torque LEXUS SC400 1991 Service Repair Manual

RECOMMENDED TOOLS (Cont'd)
For suspending engine
09090±04010Engine Sling
Device
Plug for the vacuum hose. fuel hose etc.
09258±00030Hose Plug Set
09200±00010Engine Adjust
Kit
EQUIPMENT
 Part Name\
 \
Note
 Caliper gauge\
 \

 CO/HC analyzer\
 \

 

Compression gauge
\
 
\

\
Cylinder compression pressure
 Connecting rod aligner\
 \

 Cylinder gauge\
 \

 Dial indicator\
 \

 

Engine tune±up tester
\
 
\

\

 Feeler gauge\
 \

 Micrometer\
 \

 

Straight edge\
 
\

\

 Spring tester\
 \
Valve spring
 Steel square\
 \
Valve spring
 Torque wrench\
 \

 

Vernier caliper
\
 
\

\

SSM (SPECIAL SERVICE MATERIALS)
 

Part Name 

Part No.\
 

\
Use etc.
 

Seal packing or equivalent 

08826±00080\
 

\

Camshaft bearing cap, Cylinder head cover,
Rear oil seal retainer and Oil pump
 




Adhesive 1324,
THREE BOND 1324 or equivalent
 




08833±00070
\
 



\

Drive plate mounting bolt
 




Adhesive 1344,
THREE BOND 1344,
LOCTITE 242 or equivalent 




08833±00080
\
 



\

Idler pulley mounting bolt
EM±6±
ENGINE MECHANICAL Preparation
WhereEverybodyKnowsYourName

EQUIPMENT
 


Part Name\
 
\

\
Note
 Caliper gauge\
 \

 


HC/CO meter
\
 
\

\

 


Compression gauge\
 
\

\
Cylinder compression pressure
 Connecting rod aligner\
 \

 


Cylinder gauge
\
 
\

\

 


Dial indicator
\
 
\

\

 


Engine turn±up tester\
 
\

\

 Feeler gauge\
 \

 


Micrometer
\
 
\

\

 


Precision straight edge\
 
\

\

 Spring tester\
 \
Valve spring
 


Steel square
\
 
\

\
Valve spring
 


Torque wrench\
 
\

\

 Vernier caliper\
 \

SSM (SPECIAL SERVICE MATERIALS)
 
Part Name
 
Part No.
\
 \

Use etc.  \
 \

Camshaft bearing cap  \
 \
Camshaft bearing ca
Cylinder head semi±circular plug 
Seal packing or equivalent
 
08826±00080
\
 \
Cylinder head semi±circular lug
Cylinder head cover Seal acking or equivalent 08826±00080\
 \
Cylinder head cover
Rear oil seal retainer  \
 \
Rear oil seal retainer
Oil pump  \
 \

Water inlet housing Seal packing 1282B,
Th b d 1282B i l t
 08826±00100\
 \
Water inlet housing
Water seal plate Three bond 1282B or equivalent 08826±00100\
 \
Water seal late
Water pump 

Adhesive 1324,
Three bond 1324 or equivalent
 

08833±00070
\
 

\
Drive plate mounting bolt
 
Adhesive 1344,
 \
 \

 Adhesive 1344,
Three bond 1344
,
 
08833±00080
\
 \

No.1 idler pulley mounting bolt Three bond 1344,
Loctite 242 or equivalent 08833±00080\
 \
No.1 idler ulley mounting bolt
±
ENGINE MECHANICAL PreparationEM±7
WhereEverybodyKnowsYourName

9. REMOVE NO. 3, NO. 1 AND NO. 2 CYLINDER HEADCOVERS
(a) Remove the 12 bolts and four nuts.
(b) Remove the cylinder head covers and gaskets.
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove withtiming mark º0º of the No. 1 timing belt cover.
NOTICE: Always turn the crankshaft clockwise.
(b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No. 4
timing belt cover.
If not, turn the crankshaft one revolution (360 5).
11. INSPECT VALVE CLEARANCE (a) Uniformly tighten the bearing cap bolts in severalpasses.
Torque: 20 N Vm (200 kgf Vcm, 14 ft Vlbf)
(b) Check only those valves indicated in the illustration.
w Using a feeler gauge, measure the clearance
between the valve lifter and camshaft.
w Record the valve clearance measurements of
those that are out of specification. They will be used
later to determine the required replacement
adjusting shim.
Valve clearance (Cold):
Intake 0.15±0.25 mm (0.006±0.010 in.)
Exhaust 0.25±0.35 mm (0.010±0.014 in.)
EM±12±
ENGINE MECHANICAL Engine Tune±Up
WhereEverybodyKnowsYourName

13. REINSTALL NO. 3, NO. 1 AND NO. 2 CYLINDER HEADCOVERS
(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 headcovers.
(d) Install the cylinder head cover with the 12 bolts and four
nuts.
Torque: 5.4 N Vm (55 kgf Vcm, 48 in. Vlbf)
14. R E C O N N E C T H I G H ± T E N S I O N C O R D S TO S PA R K
PLUGS
(a) Connect the high±tension cord to the spark plug.
HINT: The No. 4 high±tension cord must be raised 10 5 from
the perpendicular line.
(b) Connect the two high±tension cord clamps to the No. 3 cylinder head cover.
(c) Install the high±tension cord clamp with the bolt.
15. REINSTALL CYLINDER HEAD REAR COVER AND NO. 3 TIMING BELT COVER
(a) Using a 5 mm hexagon wrench, install the cylinder head
rear cover and No. 3 timing belt cover with the ten bolts.
(b) Install the oil filler cap.
±
ENGINE MECHANICAL Engine Tune±UpEM±17
WhereEverybodyKnowsYourName

16. REINSTALL THROTTLE BODY WITH INTAKE AIRCONNECTOR
(a) Place a new gasket so the protrusion face the intakechamber, and set the throttle body with intake air
connector.
(b) Connect the two water by±pass hoses to the throttle body.
(c) Install the VSV nut.
(d) Install the air intake connector with the four bolts and two
nuts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
(e) Connect the following hoses and connectors:
(1) PCV hose
(2) Three vacuum hoses
(3) VSV (for EGR) connector
(4) Throttle position sensor connector
(5) IAC valve connector
(6) (w/ TRAC) Sub±throttle position sensor connector
(7) (w/ TRAC) Sub±throttle actuator connector
(8) (USA spec. only) EGR gas temperature sensor connector
17. REINSTALL THROTTLE BODY BRACKET Install the throttle body bracket with the four nuts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
18. REINSTALL EGR PIPE
(a) Install a new gasket and the EGR pipe with the two bolts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
(b) Tighten the union nut.
Torque: 64 N Vm (650 kgf Vcm, 47 ft Vlbf)
EM±18±
ENGINE MECHANICAL Engine Tune±Up
WhereEverybodyKnowsYourName

23. REINSTALL THEFT DETERRENT HORN(a) Install the theft deterrent horn with the bolt.
(b) Connect the connector.
24. REINSTALL RH CYLINDER HEAD COVER (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 gasket to the cylinder head cover.
(d) Install the seal washer to the mounting bolt.
(e) Install the cylinder head cover with the eight bolts.
Torque: 5.9 N Vm (60 kgf Vcm, 52 in. Vlbf)
(g) Connect the four high±tension cords to the spark plugs.
(h) Install the rear and front high±tension cord clamps with
the two bolts.
HINT: Place the front and rear ends of the front high±tension
cord clamp on the rear high±tension cord clamp and lower
high±tension cord cover.
(i) Fit the high±tension cords to the high±tension cord clamps. (See page IG±16)
25. REINSTALL LH CYLINDER HEAD COVER (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
EM±22±
ENGINE MECHANICAL Engine Tune±Up
WhereEverybodyKnowsYourName

(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the mounting bolt.
(e) Install the cylinder head cover with the eight bolts.
Torque: 5.9 NVm (60 kgf Vcm, 52 in. Vlbf)
(f) Connect the two engine wire connectors.
(g) Connect the four injector connectors.
(h) Install the engine wire to the two wire clamps on the
delivery pipe.
(i) Connect the four high±tension cords to the spark plugs.
(j) Install the rear and front high±tension cord clamps with the two bolts.
HINT: Place the front and rear ends of the front high±tension
cord clamp on the rear high±tension cord clamp and lower
high±tension cord cover.
(k) Fit the high±tension cords to the high±tension cord clamps. (See page IG±16)
26. REINSTALL THROTTLE BODY (a) Connect the following hoses:(1) PCV hose from throttle body
(2) Water by±pass hose from throttle body
±
ENGINE MECHANICAL Engine Tune±UpEM±23
WhereEverybodyKnowsYourName

(b) Install a new gasket and throttle body with the two boltsand two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 40 mm (1.57 in.) in length.
(c) Install the water by±pass pipe (from rear water by±pass
joint) to the clamp on the engine wire cover.
(d) Connect the following hoses: (1) Water by±pass hose to the ISC valve
(2) (USA Spec.) Vacuum hose to throttle body
(3) (Exc. USA Spec.) Three vacuum hoses to throttle body
(e) Connect the following connectors: (1) Throttle position sensor connector
(2) (w/ TRAC) Sub±throttle position sensor connector
(3) (w/ TRAC) Sub±throttle actuator
27. REINSTALL HEATER WATER VALVE (a) Install the water valve and bracket assembly with thetwo bolts.
(b) Install the engine wire clamp with the bolt.
(c) Connect the VSV connector.
EM±24
±
ENGINE MECHANICAL Engine Tune±Up
WhereEverybodyKnowsYourName

28. REINSTALL RH NO.3 TIMING BELT COVER(a) Install the three gaskets to the timing belt cover.
(b) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(c) Install the timing belt cover with the three bolts.
29. REINSTALL VSV FOR EVAP SYSTEM Install the VSV with the two bolts.
30. REINSTALL LH NO.3 TIMING BELT COVER (a) Install the three gaskets to the timing belt cover.
(b) Install the cord grommet to the high±tension cord.
(c) Install the cord grommet to the timing belt cover.
(d) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(e) Install the timing belt cover with the three bolts.
31. RECONNECT PCV HOSE TO LH CYLINDER HEAD
32. RECONNECT FUEL RETURN HOSE TO FUEL RETURN PIPE
33. RECONNECT FUEL INLET HOSE TO LH DELIVERY PIPE Connect the inlet hose with two new gaskets and the
pulsation damper.
SST 09612±24014 (09617±24011)
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
33 N Vm (340 kgf Vcm, 24 ft Vlbf) for SST
HINT: Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
34. REINSTALL RH ENGINE WIRE COVER (a) Fit portions A and B of the engine wire cover, matchingthem with the lower high±tension cord cover and No.3
timing belt cover.
(b) Install the engine wire cover with the bolt.
±
ENGINE MECHANICAL Engine Tune±UpEM±25
WhereEverybodyKnowsYourName

COMPRESSION CHECK
HINT: If there is lack of power, excessive oil consumption or
poor fuel economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating tempera-
ture.
2. DISCONNECT DISTRIBUTOR CONNECTOR
3. DISCONNECT HIGH±TENSION CORDS FROM SPARK PLUGS (See steps 2 to 8 on pages EM±10 and 11)
4. DISCONNECT INJECTOR CONNECTORS
5. REMOVE SPARK PLUGS (See page IG±8)
6. CHECK CYLINDER COMPRESSION (a) Insert a compression tester into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compressionpressure.
HINT: Always use a fully charged battery to obtain engine rev-
olution of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE: This measurement must be done in as short
time as possible.
Compression:
1,226 kPa (12.5 kgf/cm
2, 178 psi) or more
Minimum pressure: 981 kPa (10.0 kgf/cm
2, 142 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders islow, pour a small amount of engine oil into the cylinder
through the spark plug hole and repeat steps (a) through
(c) for the cylinder with low compression.
w If adding oil helps the compression, the piston rings
and/or cylinder bore are probably worn or
damaged.
w If pressure stays low, a valve may be sticking or
seating improper, or there may be leakage past the
gasket.
7. REINSTALL SPARK PLUGS (See page IG±9)
Torque: 18 N Vm (180 kgf Vcm, 13 ft Vlbf)
8. RECONNECT INJECTOR CONNECTORS
9. RECONNECT HIGH±TENSION CORDS TO SPARK
PLUGS (See steps 14 to 20 on pages EM±17 to 19)
10. RECONNECT DISTRIBUTOR CONNECTOR
EM±22
±
ENGINE MECHANICAL Compression Check
WhereEverybodyKnowsYourName