lock LEXUS SC400 1991 Service Repair Manual

Standard sized Bearing Selection Chart
 


Crankshaft
number mark\
 
\

\

Cylinder block number mark
  00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
 00 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3
 01 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3
 02 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4
 03 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 04 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 

05
 

1
 

2
 

2
 

2
 

2
 

2
 

2
 

3
 


3


3
 

3
 

3
 

3
 

4
 

4
 

4
 

4
 06 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4
 07 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4
 08 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5
 09 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5
 10 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 11 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 

12
 

3
 

3
 

3
 

3
 

3
 

3
 

4
 

4
 


4


4
 

4
 

4
 

5
 

5
 

5
 

5
 

5
EXAMPLE: Cylinder block ª06º, Crankshaft ª08º
= Use bearing ª3º
V01566
(l) Remove the 10 bolts, 20 nuts and 5 main bearing caps. (Seeprocedure (a) to (c) above)
(m) Remove the 5 upper main bearings from the cylinder block.
HINT: Arrange the main bearing caps, bearings and thrust
washers in correct order.
EG±164
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CYLINDER BLOCK INSPECTION AND
REPAIR
EG1KU±01
1. CLEAN CYLINDER BLOCK
A. Remove gasket materialUsing a gasket scraper, remove all the gasket material from
the top surface of the cylinder block.
B. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder
block.
NOTICE: If the cylinder is washed at high temperatures, the
cylinder liner sticks out beyond the cylinder block, so always
wash the cylinder block at temperature of 45
or less.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure
the surface contacting the cylinder head gasket for warpage.
Maximum warpage:
0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder
block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
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4. INSPECT CYLINDER BORE DIAMETERHINT: There are 3 sizes of the standard cylinder bore diame-
ter, marked ª1º, ª2º and ª3º accordingly. The mark is stamped
on the top of the cylinder block.
Using a cylinder gauge, measure the cylinder bore diameter
at positions A, B and C in the thrust and axial directions.
Standard diameter:
Mark ª1º87.500 ± 87.510 mm (3.4449 ± 3.4453 in.)
Mark ª2º 87.510 ± 87.520 mm (3.4453 ± 3.4457 in.)
Mark ª3º 87.520 ± 87.530 mm (3.4457 ± 3.4461 in.)
Maximum diameter: 87.73 mm (3.4539 in.)
If the diameter is greater than maximum, replace the cylinder
block.
5. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge ream-
er, grind the top of the cylinder.
6. INSPECT MAIN BEARING CAP STUD BOLTS Using 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.
EG±166
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2. INSPECT PISTON
A. Inspect piston oil clearanceHINT: There are 3 sizes of the standard piston diameter,
marked ª1º, ª2º and ª3º accordingly. The mark is stamped on
the piston top.
(a) Using a micrometer, measure the piston diameter at ring angles to the piston pin center line, 49 mm (1.93 in.) f rom the
piston head.
Piston diameter:
Mark ª1º87.470 ± 87.480 mm (3.4437 ± 3.4441 in.)
Mark ª2º 87.480 ± 86.490 mm (3.4441 ± 3.4445 in.)
Mark ª3º 87.490 ± 87.500 mm (3.4445 ± 3.4449 in.)
(b) Measure the cylinder bore diameter in the thrust directions. (See step 4 on page EG±xxx)
(c) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.020 ± 0.040 mm (0.0008 ± 0.0016 in.)
Maximum oil clearance: 0.06 mm (0.0024 in.)
If the oil clearance is greater than maximum, replace all the
8 pistons. If necessary, replace the cylinder block.
HINT (Use new cylinder block):
wUse a piston with the same number mark as the cylinder
diameter marked on the cylinder block.
w The shape of the piston varies for the RH and LH banks.
The RH piston is marked with ªRº, the LH piston with ªLº.
EG±170±
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B. Inspect piston ring groove clearanceUsing a feeler gauge, measure the clearance between new
piston ring and the wall of the ring groove
Ring groove clearance:
No.10.020 ± 0.060 mm (0.0008 ± 0.0024 in.)
No.2
0.015 ± 0.055 mm (0.0006 ± 0.0022 in.)
If the clearance is not as specified, replace the piston.
C. Inspect piston ring and gap
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bottom
of the ring travel, 105 mm (4.13 in.) from the top of the cylinder
block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap: No.10.250 ± 0.450 mm (0.0098 ± 0.0177 in.)
No.2 0.350 ± 0.600 mm (0.0138 ± 0.0236 in.)
Oil (Side rail)
0.160 ± 0.500 mm (0.0059 ± 0.0197 in.)
Maximum end gap: No.11.05 mm (0.0413 in.)
No.2 1.20 mm (0.0472 in.)
Oil (Side rail) 1.10 mm (0.0433 in.)
If the end gap is greater than maximum, replace the piston
ring. If the end gap is greater than maximum, even with a new
piston ring, replace the cylinder block.
D. Inspect piston pin fit At 60 5C (140 5F), you should be able to push the piston pin
into the piston pin hole with your thumb.
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CRANKSHAFT INSPECTION
EG0BY±0D
1. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT
(a) Place the crankshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout at the centerjournal.
Maximum circle runout:
0.08 mm (0.0031 in.)
If the circle runout is greater than maximum, replace the
crankshaft.
2. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter:
66.988 ± 67.000 mm (2.6373 ± 2.6378 in.)
Crank pin diameter: 51.982 ± 52.000 mm (2.0465 ± 2.0472 in.)
If the diameter is not as specified, check the oil clearance
(See steps 3 or 6 on page EG±156 or 160). If necessary, re-
place the crankshaft.
(b) Ch e ck ea ch ma in jo u rn a l an d cra n k pin fo r t aper and
out±of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
If the taper and out±of±round is greater than maximum, re-
place the crankshaft.
EG±174
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CRANKSHAFT OIL SEALS
REPLACEMENT
EG0C0±0M
HINT: There are 2 methods (A and B) to replace the oil seal
which are as follows:
1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If oil pump is removed from cylinder block:
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its surface
is flush with the oil pump body edge.
SST 09316±60010 (09316±00010)
(c) Apply MP grease to the oil seal lip.
B. If oil pump is installed to the cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape
the screwdriver tip.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge.
SST 09316±60010 (09316±00010)
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2. REPLACE CRANKSHAFT REAR OIL SEAL
A. If rear oil seal retainer is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its surface
is flush with the rear oil seal retainer edge.
SST 09223±56010
(c) Apply MP grease to the oil seal lip.
B. If rear oil seal retainer is installed to cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape
the screwdriver tip.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223±56010
EG±176
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CYLINDER BLOCK ASSEMBLY
EG1KW±01
(See Components for Cylinder block Disassembly and As-sembly)
HINT:
wThoroughly clean all parts to be assembled.
w Before installing the parts, apply new engine oil to all
sliding and and rotating surfaces.
w Replace all gaskets. O±rings and oil seals with new
parts.
1. INSTALL MAIN BEARINGS HINT:
wMain bearings come in widths of 19.5 mm (0.768 in.) and
22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.)
bearings in the No.1 and No.5 cylinder block journal
positions with the main bearing cap. Install the 19.5 mm
(0.768 in.) bearings in the other positions.
w Upper bearings have an oil groove and oil holes lower
bearings do not.
(a) Align the bearing law with the claw groove of the cylinder block, and push in the 5 upper bearings.
(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
HINT: A number is marked on each main bearing cap to indi-
cate the installation position.
2. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
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3. PLACE CRANKSHAFT ON CYLINDER BLOCK
4. INSTALL MAIN BEARING CAPS AND LOWER THRUSTWASHERS
A. Place main bearing caps and lower thrust washers on
cylinder block
(a) Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
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 2
progressive steps (steps (b) and (d)).
w If any one of the main bearing cap stud nuts is broken
or deformed, replace it.
EG±180
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