check engine LEXUS SC400 1991 Service Repair Manual

(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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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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(e) Place 8 new insulators and the 4 spacers in position on theintake manifold.
(f) Place the 8 injectors and 2 delivery pipes assembly in position on the intake manifold.
(g) Temporarily install the connector bracket and 4 nuts.
(h) Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable cause
is incorrect installation of O±rings. Replace the O±rings.
(i) Position the injector connector upward.
(j) Tighten the 4 nuts holding the delivery pipes to the intake manifold.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
21. INSTALL FUEL RETURN PIPE
(a) Temporarily install the fuel return pipe with the bolt, 2 new
gaskets and union bolt.
(b) Tighten the union bolt holding the return pipe to the fuel pressure regulator.
Torque: 35 N Vm (360 kgf Vcm, 26 ft Vlbf)
(c) Tighten the bolt holding the return pipe to the LH cylinder
head.
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45. INSTALL LH CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of the
timing pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the ªLº mark forward.
(c) Using SST, install the pulley bolt. SST 09278±54012
Torque: 108 N Vm (1,100 kgf Vcm, 80 ft Vlbf)
46. C O N N E C T T I M I N G B E LT TO C A M S H A F T T I M I N G
PULLEYS
(See steps 10 to 40 on pages EG±61 to 72)
47. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY
48. FILL WITH ENGINE COOLANT
49. START ENGINE AND CHECK FOR LEAKS
50. CHECK TRANSMISSION FLUID LEVEL
51. PERFORM ENGINE ADJUSTMENT (See Tune±Up on pages EG±9 to 34)
52. PERFORM ROAD TEST Check for abnormal noise, shock, slipage, correct shift points
and smooth operation.
53. INSTALL ENGINE UNDER COVER
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CYLINDER BLOCK DISASSEMBLY
EG1KT±04
(See Components for Cylinder Block Disassembly and As-sembly)
1. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the oil sel retainer by prying the portions between the oil seal retainer and main bearing cap.
(c) Remove the O±ring.
2. CHECK CONNECTING ROD OIL CLEARANCE Using a dial indicator, measure the thrust clearance while
moving the connecting rod back an forth.
Standard thrust clearance:
0.160 ± 0.290 mm (0.0063 ± 0.0138 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
Connecting rod thickness:
22.880 ± 22.920 mm (0.9008 ± 0.9024 in.)
3. REMOVE CONNECTING ROD CAPS AND CHECK OILCLEARANCE
(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT: Keep the lower bearing inserted with the connecting
rod cap.
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(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.If the crank pin or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts. (See step 7 on page EG±183)
Torque:
1st 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
2nd Turn 90 5
NOTICE: Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above)
(i) Measure the Plastigage at its widest point.
Standard oil clearance: 0.027 ± 0.053 mm (0.0011 ± 0.0021 in.)
Maximum oil clearance: 0.065 mm (0.0026 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, replace the crankshaft.
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4. REMOVE PISTON AND CONNECTING RODASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top of
the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
wKeep the bearings, connecting rod and cap together.
w Arrange the piston and connecting rod assemblies in
correct order.
5. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indi cator, measure the thrust clearance while pry-
ing the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 ± 0.220 mm (0.0008 ± 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:2.440 ± 2.490 mm (0.0961 ± 0.0980 in.)
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6. REMOVE MAIN BEARING CAPS AND CHECK OILCLEARANCE
(a) Remove the 10 main bearing cap bolts.
(b) Uniformly loosen and remove the 20 main bearing cap nuts
in several passes, in the sequence shown.
(c) Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, lower bearings and lower
thrust washers (No.3 main bearing cap only).
NOTICE: Be careful not to damage the cylinder block.
HINT:
wKeep the lower bearing and main bearing cap together.
w Arrange the main bearing caps and lower thrust
washers in correct order.
(d) Lift out the crankshaft.
(e) Remove the 2 upper thrust washers. HINT:
wArrange the upper thrust washers in correct order.
w Keep the upper bearings together with the cylinder
block.
(f) Clean each main journal and bearing.
(g) Ch e ck ea ch ma in jo u rn a l an d be a rin g fo r pittin g an d scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
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CYLINDER BLOCK INSPECTION AND
REPAIR
EG1KU±01
1. CLEAN CYLINDER BLOCK
A. Remove gasket materialUsing a gasket scraper, remove all the gasket material from
the top surface of the cylinder block.
B. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder
block.
NOTICE: If the cylinder is washed at high temperatures, the
cylinder liner sticks out beyond the cylinder block, so always
wash the cylinder block at temperature of 45
or less.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure
the surface contacting the cylinder head gasket for warpage.
Maximum warpage:
0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder
block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
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