torque LEXUS SC400 1991 Service Repair Manual

PREPARATION
SST (SPECIAL SERVICE TOOLS)
RECOMMENDED TOOLS
EQUIPMENT
Part NameNote
Engine tune±up testerIgnition timing
Megger (Insulation resistance meter)Spark plug
Spark plug cleaner
Torque wrench
16 mm plug wrench
±
IGNITION SYSTEM PreparationIG±5
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4. VISUALLY INSPECT SPARK PLUGSCheck the spark plug for thread damage and insulator dam-
age.
If abnormal, replace the spark plug.
Recommended spark plug: ND PK20R11
NGK BKR6EP11
5. INSPECT ELECTRODE GAP
Maximum electrode gap: 1.3 mm (0.051 in.)
If the gap is greater than maximum, replace the spark plug.
Correct electrode gap of new spark plug:1.1 mm (0.043 in.)
NOTICE: If adjusting the gap of a new spark plug, bent
only the base of the ground electrode. Do not touch the
tip. Never attempt to adjust the gap on the used plug.
6. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and
then clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi)
Duration: 20 seconds or less
HINT: If there are traces of oil, remove it with gasoline before
using the spark plug cleaner.
7. REINSTALL SPARK PLUGS Using a 16 mm plug wrench, install the spark plug.
Torque: 18 N Vm (180 kgf Vcm, 13 ft Vlbf)
8. RECONNECT HIGH±TENSION CORDS TO SPARK
PLUGS
(See steps 4 to 13 on pages IG±16 to 19)
IG±8
±
IGNITION SYSTEM On±Vehicle Inspection
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INSTALLATION OF DISTRIBUTOR
(See Components on page IG±23)
1. INSTALL CAM POSITION SENSORS TO DISTRIBUTOR HOUSINGS
Install the cam position sensor with the bolt and screw. Install
the two cam position sensors.
Torque: 6.4 N Vm (65 kgf Vcm, 56 in. Vlbf)
HINT:
w The RH distributor housing is marked with ºRº.
w The LH distributor housing is marked with ºLº.
2. INSTALL RH DISTRIBUTOR HOUSING (a) Install the distributor housing with the three bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT:
w The RH distributor housing is marked with ºRº.
w Each bolt length is indicated in the illustration.
Bolt length: A 38 mm (1.50 in.)
B 96 mm (3.78 in.)
(b) Connect the cam position sensor connector.
3. INSTALL LH DISTRIBUTOR HOUSING (a) Install the distributor housing with the three bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT:
w The LH distributor housing is marked with ºLº.
w Each bolt length is indicated in the illustration.
Bolt length: A 38 mm (1.50 in.)
B 80 mm (3.15 in.)
4. INSTALL DISTRIBUTOR ROTORS (a) Align the protrusion of the distributor rotor with thegroove of the camshaft timing pulley.
(b) Install the distributor rotor with the two bolts. Install the two distributor rotors.
Torque: 3.8 N Vm (39 kgf Vcm, 34 in. Vlbf)
IG±26±
IGNITION SYSTEM Distributor
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5. INSTALL DISTRIBUTOR CAPSInstall the distributor cap with the three bolts. Install the two
distributor caps.
Torque: 3.8 N Vm (39 kgf Vcm, 34 in. Vlbf)
6. CONNECT HIGH±TENSION CORDS TO DISTRIBUTOR
CAPS
Connect the ten high±tension cords.
NOTICE: Connect the high±tension cord by pressing on
the correct place as shown in the illustration.
If not done this way, the high±tension cord will interfere with
the camshaft timing pulley.
7. INSTALL RH NO.2 TIMING BELT COVER (a) Install the four gaskets to the timing belt cover.
(b) Install the connector grommet to the timing belt cover.
(c) Install the timing belt cover with the five bolts.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
HINT (12 mm head bolt): Use bolts 106 mm (4.17 in.) in
length.
(d) Install the wire clamp to the timing belt cover.
(e) Install the cam position sensor wire to the wire clamp on
the timing belt cover.
(f) Install the cam position sensor connector to the ignition coil bracket.
8. INSTALL LH NO.2 TIMING BELT COVER (a) Install the two gaskets to the timing belt cover.
(b) Run the cam po sition sensor wire through the timing belt
cover hole.
(c) Install the timing belt cover and connector bracket with the three bolts.
(d) Connect the cam position sensor connector.
(e) In sta ll th e ca m po sitio n se n so r c onnector to the
connector bracket.
(f) Install the cam position sensor wire to the wire clamp on
the timing belt cover.
(g) Install the connector grommet to the timing belt cover.
±
IGNITION SYSTEM DistributorIG±27
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9. INSTALL DRIVE BELT IDLER PULLEYInstall the idler pulley and cover plate with the pulley bolt.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
10. INSTALL NO.3 TIMING BELT COVERS
(See steps 5 to 9 and 11 on pages IG±17 to 19)
11. CONNECT RADIATOR HOSE TO WATER INLET
12. C O N N E C T C A B L E TO N E G AT I V E T E R M I N A L O F BATTERY
13. FILL ENGINE WITH COOLANT (See page CO±6)
14. WARM UP ENGINE Allow the engine to warm up to normal operating tempera-
ture.
15. CONNECT TACHOMETER Connect the tester probe of a tachometer to terminal IG
of
the check (ºDIAGNOSISº) connector.
HINT: Set the tachometer to the 4±cylinder range.
NOTICE:
w Never allow the tachometer tester probe to touch ground
as it could result in damage to the igniter and/or ignition
coil.
w As some tachometers are not compatible with this
ignition system, we recommend that you confirm the
compatibility of your unit before use.
16. CHECK IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the check(ºDIAGNOSISº) connector.
SST 09843±18020
(b) C onnect the tester probe of a timing light to the
high±tension cord for No.6 cylinder.
IG±28
±
IGNITION SYSTEM Distributor
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SERVICE SPECIFICATIONS
SERVICE DATA
Oil pressureat idle speed29 kPa (0.3 kgf/cm, 4.3 psi) or more
at 3,000 rpm 294±539 kPa
(3.0±5.5 kgf/cm, 43±78 psi)
Oil pumpTip clearanceSTD0.310±0.490 mm0.0122±0.0193 in.
Limit 0.53 mm0.0209 in.
Body clearanceSTD 0.100±0.175 mm0.0039±0.0069 in.
Limit 0.20 mm0.0079 in.
Rotor clearanceSTD 0.030±0.090 mm0.0012±0.0035 in.
Limit0.12 mm0.0047 in.
TORQUE SPECIFICATIONS
Part tightenedN mkgf cmftVlbf
A/C compressor X Cylinder blockThrough bolt2626519
Bolt and nut 52530 38
Oil pressure switch X Cylinder
block14150 11
Oil drain plug X No.2 oil pan45450 33
Oil pump body cover X Oil pump
body10105 8
Plug X Oil pump body49500 36
Oil pump X Cylinder block21210 15
No.1 oil pan X Cylinder block12 mm head bolt21210 15
14 mm head bolt39400 29
Oil pan baffle plate X No.1 oil pan8.8 90 78 in.
Vlbf
Oil strainer X No.1 oil pan8.8 90 78 in. Vlbf
No.2 oil pan X No.1 oil pan8.8 90 78 in. Vlbf
Oil level sensor X No.1 oil pan5.4 5548 in. Vlbf
±
LUBRICATION SYSTEM Service SpecificationsLU±19
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SERVICE SPECIFICATIONS
SERVICE DATA
Oil pressureat idling29 kPa (0.3 kgf/cm2, 4.3 psi) or more
at 3,000 rpm 294±588 kPa
(3.0±6.0 kgf/cm2, 43±85 psi)
Oil pumpTip clearanceSTD0.110±0.240 mm0.0043±0.0094 in.
Limit 0.35 mm0.0138 in.
Side clearanceSTD 0.030±0.090 mm0.0012±0.0035 in.
Limit 0.15 mm0.0059 in.
Body clearanceSTD 0.100±0.175 mm0.0039±0.0069 in.
Limit0.30 mm0.0118 in.
TORQUE SPECIFICATIONS
Part tightenedNVmkgf Vcmft Vlbf
Oil oumo body cover X Oil pump body101058
Oil pump X Cylinder block12 mm head 16160 12
14 mm head 30310 22
Engine speed sensor X Oil pump6.465 56 in. Vlbf
Oil filter bracket X Oil pump18185 13
Oil strainer X Oil pump7.880 69 in. Vlbf
Oil strainer X Cylinder block7.880 69 in. Vlbf
No.2 oil pan X Cylinder block10 mm head 7.880 69 in. Vlbf
12 mm head 18185 13
Oil pan baffle plate X No.1 oil pan7.880 69 in. Vlbf
No.2 oil pan X No.1 oil pan7.880 69 in. Vlbf
No.2 oil pan X Cylinder block7.880 69 in. Vlbf
Oil level sensor X No.1 oil pan5.45548 in. Vlbf
LU±20±
LUBRICATION SYSTEM Service Specifications
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PREPARATION
SST (SPECIAL SERVICE TOOLS)
RECOMMENDED TOOLS
EQUIPMENT
Part NameNote
Oil pressure gauge
Precision straight edgeOil pump
Torque wrench
LUBRICANT
Item
Capacity
ClassificationItemLitersUS qtslmp. qtsClassification
Engine oilAPI grade SG, Energy±Conserving II
Dry fill606353multigrade. Recommended viscosity is
Drain and refill6.06.35.3gy
as shown, with SAE 5W±30 being the
w/ Oil filter change 4.85.14.2preferred engine oil.
w/o Oil filter change4.54.85.3
g
SSM (SPECIAL SERVICE MATERIALS)
Part NamePart No.Use etc.
Seal packing or equivalent08826±00080Oil pump, Oil pan
Adhesive 1344,
Three bond 1344,08833±00080Oil pressure switch
Loctite 242 or equivalent
LU±4±
LUBRICATION SYSTEM System Circuit, Operation
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7. REINSTALL A/C COMPRESSOR(a) Install the A/C compressor with the through bolt, fourbolts and nut.
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 compressor connector.
8. REINSTALL DRIVE BELT Install the drive belt by turning the drive belt tensioner clock-
wise.
9. WARM UP ENGINE Allow the engine to warm up to normal operating
temperature.
10. CHECK OIL PRESSURE
Oil pressure:
At idle speed 29 kPa (0.3 kgf/cm
, 4.3 psi)
or more
At 3,000 rpm 294±539 kPa (3.0±5.5 kgf/cm
, 78 psi)
11. REMOVE DRIVE BELT (See step 4)
12. DISCONNECT A/C COMPRESSOR FROM ENGINE
(See step 5)
13. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH
(a) Remove an oil pressure gauge.
(b) A p p ly a dhesive to two or three threads of the oil
pressure switch.
Adhesive: Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, install the oil pressure switch.
SST 09816±30010
Torque: 14 NVm (150 kgf Vcm, 11 ft Vlbf)
(d) Connect the compressor connector.
14. REINSTALL A/C COMPRESSOR (See step 7)
15. REINSTALL DRIVE BELT (See step 8)
16. START ENGINE AND CHECK FOR LEAKS
17. REINSTALL ENGINE UNDER COVER
LU±6
±
LUBRICATION SYSTEM Oil pressure Check
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(d) Lightly screw the oil filter into place, and tighten it untilthe gasket contacts the seat.
(e) Using SST, tighten it an additional 3/4 turn.
SST 09228±07500
3. FILL WITH ENGINE OIL (a) Clean and install the oil drain plug with a new gasket.
Torque: 45 N Vm (450 kgf Vcm, 33 ft Vlbf)
(b) Fill with fresh engine oil.
Oil grade: See page LU±5
Capacity:
Drain and refill w/ Oil filter change
4.8 liters (5.1 US qts, 4.2 lmp. qts)
w/o Oil filter change
4.5 liters (4.8 US qts, 4.0 lmp. qts)
Dry fill 5.2 liters (5.5 US qts, 4.6 lmp. qts)
(c) Reinstall the oil filler cap.
4. START ENGINE AND CHECK FOR LEAKS
5. RECHECK ENGINE OIL LEVEL (See page LU±5)
LU±8
±
LUBRICATION SYSTEM Replacement of Engine Oil and Oil Filter
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