torque LEXUS SC400 1991 Service Repair Manual

(b) Using a 16 mm spark plug wrench, remove the eightspark plugs.
7. CHECK CYLINDER COMPRESSION PRESSURE (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 pressure:
1,226 kPa (12.5 kgf/cm, 178 psi) or more
Minimum pressure: 981 kPa (10.0 kgf/cm, 142 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm, 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.
8. REINSTALL SPARK PLUGS (a) Using a 16 mm plug wrench, install the eight sparkplugs.
Torque: 18 N Vm (180 kgf Vcm, 13 ft Vlbf)
(b) C onnect the eight high±tension cords to the spark
plugs.
(c) Fit the high±tension cords to the cord clamps.
(See page IG±16)
±
ENGINE MECHANICAL Compression CheckEM±31
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3. INSPECT TIMING BELT TENSIONER(a) Visually check tensioner for oil 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 in both hands and push the push rodstrongly against the floor or wall to check that it doesn't
move.
If the push rod moves, replace the tensioner.
(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.
INSTALLATION OF TIMING BELT
(See Components pages EM±33 and 34)
1. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key on the crankshaft with the keygroove of the timing pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the flange side rearward.
SST 09223±46011
2. INSTALL NO. 1 IDLER PULLEY (a) Apply adhesive to two or three threads of the pulley boltend.
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 pulley bolt. Torque the pulley
bolt.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
(c) Check that the pulley bracket moves smoothly.
EM±46
±
ENGINE MECHANICAL Timing Belt
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3. INSTALL NO. 2 IDLER PULLEY(a) Install the idler pulley with the pulley bolt. Torque thepulley 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 andalign the timing marks of the crankshaft timing pulley
and oil pump body.
(b) Remove any oil or water on the crankshaft timing 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 (NO. 1 CRANK ANGLE SENSOR PLATE)
Install the belt guide, facing the cup side forward.
6. INSTALL TIMING BELT COVER SPACER (a) Install the gasket to the spacer.
(b) Install the spacer.
±
ENGINE MECHANICAL Timing BeltEM±47
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7. INSTALL NO.1 TIMING BELT COVER(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the four bolts.
8. INSTALL HYDRAULIC PUMP (a) Install the hydraulic pump and solenoid valve connectorclamp and engine speed sensor wire clamp with the two
bolts and two nuts.
Torque:
12 mm heads 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
Others 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
A 106 mm (4.17 in.) for 12 mm head
B 114 mm (4.49 in.) for 14 mm head
(b) Connect the solenoid valve connector.
9. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key on the crankshaft with the keygroove of the pulley.
(b) Using SST and a hammer, tap in the pulley.
SST 09223±46011
(c) Using SST, install and torque the pulley bolt.
SST 09213±70010 and 09330±00021
Torque: 245 N Vm (2,500 kgf Vcm, 181 ft Vlbf)
10. INSTALL RH CAMSHAFT TIMING PULLEY
(a) Align the knock pin on the camshaft with the knock pingroove of the timing pulley.
(b) Slide the timing pulley, facing the ºRº mark forward.
(c) Using SST, install and torque the pulley bolt.
SST 09278±54012
Torque: 108 N Vm (1,100 kgf Vcm, 80 ft Vlbf)
EM±48±
ENGINE MECHANICAL Timing Belt
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11. INSTALL LH CAMSHAFT TIMING PULLEY(a) Align the knock pin on the camshaft with the knock pingroove of the timing pulley.
(b) Slide the timing pulley, facing the ºLº mark forward.
(c) Using SST, install and torque 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 the
ºOº timing mark of the No.1 timing belt cover.
(b) (Camshaft Timing Pulley Position) Using SST, t urn the camshaft timing pulley, and align the
timing marks of the camshaft timing pulley and timing
belt rear plate.
SST 09278±54012
13. INS TALL TIMING BE LT TO LH CAMS HAFT TIMING PULLEY
(a) Align the installation mark on the timing belt with 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
±
ENGINE MECHANICAL Timing BeltEM±49
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16. INSTALL TIMING BELT TENSIONER(a) Temporarily install the tensioner with the two bolts.
(b) Alternately tighten the two bolts.
Torque: 26 N Vm (270 kgf Vcm, 20 ft Vlbf)
(c) Using pliers, remove the 1.27 mm hexagon wrench from
the tensioner.
17. CHECK VALVE TIMING (a) Turn the crankshaft pulley two revolutions from TDC toTDC.
NOTICE: Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as shown in the figure.
If the marks do not align, remove the timing belt and reinstall
it.
18. INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the eight spark plugs.
Torque: 18 N Vm (180 kgf Vcm, 13 ft Vlbf)
±
ENGINE MECHANICAL Timing BeltEM±51
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19. INSTALL DRIVE BELT TENSIONERInstall the tensioner with the bolt and two nuts.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
HINT: Use bolt 106 mm (4.17 in.) in length.
20. INSTALL ALTERNATOR (a) Install the alternator and A/T oil cooler pipe bracket withthe bolt and nut.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
(b) Connect the alternator connector.
(c) Connect the alternator wire with the nut and cap.
21. 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.
22. 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.)
23. 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)
EM±52±
ENGINE MECHANICAL Timing Belt
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24. 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)
25. 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 (12 mm head bolt):
16 NVm (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 connector to the ignition
coil bracket.
26. 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) Install cam position sensor c onnector to connector
bracket.
(f) Install the connector grommet to the timing belt cover hole.
27. INSTALL DRIVE BELT IDLER PULLEY Install the idler pulley and cover plate with the pulley bolt.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
±
ENGINE MECHANICAL Timing BeltEM±53
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37. INSTALL A/C COMPRESSOR(a) In sta ll th e A/C co mp re sso r, co mp re sso r sta y an dground cable with the three bolts and nut.
Torque: Bolt 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
Nut 29 N Vm (300 kgf Vcm, 22 ft Vlbf)
(b) Connect the A/C compressor connector.
38. INSTALL RADIATOR AND RESERVOIR TANK (See steps 25 and 26 on pages EM±174 to 175)
39. INSTALL DRIVE BELT Install the drive belt by turning the drive belt tensioner coun-
terclockwise.
HINT: The pully bolt for the belt tensioner has a lefthand
thread.
40. INSTALL BATTERY
41. FILL WITH ENGINE COOLANT (See page CO±7)
42. CHECK IGNITION TIMING (See page IG±28)
Ignition timing:
8±125 BTDC @ idle
(w/ Terminals TE1 and E1 connected)
43. INSTALL ENGINE UNDER COVER
±
ENGINE MECHANICAL Timing BeltEM±57
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E. Inspect camshaft gear springUsing a vernier caliper, measure the free distance between
the spring ends.
Free distance: 18.2±18.8 mm (0.712±0.740 in.)
If the free distance is not as specified, replace the gear
spring.
F. Inspect camshaft journal oil clearance (a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaftjournals.
(d) Install the bearing caps. (See step 7 on pages EM±95 to 101)
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
NOTICE: Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
Exhaust camshaft thrust portion 0.025±0.061 mm
(0.0010±0.0024 in.)
Others 0.030±0.067 mm (0.0012±0.0026 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder
head as a set.
(g) Completely remove the Plastigage.
EM±86
±
ENGINE MECHANICAL Cylinder Heads
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