LEXUS SC400 1991 Service Repair Manual

(g) Install the scuff plate.
(h) Connect the connectors.
(i) Install the lower instrument panel finish panel and glovecompartment door assembly with the four screws.
(j) Install the instrument panel under cover with the two clips.
12. INSTALL CHARCOAL CANISTER (a) Install the charcoal canister.
(b) Connect the vacuum hose and air hose to the charcoalcanister.
13. CONNECT HOSES Connect the following hose and ground strap:(1) Heater water hose to water by±pass pipe
(2) Heater water hose to heater water valve
(3) Vacuum hose to brake booster union on air intake
chamber
(4) Vacuum hose (from VSV for heater water valve) to
air intake chamber
(5) Ground strap to bracket on body
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(6) Two fuel hoses to fuel tubes
14. INSTALL A/C COMPRESSOR (a) In sta ll th e A/C co mp re sso r, co mp re sso r sta y an dground cable with the nut and three bolts.
Torque: Bolt 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
Nut 29 N Vm (300 kgf Vcm, 22 ft Vlbf)
(b) Connect the A/C compressor connector.
15. INSTALL PS PUMP Install the PS pump with the three bolts and nut. Alternately
tighten the bolts and nut.
Torque: Bolt 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
Nut 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
16. INSTALL PS RESERVOIR TANK AND BRACKET
Install the reservoir tank and bracket assembly with the three
bolts.
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17. INSTALL PS TUBESInstall the PS tube clamp with the bolt.
18. INSTALL ALTERNATOR (a) Install the alternator and A/T oil cooler pipe bracket withthe bolt and nut.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
(b) Connect the alternator connector.
(c) Connect the alternator wire with the nut and cap.
19. INSTALL WIRE CLAMP (FOR ALTERNATOR) AND VSV (FOR EVAP SYSTEM)
(a) Install the wire clamp to the VSV bracket.
(b) Install the VSV with the two bolts.
20. CONNECT PS SOLENOID VALVE CONNECTOR
21. CONNECT ENGINE WIRE CONNECTORS
22. CONNECT THEFT DETERRENT HORN CONNECTOR
23. INSTALL GROUND CABLE TO BODY
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24. CONNECT IGNITER CONNECTOR(a) Connect the two igniter connectors.
(b) Install the wire clamp.
25. INSTALL RADIATOR (a) Install the two lower radiator supports to the radiator.
(b) Place the radiator on the body bracket.
(c) Slightly lift the radiator, and connect the two cooler hose(for cooling fan) to the hose clamp on the radiator fan
shrould.
(d) Install the upper radiator support with the two bolts and screw. Install the two upper radiator supports.
(e) Connect the following hoses: (1) Pressure hose to hydraulic pump
(2) Suction hose to hydraulic pump
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(3) Two oil cooler hoses (for A/T) to radiator
(4) Two radiator hoses
(5) Two oil cooler hoses (for cooling fan) to pipes
(f) Connect the water temperature sensor connector.
(g) Install the wire clamp (for water temperature sensor) to the radiator fan shrould.
26. INSTALL RADIATOR RESERVOIR TANK (a) Install the reservoir tank to the reservoir tank bracket.
(b) Install the reservoir tank bracket with the two bolts.
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(c) Connect the following hoses:(1) Reservoir hose to water inlet housing
(2) Reservoir hose to radiator
(d) Connect the coolant level sensor connector.
27. INSTALL INTAKE AIR CONNECTOR (a) Connect the intake air connector to the throttle body.
(b) Install the hose clamp and mounting bolt.
(c) Connect the following hoses:(1) Air hose to ISC valve
(2) Air hose (from PS air control valve) to air intake chamber
28. CONNECT VACUUM HOSE (A) (FROM PS AIR CONTROL VALVE) TO AIR INTAKE CHAMBER
29. INSTALL AIR CLEANER AND AIR FLOW METER (a) Connect the air cleaner case to the air duct.
(b) Connect the air cleaner hose to the intake air connector.
(c) Install the four mounting bolts and hose clamp.
(d) Connect the air flow meter connector.
30. 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
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31. INSTALL THROTTLE BODY COVERInstall the throttle body cover and hose clamp with the two
bolts and cap nut.
32. INSTALL DRIVE BELT Install the drive belt by turning the drive belt tensioner coun-
terclockwise.
HINT: The pulley bolt for the belt tensioner has a left±hand
thread.
33. INSTALL BATTERY
34. FILL WITH ENGINE COOLANT (See page CO±7)
35. FILL COOLING FAN RESERVOIR TANK WITH FLUID (See page CO±23)
36. FILL WITH ENGINE OIL (See page LU±7)
Capacity:
Drain and refill
w/Oil filter change4.8 liters (5.1 US qts, 4.2 lmp. qts)
w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 lmp. qts)
Dry fill 6.0 liters (6.3 US qts, 5.3 lmp. qts)
37. START ENGINE AND CHECK FOR LEAKS
38. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
39. CHECK IGNITION TIMING (See page IG±28)
Ignition timing:
8±125 BTDC @ idle
(w/ Terminals TE1 and E1 connected)
40. INSTALL ENGINE UNDER COVER
41. INSTALL HOOD
42. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
32. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS
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SERVICE SPECIFICATIONS
SERVICE DATA
 Engine tune±up Battery specific gravity  1.27±1.29 g  (when fully charged at 205C (68 5F))  High±tension cord resistance Limit 25 k
per cord  Valve clearance Intake 0.15 ± 0.25 mm 0.006 ± 0.010 in.   Exhaust 0.25 ± 0.35 mm 0.010 ± 0.014 in.
  Ignition timing 8±12 5 BTDC @ idle
   (w/ Terminals TE1 and E1 connected)
  Idle speed 700 + 50 rpm
 


Intake
manifold 


at Idle speed 


 


60 kPa 450 mmHg 17.7 in.Hg
vacuum vacuum  
Compressionat 250 rpmSTD1,226 kPa (12.5 kgf/cm, 178 psi) or more pressure  Limit 981 kPa 10.0 kgf/cm 142 psi  Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm, 14 psi) or less Timing belt ten- Protrusion from housing end 10.5 ± 11.5 mm 0.413 ± 0.453 in. g
sioner g  
 Cylinder head Warpage Cylinder block side Limit 0.10 mm 0.0039 in.
 
y
 Manifold side Limit 0.10 mm 0.0039 in.
  Valve seat Refacing angle 30
5, 45 5, 75 5
  Contacting angle 455
Contacting width1.0 ± 1.4 mm0.039 ± 0.055 in.  Cylinder head bolt thread outside diam4eter 
   STD 9.770 ± 9.960 mm 0.3846 ± 0.3921 in.   Limit 9.60 mm 0.3780 in. Valve guide Inside diameter 6.010 ± 6.030 mm 0.2366 ± 0.2374 in.
 
g
bushing Outside diameter (for repair part) STD 11.048 ± 11.059 mm 0.4350 ± 0.4354 in.
 
g
  O/S 0.05 11.098 ± 11.109 mm 0.4369 ± 0.4374 in.
 Valve Valve overall length STD Intake 94.95 mm 3.7382 in.
    Exhaust 96.90 mm 3.8150 in.
LimitIntake94.45 mm3.7185 in.    Exhaust 96.40 mm 3.7953 in.  Valve face angle   44.5 5  Stem diameter  Intake 5.970 ± 5.985 mm 0.2350 ± 0.2356 in.    Exhaust 5.965 ± 5.980 mm 0.2356 ± 0.2354 in.
  Stem oil clearance STD Intake 0.025 ± 0.060 mm 0.0010 ± 0.0024 in.
    Exhaust 0.030 ± 0.065 mm 0.0012 ± 0.0026 in.
   Limit Intake 0.08 mm 0.0031 in.
Exhaust0.10 mm0.0039 in.  Margin thickness  STD 1.0 mm 0.039 in.    Limit 0.5 mm 0.020 in. Valve spring Squareness Limit 2.0 mm 0.079 in. g Free length  43.6 mm 1.717 in.
  Installed tension at 32.9 mm (1.295 in.) 186±206 N 
    (19.0 ± 21.0 kgf, 41.9 ± 46.3 lbf)
 Valve lifter Lifter diameter 30.966±30.976 mm 1.2191±1.2195 in.
  Lifter bore diameter  31.000±31.016 mm 1.2205±1.2211 in.
Oil clearanceSTD0.024±0.050 mm0.0009±0.0020 in.   Limit 0.07 mm 0.0028 in.
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SERVICE DATA (Cont'd)
 Camshaft Thrust clearance STD 0.040±0.090 mm 0.0016±0.0035 in.
   Limit 0.12 mm 0.0047 in.
  Journal oil clearance 
   STD Exhaust camshaft thrust portion 0.025±0.061 mm 0.0010±0.0024 in.
   Others 0.030±0.067 mm 0.0012±0.0026 in.
Limit0.10 mm0.0039 in.  Journal diameter 
   Exhaust camshaft thrust portion 23.959±23.975 mm 0.9433±0.9439 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 backlash STD 0.020±0.200 mm 0.0008±0.0079 in.
Limit0.30 mm0.0188 in.  Camshaft gear spring end free distance 18.2±18.8 mm 0.712±0.740 in. Manifold Warpage Limit Intake 0.15 mm 0.0059 in.   Exhaust 1.00 mm 0.0394 in. Air intake Warpage Limit 0.15 mm 0.0059 in. chamber  
 Cylinder block Cylinder head surface warpage Limit 0.07 mm 0.0028 in.
  Cylinder bore diameter STD 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.
   Limit 87.73 mm 3.4539 in.
  Main bearing cap stud bolt 
tension portion diameterSTD7.500±7.600 mm0.2953±0.2992 in.   
Limit
 
7.40 mm
 
0.2913 in. Piston and Piston diameter Mark 1 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 in.
   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.
LimitNo.11.05 mm0.0413 in.   No.2 1.20 mm 0.0472 in.   Oil 1.10 mm 0.0433 in.
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SERVICE DATA (Cont'd)
 Connecting rod Thrust clearance STD 0.160±0.330 mm 0.0063±0.0114 in.
   Limit 0.35 mm 0.138 in.
  Connecting rod thickness 22.880±22.920 mm 0.9008±0.9024 in.
  Connecting rod bearing center wall thickness 
   Mark 2 1.484±1.487 mm 0.0584±0.0585 in.
Mark 31.487±1.490 mm0.0585±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 bending 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.
  Connecting rod bushing inside diameter 22.005±22.017 mm 0.8663±0.8668 in.
Piston pin diameter21.997±22.009 mm0.8660±0.8665 in.  Connecting rod bushing oil clearance STD 0.005±0.011 mm 0.0002±0.0004 in.   Limit 0.05 mm 0.0020 in.  Connecting rod tension portion diameter 
   STD 7.200±7.300 mm 0.2835±0.2874 in.   Limit 7.00 mm 0.2756 in.
 Crankshaft Thrust clearance STD 0.020±0.220 mm 0.0008±0.0087 in.
   Limit 0.30 mm 0.0118 in.
  Thrust washer thickness STD 2.440±2.490 mm 0.0961±0.0980 in.
  Main journal bore diameter on cylinder block 67.026±67.033 mm 2.6388±2.6391 in.
  (with main bearing) 
Main journal oil clearanceSTD0.026±0.045 mm0.0010±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 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 0.08 mm 0.0031 in.
  Main journal taper and out±of±round Limit 0.02 mm 0.0008 in.
Crank pin taper and out±of±roundLimit0.02 mm0.0008 in.
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