LEXUS SC400 1991 Service Repair Manual

 
Camshaft Thrust clearance STD 0.040±0.090 mm (0.0016±0.0035 in.)
   Limit 0.12 mm (0.0047 in.)
  Journal oil clearance  
  Exhaust camshaft thrust portion STD 0.025±0.061 mm (0.0010±0.0024 in.)  
Others
 
STD
 
0.030±0.067 mm (0.0012±0.0026 in.)   
Limit
 
0.10 mm (0.0039 in.)  Journal diameter  
  Exhaust camshaft thrust portion  23.959±23.975 mm (0.9433±0.9539 in.)  Others  26.954±26.970 mm (1.0612±1.0618 in.)  Circle runout Limit 0.08 mm (0.0031 in.)  Cam lobe height STD (Intake) 41.710±41.810 mm (1.6421±1.6461 in.)   (Exhaust) 41.910±42.010 mm (1.6500±1.6539 in.)   Limit (Intake) 41.56 mm (1.6362 in.)
   (Exhaust) 41.76 mm (1.6441 in.)
  Camshaft gear backslash STD 0.020±0.200 mm (0.0008±0.0079 in.)
   Limit 0.30 mm (0.0188 in.)
  Camshaft gear spring end free distance  18.2±18.8 mm (0.712±0.740 in.)
 Air intake Warpage Limit 0.15 mm (0.0059 in.)
 chamber
 Manifold Warpage Limit (Intake) 0.15 mm (0.0059 in.)
   (Exhaust) 1.00 mm (0.0394 in.)
 Cylinder block Cylinder head surface warpage Limit 0.07 mm (0.0028 in.)
  Cylinder bore±diameter Mark 1 87.500±87.510 mm (3.4449±3.4453 in.)
   Mark 2 87.510±87.520 mm (3.4453±3.4457 in.)
   Mark 3 87.520±87.530 mm (3.4457±3.4461 in.)
Limit87.73 mm (3.4539 in.)  
Main journal bore diameter (Reference)
 
Mark 00
 
72.000 mm (2.8346 in.)   Mark 01 72.001 mm (2.8347 in.)   Mark 02 72.002 mm (2.8347 in.)   Mark 03 72.003 mm (2.8348 in.)   Mark 04 72.004 mm (2.8348 in.)   Mark 05 72.005 mm (2.8348 in.)   Mark 06 72.006 mm (2.8349 in.)   Mark 07 72.007 mm (2.8349 in.)
   Mark 08 72.008 mm (2.8350 in.)
   Mark 09 72.009 mm (2.8350 in.)
   Mark 10 72.010 mm (2.8350 in.)
   Mark 11 72.011 mm (2.8351 in.)
   Mark 12 72.012 mm (2.8351 in.)
   Mark 13 72.013 mm (2.8352 in.)
   Mark 14 72.014 mm (2.8352 in.)
   Mark 15 72.015 mm (2.8352 in.)
   Mark 16 72.016 mm (2.8353 in.)
 Main bearing cap stud bolt tension portion diameter
   STD 7.500±7.600 mm (0.2953±0.2992 in.)
   Limit 7.40 mm (0.2913 in.)
±
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Piston and Piston diameter STD (Mark1) 87.470±87.480 mm (3.4437±3.4441 in.)
 piston ring  (Mark 2) 87.480±87.490 mm (3.4441±3.4445 in.)   (Mark 3) 87.490±87.500 mm (3.4445±3.4449 in.)  Piston oil clearance STD 0.020±0.040 mm (0.0008±0.0016)   Limit 0.06 mm (0.0024 in.)  Piston ring groove clearance No.1 0.020±0.060 mm (0.0008±0.0024 in.)   No.2 0.015±0.055 mm (0.0006±0.0022 in.)  Piston ring end gap STD (No.1) 0.250±0.450 mm (0.0098±0.0177 in.)
   (No.2) 0.350±0.600 mm (0.0138±0.0236 in.)
   (Oil) 0.150±0.500 mm (0.0059±0.0197 in.)
   Limit (No.1) 1.05 mm (0.0413 in.)
   (No.2) 1.20 mm (0.0472 in.)
   (Oil) 1.10 mm (0.0433 in.)
 Connecting Thrust clearance STD 0.160±0.290 mm (0.0063±0.0138 in.)
 rod  Limit 0.35 mm (0.0138 in.)
  Connecting rod thickness  22.880±22.920 mm (0.9008±0.9024 in.)
  Connecting rod big end inside diameter (Ref-
erence)  
   Mark 1 55.000±55.006 mm (2.1654±2.1656 in.)   Mark 2 55.006±55.012 mm (2.1656±2.1658 in.)   Mark 3 55.012±55.018 mm (2.1658±2.1661 in.)   Mark 4 55.018±55.024 mm (2.1661±2.1663 in.)  Connecting rod bearing center wall thickness  
  (Reference) Mark 2 1.484±1.487 mm (0.0584±0.0585 in.)   Mark 3 1.487±1.490 mm (0.0585±0.0587 in.)
   Mark 4 1.490±1.493 mm (0.0587±0.0588 in.)
   Mark 5 1.493±1.496 mm (0.0588±0.0589 in.)
   Mark 6 1.496±1.499 mm (0.0589±0.0590 in.)
   Mark 7 1.499±1.502 mm (0.0590±0.0591 in.)
  Connecting rod oil clearance STD 0.027±0.053 mm (0.0011±0.0021 in.)
   Limit 0.065 mm (0.0026 in.)
 \
 \
Rod bend Limit per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
 \
 \
Rod twist Limit per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)
  Bushing inside diameter  22.005±22.017 mm (0.8663±0.8668 in.)
  Piston pin diameter  21.997±22.009 mm (0.8660±0.8665 in.)
  Bushing oil clearance STD 0.005±0.011 mm (0.0002±0.0004 in.)
Limit0.05 mm (0.0020 in.)  
Connecting rod bolt tension portion diameter
 
STD
 
7.200±7.300 mm (0.2835±0.2874 in.)   
Limit
 
7.00 mm (0.2756 in.)
EG±208±
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Crankshaft Thrust clearance STD 0.020±0.220 mm (0.0008±0.0087 in.)
   Limit 0.30 mm (0.0118 in.)
  Thrust washer thickness  2.440±2.490 mm (0.0961±0.0980 in.)
  Main journal bore diameter on cylinder block  67.026±67.033 mm (2.8388±2.6391 in.)  
(with main bearing)
  
  
Main journal oil clearance
 
STD
 
0.026±0.045 mm (0.0010±0.0018 in.)   Limit 0.055 mm (0.0022 in.)  Main journal diameter  66.988±67.000 mm (2.6373±2.6378 in.) \
 \
Main bearing center wall thickness (Reference) 
   Mark 1 2.486±2.489 mm (0.0979±0.0980 in.)   Mark 2 2.489±2.492 mm (0.0980±0.0981 in.)   Mark 3 2.492±2.495 mm (0.0981±0.0982 in.)   Mark 4 2.495±2.498 mm (0.0982±0.0983 in.)
   Mark 5 2.498±2.501 mm (0.0983±0.0985 in.)
  Crank pin diameter  51.982±52.000 mm (2.0465±2.0472 in.)
  Circle runout Limit 0.08mm (0.0031 in.)
  Main journal taper and out±of±round Limit 0.02mm (0.0008 in.)
  Crank pin taper and out±of±round Limit 0.02mm (0.0008.in)
EGOC6±0C
TORQUE SPECIFICATION
 Part tightened  NVm kgf Vcm ft Vlbf
 No.1 idler pulley x Cylinder Block  34 350 25
 No.2 idler pulley x Cylinder block3435025
 Hydraulic pump x Cylinder block for 12 mm head 16 160 12

yy
for 14 mm head3031022 Crankshaft pulley x Crankshaft  245 2,500 181 Camshaft timing pulley x Camshaft  108 1,100 80 Timing belt tensioner x Oil pump  26 270 20 Spark plug x Cylinder head  18 180 13
 Drive belt tensioner x Cylinder block  16 160 12
 Generator x Generator bracket  37 380 27
 Generator x Cylinder block3738027
 Distributor housing x Cylinder head1818513
 Distributor rotor x Camshaft timing pulley3.83934 in.
lbf
 Distributor cap x Distributor housing3.83934 in.
lbf
 RH No.2 timing belt cover x Cylinder blockfor 12 mm head1818513
Drive belt idler pulley x Fan bracket3738027 
A/C compressor x Cylinder block4950036 A/C compressor x Fan bracket  49 500 36 A/C compressor stay x Oil filter bracket  29 300 22 Upper radiator support x Body  12 120 9 Exhaust manifold x Cylinder head  44 450 33
 Cylinder head x Cylinder block 1st 39 400 29
  2nd Turn 90 5  
 Camshaft bearing cap x Cylinder head  16 160 12
 Cylinder head cover x Cylinder head  5.9 60 52 in.Vlbf
Engine hanger x Cylinder head3738027 EGR pipe x RH exhaust pipe  18 185 13 Rear water bypass joint x Cylinder head  18 185 13
±
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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±
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\
 \

Front suspension crossmember x Engine mounting insulator  59 600 43
\
 \
PS pump x Cylinder head for bolt 39 400 29
\
 \
 for nut 43 440 32
\
 \
Propeller shaft x Transmission  79 805 58\
 \

Propeller shaft x Differential
  
79
 
805
 
58\
 \

Propeller shaft x Body
  
37
 
375
 
27\
 \
Center floor crossmember brace x Body  13 130 9\
 \
Fuel inlet hose x Fuel tube  30 310 22\
 \
TWC (Front) x Exhaust manifold  62 530 46\
 \
Front exhaust pipe x TWC (Front)  43 440 32\
 \
Front exhaust pipe support bracket x Transmission  43 440 32\
 \
Front exhaust pipe x Center Exhaust pipe  43 440 32\
 \
Center exhaust pipe x Tailpipe  44 195 14
\
 \
Main heated oxygen Exhaust manifold  44 450 33
\
 \
Sub heated oxygen sensor x Front exhaust pipe  44 450 33
±
1UZ ± FE ENGINE ENGINE MECHANICALEG±211
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1UZ±FE ENGINE
EG±1
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EG10Y±03
ENGINE MECHANICAL
DESCRIPTION
The 1 UZ±FE engine is a V±8, 4.0 liter DOHC 32±valve engine.
OPERATION
EG21L±01
EG±2±
1UZ±FE ENGINE ENGINE MECHANICAL
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EG10Y±03
ENGINE MECHANICAL
DESCRIPTION
The 1 UZ±FE engine is a V±8, 4.0 liter DOHC 32±valve engine.
OPERATION
EG21L±01
EG±2±
1UZ±FE ENGINE ENGINE MECHANICAL
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±
1UZ±FE ENGINE ENGINE MECHANICALEG±3
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The 1 UZ±FE engine has 8±cylinders in a V±arrangement at a bank an\
gle of 905. From the front of the RH
bank cylinders are numbered 2 ± 4 ± 6 ± 8, and from the front of t\
he LH bank cylinders are 1 ± 3 ± 5 ± 7.
The crankshaft is supported by 5 bearings inside the crankcase. These beari\
ngs are made of a copper and
lead alloy.
The crankshaft is integrated with 8 weights for balance. Oil holes are plac\
ed in the center of the crankshaft
to supply oil to the connecting rods, bearing, pistons and other component\
s.
The ignition order is 1 ± 8 ± 4 ± 3 ± 6 ± 5 ± 7 ± 2. T\
he cylinder head is made of alminum alloy, with a cross
flow type intake and exhaust layout and with pent±roof type combustion chambers. The spark plugs are
located in the center of the combustion chambers.
At the front and rear of the intake manifold, a water passage has been p\
rovided which connects the RH
and LH cylinder heads.
Exhaust and intake valves are equipped with irregular pitch springs made\
of special valve spring carbon
steel which are capable of functioning at all engine speeds.
The RH and LH intake camshaft are driven by a timing belt, and a gear on\
the intake camshaft engages
with a gear on the exhaust camshaft to drive it. The cam journal is supp\
orted at 5 (intake) or 4 (exhaust)
places between the valve lifters of each cylinder and on the front end o\
f the cylinder head. Lubrication of
the cam journals and gears is accomplished by oil being supplied through th\
e oiler port in the center of the
camshaft.
Adjustment of the valve clearance is done by means of an outer shim type\
system, in which valve adjusting
shims are located above the valve lifters. This permits replacement of the sh\
ims without removal of the
camshafts.
Pistons are made of high temperature±resistant aluminum alloy, and a depression is built into the piston
head to prevent interference with the valves.
Piston pins are the full±floating type, with the pins fastened to neither the piston boss nor the connecting
rods. Instead, snap rings are fitted on both ends of the pins, preventing the\
pins from falling out.
The No.1 compression ring is made of steel and the No.2 compression ring\
is made of cast iron. The oil
ring is made of a combination of steel and stainless steel. The outer diamet\
er of each piston ring is slightly
larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls
when they are mounted on the piston. Compression rings No.1 and No.2 work to\
prevent gas leakage from
the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combus-
tion chambers.
The cylinder block is made of aluminum alloy with a bank of 90 5. Cast iron cylinders are installed inside
the cylinder block. It has 8 cylinders which are approximately twice the le\
ngth of the piston stroke. The top
of each cylinder is closed off by the cylinder head and the lower end of the cylinders becomes the crank-
case, in which the crankshaft is installed. In addition, the cylinder block c\
ontains a water jacket, through
which coolant is pumped to cool the cylinders.
The No.1 and No.2 oil pans are bolted onto the bottom of the cylinder bl\
ock. The No.1 oil pan is made of
aluminum alloy. The No.2 oil pan is an oil reservoir made of pressed steel sheet. An o\
il level sensor is
installed in the No.1 oil pan (If oil level drops below a set level, a warning light\
s up.). And oil pan baffle plate
keeps sufficient oil in the bottom of the No.2 oil pan even when the vehicle is t\
ilted. This dividing plate also
prevents the oil from marking waves when the vehicle is stopped suddenly\
and the oil shifts away from the
oil pump suction pipe.
Plastic region tighten bolts are used for the cylinder head, main bearin\
g cap and connecting rod.
EG±4
±
1UZ±FE ENGINE ENGINE MECHANICAL
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