LEXUS SC400 1991 Service Repair Manual

(f) Install the other 4 bearing caps in the sequence shown withthe arrow marks facing rearward.
HINT: Align the arrow marks at the front and rear of the cylin-
der head with the mark on the bearing cap.
(g) Apply a light coat of engine oil on the threads and under the heads (A only) of the bearing cap bolts.
HINT: Do not apply engine oil under the heads of the bearing
cap bolt (B).
(h) Install a new seal washer to the bearing cap bolt (B). Install the 8 bearing cap bolts as shown.
HINT:
wUse bearing cap bolts 38 mm (1.50 in.) in length. The
bolts are black (A) or silver (B) in color. Install the 2 silver
bolts to the front bearing cap. Install the 6 black bolts to
the other positions.
w After installing the oil feed pipe, install the 2 bolts to rear
bearing cap as directed in step B (i).
(i) Uniformly tighten the 8 bearing cap bolts in several passes, in the sequence shown.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
B. Install exhaust camshaft to RH cylinder head
(a) Set the timing mark (1 dot mark) of the camshaft drive gear
at 10
angle by turning the hexagon wrench head portion of
the intake camshaft with a wrench.
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(b) Apply MP grease to the thrust portion of the exhaustcamshaft.
(c) Align the timing marks (1 dot mark) of the camshaft drive and
driven gears.
(d) Place the exhaust camshaft on the cylinder head.
(e) Check that the exhaust camshaft moves smoothly in the thrust direction.
(f) Install the rear bearing cap (mark ªE1º) with the arrow mark facing rearward.
HINT:
wInstalling the rear bearing cap will determine the thrust
portion of the camshaft.
w Align the allow marks at the front and rear of the cylinder
head with the mark on the bearing cap.
(g) Install the other 3 bearing caps in the sequence shown with the arrow marks facing rearward.
HINT: Align the arrow marks at the front and rear of the cylin-
der 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 10 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 feed pipe. Install the eight 38 mm (1.50 in.) bolts in the
other positions.
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(j) Uniformly tighten the 8 bolts on the bearing caps of theexhaust camshaft in several passes, in the sequence shown.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
(k) Alternately tighten the 2 bolts on the rear bearing caps of the
intake camshaft in several passes.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
(l) Boring the service bolt installed in the driven subgear upward
by turning the hexagon wrench head portion of the camshaft
with a wrench.
(m) Remove the service bolt.
C. Install intake camshaft to LH cylinder head
(a) Apply MP grease to the thrust portion of the intake camshaft.
(b) Place the intake camshaft at 60
angle of the timing mark (1
dot mark) on the cylinder head.
(c) Remove any old packing (FIPG) material.
(d) Apply seal packing to the bearing cap (mark ª11º) as shown.
Seal packing: Part No. 08826±00080 or equivalent
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(e) Install the front bearing cap (mark ª11º) with the arrow markfacing forward.
HINT:
wInstalling the front bearing cap will determine the thrust
portion of the camshaft.
w Align the allow marks at the front and rear of the cylinder
head with the mark on the bearing cap.
(f) Install the other 4 bearing caps in the sequence shown with the arrow marks facing rearward.
HINT: Align the arrow marks at the front and rear of the cylin-
der head with the mark on the bearing cap.
(g) Apply a light coat of engine oil on the threads and under the heads (A only) of the bearing cap bolts.
HINT: Do not apply engine oil under the heads of the bearing
cap bolt (B).
(h) Install a new seal washer to the bearing cap bolt (B). Install the 8 bearing cap bolts as shown.
HINT:
wUse bearing cap bolts 38 mm (1.50 in.) in length. The
bolts are black (A) or silver (B) in color. Install the 2 silver
bolts to the front bearing cap. Install the 6 black bolts to
the other positions.
w After installing the oil feed pipe, install the 2 bolts to the
bearing cap 2nd from the front as directed in step B (i).
(i) Uniformly tighten the 8 bearing cap bolts in several passes, in the sequence shown.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
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D. Install exhaust camshaft to LH cylinder head
(a) Set the timing mark (2 dot marks) of the camshaft drive gearat 15
angle by turning the hexagon wrench head portion of
the intake camshaft with a wrench.
(b) A p p ly MP gre a se to th e th ru st po rtio n of th e ex haust
camshaft.
(c) Align the timing marks (2 dot marks) of the camshaft drive and
driven gears.
(d) Place the exhaust camshaft on the cylinder head.
(e) Check that the exhaust camshaft moves smoothly in the thrust direction.
(f) Install the front bearing cap (mark ªE1º) with the arrow mark facing forward.
HINT:
wInstalling the front bearing cap will determine the thrust
portion of the camshaft.
w Align the allow marks at the front and rear of the cylinder
head with the mark on the bearing cap.
(g) Install the other 3 bearing caps in the sequence shown with the arrow marks facing forward.
HINT: Align the arrow marks at the front and rear of the cylin-
der head with the mark on the bearing cap.
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(h) Apply a light coat of engine oil on the threads and under theheads of the bearing cap bolts.
(i) Install the oil feed pipe and 10 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 feed pipe. Install the eight 38 mm (1.50 in.) bolts in the
other positions.
(j) Uniformly tighten the 8 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)
(k) Alternately ti ghten the 2 bolts on the bearing cap of the intake
camshaft 2nd from the front in several passes.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
(l) Boring the service bolt installed in the driven subgear upward
by turning the hexagon wrench head portion of the camshaft
with a wrench.
(m) Remove the service bolt.
8. CHECK AND ADJUST VALVE CLEARANCE (See steps 19 to 22 on pages EG±19 to 21)
Turn the camshaft and position the cam lobe upward, and
check and adjust the valve clearance.
Valve clearance (Cold):
Intake0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust 0.25 ± 0.35 mm (0.010 ± 0.014 in.)
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EG22W±02
9. INSTALL CAMSHAFT OIL SEALS
(a) Apply MP grease to a new oil seal lip.
(b) Using SST and a hammer, tap in the 2 oil sealsSST 09223±46011
10. INSTALL SEMI±CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi±circular plug grooves.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the 4 semi±circular plugs to the cylinder heads.
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11. INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads as shown in theillustration.
Seal packing:
Part No. 08826±00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 8 bolts. Uniformlytighten the bolts in several passes. Install the 2 cylinder head
covers.
Torque: 5.9 N Vm (60 kgf Vcm, 52 in. Vlbf)
12. INSTALL ENGINE HANGERS
Install the engine hanger with the 2 bolts. Install the 2 engine
hangers.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
13. INSTALL ENGINE WIRE TO CYLINDER HEADS
(a) Install the engine wire protector to the RH cylinder head with
the 2 bolts.
(b) Install the ground strap to RH cylinder head with the bolt.
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(c) Install the engine wire protector to the LH cylinder head withthe 5 bolts.
14. INSTALL EGR PIPE Install a new gasket and EGR pipe to the RH exhaust man-
ifold with 2 new nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
15. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
(a) Install a new O±ring to the dipstick guide.
(b) Apply soapy water to the O±ring.
(c) Push in the dipstick guide end into the guide hole of the No.1
oil pan.
(d) Install the dipstick guide with the bolt.
(e) Install the dipstick.
16. I N S TA L L O I L D I P S T I C K A N D G U I D E F O R TRANSMISSION
17. INSTALL REAR WATER BYPASS JOINT
(a) Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Install the water bypass pipe to the LH rear engine hanger
with the bolt.
18. INSTALL FRONT WATER BYPASS JOINT
(a) Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
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(b) Install the engine wire protector with the bolt.
(c) Connect the following connectors:(1) ECT sensor connector
(2) ECT sender gauge connector
19. INSTALL INTAKE MANIFOLD
(a) Place 2 new gaskets on the cylinder heads with white 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 on the cylinder heads with the
arrow mark facing forward.
NOTICE: Be careful of the installation direction.
(c) Install and uniformly tighten the 6 bolts and 4 nuts in severalpasses.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolt 30 mm (1.18 in.) in length.
20. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new O±ring, and install it to the injector.
(c) While turning the injector clockwise and counterclockwise, push it to the delivery pipe. Install the 8 injectors.
(d) Position the injector connector outward.
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