ect LEXUS SC300 1991 Service Repair Manual

5. INSTALL NO.1 OIL PAN(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the No.1
oil pan and cylinder block.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
NOTICE: Do not use a solvent which will affect the
painted surfaces.
(b) Apply seal packing to the No.1 oil pan as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
w Install a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
HINT: Avoid applying an excessive amount to the surface. w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Temporarily install the No.1 oil pan with the sixteen bolts
and two nuts.
HINT: Each bolt length is indicated in the illustration.
Bolt length:
A 20 mm (0.78 in.) for 10 mm head
B 35 mm (1.38 in.) for 10 mm head
C 55 mm (2.17 in.) for 12 mm head
(d) Set the No.1 oil pan as shown in the illustration.
NOTICE: Make sure the clearance between the rear ends
of the oil pan and cylinder block is 0.2 mm (0.008 in.) or
less. If the clearance is more than 0.2 mm (0.008 in.), the
oil pan will be stretched.
(e) Tighten the sixteen bolts and two nuts.
Torque:
10 mm head 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
12 mm head 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
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6. INSTALL OIL PAN BAFFLE PLATEInstall the baffle plate with the six bolts and two nuts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
HINT: Use bolts 14 mm (0.55 in.) in length.
7. INSTALL NO.2 OIL PAN (a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the No.1
and No.2 oil pans.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
NOTICE: Do not use a solvent which will affect the
painted surfaces.
(b) Apply seal packing to the No.2 oil pan as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
w Install a nozzle that has been cut to a 3±4 mm
(0.12±0.16 in.) opening.
HINT: Avoid applying an excessive amount to the surface. w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Install the No.2 oil pan with the twelve bolts and two nuts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
HINT: Use bolts 14 mm (0.55 in.) in length.
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8. INSTALL OIL LEVEL SENSOR(a) Install a new gasket to the level sensor.
(b) Install the level sensor with the four bolts.
Torque: 5.4 N Vm (55 kgf Vcm, 48 in. Vlbf)
HINT: Use bolts 16 mm (0.63 in.) in length.
(c) Connect the level sensor connector.
9. INSTALL BRACKET OF MAIN OXYGEN SENSOR CONNECTOR TO NO.1 OIL PAN
Install the connector bracket with bolt.
10. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK (a) Install a new O±ring to the dipstick guide.
(b) Apply soapy water to the O±ring.
(c) Push in the dipstick guide into the guide hole of the No.1
oil pan.
(d) Install the engine wire bracket and dipstick guide with bolt.
(e) Install the oil dipstick.
11. INSTALL CRANKSHAFT TIMING PULLEY, NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY
(See steps 1 to 3 on pages EM±46 and 47)
12. INSTALL TIMING BELT
(See steps 4 to 35 on pages EM±47 to 56)
13. REMOVE ENGINE STAND FROM ENGINE
14. ASSEMBLE ENGINE AND TRANSMISSION (See pages EM±165 and 166)
15. INSTALL ENGINE WITH TRANSMISSION (See pages EM±167 to 177)
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REMOVAL OF OIL PUMP
(See Components on page LU±9)
HINT: When repairing the oil pump, the oil pan and strainer
should be removed and cleaned.
1. REMOVE ENGINE WITH TRANSMISSION (See pages EM±62 to 72)
2. SEPARATE ENGINE AND TRANSMISSION (See page EM±73)
3. INSTALL ENGINE TO ENGINE STAND FOR REMOVAL
4. REMOVE TIMING BELT (See steps 2 to 10 on pages EM±24 to 26)
5. REMOVE IDLER PULLEY AND CRANKSHAFT TIMING PULLEY
(See steps 11 and 12 on page EM±26)
6. REMOVE OIL DIPSTICK AND GUIDE (a) Remove the mounting bolt.
(b) Pull out the dipstick guide together with dipstick.
(c) Remove the O±ring from the dipstick guide.
7. REMOVE OIL LEVEL SENSOR (a) Disconnect the level sensor connector.
(b) Remove the four mounting bolts and level sensor.
(c) Remove the gasket from the level sensor.
NOTICE: Be careful not to drop the oil level sensor when
removing it.
8. REMOVE NO.2 OIL PAN (a) Remove the 14 mounting bolts and two nuts.
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DISASSEMBLY OF OIL PUMP
(See Components on page LU±12)
1. REMOVE RELIEF VALVE (a) Slighty mount the pump body in a vise.
(b) Remove the plug, gasket, compression spring and reliefvalve.
NOTICE: Be careful not to damage the pump body.
2. REMOVE DRIVE AND DRIVEN ROTORS Remove the ten screws, pump body cover, the drive and
driven rotors.
INSPECTION OF OIL PUMP
1. INSPECT RELIEF VALVECoat the valve with engine oil and check that it falls smoothly
into the valve hole on its own weight.
If it doesn't, replace the relief valve. If necessary, replace the
oil pump assembly.
2. INSPECT DRIVE AND DRIVEN ROTORS
A. Place drive and driven rotors into oil pump body The marks on the rotors must face up.
B. Inspect rotor tip clearance Using a feeler gauge, measure the clearance between the
drive and driven rotors.
Standard tip clearance: 0.310±0.490 mm
(0.0122±0.0193 in.)
Maximum tip clearance: 0.53 mm (0.0209 in.)
If the tip clearance is greater than maximum, replace the ro-
tors as a set.
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C. Inspect rotor body clearanceUsing a feeler gauge, measure the clearance between the
driven rotor and pump body.
Standard body clearance: 0.100±0.175 mm
(0.0039±0.0069 in.)
Maximum body clearance: 0.20 mm (0.0079 in.)
If the body clearance is greater than maximum, replace the
rotors as a set. If necessary, replace the oil pump assembly.
D. Inspect rotor side clearance Using a feeler gauge and precision straight edge, measure
the clearance between the rotors and precision straight
edge.
Standard side clearance: 0.030±0.090 mm
(0.0012±0.0035 in.)
Maximum side clearance: 0.12 mm (0.0047 in.)
If the side clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
E. Remove drive and driven rotors
REPLACEMENT OF CRANKSHAFT
FRONT OIL SEAL
(See page EM±92)
ASSEMBLY OF OIL PUMP
(See Components on page LU±12)
1. INSTALL DRIVE AND DRIVEN ROTORS (a) Place the drive and driven rotors into oil pump body with
the mark facing upward.
(b) Install the pump body cover with the ten screws.
Torque: 10 N Vm (105 kgf Vcm, 8 ft Vlbf)
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2. INSTALL RELIEF VALVE(a) Slighty mount the pump body in a vise.
NOTICE: Be careful not to damage the pump body.
(b) Insert the relief valve and compression spring into the oil
pump body hole.
(c) Install the plug with a new gasket.
Torque: 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
INSTALLATION OF OIL PUMP
(See Components on page LU±9)
1. INSTALL OIL PUMP (a) Place two new O±rings in position on the cylinder block.
(b) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil
pump cylinder block.
w Using a razor blade gasket scraper, remove all the
old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
debris.
w Using a non±residue solvent, clean both sealing
surfaces.
NOTICE: Do not use a solvent which will affect the
painted surfaces.
(c) Apply seal packing to the oil pump as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
w Install a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
HINT: Avoid applying an excessive amount to the surface. Be
particularly careful near oil passages. w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
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(d) Install the oil pump with the seven bolts (A) and two bolts
(B).
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
HINT: Hand tighten the (A) bolts first.
2. INSTALL NO.1 OIL PAN (a) Place a new O±ring in the position on the cylinder block.
(b) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No.1
oil pan and cylinder block.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w thoroughly clean all components to remove all the
debris.
w Using a non±residue solvent, clean both sealing
surfaces.
NOTICE: Do not use a solvent which will affect the
painted surfaces.
(c) Apply seal packing to the No.1 oil pan as shown in the illustration.
Seal packing: Parts No. 08826±00080 or equivalent
w Install a nozzle that has been cut to a 3±4 mm
(0.12±0.16 in.) opening.
HINT: Avoid applying an excessive amount to the surface. w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(d) Install the No.1 oil pan with the 22 bolts.
Torque: 12 mm head bolt 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
14 mm head bolt 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
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3. INSTALL OIL PAN BAFFLE PLATEInstall the baffle plate with the five bolts and two nuts.
Torque: 8.8 N Vm (90 kgf Vcm, 78 in. Vlbf)
4. INSTALL OIL STRAINER
Install a new gasket and the oil strainer with the bolt and two
nuts.
Torque: 8.8 N Vm (90 kgf Vcm, 78 in. Vlbf)
5. INSTALL NO.2 OIL PAN
(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the No.1
and No.2 oil pans.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components ro remove all the
debris.
w Using a non±residue solvent, clean both sealing
surfaces.
NOTICE: Do not use a solvent which will affect the
painted surfaces.
(b) Apply seal packing to the No.2 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
w Install a nozzle that has been cut to a 3±4 mm
(0.12±0.16 in.) opening.
HINT: Avoid applying an excessive amount to the surface.
w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Install the No.2 oil pan with the 14 bolts and two nuts.
Torque: 8.8 N Vm (90 kgf Vcm, 78 in. Vlbf)
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6. INSTALL OIL LEVEL SENSOR(a) Install a new gasket to the level sensor.
(b) Install the level sensor with the four bolts.
Torque: 5.4 N Vm (55 kgf Vcm, 48 in. Vlbf)
(c) Connect the level sensor connector.
7. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK (a) Install a new O±ring on the dipstick guide.
(b) Apply soapy water on the O±ring.
(c) Push in the dipstick guide into the guide hole of the No.1
oil pan.
(d) Install the guide with the mounting bolt.
8. INSTALL CRANKSHAFT TIMING PULLEY AND IDLER PULLEY
(See steps 1 and 2 on page EM±29)
9. INSTALL TIMING BELT (See steps 3 to 14 on pages EM±29 to 33)
10. REMOVE ENGINE STAND FROM ENGINE
11. ASSEMBLE ENGINE AND TRANSMISSION (See page EM±103)
12. INSTALL ENGINE WITH TRANSMISSION (See pages EM±104 to 112)
LU±18
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