engine LEXUS SC400 1991 Service Repair Manual

(b) Install the engine wire cover with the 3 bolts.
(c) Connect the following connector:wCrankshaft position sensor connector
w Oil pressure switch connector
w Oil level sensor connector
7. INSTALL WATER BYPASS PIPE
(a) Install a new O±ring to the water bypass pipe.
(b) Apply soapy water to the O±ring.
(c) Push the water bypass pipe end into the pipe hole of the water pump.
(d) Install the water bypass pipe with the 2 bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
8. INSTALL KNOCK SENSORS
(a) Using SST, install the 2 knock sensors.
SST 09816±30010
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
(b) Connect the 2 knock sensor connectors.
9. INSTALL STARTER
(a) Install the engine wire clamp to the bracket on the starter.
(b) Connect the starter wire with the nut.
(c) Connect the starter connector.
(d) Install the starter with the 2 bolts.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
EG±188±
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10. INSTALL RH ENGINE MOUNTING BRACKETInstall the mounting bracket with the 4 bolts.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
HINT: The RH mounting bracket is marked with ªRº.
11. INSTALL LH ENGINE MOUNTING BRACKET
(a) Install the mounting bracket with the 4 bolts. HINT: The LH mounting bracket is marked with ªLº
Torque: 37 N Vm, (380 kgf Vcm, 27 ft Vlbf)
(b) Install the engine with to the mounting bracket with the bolt.
12. INSTALL CYLINDER HEADS
(See pages EG±109 to 136)
13. INSTALL TIMING BELT AND PULLEYS (See pages EG±60 to 72)
14. DISCONNECT ENGINE FROM ENGINE STAND
15. INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equivalent
(b) Install the front spacer, drive plate and rear plate on thecrankshaft.
(c) Install and uniformly tighten the 8 bolts in several passes, in
the sequence shown.
Torque: 98 N Vm (1,000 kgf Vcm, 72 ft Vlbf)
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ENGINE & TRANSMISSION ASSEMBLY
EG34U±01
(See Components for Engine & Transmission Separation and
Assembly)
1. INSTALL TRANSMISSION TO ENGINE
(See page AT±23)
2. CONNECT ENGINE WIRE
(a) Connect the following parts: (1) O/D direct clutch speed sensor connector
(2) No.1 VSS connector for speedometer
(3) No.2 VSS connector for ECM
(4) PNP switch connector
(5) Solenoid connector
(b) Install the 5 wire clamps to the brackets on the transmission.
EG±190
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3. INSTALL OIL COOLER PIPE FOR TRANSMISSION
(a) Temporarily install the oil cooler pipe with the 2 pipe bracketsand 2 bolts.
(b) C onnect the 2 oil cooler pipes to the unions on the
transmission.
Torque: 34 N Vm (350 kgf Vcm, 26 ft Vlbf)
(c) Tighten the 2 pipe clamp bolts.
4. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR
TRANSMISSION
(a) Install a new O±ring to the dipstick guide
(b) Apply soapy water to the O±ring
(c) Connect the dipstick guide end to the dipstick tube of the oil
pan.
(d) Install the dipstick guide with the bolt.
(e) Install the dipstick.
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ENGINE INSTALLATION
EG2HW±02
(See Components for Engine Removal and Installation)
1. INSTALL ENGINE AND TRANSMISSION ASSEMBLY INVEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine and transmission assembly into the engine compartment.
NOTICE: Be careful not to hit the PS gear housing and
PNP switch.
(c) Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
(d) Keep the engine level.
(e) Install the rear engine mounting member with the 4 bolts and 4 nuts.
Torque:
25 NVm (250 kgf Vcm, 19 ft Vlbf) for bolt
13 N Vm (135 kgf Vcm, 10 ft Vlbf) for nut
(f) Install the 2 nuts holding the engine mounting brackets to the
front suspension crossmember.
Torque: 59 N Vm (600 kgf Vcm, 43 ft Vlbf)
EG±192±
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2. CONNECT TRANSMISSION CONTROL ROD FROMSHIFT LEVER
Connect the control rod to the shift lever with the nut.
3. INSTALL PROPELLER SHAFT (See page PR±12)
4. INSTALL CENTER FLOOR CROSSMEMBER BRACE Install the crossmember brace with the 4 nuts.
Torque: 13 N Vm (130 kgf Vcm, 9 ft Vlbf)
5. INSTALL HEAT INSULATOR FOR FRONT EXHAUST PIPE
Install the heat insulator with the 4 bolts.
6. INSTALL CENTER EXHAUST PIPE Install the 2 hooks of the exhaust pipe to the rings on the ex-
haust pipe brackets.
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7. INSTALL TAILPIPE
(a) Install the hook of the tailpipe to the ring on the tailpipebracket.
(b) Install a new gasket and tailpipe to the center exhaust pipe with 2 bolts. Install the 2 tailpipes.
Torque: 19 N Vm (195 kgf Vcm, 14 ft Vlbf)
8. INSTALL TWC (FRONT)
Using a 14 mm deep socket wrench, install a new gasket and
the TWC with 3 new nuts. Install the 2 TWC.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
9. INSTALL FRONT EXHAUST PIPE
(a) Temporarily install the pipe support bracket with the 4 bolts.
(b) Temporarily install 3 new gaskets and the exhaust pipe with
the 6 bolts and nuts.
(c) Tighten the 4 bolts and nuts holding the TWC to the front exhaust pipe.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(d) Tighten the 2 bolts and nuts holding the front exhaust pipe to
the center exhaust pipe.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(e) Tighten the 4 bolts holding the pipe support bracket to the
transmission.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
10. INSTALL SUB HEATED OXYGEN SENSORS
Install the 2 oxygen sensors to the front exhaust pipe.
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
HINT:
w Before installing the oxygen sensor, twist the sensor
wire counterclockwise 3 1/2 turns.
w After installing the oxygen sensor, check that the sensor
wire is not twisted. If it is twisted, remove the oxygen
sensor and reinstall it.
EG±194
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11. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel.NOTICE: Be careful not to damage the engine wire. Tape
the engine wire.
(b) Install the engine wire retainer with the 3 bolts.
(c) Connect the following connectors: (1) 2 connectors to ECM
(2) Connector to ABS & TRAC ECU
(3) 2 connectors to TRAC ECU
(4) 4 connectors to connector cassette
(5) Connector to A/C control assembly
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(d) Install the ECM with the nut.
(e) Install the ECM protector with the 2 nuts.
(f) Install the floor carpet.
(g) Install the scuff plate.
(h) Connect the connectors.
(i) Install the lower instrument panel finish panel and glovecompartment door assembly with the 4 screws.
(j) Install the instrument panel under cover with the 2 clips.
EG±196
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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 hoses and ground strap:
(1) Heater water hose to water bypass hose
(2) Heater water hose to heater water valve
(3) Brake booster hose to union on air intake chamber
(4) Vacuum hose (from VSV for heater water valve) to air in-
take chamber
(5) Ground strap to bracket on body
(6) Fuel inlet hose to fuel tube
SST 09278±54012
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
(7) Fuel return hose to return pipe
14. INSTALL AIR CONDITIONING (A/C) COMPRESSOR
(a) Install the A/C compressor, compressor stay and ground cable with the nut and 3 bolts.
Torque:
49 NVm (500 kgf Vcm, 36 ft Vlbf) for bolt
29 N Vm (300 kgf Vcm, 22 ft Vlbf) for nut
(b) Connect the A/C compressor connector.
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