Lexus SC300 / Lexus SC400. Manual - part 578

38. (USA Spec.)

INSTALL EGR VALVE
(a)  Place a new gasket on the EGR valve adaptor.
NOTICE:

•

Do not touch the adapter and EGR valve surfaces of the

gasket with your hand.

•

Align the port holes of the gasket and adaptor. Be careful

of the installation direction.

(b)  Install the EGR valve with the two nuts.

Torque: 18 N

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

(c)  Connect the following hoses:

(1)

Water by–pass pipe hose to ISC valve

(2)

Water by–pass pipe hose to water by–pass pipe
(from rear water by–pass joint)

(d)  Connect the EGR valve connector.

39.  (Exc. USA Spec.)

INSTALL EGR VALVE AND VACUUM MODULATOR
(a)  Place a new gasket on the EGR valve adaptor.
NOTICE:

•

Do not touch the adapter and EGR valve surfaces of the

gasket with your hand.

•

Align the port holes of the gasket and adaptor. Be careful

of the installation direction.

(b) Install the EGR valve and vacuum and modulator

assembly with the two nuts and bolt.

Torque (Nut): 18 N

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

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(c)  Connect the following hoses:

(1)

Water by–pass pipe hose to ISC valve

(2)

Water by–pass pipe hose to water by–pass pipe
(from rear water by–pass joint)

(3)

Two vacuum hoses to VSV for EGR system

40. INSTALL 

VACUUM 

PIPE

(a)  Install the vacuum pipe, vacuum hoses assembly and

EGR water by–pass pipe (USA spec. only) with the two
bolts.

(b)  Connect the following hoses:

(1)

(USA Spec.)
Vacuum hose to throttle body

(2)

(Exc. USA Spec.)
Three vacuum hoses to throttle body

(3)

Vacuum hose to fuel pressure regulator

(4)

Two vacuum hoses to VSV for fuel pressure control
system

(5)

(Exc. USA Spec.)
Two vacuum hoses to EGR vacuum modulator

(6)

Two vacuum hoses (from VSV for EVAP system) to
vacuum pipe

(7)

Vacuum hose (from VSV for fuel pressure control
system) to air intake chamber

(8)

Vacuum hose (from charcoal canister) to vacuum
pipe

EM–112

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41.  INSTALL TIMING BELT REAR PLATES

Install the rear plate with the two bolts. Install the two rear
plates.

Torque: 7.8 N

⋅

m (80 kgf

⋅

cm, 69 in.

⋅

lbf)

42.  INSTALL WATER INLET AND INLET HOUSING

(a)  Remove any old packing (FIPG) material.

•

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) materials from the gasket
surfaces and sealing groove.

•

Thoroughly clean all components to remove all the
loose materials.

•

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

•

Install a nozzle that has been cut to a 2–3 mm
(0.08–0.12 in.) opening.

•

Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.

•

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

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

HINT: Use bolts 25 mm (0.98 in.) in length.

(g)  Connect the water by–pass hose to the ISC valve.

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43.  INSTALL RH IGNITION COIL

Install the ignition coil with the two bolts.

44.  CONNECT CONTROL CABLES TO THROTTLE BODY

Connect the following cables:

(1)

Accelerator cable

(2)

A/T throttle cable

(3)

(w/ Cruise Control System)

Cruise control actuator cable

45.  INSTALL THROTTLE BODY COVER

Install the throttle body cover and hose clamp with the two
bolts and cap nut.

46.  INSTALL CATALYTIC CONVERTERS (MAIN)

(a)  Install a new gasket and the catalytic converter to the

exhaust manifold with the three new bolts. Install the two
catalytic converters.

Torque: 62 N

⋅

m (630 kgf

⋅

cm, 46 ft

⋅

lbf)

(b)  Install a new gasket to each front end of the front

exhaust pipe.

(c) Connect the front exhaust pipe to the catalytic

converters.

(d) Temporarily 

install 

the 

four 

bolts 

holding 

the 

pipe

support bracket to the transmission.

(e)  Install the four bolts and nuts holding the catalytic

converters to the front exhaust pipe.

Torque: 43 N

⋅

m (440 kgf

⋅

cm, 32 ft

⋅

lbf)

(f)  Tighten the four bolts holding the pipe support bracket

to the transmission.

Torque: 43 N

⋅

m (440 kgf

⋅

cm, 32 ft

⋅

lbf)

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