1991 LEXUS SC400 length

(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 1.4 kW
No±load characteristicCurrent 90 A or less at 11.5 V
rpm 3,500 rpm or more
Brush lengthSTD 15.5 mm0.610 in.
Limit 10.0 mm0.394 in.
CommutatorOuter diameter STD 30 mm1.18 in.
Limit 29 mm1.14 in.
Undercut depth STD 0.6 mm0.024 in.
Limit 0.2 mm0.008 in.
Circle runout Limit 0.05 mm0.0020 in.
Spring installed loadSTD 18±24 N
(1.79 ± 2.41 kgf, 3.9 ± 5.3 lbf)
Limit12 N1.2 kgf2.6 lbf
TORQUE SPECIFICATIONS
Part tightenedNVmkgf Vcmft Vlbf
Starter x Cylinder block3940029
±
STARTING SYSTEM Service SpecificationsST±15
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VANE PUMPThe main component parts of the vane pump, such as the cam ring, rotor, vanes and flow control valve
are high precision parts and must be handled carefully. Also, because this pump produces a very high fluid
pressure, O±rings are used for sealing each part. When reassembling t\
he pump, always use new O±rings.
In the flow control valve, there is a relief valve which controls the maximum pressu\
re of the pump. The
amount of this maximum pressure is very important; if it is too low, there will be insufficient power steering
assistance and if too high, it will have an adverse effect on the pressure hoses, oil seals, etc. If the maximum
pressure is either too high or too low due to a faulty relief valve, do \
not disassemble or adjust the relief valve,
but replace the flow control valve as an assembly.
The clearance between the flow control valve and pump body installation hol\
e is very important. After
manufacture, the factory measures the size of the installation hole and outer circumf\
erence of the flow con-
trol valve, and punches a mark accordingly. Therefore, when replacing the flow control valve, be sure to
do so with one having the same mark in order to ensure the proper cleara\
nce.
The functional parts of the pump which produce fluid pressure are the cam r\
ing, rotor and vanes, and these
should be checked for wear. If the clearance between each is not within standard when reassembling\
, any
worn parts should be replaced.
In this case, the replaced cam ring and rotor should be of the same length\
(have the same mark), and the
vanes should be replaced with those having a length corresponding to that mark, other\
wise the proper
thrust clearance cannot be obtained. If there is too much thrust clearance, there will be insufficient fluid
pressure at low speeds. If there is too little thrust clearance, it may \
result in seizure of the vanes.
±
STEERING POWER STEERINGSR±105
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Maximum clearance:0.07 mm (0.0028 in.)
If more than maximum, replace the entire power steering
pump.
2. INSPECT ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and length of the vane plates.
Minimum height:
8.0 mm (0.315 in.)
Minimum thickness: 1.77 mm (0.0697 in.)
Minimum length:
14.97 mm (0.5894 in.)
(b) Using a feeler gauge, measure the clearance between therotor groove and vane plate.
Maximum clearance:
0.03 mm (0.0012 in.)
If more then maximum, replace the vane plate and/or rotor
with one having the same mark stamped on the cam ring.
Inscribed mark:1, 2, 3, 4 or None
HINT: There are 5 vane lengths with the following rotor and
cam ring marks:
 Rotor and camring number Vane length mm (in.)
 None 14.996±14.998 (0.59039±0.59047) 1 14.994±14.996 (0.59031±0.59039) 2 14.992±14.994 (0.59023±0.59031)
 3 14.990±14.992 (0.59016±0.59024)
 4 14.988±14.990 (0.59007±0.59016)
3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight.
SR±124
±
STEERING POWER STEERING
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(b) Check the flow control valve for leakage.Close one of the holes and apply compressed air 392 ±490
kPa (4±5 kgf/ cm
2, 57±71 psi) into the opposite side, and con-
firm that air does not come out from the end holes.
If necessary, replace the valve with one having the same let-
ter as inscribed on the front housing.
Inscribed mark:
A, B, C, D, E or F
4. INSPECT FLOW CONTROL SPRINGUsing a calipers, measure the free length of the spring.
Minimum spring length:
36 mm (1.42 in.)
If not within specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, tap out the oil seal. SST 09631±10030
(b) Using a 22 mm socket wrench and hammer, drive in a new oil seal.
NOTICE: Make sure you install the oil seal facing the correct
direction.
(c) Coat the oil seal lip with power steering fluid.
±
STEERING POWER STEERINGSR±125
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(f) Using SST and a torque meter, tighten the rack guide springcap until the preload is within specification.
SST 09612±24014 (09612±10022)
09616±00010
Preload (turning):
0.9±1.9 N Vm (9±20 kgf Vcm 7.9±17.3 in. Vlbf)
13. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the lock nut.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using SST, install and torque the lock nut.SST 09612±24014 (09612±10022, 09617±24020)
Torque: 56 N Vm (570 kgf Vcm, 41 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 340 mm
(13.39 in.).
(c) Recheck the total preload.
Preload (turning):
0.9±1.9 N Vm (9±20 kgf Vcm 7.9±17.3 in. Vlbf)
14. INSTALL DUST COVER
15. INSTALL CLAW WASHERS AND RACK ENDS
(a) Install new claw washer.
HINT: Align the claws of the claw washer with the rack
grooves.
(b) Using SST, install and torque the rack end. SST 09612±24014 (09617±24011)
09617±14010
Torque: 92 N Vm (940 kgf Vcm, 68 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 340 mm
(13.39 in.).
(c) Using a brass bar and hammer, stake the claw washer.
±
STEERING POWER STEERINGSR±161
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16. INSTALL RACK BOOTS, CLAMPS AND CLIPS
(a) Ensure that the tube hole is not clogged with grease.HINT: If the tube hole is clogged, the pressure inside the boot
will change after it is assembled and the steering wheel
turned.
(b) Install the boot.
NOTICE: Be careful not to damage or twist the boot.
(c) Install the clamp and clip to the boot.
17. INSTALL TIE ROD ENDS
(a) Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
(b) After adjusting toe±in, torque the lock nut.
Torque: 56 N Vm (570 kgf Vcm, 41 ft Vlbf)
18. INSTALL RIGHT AND LEFT TURN PRESSURE TUBES
(a) Install a new union seat.
(b) Using SST, tighten nut.
SST 09633±00020
Torque: 24 N Vm (240 kgf Vcm, 17 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
(c) Install the union bolt over the new gaskets and torque it.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
SR±162±
STEERING POWER STEERING
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SERVICE SPECIFICATIONS
SERVICE DATA
SR0GP±01\
 \
Steering wheel freeplay Maximum\
\
30 mm (1.18 in.)
\
 \
STEERING COLUMN\
\
\
 \
Pawl stopper Mark\
\
\
 \
1 or A\
\
12.68±12.74 mm (0.4992±0.5016 in.)
\
 \
2 or B\
\
12.61±12.67 mm (0.4965±0.4988 in.)
\
 \
3 or C\
\
12.54±12.60 mm (0.4937±0.4961 in.)
\
 \
4 or D\
\
12.47±12.53 mm (0.4909±0.4933 in.)
\
 \
5 or E\
\
12.40±12.46 mm (0.4882±0.4906 in.)
\
 \
6 or F\
\
12.33±12.39 mm (0.4854±0.4878 in.)
\
 \
7 or G\
\
12.26±12.32 mm (0.4827±0.4850 in.)
\
 \
PS ON±VEHICLE INSPECTION\
\
\
 \
Maximum rise of oil level\
\
Below 5 mm (0.20 in.)
\
 \
Oil pressure at idle speed with valve closed Minimum\
\
7,355±7,845 kPa (75±80 kgf/cm2, 1,067±1,137 psi)
\
 \
Steering effort at idle speed Maximum\
\
40 N (4.1 kgf, 9.0 lbf)
\
 \
PS PUMP\
\
\
 \
Rotor shaft bushing oil clearance (SC 400) STD\
\
0.01±0.03 mm (0.0004±0.0012 in.)
\
 \
Rotor shaft bushing oil clearance (SC 400) Maximum\
\
0.07 mm (0.0028 in.)
\
 \
Rotor shaft bushing oil clearance (SC 300) STD\
\
0.03±0.05 mm (0.0012±0.0020 in.)
\
 \
Rotor shaft bushing oil clearance (SC 300) Maximum\
\
0.07 mm (0.0028 in.)
\
 \
Vane plate to rotor groove clearance (SC 400)\
\
0.03 mm (0.0012 in.) or less
\
 \
Vane plate to rotor groove clearance (SC 300)\
\
0.04 mm (0.0016 in.) or less
\
 \
Vane plate length (SC 400) Minimum\
\
14.97 mm (0.5894 in.)
\
 \
Vane plate height (SC 400) Minimum\
\
8.0 mm (0.315 in.)
\
 \
Vane plate thickness (SC 400) Minimum\
\
1.77 mm (0.0697 in.)
\
 \
Vane plate length (SC 300) Minimum\
\
14.97 mm (0.5894 in.)
\
 \
Vane plate height (SC 300) Minimum\
\
8.5 mm (0.335 in.)
\
 \
Vane plate thickness (SC 300) Minimum\
\
1.37 mm (0.0539 in.)
\
 \
Vane plate length (SC 400) Rotor and cam ring mark\
\
\
 \
NONE\
\
14.996±14.998 mm (0.59039±0.59047 in.)
\
 \
1\
\
14.994±14.996 mm (0.59031±0.59039 in.)
\
 \
2\
\
14.992±14.994 mm (0.59023±0.59031 in.)
\
 \
3\
\
14.990±14.992 mm (0.59016±0.59024 in.)
\
 \
4\
\
14.988±14.990 mm (0.59007±0.59016 in.)
\
 \
Vane plate length (SC 300) Rotor and cam ring mark\
\
\
 \
NONE\
\
14.999±15.001 mm (0.59051±0.59059 in.)
\
 \
1\
\
14.997±14.999 mm (0.59043±0.59051 in.)
\
 \
2\
\
14.995±14.997 mm (0.59035±0.59043 in.)
\
 \
3\
\
14.993±14.995 mm (0.59027±0.59035 in.)
\
 \
4\
\
14.991±14.993 mm (0.59020±0.59027 in.)
±
STEERING SERVICE SPECIFICATIONSSR±169
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