LEXUS SC400 1991 Service Repair Manual

ASSEMBLY OF CYLINDER BLOCK
(See Components on page EM±75)HINT:
wThoroughly clean all parts to be assembled.
w Before installing the parts, apply new engine oil to all
sliding and rotating surfaces.
w Replace all gaskets, O±rings and oil seals with new
parts.
NOTICE: Apply a generous amount of oil on the sliding
surface of the b earing, and not on the back of it or on the
surface to which it is installed.
1. INSTALL MAIN BEARINGS HINT: The No. 1 main bearing is different from the rest of the
bearing.
(a) Align the bearing claw with the claw groove of the mainbearing cap or cylinder block.
NOTICE: Install the bearing with the oil hole in the cylin-
der block.
(b) Instal the bearings in the cyli nder block and main
bearing caps.
2. INSTALL UPPER THRUST WASHERS Install the thrust washers under the No. 4 main journal posi-
tion of the block with the oil grooves facing outward.
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3. PLACE CRANKSHAFT ON CYLINDER BLOCK
4. INSTALL MAIN BEARING CAP AND LOWER THRUSTWASHERS
A. Place main bearing cap and lower thrust washers on cyl- inder block
(a) Install the lower thrust washers on the No. 4 mainbearing with the grooves facing outward.
(b) Install the main bearing caps in numerical order with the arrows facing forward.
B. Install main bearing cap bolts HINT:
wThe main bearing cap bolts are tightened in two
progressive steps (steps (b) and (d)).
w If any of the main bearing bolts break or deform, replace
them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) First, install and uniformly tighten the 14 main bearing
cap bolts in several passes in the sequence shown.
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.
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(c) Mark the front of the main bearing cap bolt head withpaint.
(d) Second, retighten the main bearing cap bolts 90
in the
numerical order shown above.
(e) Check that the painted mark is now at a 90
angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance. (See step 5 on page EM±80)
5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
6. INSTALL CONNECTING ROD CAPS
A. Place connecting rod cap on connecting rod (a) Match the numbered c onnecting rod cap with the
connecting rod.
(b) Install the connecting rod cap by aligning the dowel pin to the corrosponding hole.
B. Install connecting rod cap bolts HINT:
wThe connecting rod cap bolts are tightened in two
progressive steps (steps (b) and (d)).
w If any of the connecting rod bolts break or deform,
replace them.
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(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) At first, install and alternately tighten the bolts of the connecting rod cap in several passes.
Torque: 29 N Vm (300 kgf Vcm, 22 ft Vlbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the connecting rod cap bolt with paint.
(d) Retighten the connecting rod cap bolts 905 in the
numerical order shown.
(e) Check that the painted mark is now at a 905 angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance. (See step 2 on page EM±77)
7. INSTALL REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the retainer
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 debris.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer 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.
w Parts must be assembled within 3 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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(c) Install the retainer with the six bolts.
Torque: 5.9 NVm (60 kgf Vcm, 52 in. Vlbf)
POST ASSEMBLY
(See Components on page EM±75)
1. INSTALL OIL PUMP (See page LU±15)
2. INSTALL OIL FILTER BRACKET
(a) Place a new O±ring in position on the oil filter bracket.
(b) Install a new gasket to the union bolt.
(c) Install the oil filter bracket with the union bolt.
Torque: 88 N Vm (900 kgf Vcm, 65 ft Vlbf)
3. INSTALL LH ENGINE MOUNTING BRACKET
Install the mounting bracket with the four bolts.
Torque: 58 N Vm (590 kgf Vcm, 43 ft Vlbf)
HINT: The LH mounting bracket is marked ºLF±Zº.
4. INSTALL RH ENGINE MOUNTING BRACKET Install the mounting bracket with the four bolts.
Torque: 58 N Vm (590 kgf Vcm, 43 ft Vlbf)
HINT: The RH mounting bracket is marked ºRR±Zº.
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5. INSTALL KNOCK SENSORS AND OIL PRESSURESWITCH
Using SST, install the two knock sensors and oil pressure
switch.
SST 09816±30010
Torque:
Knock sensor 44 N Vm
(450 kgf Vcm, 33 ft Vlbf)
Oil pressure switch 14 N Vm
(150 kgf Vcm, 11 ft Vlbf)
6. INSTALL FUEL PIPE SUPPORT
Torque: 14 N Vm (145 kgf Vcm, 10 ft Vlbf)
7. INSTALL CYLINDER HEAD
(See pages EM±54 to 57)
Torque: 1st 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
2nd turn 90 5
3rd turn 90 5
8. INSTALL FUEL PRESSURE PULSATION DAMPER
(See step 1 on page FI±36)
Torque: 41 N Vm (420 kgf Vcm, 30 ft Vlbf)
35 N Vm (350 kgf Vcm, 25 ft Vlbf) for SST
9. INSTALL WATER PUMP AND BY±PASS PIPE
(a) Install the water pump. (See page CO±7)
(b) Install the No. 2 water by±pass pipe with the bolt.
(c) Connect the No. 2 water by±pass hose to the engine hanger.
10. INSTALL THROTTLE BODY WITH INTAKE AIR
CONNECTOR
(See page EM±18)
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
11. INSTALL TIMING PULLEYS AND BELT
(See pages EM±29 to 33)
12. INSTALL GENERATOR
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
13. REMOVE ENGINE STAND FROM ENGINE
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14. (M/T)INSTALL FLYWHEEL
HINT: The flywheel bolts are tightened in two progressive
steps, (b) and (d).
(a) Install the flywheel on the crankshaft.
(b) Install and uniformly tighten the eight mount bolts inseveral passes in the sequence shown.
Torque: 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
(c) Mark the flywheel bolt with paint.
(d) Second, retighten the flywheel bolts by an additional
90
.
(e) Check that the painted mark is now at a 90
angle to (c).
15. (A/T) INSTALL DRIVE PLATE
(a) Apply adhesive to two or three threads of the mountingbolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324 or
equivalent
(b) Install the front spacer, drive plate and rear spacer on the crankshaft.
(c) Install and uniformly tighten the eight mounting bolts in
several passes in the sequence shown.
Torque: 98 N Vm (1,000 kgf Vcm, 72 ft Vlbf)
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ASSEMBLY OF ENGINE AND
TRANSMISSION
(See Components on page EM±73)1. (M/T) INSTALL CLUTCH DISC AND COVER
Torque: 19 N Vm (195 kgf Vcm, 14 ft Vlbf)
2. ASSEMBLE ENGINE AND TRANSMISSION
(See page AT±31)
Torque:
14 mm head bolt 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
17 mm head bolt 72 N Vm (730 kgf Vcm, 53 ft Vlbf)
3. INSTALL STARTER
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
4. CONNECT ENGINE WIRE TO TRANSMISSION
5. (A/T)
INSTALL OIL COOLER PIPE
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
6. (A/T)
INSTALL OIL DIPSTICK GUIDE FOR TRANSMISSION
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INSTALLATION OF ENGINE
(See Components on pages EM±62 to 64)
1. INSTALL ENGINE AND TRANSMISSION ASSEMBLY INVEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the
engine compartment.
CAUTION: Install carefully without damaging the power
steering gear housing or the park/neutral position switch
(A/T only).
(c) Insert the stud bolts of the front engine m ounting
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 four bolts and four nuts.
Torque: Nut 13 N Vm (135 kgf Vcm, 10 ft Vlbf)
Bolt 25 N Vm (260 kgf Vcm, 19 ft Vlbf)
2. INSTALL INTERMEDIATE SHAFT
(a) Remove SST.
SST 09325±20010 (M/T)
09325±40010 (A/T)
(b) Insert the yoke into the transmission.
(c) Align the matchmarks on the flanges and connect thepropeller shaft with the four bolts, washers and nuts.
(d) Torque the bolts and nuts.
Torque: 74 N Vm (750 kgf Vcm, 54 ft Vlbf)
(e) Torque the bolts.
Torque: 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
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HINT: Adjust the center support bearing to keep the intervals
as shown with the vehicle in the unladen condition.
Under the same condition, check if the center line of the cen-
ter support bearing is at right angles to the shaft axial direc-
tion.
(f) Inspect the joint angle. (See page PR±13)
3. (A/T) CONNECT TRANSMISSION CONTROL ROD
Connect the control rod to the shift lever with the nut.
4. INSTALL EXHAUST PIPE HEAT INSULATOR Install the heat insulator with the four nuts as shown.
5. INSTALL NO. 2 FRONT EXHAUST PIPE (a) Install new two gaskets and No. 2 front exhaust pipe with
new four nuts.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
(b) Install a new gasket and the No. 2 front exhaust pipe to
the front exhaust pipe with the two bolts and nuts.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
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