engine LEXUS SC400 1991 Service Repair Manual

(d) If there is wear or damage on only one side of the belt, checkthe belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check the timing cover for damage, gasket has been installed correctly, and
the foreign material on the pulley teeth. If necessary, replace
the timing belt.
2. INSPECT IDLER PULLEYS Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
3. INSPECT TIMING BELT TENSIONER
(a) Visually check tensioner for leakage. HINT: If there is only the faintest trace of oil on the seal on the
push rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
(b) Hold the tensioner with both hands, and push the push rod firmly against floor or wall to check that it doesn't move.
If push rod moves, replace the tensioner.
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(c) Measure the protrusion of the push rod from the housing end.
Protrusion:
10.5 ± 11.5 mm (0.413 ± 0.453 in.)
If the protrusion is not as specified, replace the tensioner.
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TIMING BELT INSTALLATION
See Components for Removal and Installation:
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of thepulley.
(b) Using SST and a hammer, tap in the timing pulley, facing the flange side inward.
SST 09223±46011
2. INSTALL NO.1 IDLER PULLEY
(a) Apply adhesive 2 or 3 threads of the pivot bolt.
Adhesive: Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer and
idler pulley with the pivot bolt.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
(c) Check that the pulley bracket moves smoothly.
3. INSTALL NO.2 IDLER PULLEY
(a) Install the idler pulley with the bolt.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL TIMING BELT
NOTICE: The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft and align
the timing marks of the crankshaft timing pulley and oil pump
body.
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(b) Remove any oil or water on the crankshaft pulley, oil pumppulley, water pump pulley, No.1 idler pulley and No.2 idler
pulley, and keep them clean.
(c) Align the installation mark on the timing belt with the dot mark
of the crankshaft timing pulley.
(d) Install the timing belt on the crankshaft timing pulley. No.1 idler pulley and No.2 idler pulley.
5. INSTALL TIMING BELT GUIDE (CRANKSHAFT ANGLE SENSOR PLATE)
Install the belt guide, facing the cup side outward.
6. INSTALL TIMING BELT COVER SPACER
(a) Install the gasket to the cover spacer.
(b) Install the cover spacer.
7. INSTALL NO.1 TIMING BELT COVER
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the 4 bolts.
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8. INSTALL HYDRAULIC PUMP
(a) Install the hydraulic pump, solenoid valve connector clampand crankshaft position sensor wire clamp 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
(b) Connect the solenoid valve connector.
9. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the crankshaft pulley.
(b) Using SST and a hammer, tap in the crankshaft pulley. SST 09223±46011
(c) Using SST, install the pulley bolt. SST 09213±70010, 09330±00021
Torque: 245 N Vm (2,500 kgf Vcm, 181 ft Vlbf)
10. 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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11. 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)
12. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Crankshaft Pulley Position:
Turn the crankshaft pulley, and align its groove with timing
mark ª0º of the No. 1 timing belt cover.
(b) (Camshaft Timing Pulley Position) Using SST, turn the camshaft timing pulley, and align the tim-
ing marks of the camshaft timing pulley and timing belt rear
plate.
SST 09278±54012
13. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY
(a) Align the installation mark on the timing belt with the the end
of the hydraulic pump.
(b) Remove any oil or water on the LH camshaft timing pulley, and keep it clean.
(c) Using SST, slightly turn the LH camshaft timing pulley
clockwise. Align the installation mark on the timing belt with
the timing mark of the camshaft timing pulley, and hang the
timing belt on the LH camshaft timing pulley.
SST 09278±54012
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(d) Using SST, align the timing marks of the LH camshaft timingpulley and timing belt rear plate.
SST 09278±54012
(e) C h e c k t h a t t h e t i m i n g b e l t h a s t e n s i o n b e t w e e n t h e
crankshaft timing pulley and LH camshaft timing pulley.
14. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY
(a) Remove any oil or water on the RH camshaft timing pulley
and water pump pulley, and keep them clean.
(b) Using SST, slightly turn the RH camshaft timing pulley clockwise. Align the installation mark on the timing belt with
the timing mark of the camshaft timing pulley, and hang the
timing belt on the RH camshaft timing pulley.
SST 09278±54012
(c) Using SST, align the timing marks of the RH camshaft timing pulley and timing belt rear plate.
SST 09278±54012
(d) Check that the timing belt has tension between the RH camshaft timing pulley and LH camshaft timing pulley.
15. SET TIMING BELT TENSIONER
(a) Using a press, slowly press in the push rod using 981 ± 9,807
N (100 ± 1,000 kgf, 220 ± 2,205 lbf) of force.
(b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting
position of the push rod.
(c) Release the press.
(d) Install the dust boot to the belt tensioner.
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16. INSTALL TIMING BELT TENSIONER
(a) Temporarily install the belt tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.
Torque: 26 NVm (270 kgf Vcm, 20 ft Vlbf)
(c) Using pliers, remove the 1.27 mm hexagon wrench from the
belt tensioner.
17. CHECK VALVE TIMING
(a) Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft pulley clockwise.
(b) Check that each pulley aligns with the timing marks as shown
in the illustration.
If the timing marks do not align, remove the timing belt and
reinstall it.
18. INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the 8 spark plugs.
Torque: 18 N Vm (180 kgf Vcm, 13 ft Vlbf)
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19. INSTALL DRIVE BELT TENSIONERInstall the belt tensioner with the bolt and 2 nuts.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
HINT: Use bolt 106 mm (4.18 in.) in length.
20. INSTALL GENERATOR
(a) Install the generator and transmission oil cooler pipe bracket with the bolt and nut.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
(b) Connect the generator connector.
(c) Connect the generator wire with the nut and cap.
21. INSTALL RH DISTRIBUTOR HOUSING
Install the distributor housing with the 3 bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT:
w The RH distributor housing is marked with ªRº.
w Each bolt length is indicated in the illustration.
Bolt length:
38 mm (1.50 in.) for A
96 mm (3.78 in.) for B
22. INSTALL LH DISTRIBUTOR HOUSING Install the distributor housing with the 3 bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT:
w The LH distributor housing is marked with ªLº.
w Each bolt length is indicated in the illustration.
Bolt length:
38 mm (1.50 in.) for A
80 mm (3.15 in.) for B
23. INSTALL DISTRIBUTOR ROTORS
(a) Align the protrusion of the distributor rotor with the groove the
camshaft timing pulley.
(b) Install the distributor rotor with the 2 bolts. Install the 2 distributor rotors.
Torque: 3.8 N Vm (39 kgf Vcm, 34 in. Vlbf)
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24. INSTALL DISTRIBUTOR CAPSInstall the distributor cap with the 3 bolts. Install the 2 distribu-
tor caps.
Torque: 3.8 N Vm (39 kgf Vcm, 34 in. Vlbf)
25. INSTALL RH NO.2 TIMING BELT COVER
(a) Install the 4 gaskets to the timing belt cover.
(b) Install the wire grommet to the timing belt cover.
(c) Fit the timing belt cover, matching it with the hydraulic pump.
(d) Fit the timing belt cover holes, matching them with the 2
grommets on the distributor cap.
(e) Install the timing belt cover with the 5 bolts.
Torque:
18 NVm (185 kgf Vcm, 13 ft Vlbf) for 12 mm head
HINT (for 12 mm head): Use bolts 106 mm (4.17 in.) in length.
(f) Install the wire clamp to the timing belt cover.
(g) Install the camshaft position sensor connector to the ignition coil bracket.
26. INSTALL LH NO.2 TIMING BELT COVER
(a) Install the 2 gaskets to the timing belt cover.
(b) Run the camshaft position sensor wire through the timing belt
cover hole.
(c) Fit the timing belt cover, matching it with the hydraulic pump.
(d) Fit the timing belt cover holes, matching them with the 2 grommets on the distributor cap.
(e) Install the timing belt cover and connector bracket with the 3 bolts.
(f) Install the wire grommet to the timing belt cover.
(g) In sta ll th e ca msh a ft po sitio n se n so r c onnector to the
connector bracket.
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27. INSTALL DRIVE BELT IDLER PULLEYInstall the idler pulley and cover plate with the bolt.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
28. INSTALL HIGH±TENSION CORDS, CORD CLAMPS AND
CORD COVER ASSEMBLY
(a) C onnect the high±tension cords to the spark plugs,
distributor caps and RH ignition coil.
(b) Install the lower high±tension cord cover with the bolt.
(c) Connect the RH front high±tension cord clamp to the lower high±tension cord cover.
(d) Place the RH front high±tension cord clamp to the RH rear
high±tension cord clamp.
(e) Install the 2 bolts holding the RH high±tension cord clamps to the RH cylinder head cover.
(f) Connect the No.2 high±tension cord to the cord clamp on the
RH front high±tension cord clamp.
(g) Connect the LH front high±tension cord clamp to the lower high±tension cord cover.
(h) Place the LH front high±tension cord clamp to the LH rear
high±tension cord clamp.
(i) Install the 2 bolts holding the LH high±tension cord clamps to the LH cylinder head cover.
(j) Connect the No.1 high±tension cord to the cord clamp on the
LH front high±tension cord clamp.
29. INSTALL RH NO.3 TIMING BELT COVER
(a) Install the 3 gaskets to the timing belt cover.
(b) Fit the portion A of the timing belt cover, matching it with the lower high±tension cord cover.
(c) Install the timing belt cover with the 4 bolts.
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