LEXUS SC400 1991 Service Repair Manual

(d) Using a plastic±faced hammer, lightly tap the valve stem
tip to assure proper fit.
4. INSTALL VALVE LIFTERS AND SHIMS (a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
INSTALLATION OF CYLINDER HEAD
(See Components on pages EM±34 and 35)1. INSTALL CYLINDER HEAD
A. Place cylinder head on cylinder block (a) Place a new cylinder head gasket in position on thecylinder block.
NOTICE: Be sure to install it correctly.
(b) Place the cylinder head in position on the cylinder head
gasket and connect the heater water hose to the union.
B. Install cylinder head bolts
HINT:
wThe cylinder head bolts are tightened in two progressive
steps (steps (c) and (f)).
w If any of bolts break or deform, replace them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the 14 plate washers to each cylinder head bolt.
(c) First, using a 10 mm bi±hexagon wrench, uniformly tighten the cylinder head bolts in several passes in the
sequence shown.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
If any one of the bolts does not meet the torque specification,
replace the bolt.
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(d) Mark the front of the cylinder head bolt head with paint.
(e) Second retighten the cylinder head bolts 90
in the
numerical order shown above.
(f) Third retighten cylinder head bolts by an additional 90
.
(g) Check that the painted mark is now turned to the rear.
2. INSTALL CAMSHAFTS (a) Apply engine oil to the thrust portion of the camshaft.
(b) Place the camshaft on the cylinder head with the camlobe facing up as shown.
(c) Place the No.3 and No.7 bearing caps in their proper location.
(d) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(e) Temporarily tighten these bearing cap bolts uniformly
and alternately in several passes until the bearing caps
are snug with the cylinder head.
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ENGINE MECHANICAL Cylinder HeadEM±55
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(f) Apply MP grease to a new camshaft oil seal lip.
(g) Install the oil seal to the camshaft.
(h) Clean the installed surfaces of the No. 1 bearing capand cylinder head with cleaner.
(i) Apply seal packing to the No. 1 bearing cap as shown.
Seal packing: Part No. 08826±00080 or equivalent
(j) Install other bearing caps in their proper locations.
(k) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(l) Install and uniformly tighten the 14 bearing cap bolts on
one side in several passes in the sequence shown.
Torque: 20 N Vm (200 kgf Vcm, 14 ft Vlbf)
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(m) Using SST, push the oil seal as far as it would go.
SST 09316±60010 (09316±00010, 09316±00050)
(n) Rotate the camshaft with a wrench at the hexagonposition, bring the forward straight pin up.
(o) Loosen the two bearing cap bolts as shown, until they
can be turned by hand; retighten in several passes.
Torque: 20 N Vm (200 kgf Vcm, 14 ft Vlbf)
(p) Turn the camshaft 1/3 of revolution.
(q) Loosen the two bearing cap bolts as shown, until they
can be turned by hand; retighten in several passes.
Torque: 20 N Vm (200 kgf Vcm, 14 ft Vlbf)
(r) Turn the camshaft a further 1/3 of a revolution.
(s) Loosen the two bearing cap bolts as shown, until they
can be turned by hand; retighten is several passes.
Torque: 20 N Vm (200 kgf Vcm, 14 ft Vlbf)
3. CHECK AND ADJUST VALVE CLEARANCE
(See steps 12 and 13 on pages EM±12 to 16)
Turn the camshaft, and position the cam lobe upward, check
and adjust the valve clearance.
Valve clearance:
Intake 0.15±0.25 mm (0.006±0.010 in.)
Exhaust 0.25±0.35 mm (0.010±0.014 in.)
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ENGINE MECHANICAL Cylinder HeadEM±57
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4. INSTALL NO. 4 TIMING BELT COVERInstall the No. 4 timing belt cover with four bolts.
Torque: 8.8 N Vm (90 kgf Vcm, 78 in. Vlbf)
5. INSTALL CAMSHAFT TIMING PULLEYS
(a) Align the camshaft knock pin with the groove in thepulley, and slide on the pulley.
(b) Temporarily install the timing pulley bolt.
(c) Hold the hexagon portion of the camshaft with a wrench,
and tighten the timing pulley bolt.
Torque: 79 N Vm (810 kgf Vcm, 59 ft Vlbf)
6. INS TALL NO . 3 NO . 1 AND NO . 2 CY LINDE R HE AD
COVERS
(a) Remove any oil packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in theillustration.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gaskets to the No. 1 and No. 2 cylinder head covers.
(d) Install the cylinder head cover with the 12 bolts and four
nuts.
Torque: 5.4 N Vm (55 kgf Vcm, 48 in. Vlbf)
7. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the sixbolts and two nuts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
(b) Install the intake manifold stay with the two bolts.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
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8. CONNECT ENGINE WIRE TO INTAKE MANIFOLD(a) Install the harness protector to the intake manifold withthe two bolts.
(b) Install the three clamp bolts and two nuts.
(c) Connect the following connectors:
(1) Engine coolant temperature sensor connector
(2) Engine coolant temperature sender gauge connec- tor
(3) Two knock sensor connectors
(4) Oil pressure switch connector
(5) Oil level sensor connector
(6) A/C compressor connector
9. INSTALL NO. 1 AND NO. 2 FUEL PIPES
Torque: 8.8 N Vm (90 kgf Vcm, 78 in. Vlbf)
10. INSTALL DELIVERY PIPE AND INJECTORS
(See steps 1, 3, 6 and 7 on pages FI±33 and 34)
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
11. INSTALL AIR INTAKE CHAMBER
(a) Install a new gasket and the intake chamber with the five
bolts and two nuts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
(b) Install the check connector and harness protector to the
air intake chamber with the two bolts.
(c) Connect the following hoses: (1) Vacuum hose to brake booster union
(2) Vacuum hose (to ACIS vacuum tank)
(3) Vacuum sensing hose
(4) Air hose (to PS air control valve)
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ENGINE MECHANICAL Cylinder HeadEM±59
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(d) Install the intake chamber stay with the bolt and nut.Install the No. 1 and No. 2 stay.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: The No. 1 stay is marked ºFº and No. 2 stay is marked
with ºRº.
12. INS TALL OIL DIP S TICK GUIDE S FO R ENG INE AND TRANSMISSION (A/T)
(a) Install a new O±ring on the dipstick guide.
(b) Apply soapy water on the O±ring.
(c) Connect the dipstick guide end to the tube of the oil pan.
(d) Install the dipstick guide with a bolt.
(e) Connect the fuel return hose to the engine oil dipstick guide.
13. INSTALL VACUUM CONTROL VALVE SET AND NO. 2 VACUUM PIPE
(a) Install the vacuum control valve set and vacuum pipewith the four nuts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
(b) Connect the following hoses:
(1) Vacuum hose to ACIS vacuum tank
(2) Three vacuum hoses to VSV
(c) Connect the two connectors to the VSV.
14. INSTALL WATER OUTLET AND NO. 1 BY±PASS HOSE (a) Insert the No. 1 by±pass hose to the intake manifold,and connect the hose to the clamp.
(b) Install the water outlet with the two nuts and bolt.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
15. INSTALL WATER BY±PASS OUTLET AND NO. 1 WATER
BY±PASS PIPE
(a) Install two new O±rings to the No. 1 water by±pass pipe.
(b) Install a new O±ring and the water by±pass outlet with the two bolts.
Torque: 8.8 N Vm (90 kgf Vcm, 78 in. Vlbf)
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16. INSTALL EXHAUST MANIFOLD(a) Install a new gasket and the exhaust manifold with thefour nuts. Install the No. 1 and No. 2 exhaust manifolds.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
(b) Install the manifold heat insulator with the four nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(c) Connect the two oxygen sensor connectors.
17. INSTALL NO. 2 FRONT EXHAUST PIPE (See step 5 on page EM±105)
18. INSTALL TIMING BELT (See steps 8 to 14 on pages EM±30 to 33)
19. INSTALL RADIATOR AND WATER PUMP PULLEY (See steps 15, 16, 19 and 24 on pages EM±110 to 112)
20. INSTALL SPARK PLUGS (See step 6 on page IG±9)
Torque: 18 N Vm (180 kgf Vcm, 13 ft Vlbf)
21. CONNECT HIGH±TENSION CORDS TO SPARK PLUGS
(See steps 14 to 21 on pages EM±17 to 21)
22. FILL ENGINE WITH COOLANT (See page CO±5)
Capacity (w/ Heater): M/T 8.5 liters (9.0 US qts, 7.5 lmp. qts)
A/T 8.4 liters (8.9 US pts, 7.4 lmp. qts)
23. START ENGINE AND CHECK FOR LEAKS
24. (A/T)CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
(See page MA±11)
NOTICE: Do not overfill.
25. CHECK IGNITION TIMING (See page IG±14)
Ignition timing: 105 BTDC @ idle
(w/ Terminals TE1 and E1 connected)
26. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
27. RECHECK ENGINE COOLANT LEVEL
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CYLINDER HEADS
COMPONENTS FOR REMOVAL AND
INSTALLATION
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COMPONENTS FOR REMOVAL AND
INSTALLATION (Cont'd)
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ENGINE MECHANICAL Cylinder HeadsEM±59
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