVE LH ENGINE MOUNTING BRACKET
(a) Remove the 4 bolts and mounting bracket.
(b) Remove the bolt, and disconnect the engine wire from the mounting bracket.
7. REMOVE STARTER
(a) Remove the 2 bolts, and disconnect the starter from the cylinder block.
±
1UZ±FE ENGINE ENGINE MECHANICALEG±153
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(b) Disconnect the engine wire clamp from the bracket on thestarter.
(c) Remove the nut, and disconnect the starter wire.
(d) Disconnect the starter connector, and remove the starter.
8. REMOVE KNOCK SENSORS
(a) Disconnect the 2 knock sensor connectors.
(b) Using SST, remove the 2 knock sensors.
SST 09816±30010
9. REMOVE WATER BYPASS PIPE
(a) Remove the 2 bolts.
(b) Pull out the water bypass pipe from the water pump.
(c) Remove the O±ring from the water bypass pipe.
10. REMOVE ENGINE WIRE
(a) Disconnect the following connector: wCrankshaft position sensor connector
w Oil pressure switch connector
w Oil level sensor connector
(b) Remove the 3 bolts and engine wire cover from the LH side of the cylinder block.
(c) Remove the 2 bolts and engine wire.
EG±154
±
1UZ±FE ENGINE ENGINE MECHANICAL
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(b) Install the engine wire cover with the 3 bolts.
(c) Connect the following connector:wCrankshaft position sensor connector
w Oil pressure switch connector
w Oil level sensor connector
7. INSTALL WATER BYPASS PIPE
(a) Install a new O±ring to the water bypass pipe.
(b) Apply soapy water to the O±ring.
(c) Push the water bypass pipe end into the pipe hole of the water pump.
(d) Install the water bypass pipe with the 2 bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
8. INSTALL KNOCK SENSORS
(a) Using SST, install the 2 knock sensors.
SST 09816±30010
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
(b) Connect the 2 knock sensor connectors.
9. INSTALL STARTER
(a) Install the engine wire clamp to the bracket on the starter.
(b) Connect the starter wire with the nut.
(c) Connect the starter connector.
(d) Install the starter with the 2 bolts.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
EG±188±
1UZ±FE ENGINE ENGINE MECHANICAL
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PREPARATION FOR DISASSEMBLY
(See Components on page EM±131)
1. REMOVE DRIVE PLATE Remove the eight bolts, two spacers and drive plate.
2. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
3. REMOVE TIMING BELT AND PULLEYS (See pages EM±36 to 44)
4. REMOVE Cylinder Block (See pages EM±61 to 75)
5. REMOVE RH ENGINE MOUNTING BRACKET Remove the four bolts and mounting bracket.
6. REMOVE LH ENGINE MOUNTING BRACKET (a) Remove the clamp bolt, and disconnect the engine wirefrom the engine mounting bracket.
(b) Remove the four bolts and mounting bracket.
7. REMOVE STARTER (a) Remove the two bolts, and disconnect the starter fromthe cylinder block.
EM±132
±
ENGINE MECHANICAL Cylinder Block
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(b) Disconnect the wire clamp from the bracket on thestarter.
(c) Remove the nut, and disconnect the wire.
(d) Disconnect the connector, and remove the starter.
8. REMOVE KNOCK SENSORS (a) Disconnect the two knock sensor connectors.
(b) Using SST, remove the two knock sensors.
SST 09816±30010
9. REMOVE WATER BY±PASS PIPE (a) Remove the two bolts.
(b) Pull out the by±pass pipe from the water pump.
(c) Remove the O±ring from the by±pass pipe.
10. REMOVE ENGINE WIRE (a) Disconnect the following connectors:(1) Oil level sensor connector
(2) Oil pressure switch connector
(b) Remove the three bolts and wire cover from the LH side
of the cylinder block.
(c) Remove the two bolts and engine wire.
±
ENGINE MECHANICAL Cylinder BlockEM±133
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8. INSTALL KNOCK SENSORS(a) Using SST, install the two knock sensors.
SST 09816±30010
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
(b) Connect the two knock sensor connectors.
9. INSTALL STARTER (a) Install the wire clamp to the bracket on the starter.
(b) Connect the wire to the starter with the nut.
(c) Connect the connector to the starter.
(d) Install the starter with the two bolts.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
10. INSTALL RH ENGINE MOUNTING BRACKET
Install the mounting bracket with the four bolts.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
HINT: The RH mounting bracket is marked with ºRº.
11. INSTALL LH ENGINE MOUNTING BRACKET (a) Install the mounting bracket with the four bolts.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
HINT: The LH mounting bracket is marked with ºLº.
(b) Install the engine wire to the mounting bracket with the
bolt.
EM±164
±
ENGINE MECHANICAL Cylinder Block
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(h) Disconnect the following connectors:(1) Two connectors from engine (& ECT) ECU
(2) Connector from ABS & TRAC ECU
(3) Two connectors from TRAC ECU
(4) Four connectors from connector cassette
(5) Connector from A/C control assembly
(i) Pull out the engine wire from the cabin.
14. DISCONNECT PS PIPE FROM ENGINE Remove the two clamp bolts, and disconnect the PS pipe.
15. DISCONNECT HOSE, STARTER WIRE AND GROUND STRAP
(a) Remove the union bolt and two gaskets, disconnect thefuel inlet hose, and suspend the hose union end
upward.
HINT:
w Put a suitable container or shop towel under the fuel
pipe support.
w Slowly loosen the union bolt.
(b) Remove the nut and disconnect the starter wire.
(c) Disconnect the starter wire from the wire clamp.
(d) Disconnect the ground strap from the transmission.
16. (M/T)
DISCONNECT CLUTCH RELEASE CYLINDER FROM TRANS-
MISSION
Remove the two bolts and pull out the release cylinder.
EM±70
±
ENGINE MECHANICAL Cylinder Block
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