torque LEXUS SC400 1991 Service Repair Manual

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)
EM±102±
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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
±
ENGINE MECHANICAL Cylinder BlockEM±103
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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)
EM±104±
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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)
±
ENGINE MECHANICAL Cylinder BlockEM±105
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6. (M/T)INSTALL CLUTCH RELEASE CYLINDER
Install the clutch release cylinder and torque the two bolts.
Torque: 12 N Vm (120 kgf Vcm, 9 ft Vlbf)
7. INSTALL GROUND STRAP, STARTER WIRE AND HOSE
(a) Install the ground strap to the transmission.
(b) Install the starter wire with the nuts.
(c) Install the starter wire with the wire clamp.
(d) Install two new gaskets and fuel inlet hose with the union
bolt.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
8. INSTALL PS PIPE
Install the PS pipe with the two clamp bolts.
9. CONNECT ENGINE WIRE TO CABIN (a) Push in the engine wire through the cowl panel.
(b) Connect the following connectors:(1) Two connectors to ECM
(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
EM±106
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(p) Connect the fuel return hose to the No. 2 fuel pipe andengine oil dipstick guide clamp.
(q) Connect the brake booster vacuum hose to the union.
12. INSTALL A/C COMPRESSOR (a) Install the A/C compressor with the through bolt, nut and
three bolts.
Torque: Through bolt 26 N Vm (265 kgf Vcm, 19 ft Vlbf)
Bolt and nut 52 N Vm (530 kgf Vcm, 38 ft Vlbf)
(b) Connect the A/C compressor connector.
13. INSTALL PS PUMP (a) Install the PS pump and pump rear stay with the threebolts and nut. Alternately tighten the bolts and nut.
Torque:
(A) 58 N Vm (590 kgf Vcm, 43 ft Vlbf)
(B) 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
(b) Connect the following hoses:
(1) PS air hose to No. 4 timing belt cover
(2) PS air hose to air intake chamber
14. INSTALL CHARCOAL CANISTER (a) Install the charcoal canister.
(b) Connect the vacuum hose and air hose to the charcoalcanister.
15. INSTALL RADIATOR (a) Place the radiator on the body bracket.
(b) Install the upper radiator support with the two bolts andscrew. Install the two upper radiator supports.
EM±110
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(c) Connect the following hoses:(1) Reservior hose to radiator
(2) Upper radiator hose to water inlet
(3) Lower radiator hose to water outlet
(4) (A/T)
Two oil cooler hoses to radiator
16. INS TALL WATE R PUMP PULLE Y, FAN WITH FLUID COUPLING AND DRIVE BELT
(a) Align the matchmarks, and install the water pump pulley
and fan with fluid coupling with the four nuts.
(b) Install the drive belt by turning the drive belt tensioner clockwise.
(c) Stretch the belt tight and tighten the four nuts.
Torque: 16 N Vm (165 kgf Vcm, 12 ft Vlbf)
17. INSTALL AIR CLEANER ASSEMBLY
(a) Connect the air cleaner hose to the throttle body.
(b) Install the air cl eaner case with the three mounting bolts.
±
ENGINE MECHANICAL Cylinder BlockEM±111
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SERVICE DATA (Cont'd)
TORQUE SPECIFICATIONS
\
\
Part tightened  NVm kgf Vcm ft Vlbf
\
\
Camshaft bearing cap X Cylinder head  20 200 14
\
No.1 cylinder head cover X Cylinder head5.45548 in. Vlbf\
\
No.2 cylinder head cover X Cylinder head  5.4 55 48 in. Vlbf\
\
Intake air connector X Air intake chamber  21 210 15\
\
Throttle body bracket X Throttle body  21 210 15\
\
Throttle body bracket X Cylinder head  21 210 15
\
\
EGR pipe X Intake manifold  21 210 15
\
\
EGR pipe X EGR valve  64 650 47
\
\
Spark plug X Cylinder head  18 180 13
\
\
Throttle body X Intake air connector  21 210 15
\
\
Idler pulley X Oil pump  34 350 25
\
Crankshaft pulley X Crankshaft3243,300239\
\
Camshaft timing pulley X Camshaft  79 810 59\
\
Timing belt tensioner X Oil pump  26 270 20\
\
Drive belt tensioner X Cylinder head  21 210 15\
\
EGR cooler X Cylinder head  14 140 10
\


\
Engine coolant temperature sensor X Cylinder
head 


 


20 


200 


14
\


\
Engine coolant temperature sender gauge X Cylin-
der head 


 


20 


200 


14
\
\
Engine hanger X Cylinder head  39 400 29
\
Cylinder head X Cylinder block1st3435025\
\
 2nd Turn 90
5  
\
\
 3rd Turn 905  
\
\
No.4 Timing belt cover X Cylinder head  8.8 90 78 in.Vlbf\
\
Intake manifold X Cylinder head  21 210 15
\
\
Intake manifold stay X Intake manifold  39 400 29
\
\
Intake manifold stay X Cylinder head  39 400 29
\
\
No.1 fuel pipe X Intake manifold  8.8 90 78 in. Vlbf
\
\
No.2 fuel pipe X Intake manifold  8.8 90 78 in. Vlbf
\
\
Delivery pipe X Intake manifold  21 210 15
\
\
Air intake chamber X Intake manifold  21 210 15
\
Air intake chamber stay X Air intake chamber1818513\
\
Air intake chamber stay X Cylinder head  18 185 13\
\
Vacuum control valve set X Intake manifold  21 210 15\
\
No.2 vacuum pipe X Air intake chamber  21 210 15\
\
Water outlet X Cylinder head  21 210 15
\
\
Water by±pass outlet X Cylinder head  8.8 90 78 in. Vlbf
\
\
Exhaust manifold X Cylinder head  39 400 29
\
\
Exhaust manifold heat insulator X Exhaust manifold  18 185 13
EM±116±
ENGINE MECHANICAL Service Specifications
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TORQUE SPECIFICATIONS (Cont'd)
 Part tightened  NVm kgf Vcm ft Vlbf
 Main bearing cap X Cylinder block 1st 44 450 33
  2nd Turn 90 5  
 Connecting rod cap X Connecting rod 1st 29 300 22
2ndTurn 905 Rear oil seal retainer X Cylinder block  5.9 60 52 in.Vlbf Oil filter bracket X Cylinder block  88 900 65 LH engine mounting bracket X Cylinder block  58 590 43 RH engine mounting bracket X Cylinder block  58 590 43
 Knock sensor X Cylinder block  44 450 33
 Oil pressure switch X Cylinder block  14 150 11
 Fuel pipe support X Cylinder block  14 145 10
 Fuel pressure pulsation damper  41 420 30
  (for SST) 35 350 25
 Generator X Cylinder block  37 380 27
Flywheel X Crankshaft (M/T)1st4950036  2nd Turn 90 5  
 Drive Plate X Crankshaft (A/T)  98 1,000 72 Starter X Transmission  39 400 29 Oil cooler pipe X Transmission (A/T)  34 350 25
 Rear engine mounting member X Body  25 260 19
 


Rear engine mounting member X Engine mounting
insulator 


 


13 


135 


10
 Intermediate shaft X Propeller shaft  74 750 54
 Propeller shaft center bearing X Body  49 500 36
No.2 front exhaust pipe X Exhaust manifold6263046 Front exhaust pipe X No.2 front exhaust pipe  43 440 
 Clutch release cylinder X Transmission (M/T)  12 120 9 Fuel inlet hose X Fuel pipe support  34 350 25 A/C compressor X Cylinder block Through bolt 26 265 19
  Bolt and nut 52 530 38
 PS pump X Cylinder block  58 590 43
 PS pump X A/C compressor  58 590 43
 PS pump X Pump rear stay  39 400 29
 Cylinder block X Pump rear stay  39 400 29
 Fluid coupling X Water water pump  16 165 12
±
ENGINE MECHANICAL Service SpecificationsEM±117
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INSPECTION OF INJECTORS
1. INSPECT INJECTOR INJECTIONCAUTION: Keep injector clear of sparks during the test.
(a) Disconnect the fuel inlet hose from the fuel tube.
(b) Connect SST (hose) to the fuel inlet tube with SST(union). Tighten the flare nut on the fuel tube.
SST 09268±41045 (90405±52010)
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Use SST. (See page FI±15)
SST 09631±22020
(c) Loosen the lock nut, and remove the pressure regulator from the RH delivery pipe. Remove the O±ring from the
pressure regulator.
(d) Install a new O±ring to the fuel inlet of the pressure regulator.
(e) Connect SST (hose) to the pressure regulator with SST (union). Tighten the lock nut on the pressure regulator.
SST 09268±41045 (09268±52010)
Torque: 29 N Vm (300 kgf Vcm, 22 ft Vlbf)
(f) Connect the fuel return hose to the fuel outlet of the
pressure regulator with SST (union), two new gaskets
and union bolt.
SST 09268±41045 (09268±41070)
FI±52EFI SYSTEM ± Fuel System (Injectors)
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