torque LEXUS SC400 1991 Service Repair Manual

43. INSTALL RH IGNITION COILInstall the ignition coil with the two bolts.
44. CONNECT CONTROL CABLES TO THROTTLE BODY Connect the following cables:(1) Accelerator cable
(2) A/T throttle cable
(3) (w/ Cruise Control System)
Cruise control actuator cable
45. INSTALL THROTTLE BODY COVER Install the throttle body cover and hose clamp with the two
bolts and cap nut.
46. INSTALL CATALYTIC CONVERTERS (MAIN) (a) Install a new gasket and the catalytic converter to theexhaust manifold with the three new bolts. Install the two
catalytic converters.
Torque: 62 N Vm (630 kgf Vcm, 46 ft Vlbf)
(b) Install a new gasket to each front end of the front
exhaust pipe.
(c) C onnect the front exhaust pipe to the catalytic
converters.
(d) Te mp o ra rily in sta ll th e fo u r bo lts ho ld in g th e pip e support bracket to the transmission.
(e) Install the four bolts and nuts holding the catalytic
converters to the front exhaust pipe.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(f) Tighten the four bolts holding the pipe support bracket
to the transmission.
Torque: 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
EM±114±
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47. INSTALL PS PUMP(a) In sta ll th e PS pu mp with th e th re e bo lts an d nu t.Alternately tighten the bolts and nut.
Torque:
Bolt 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
Nut 43 N Vm (440 kgf Vcm, 32 ft Vlbf)
(b) Connect the vacuum hose to the vacuum pipe.
48. INSTALL HYDRAULIC PUMP AND CAMSHAFT TIMING PULLEYS
(See steps 8, 10 and 11 on pages EM±48 to 49)
49. INSTALL HYDRAULIC PUMP AND CAMSHAFT TIMING PULLEYS
(See steps 12 to 43 on pages EM±49 to 57)
50. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
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ENGINE MECHANICAL Cylinder HeadsEM±115
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(d) Clean the crank pin and bearings.
(e) C h e c k t h e c r a n k p i n a n d b e a r i n g f o r p i t t i n g a n dscratches.
If the crank pin or bearing are damaged, replace the bear-
ings. If necessary, replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the two bolts.
(See step 6 on pages EM±159 and 160)
Torque: 1st 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
2nd Turn 90 5
NOTICE: Do not turn the crankshaft.
(h) Remove the two bolts, connecting rod cap and lower
bearing. (See procedure (b) and (c) above)
(i) Measure the Plastigage at widest point.
Standard oil clearance: 0.027±0.053 mm (0.0011±0.0021 in.)
Maximum oil clearance: 0.065 mm (0.0026 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, replace the crankshaft.
EM±136
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(c) Using two screwdrivers, pry out the main bearing cap,and remove the five main bearing cap, lower main
bearings and two lower thrust washers (No.3 main
bearing cap only).
NOTICE: Be careful not to damage the cylinder block.
HINT:
w Keep the lower main bearing and main bearing cap
together.
w Arrange the main bearing caps and lower thrust
washers in correct order.
(d) Lift out the crankshaft.
(e) Remove the two upper thrust washers.
HINT:
w Arrange the upper thrust washers in correct order.
w Keep the upper main bearings together with the cylinder
block.
(f) Clean each main journal and bearing.
(g) Check each main journal and bearing for pitting and scratches.
If the journal or bearing are damaged, replace the bearings.
If necessary, replace the crankshaft.
(h) Install the five main bearing caps with the twenty nuts and ten bolts. Do not install the crankshaft.
(See step 4 on pages EM±157 and 158)
Torque:
Nut 1st 27 N Vm (275 kgf Vcm, 20 ft Vlbf)
2nd Turn 90 5
Bolt 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
(i) Using a cylinder gauge, measure the inside diameter of
the main bearing.
Bearing inside diameter: 67.026±67.033 mm
(2.6388±2.6391 in.)
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ENGINE MECHANICAL Cylinder BlockEM±139
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6. INSPECT MAIN BEARING CAP STUD BOLTSUsing a vernier caliper, measure the tension portion diameter
of the stud bolt.
Standard diameter: 7.500±7.600 mm
(0.2953±0.2992 in.)
Minimum diameter: 7.40 mm (0.2913 in.)
If the diameter is less than minimum, replace the stud bolt.
7. IF NECESSARY, REPLACE MAIN BEARING CAP STUD BOLTS
(a) Using the two main bearing cap nuts, remove the studbolt.
(b) Apply a light coat of engine oil on the threads and under
the flange of the stud bolt.
(c) Using the two main bearing cap nuts, install and torque
the stud bolt.
Torque: 10 N Vm (100 kgf Vcm, 7 ft Vlbf)
HINT: Stud bolts come in lengths of 90.0 mm (3.543 in.) and
101.5 mm (3.996 in.). Install the 101.5 mm (3.996 in.) bolts
in inside positions. Install the 90.0 mm (3.543 in.) bolts in out-
side positions.
DISASSEMBLY OF PISTON AND
CONNECTING ROD ASSEMBLIES
1. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
EM±144
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3. PLACE CRANKSHAFT ON CYLINDER BLOCK
4. INSTALL MAIN BEARING CAP AND LOWER THRUSTWASHERS
A. Place main bearing cap and lower thrust washers on cyl-
inder block
(a) Install the two thrust washers on the No.3 main bearing cap with the grooves facing outward.
(b) Install the main bearing caps in their proper location.
(c) Place the five bearing caps in position on cylinder block.
HINT: Place the bearing caps level and let them return to their
original position by their own weight.
NOTICE: Do not install the main bearing cap by tapping
it.
B. Install main bearing cap nuts HINT:
wThe main bearing cap nuts are tightened in two
progressive steps (steps (b) and (d)).
w If any one of the main bearing cap stud bolts is broken
or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the main bearing caps.
(b) Install and uniformly tighten the twenty main bearing cap
nuts in several passes in the sequence shown.
Torque: 27 N Vm (275 kgf Vcm, 20 ft Vlbf)
If any one of the main bearing cap nuts does not meet the
torque specification, replace the main bearing cap stud bolt.
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ENGINE MECHANICAL Cylinder BlockEM±157
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(c) Mark the front of the main bearing cap nut with paint.
(d) R e t i g h t e n t h e m a i n b e a r i n g c a p n u t s 9 0 5 i n t h enumerical order shown.
(e) Check that the painted mark is now at a 905 angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance. (See step 5 on page EM±138)
C. Install main bearing cap bolts (a) Install a new seal washer to the main bearing cap bolt.
(b) Install the ten main bearing cap bolts.
Torque: 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
NOTICE: The shape of the piston varies for the RH and LH
banks. The RH piston is marked with ºRº, the LH piston
with ºLº.
EM±158
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6. INSTALL CONNECTING ROD CAPS
A. Place connecting rod cap on connecting rod(a) Match the numbered c onnecting rod cap with the
connecting rod.
(b) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod
cap.
(c) Check that the outside mark on the connecting rod cap is facing in correct direction.
B. Install connecting rod cap bolts HINT:
wThe connecting rod cap bolts are tightened in two
progressive steps (steps (b) and (d)).
w If any one of the connecting rod bolts is broken or
deformed, replace it.
(a) Apply a light of engine oil on the threads and under the
heads of the connecting rod cap bolts.
(b) Usin g SS T, in sta ll an d alte rn a te ly tig h te n th e two connecting rod cap bolts in several passes.
SST 09011±38121
Torque: 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the connecting rod cap bolt.
(c) Mark the front of the connecting rod cap bolt with paint.
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ENGINE MECHANICAL Cylinder BlockEM±159
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(d) Retighten the connecting rod cap bolts 905 in thenumerical order shown.
(e) Check that the painted mark is now at a 905 angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance. (See step 2 on page EM±135)
7. INSTALL REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the retainer
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 retainer as shown in the illustration.
Seal packing: Part No.08826±00080 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 3 minutes of
application. Otherwise the material must be removed
and reapplied.
w Immediately remove nozzle from the tube and reinstall
cap.
(c) Place a new O±ring in position on the cylinder block.
(d) Install the retainer with the seven bolts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
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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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ENGINE MECHANICAL Cylinder BlockEM±161
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