LEXUS SC400 1991 Service Repair Manual

POST ASSEMBLY
(See Components on page EM±131)
1. INSTALL WATER SEAL PLATE (a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the seal
plate 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 the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the seal plate as shown in the
illustration.
Seal packing: Part No.08826±00100 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 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Install the seal plate with the two nuts.
Torque: 14 N Vm (145 kgf Vcm, 10 ft Vlbf)
2. INSTALL ALTERNATOR BRACKET
Install the bracket with the bolt.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
3. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the oil
pump 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 the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump 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) Place a new O±ring in position on the cylinder block.
(d) Engage the spline teeth of the oil pump drive gear withthe large teeth of the crankshaft, and slide the oil pump.
(e) Install the oil pump with the eight bolts.
Torque: 12 mm head 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
14 mm head 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
A 50 mm (1.97 in.) for 12 mm head
B 106 mm (4.17 in.) for 12 mm head
C 30 mm (1.18 in.) for 12 mm head
D 40 mm (1.57 in.) for 14 mm head
4. INSTALL NO. 1 OIL PAN AND NO. 2 OIL PANS (See steps 4 to 9 on pages LU±16 to 19)
5. INSTALL WATER PUMP (a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the water
pump 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 the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
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(b) Apply seal packing to the sealing groove of the waterpump 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 the water pump with the five bolts, two stud bolts and nut.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 30 mm (1.18 in.) in length.
6. INSTALL ENGINE WIRE (a) Install the engine wire to the LH side of the cylinder block
with the two bolts.
(b) Install the wire cover with the three bolts.
(c) Connect the following connectors: (1) Oil level sensor connector
(2) Oil pressure switch connector
7. INSTALL WATER BY±PASS PIPE (a) Install a new O±ring to the by±pass pipe.
(b) Apply soapy water to the O±ring.
(c) Pull in the by±pass pipe end into the pipe hole of thewater pump.
(d) Install the water by±pass pipe with the two bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
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8. INSTALL KNOCK SENSORS(a) Using SST, install the two knock sensors.
SST 09816±30010
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
(b) Connect the two knock sensor connectors.
9. INSTALL STARTER (a) Install the wire clamp to the bracket on the starter.
(b) Connect the wire to the starter with the nut.
(c) Connect the connector to the starter.
(d) Install the starter with the two bolts.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
10. INSTALL RH ENGINE MOUNTING BRACKET
Install the mounting bracket with the four bolts.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
HINT: The RH mounting bracket is marked with ºRº.
11. INSTALL LH ENGINE MOUNTING BRACKET (a) Install the mounting bracket with the four bolts.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
HINT: The LH mounting bracket is marked with ºLº.
(b) Install the engine wire to the mounting bracket with the
bolt.
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12. INSTALL CYLINDER HEADS(See pages EM±92 to 115)
13. INSTALL TIMING PULLEYS AND BELT (See pages EM±48 to 57)
14. REMOVE ENGINE STAND FROM ENGINE
15. INSTALL DRIVE PLATE (a) Apply adhesive to two or three threads of the mountingbolt end.
Adhesive: Part No.08833±00070, THREE BOND 1324 or equiva-
lent
(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)
ASSEMBLY OF ENGINE AND
TRANSMISSION
(See Components on page EM±129)
1. ASSEMBLE ENGINE AND TRANSMISSION (See AT section)
2. INSTALL OIL COOLER PIPE (a) Temporarily install the two mounting bolts.
(b) Connect the two oil cooler pipes to the unions on thetransmission. Tighten the union nuts.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
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3. INSTALL DIPSTICK GUIDE FOR TRANSMISSION(a) Install a new O±ring to the dipstick guide.
(b) Apply soapy water to the O±ring.
(c) Connect the dipstick guide end to the tube of the oil pan,
and install the dipstick guide with the bolt.
(d) Install the dipstick.
4. CONNECT ENGINE WIRE TO TRANSMISSION (a) Connect the following connectors:(1) O/D direct clutch speed sensor connector
(2) No.1 speed sensor connector
(3) No.2 speed sensor connector
(4) Neutral start switch connector
(b) Install the five wire clamps to the brackets on the transmission.
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INSTALLATION OF ENGINE
(See Components on pages EM±116 to 118)
1. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the
engine compartment.
CAUTION: Be careful not to hit the PS gear housing or
neutral start switch.
(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 with the front mark facing forward.
Install the ground strap.
Torque: Nut 13 N Vm (135 kgf Vcm, 10 ft Vlbf)
Bolt 25 N Vm (260 kgf Vcm, 19 ft Vlbf)
(f) In sta ll th e two nu ts ho ld in g th e en g in e m ounting
brackets to the front suspension crossmember.
Torque: 59 N Vm (600 kgf Vcm, 43 ft Vlbf)
3. CONNECT TRANSMISSION CONTROL ROD
Connect the control rod to the shift lever with the nut.
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4. INSTALL PROPELLER SHAFT(See PR section)
5. INSTALL CENTER FLOOR BRACE Install the brace with the four nuts.
Torque: 13 N Vm (130 kgf Vcm, 9 ft Vlbf)
6. INSTALL EXHAUST PIPE HEAT INSULATOR
Install the heat insulator with the four nuts.
7. INSTALL CENTER EXHAUST PIPE Install the two hooks of the exhaust pipe to the rings on the
exhaust pipe brackets.
8. INSTALL TAILPIPE (a) Install the tailpipe hook to the ring on the tailpipebrackets.
(b) Install a new gasket and the tailpipe to the center exhaust pipe with the two bolts. Install the two tailpipe.
Torque: 19 N Vm (195 kgf Vcm, 14 ft Vlbf)
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9. INSTALL CATALYTIC CONVERTERS (MAIN)Install a new gasket and the catalytic converter with three
new nuts. Install the two catalytic converters.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
10. INSTALL FRONT EXHAUST PIPE
(a) Temporarily install the pipe support stay with the fourbolts.
(b) Install three new gaskets, the exhaust pipe and pipe support stay with the six bolts and nuts.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(c) Tighten the four bolts holding the pipe support bracket
to the transmission.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(d) Install the two sub±oxygen sensors to the exhaust pipe.
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
HINT:
w Before installing the s ub±oxygen sensor, twist the
sensor wire counterclockwise 3 1/2 turns.
w After installing the sub±oxygen sensor, check that the
sensor wire is not twisted. If it is twisted, remove the
sub±oxygen sensor and reinstall it.
(e) Install the wire grommets to the floor.
11. CONNECT ENGINE WIRE TO CABIN (a) Push in the engine wire through the cowl panel.
(b) Install the engine wire clamp with the three bolts.
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(c) Connect the following connectors:(1) Two connectors to engine & ECT ECU
(2) Connectors to ABS & TRAC ECU
(3) Two connectors to TRAC ECU
(4) Four connectors to connector cassette
(5) Connector to A/C control assembly
(d) Install the engine & ECT ECU with the nut.
(e) Install the ECU protector with the two nuts.
(f) Install the floor carpet.
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