torque LEXUS SC400 1991 Service Repair Manual

36. INSTALL TIMING BELT REAR PLATESInstall the rear plate with the 2 bolts. Install the 2 rear plates.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
37. INSTALL WATER INLET AND INLET HOUSING
(a) Remove any old packing (FIPG) material and be careful not
to drop any oil on the contact surfaces of the water inlet
housing and water pump.
wUsing 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.
(b) Apply seal packing to the sealing groove of water inlet
housing as shown in the illustration.
Seal packing:
Part No. 08826±00100 or equivalent
wInstall a nozzle that has been cut to a 2±3 mm (0.08±0
12 in.) opening.
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 a new O±ring to the water inlet housing.
(d) Apply soapy water on the O±ring.
(e) Push the water inlet housing end into the water pump hole.
(f) Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 25 mm (0.98 in.) in length.
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(g) Connect the water bypass hose to the IAC valve.
38. INSTALL RH IGNITION COIL
(a) Install the ignition coil with the 2 bolts.
(b) Connect the ignition coil connector.
39. CONNECT CONTROL CABLES TO THROTTLE BODYConnect the following cables:
(1) Accelerator cable
(2) Transmission throttle control cable
(3) Cruise control actuator cable
40. INSTALL THROTTLE BODY COVER
(a) Install the thro ttle body cover and hose clamp with the cap nut
and 2 bolts.
(b) Install the EVAP hose to the hose clamp.
41. INSTALL POWER STEERING (PS) PUMP
(a) Install the PS pump with the nut and 3 bolts. Alternately tighten the bolts and nut.
Torque:
39 NVm (400 kgf Vcm, 29 ft Vlbf) for bolt
43 N Vm (440 kgf Vcm, 32 ft Vlbf) for nut
EG±134±
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(b) Connect the vacuum hose to the air intake chamber.
42. INSTALL TWC (FRONT)
(a) Using a 14 deep socket wrench, install a new gasket and theTWC with 3 new nuts. Install the 2 TWC.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
(b) Te m p o r a r i l y i n s t a l l t h e p i p e s upport bracket to the
transmission with the 4 bolts.
(c) Install a new gasket to each front end of the front exhaust
pipe.
(d) Connect the front exhaust pipe to the 2 TWC with the 4 bolts and 4 new nuts.
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)
43. INSTALL HYDRAULIC PUMP
Install the hydraulic pump with the 2 bolts and 2 nuts.
Torque:
16 NVm (160 kgf Vcm, 12 ft Vlbf) for 12 mm head
30 N Vm (310 kgf Vcm, 22 ft Vlbf) for 14 mm head
HINT: Each bolt length is indicated in the illustration.
Bolt length:
106 mm (4.17 in.) for A of 12 mm head
114 mm (4.49 in.) for B of 14 mm head
44. INSTALL RH 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 ªRº mark forward.
(c) Using SST, install the pulley bolt. SST 09278±54012
Torque: 108 N Vm (1,100 kgf Vcm, 80 ft Vlbf)
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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
EG±136
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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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(h) Install the 5 main bearing caps with the 20 nuts and ten bolts.
Do not install the crankshaft.
(See step 4 on page EG±180)
Torque:
Nut1st 27 N Vm (275 kgf Vcm, 20 ft Vlbf)
2nd Turn 90 5
Bolt 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
(i) Using a cylinder gauge, measure the inside diameter of the
the main bearing.
Bearing inside diameter:
67.026 ± 67.033 mm (2.6388 ± 2.6391 in.)
(j) Using a, micrometer measure the diameter of the mainjournal
Main journal diameter:
66.988 ± 67.000 mm (2.6373 ± 2.6378 in.)
(k) Subtract the main journal diameter measurement from themain bearing inside diameter measurement.
Standard clearance:
0.026 ± 0.045 mm (0.0010 ± 0.0018 in.)
Maximum clearance: 0.055 mm (0.0022 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, replace the crankshaft.
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7. IF NECESSARY, REPLACE MAIN BEARING CAP STUDBOLTS
(a) Using the 2 main bearing cap nuts, remove the stud bolt.
(b) Apply a light coat of engine oil on the threads and under
flange of new stud bolts.
(c) Using the 2 main bearing cap nuts, install the stud bolt.
Torque: 15 N Vm (150 kgf Vcm, 11 ft Vlbf)
HINT: Stud bolts come in lengths of 90.0 mm (3.543 in.) and
101.5 mm (3.996 in.). Install the 101.5 mm (3.996 in.) bolts
in inside positions. Install the 90.0 mm (3.543 in.) bolts in out-
side positions.
PISTON AND CONNECTING ROD
DISASSEMBLY
EG0BV±06
1. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
2. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression rings.
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(a) Apply a light coat of engine oil on the threads and under themain bearing cap nuts.
(b) Install and uniformly tighten the 20 main bearing cap nuts in
several passes, in the sequence shown.
Torque: 27 N Vm (275 kgf Vcm, 20 ft Vlbf)
If any one of the main bearing cap nuts does not meet the
torque specification, replace the main bearing cap stud bolt.
(c) Mark the front of the main bearing cap nut with paint.
(d) Retighten the main bearing cap bolts 90
in the numerical
order shown.
(e) Check that the painted mark is now at a 90
angle to the front.
C. Install main bearing cap bolts
(a) Install a new seal washer to the main bearing cap bolt.
(b) Install and uniformly tighten the 10 main bearing cap bolts.
Torque: 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
(c) Check that the crankshaft turns smoothly.
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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B. Install connecting rod cap boltsHINT:
wThe connecting rod cap bolts are tightened in 2
progressive steps (steps (b) and (d)).
w If any one of the connecting rod cap bolts is broken or
deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap bolts
in several passes.
Torque: 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolt with paint.
(d) Retighten the cap nuts 90
as shown.
(e) Check that the painted mark is now at a 90
angle to the front.
(f) Check that the crankshaft turns smoothly.
8. CHECK CONNECTING ROD OIL CLEARANCE
Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and 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.)
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9. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful notto drop any oil on the contact surfaces of the oil seal retainer
and cylinder block.
wUsing a razor blade and gasket scraper, remove all the
oil packing (FIPG) material from the gasket surfaces and
sealing grooves.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing:
Part No. 08826±00080 or equivalent
wIn sta ll a no zzle th a t ha s be e n cu t to a 2 ± 3 mm
(0.08±0.12) opening.
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 a new O±ring to the cylinder block.
(d) Install the oil seal retainer with the 7 bolts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
EG±184±
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