clock LEXUS SC400 1991 Service Workshop Manual

REMOVAL OF TIMING BELT
(See Components on page EM±23)1. REMOVE WATER PUMP PULLEY AND RADIATOR (See steps 1 to 3, 6 and 7 on pages EM±64 and 66)
2. REMOVE NO. 3 AND NO. 2 TIMING BELT COVERS (a) Remove the oil filler cap.
(b) Using a 5 mm hexagon wrench, remove the nine bolts,No. 3, No. 2 timing belt covers and gasket.
3. REMOVE DRIVE BELT TENSIONER Remove the three bolts and tensioner.
4. SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove withtiming mark º0º of the No. 1 timing belt cover.
NOTICE: Always turn the crankshaft clockwise.
(b) Check that the timing marks of the camshaft timing pulleys are aligned with the timing marks of the No. 4
timing belt cover.
If not, turn the crankshaft one revolution (360 5).
5. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS
HINT: (Re±using timing belt)
Place matchmarks on the timing belt and camshaft timing
pulleys as shown in the illustration.
EM±24
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ENGINE MECHANICAL Timing Belt
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11. 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) R e m o v e t h e 1 . 5 0 m m h e x agon wrench from the
tensioner with pliers.
12. 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.
13. INSTALL DRIVE BELT TENSIONER Install the tensioner with the three bolts.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
NOTICE: Be careful not to drop the bolts inside the timing
belt cover.
EM±32
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ENGINE MECHANICAL REPAIR INSTRUCTIONS
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REMOVAL OF TIMING BELT
(See Components on pages EM±33 and 34)
1. REMOVE BATTERY CAUTION: Work must be started after approx. 20 se-
conds or longer from the time the ignition switch is
turned to the ºLOCKº position and the negative (±) termi-
nal cable is disconnected from the battery.
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT (See page CO±6)
4. 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 belt tensioner has a left±hand
thread.
5. REMOVE RESERVOIR TANK RADIATOR (See steps 12 and 13 on pages EM±120 and 121)
6. REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES
(a) Disconnect the compressor connector.
(b) Remove the mounting nut, and disconnect the groundcable.
(c) Remove the mounting bolt and compressor stay.
(d) R e m o v e t h e t w o b o l t s , a n d d i s c onnect the A/C
compressor from the engine.
HINT: Put aside the compressor, and suspend it.
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ENGINE MECHANICAL Timing BeltEM±35
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(b) Check that the timing marks of the camshaft timingpulleys and timing belt rear plates aligned.
If not, turn the crankshaft one revolution (360 5).
27. REMOVE TIMING BELT TENSIONER HINT:
w(Re±using timing belt)
If the installation marks have disappeared, before re-
moving the timing belt, place new installation marks on
the timing belt to match the timing marks of the camshaft
timing pulleys, and place a new installation mark on the
timing belt to match the end of the hydraulic pump.
w (When replacing timing belt tensioner only)
To avoid meshing of the timing pulley and timing belt, se-
cure one of them with string. And place matchmarks on
the timing belt and RH camshaft timing pulley.
Alternately loosen the two bolts, and remove them, the ten-
sioner and dust boot.
28. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS
(a) Using SST, loosen the tension between the LH and RHcamshaft timing pulleys by slightly turning the LH
camshaft timing pulley clockwise.
SST 09278±54012
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ENGINE MECHANICAL Timing BeltEM±41
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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
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(d) Using SST, align the timing marks of the LH camshaftpulley and timing belt rear plate.
SST 09278±54012
(e) Check that the timing belt has tension between the crankshaft timing pulley and LH camshaft timing pulley.
14. INSTALL TIMING BELT TO RH CAMSHAFT TIMING PULLEY
(a) Remove any oil or water on the RH camshaft timing andwater pump pulley, and keep them clean.
(b) Using SST, slightly turn the RH 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 RH camshaft timing pulley.
SST 09278±54012
(c) Using SST, align the timing marks of the RH camshaft pulley and timing belt rear plate.
SST 09278±54012
(d) Check that the timing belt has tension between the RH
camshaft timing pulley and LH camshaft pulley.
15. SET TIMING BELT TENSIONER (a) Using a press, slowly press in the push rod using981±9,807 N (100±1,000 kgf, 220±2,205 lbf) of
pressure.
(b) Align the holes of the push rod and housing, pass a 1.27
mm hexagon wrench through the holes to keep the
setting position of the push rod.
(c) Release the press.
(d) Install the dust boot to the tensioner.
EM±50
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ENGINE MECHANICAL Timing Belt
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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)
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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
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(c) Uniformly loosen and remove the eight bearing capbolts in several passes in the sequence shown.
(d) Remove the four bearing caps, oil seal and intake camshaft.
HINT: Arrange the bearing caps in correct order.
42. DISASSEMBLE EXHAUST CAMSHAFTS (a) M ount the hexagon wrench head portion of the
camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
(b) Insert a service bolt (A) into the service hole of the camshaft sub±gear.
(c) Using a screwdriver, turn the sub±gear clockwise, and
remove the service bolt (B).
NOTICE: Be careful not to damage the camshaft.
(d) Using snap ring pliers, remove the snap ring.
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ENGINE MECHANICAL Cylinder HeadsEM±73
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(d) Insert a service bolt (A) into the service hole of thecamshaft sub±gear.
(e) Using a screwdriver, align the service holes and teeth of the camshaft driven gear and sub±gear by turning
camshaft sub±gear clockwise, and install a service bolt
(B).
NOTICE: Be careful not to damage the camshaft.
(f) Remove the service bolt (A).
7. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is
small, the camshaft must be held level while it is being
installed. If the camshaft is not kept level, the portion of
the cylinder head receiving the shaft thrust may crack or
be damaged causing the camshaft to seize or break. To
avoid this, the following steps should be carried out.
A. Install intake camshaft to RH cylinder head (a) Apply MP grease to the thrust portion of the camshaft.
(b) Place the intake camshaft at 45 ° angle of the timing
mark (one dot mark) on the cylinder head.
(c) Remove any old packing (FIPG) material.
(d) Apply seal packing to the bearing cap (mark ºI6º) as shown.
Seal packing: Part No. 08826±00080 or equivalent
(e) Install the front bearing cap (mark ºI6º) with the arrow mark facing rearward.
HINT:
w Installing the front bearing cap will determine the thrust
position of the camshaft.
w Align the arrow marks at front and rear of the cylinder
head with the mark on the bearing cap.
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ENGINE MECHANICAL Cylinder HeadsEM±95
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