lock LEXUS SC400 1991 Service Repair Manual

CYLINDER BLOCK
COMPONENTS FOR ENGINE REMOVAL AND
INSTALLATION
EG251±01
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ENGINE REMOVAL
EG24W±02
(See Components for Engine Removal and Installation)
1. REMOVE BATTERYCAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the ªLOCKº posi-
tion and the negative (±) terminal cable is disconnected
from the battery.
2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tension-
er counterclockwise, and remove the drive belt.
HINT: The pulley bolt for the drive belt tensioner has a left±
hand thread.
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COMPONENTS FOR CYLINDER BLOCK
DISASSEMBLY AND ASSEMBLY
EG0BS±0E
EG±152±
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PREPARATION FOR DISASSEMBLY
EG34Y±01
(See Components for Cylinder Block Disassembly and As-sembly)
1. REMOVE DRIVE PLATE Remove the 8 bolts, front spacer drive plate and rear spacer.
2. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
3. REMOVE TIMING BELT AND PULLEYS (See pages EG±49 to 57)
4. REMOVE CYLINDER HEAD (See pages EG±75 to 93)
5. REMOVE RH ENGINE MOUNTING BRACKET Remove the 4 bolts and mounting bracket.
6. REMOVE LH ENGINE MOUNTING BRACKET
(a) Remove the 4 bolts and mounting bracket.
(b) Remove the bolt, and disconnect the engine wire from the mounting bracket.
7. REMOVE STARTER
(a) Remove the 2 bolts, and disconnect the starter from the cylinder block.
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(b) Disconnect the engine wire clamp from the bracket on thestarter.
(c) Remove the nut, and disconnect the starter wire.
(d) Disconnect the starter connector, and remove the starter.
8. REMOVE KNOCK SENSORS
(a) Disconnect the 2 knock sensor connectors.
(b) Using SST, remove the 2 knock sensors.
SST 09816±30010
9. REMOVE WATER BYPASS PIPE
(a) Remove the 2 bolts.
(b) Pull out the water bypass pipe from the water pump.
(c) Remove the O±ring from the water bypass pipe.
10. REMOVE ENGINE WIRE
(a) Disconnect the following connector: wCrankshaft position sensor connector
w Oil pressure switch connector
w Oil level sensor connector
(b) Remove the 3 bolts and engine wire cover from the LH side of the cylinder block.
(c) Remove the 2 bolts and engine wire.
EG±154
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11. REMOVE WATER PUMP
(a) Remove the 5 bolts, 2 stud bolts and nut.
(b) Using a screwdriver remove the water pump by prying theportions between the water pump and cylinder block.
12. REMOVE NO.2 AND NO.1 OIL PANS
(See steps 9 to 14 on pages EG±501 and 502)
13. REMOVE OIL PUMP
(a) Remove the 8 bolts.
(b) Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block.
(c) Remove the O±ring from the cylinder block.
14. REMOVE GENERATOR BRACKET
Remove the bolt and generator bracket.
15. REMOVE WATER SEAL PLATE
Remove the 2 bolts and seal plate.
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CYLINDER BLOCK DISASSEMBLY
EG1KT±04
(See Components for Cylinder Block Disassembly and As-sembly)
1. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the oil sel retainer by prying the portions between the oil seal retainer and main bearing cap.
(c) Remove the O±ring.
2. CHECK CONNECTING ROD OIL CLEARANCE Using a dial indicator, measure the thrust clearance while
moving the connecting rod back an forth.
Standard thrust clearance:
0.160 ± 0.290 mm (0.0063 ± 0.0138 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
Connecting rod thickness:
22.880 ± 22.920 mm (0.9008 ± 0.9024 in.)
3. REMOVE CONNECTING ROD CAPS AND CHECK OILCLEARANCE
(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT: Keep the lower bearing inserted with the connecting
rod cap.
EG±156
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4. REMOVE PISTON AND CONNECTING RODASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top of
the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
wKeep the bearings, connecting rod and cap together.
w Arrange the piston and connecting rod assemblies in
correct order.
5. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indi cator, measure the thrust clearance while pry-
ing the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 ± 0.220 mm (0.0008 ± 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:2.440 ± 2.490 mm (0.0961 ± 0.0980 in.)
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6. REMOVE MAIN BEARING CAPS AND CHECK OILCLEARANCE
(a) Remove the 10 main bearing cap bolts.
(b) Uniformly loosen and remove the 20 main bearing cap nuts
in several passes, in the sequence shown.
(c) Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, lower bearings and lower
thrust washers (No.3 main bearing cap only).
NOTICE: Be careful not to damage the cylinder block.
HINT:
wKeep the lower 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 2 upper thrust washers. HINT:
wArrange the upper thrust washers in correct order.
w Keep the upper bearings together with the cylinder
block.
(f) Clean each main journal and bearing.
(g) Ch e ck ea ch ma in jo u rn a l an d be a rin g fo r pittin g an d scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
EG±160
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HINT: If using a standard bearing, replace it with one having
the same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft, then
refer to the table below for the appropriate bearing number.
There are 5 sizes of the standard bearings, marked ª1º, ª2º,\
ª3º, ª4º and ª5º accordingly.
EXAMPLE: Cylinder block ª06º (A) + Crankshaft ª08º (B)
= Total number 14 (Use bearing ª3º)
V01565
Reference:
Cylinder block main journal bore diameter (A):
Mark ª00º72.000 mm (2.8346 in.)
Mark ª01º 72.001 mm (2.8347 in.)
Mark ª02º 72.002 mm (2.8347 in.)
Mark ª03º 72.003 mm (2.8348 in.)
Mark ª04º 72.004 mm (2.8348 in.)
Mark ª05º 72.005 mm (2.8348 in.)
Mark ª06º
72.006 mm (2.8349 in.)
Mark ª07º 72.007 mm (2.8349 in.)
Mark ª08º
72.008 mm (2.8350 in.)
Mark ª09º 72.009 mm (2.8350 in.)
Mark ª10º 72.010 mm (2.8350 in.)
Mark ª11º 72.011 mm (2.8351 in.)
Mark ª12º 72.012 mm (2.8351 in.)
Mark ª13º 72.013 mm (2.8352 in.)
EG±162±
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