1991 LEXUS SC400 length

(e) Check that the exhaust camshaft moves smoothly in the
thrust direction.
(f) Install the front bearing cap with the arrow mark facing forward.
HINT:
w Installing the front bearing cap will determine the thrust
position of the camshaft.
w Align the arrow marks at front and rear of the cylinder
head with the mark on the bearing cap.
(g) Install the other bearing caps in the sequence shown with the arrow mark facing forward.
HINT: Align the arrow marks at front and rear of the cylinder
head with the mark on the bearing cap.
(h) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(i) Install the oil feed pipe and ten bolts.
HINT: Use bearing cap bolts 38 mm (1.50 in.) and 52 mm
(2.05 in.) in length. Use black colored 38 mm (1.50 in.) bolts.
Install the two 52 mm (2.05 in.) bolts in outside positions of
the oil pipe. Install the eight 38 mm (1.50 in.) bolts in the other
positions.
(j) Uniformly tighten the eight bearing cap bolts on the
bearing caps of the exhaust camshaft in several passes
in the sequence shown.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
EM±100±
ENGINE MECHANICAL Cylinder Heads
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19. INSTALL REAR WATER BY±PASS JOINT(a) Install two new gaskets and the water by±pass joint with
the four nuts. Alternately tighten the nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Install the bolt holding the water by±pass pipe to the
engine hanger.
20. INSTALL FRONT WATER BY±PASS JOINT (a) Install two new gaskets and the water by±pass joint with
the four nuts. Alternately tighten the nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Install the engine wire clamp with the bolt.
(c) Connect the following connectors:
(1) Water temperature sensor connector
(2) Cold start injector time switch connector
(3) Water temperature sender gauge connector
21. INSTALL INTAKE MANIFOLD (a) Place two new gaskets on the cylinder heads with thewhite painted mark facing upward.
NOTICE: Align the port holes of the gasket and cylinder
head. Be careful of the installation direction.
(b) Place the intake manifold in position on the cylinder head with the arrow mark facing forward.
NOTICE: Be careful of the installation direction.
(c) Install and uniformly tighten the six mounting bolts and
four mounting nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 30 mm (1.18 in.) in length.
EM±104
±
ENGINE MECHANICAL Cylinder Heads
WhereEverybodyKnowsYourName

25. INSTALL ENGINE WIRE TO INTAKE MANIFOLDInstall the engine wire with the two bolts.
26. TEMPORARILY INSTALL EGR PIPE TO RH CYLINDER HEAD
Temporarily install a new gasket and the EGR pipe with the
two bolts.
HINT: Use bolt 25 mm (0.98 in.) in length.
27. CONNECT FUEL RETURN HOSE TO FUEL RETURN PIPE
28. CONNECT FUEL INLET HOSE TO LH DELIVERY PIPE Connect the inlet hose with two new gaskets and the pulsa-
tion damper.
SST 09612±24012 (09617±24011)
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
33 N Vm (340 kgf Vcm, 24 ft Vlbf) for SST
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
29. CONNECT HEATER WATER HOSES Connect the following hoses:(1) Water hose to water by±pass pipe
(2) Water hose to rear water by±pass joint
30. INSTALL AIR INTAKE CHAMBER (a) Install the cold start injector, tube and wire assemblywith the three bolts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
±
ENGINE MECHANICAL Cylinder HeadsEM±107
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(b) Place four new gaskets on the intake manifold.
HINT: Gaskets can only be used twice before being replaced.
(c) Place the air intake chamber on the intake manifold.
(d) Temporarily connect the EGR pipe to the air intakechamber with a new gasket and the two bolts.
HINT: Use bolts 20 mm (0.79 in.) in length.
(e) Temporarily install the air intake chamber and following
parts with the four bolts and eight nuts:
(1) VSV for fuel pressure control system
(2) (Exc. USA Spec.) VSV for EGR system
(3) A/T throttle cable bracket
(4) Check connector (ºDIAGNOSISº) connector
(f) Uniformly tighten the bolts and nuts in several passes.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 40 mm (1.57 in.) in length.
(g) Tighten the two bolts holding the EGR pipe to the air
intake chamber.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(h) Tighten the two bolts holding the EGR pipe to the RH
cylinder head.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(i) Connect the cold start injector tube to the RH delivery
pipe with the two new gaskets and the union bolt.
Torque: 15 N Vm (150 kgf Vcm, 11 ft Vlbf)
(j) Connect the following connectors:
w Cold start injector connector
w SV connector for fuel pressure control system
w (Exc. USA Spec.)
VSV connector for EGR system
EM±108
±
ENGINE MECHANICAL Cylinder Heads
WhereEverybodyKnowsYourName

31. INSTALL ACCELERATOR BRACKETInstall the bracket with the bolt and stud bolt.
32. INSTALL BRAKE BOOSTER UNION Install the union with two new gaskets and the union bolt.
Torque: 29 N Vm (300 kgf Vcm, 22 ft Vlbf)
33. CONNECT VACUUM HOSES
Connect the following hoses:(1) Vacuum hose to brake booster union
(2) Vacuum hose (from VSV for heater water valve) to
air intake chamber
34. INSTALL THROTTLE BODY (a) Connect the following hoses:(1) Water by±pass hose to throttle body
(2) PCV 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.
(d) Connect the following connectors: (1) Throttle position sensor connector
(2) (w/ TRAC) Sub±throttle position sensor connector
(3) (w/ TRAC) Sub±throttle actuator connector
±
ENGINE MECHANICAL Cylinder HeadsEM±109
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35. INSTALL HEATER WATER VALVE(a) Install the water valve and bracket assembly with thetwo bolts.
(b) Install the engine wire clamp with the bolt.
(c) Connect the VSV connector.
36. INSTALL ISC VALVE (a) Install a new gasket and the ISC valve with the two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Connect the water by±pass hose (from throttle body) to
the ISC valve.
(c) Connect the ISC valve connector.
37. INSTALL EGR VALVE ADAPTOR (a) Install a new gasket, the adaptor and connector bracket(USA spec. only) with the two bolts and two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 20 mm (1.79 in.) in length.
NOTICE: Do not touch the air intake chamber and adap-
tor surfaces of the gasket with your hand.
(b) Connect the PCV hose to cylinder head.
(c) (USA Spec. only)
Connect the EGR gas temperature sensor connector.
EM±110
±
ENGINE MECHANICAL Cylinder Heads
WhereEverybodyKnowsYourName

41. INSTALL TIMING BELT REAR PLATESInstall the rear plate with the two bolts. Install the two rear
plates.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
42. INSTALL WATER INLET AND INLET HOUSING
(a) Remove any old packing (FIPG) material.w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) materials from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose materials.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the sealing groove of the water inlet housing as shown in the illustration.
Seal packing: Part No.08826±00100 or equivalent
w Install a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Install a new O±ring to the water inlet housing.
(d) Apply soapy water to the O±ring.
(e) Push the water inlet housing end into the water pump hole.
(f) Install the water inlet and housing assembly with the two
bolts. Alternately tighten the bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 25 mm (0.98 in.) in length.
(g) Connect the water by±pass hose to the ISC valve.
±
ENGINE MECHANICAL Cylinder HeadsEM±113
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(g) Install the grommet and a new O±ring to the injector.
(h) Connect SST (hose) to the injector with SST (union),and hold the injector and union with SST (clamp).
SST 09268±41045
(i) Put the injector into the graduated cylinder.
HINT: Install a suitable vinyl hose onto the injector to prevent
gasoline from splashing out.
(j) Using SST, connect terminals +B and FP of the check (ºDIAGNOSISº) connector.
SST 09843±18020
(k) Reconnect the cable to negative (±) terminal of battery.
(l) Turn the ignition switch ON.
NOTICE: Do not start the engine.
(m) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a
graduated cylinder. Test each injector two or three
times.
SST 09842±30070
Volume: 55±70 cc (3.4±4.3 cu in.) per 15 sec.
Difference between each injector:
10 cc (0.6 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE (a) In the condition above, disconnect the test probes ofSST (wire) from the battery and check the fuel leakage
from the injector.
SST 09842±30070
Fuel drop: One drop or less per minute
(b) Disconnect the battery negative (±) cable.
(c) Remove SST.
SST 09268±41045 and 09843±18020
(d) Reconnect the fuel inlet hose to the fuel tube.
SST 09631±22020
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Use a torque wrench with a fulerum length of 30 cm
(11.81 in.). FI±53
EFI SYSTEM
± Fuel System (Injectors)
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