engine LEXUS SC400 1991 Service Repair Manual

13. DISCONNECT ENGINE WIRE FROM CABIN(a) Remove the two clips, and pull out the instrument panelunder cover.
(b) Remove the four mounting screws.
(c) Disc onnect the connectors, and remove the lower
instrument panel finish panel and glove compartment
door assembly.
(d) Pull out the scuff plate.
(e) Take out the front side of the floor carpet.
(f) Remove the two nuts and ECU protector.
(g) Remove the nut, and disconnect the engine (& ECT) ECU from the floor panel.
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(h) Disconnect the following connectors:(1) Two connectors from engine (& ECT) ECU
(2) Connector from ABS & TRAC ECU
(3) Two connectors from TRAC ECU
(4) Four connectors from connector cassette
(5) Connector from A/C control assembly
(i) Pull out the engine wire from the cabin.
14. DISCONNECT PS PIPE FROM ENGINE Remove the two clamp bolts, and disconnect the PS pipe.
15. DISCONNECT HOSE, STARTER WIRE AND GROUND STRAP
(a) Remove the union bolt and two gaskets, disconnect thefuel inlet hose, and suspend the hose union end
upward.
HINT:
w Put a suitable container or shop towel under the fuel
pipe support.
w Slowly loosen the union bolt.
(b) Remove the nut and disconnect the starter wire.
(c) Disconnect the starter wire from the wire clamp.
(d) Disconnect the ground strap from the transmission.
16. (M/T)
DISCONNECT CLUTCH RELEASE CYLINDER FROM TRANS-
MISSION
Remove the two bolts and pull out the release cylinder.
EM±70
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17. REMOVE NO. 2 FRONT EXHAUST PIPE(a) Remove the two bolts and nuts holding the front exhaust
pipe to the No. 2 front exhaust pipe.
(b) Remove the gasket and disconnect the front exhaust
pipe.
(c) Remove the four nuts, No. 2 front exhaust pipe and two gaskets.
18. REMOVE EXHAUST PIPE HEAT INSULATOR Remove the four nuts and heat insulator.
19. (A/T)
DISCONNECT TRANSMISSION CONTROL ROD
Remove the nut and disconnect the control rod from the shift
lever.
20. REMOVE INTERMEDIATE SHAFT (a) Remove the two center support bearing set bolts andthe adjusting washers.
HINT: Some vehicles are not equipped with an adjusting
washer.
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(b) Place the matchmarks on the both flanges.
(c) Remove the four bolts, washers, nuts and intermediateshaft.
(d) Insert SST in transmission to prevent oil leakage.
SST 09325±20010 (M/T)
09325±40010 (A/T)
21. REMOVE ENGINE AND T RANSMISSION ASSEMBLY
FROM VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Remove the two nuts holding the engine to the front suspension crossmember.
(c) Remove the four bolts, four nuts and rear engine mounting member.
(d) Lift the engine out of the vehicle slowly and carefully.
NOTICE: Remove carefully without damaging the power
steering gear housing or the park/neutral position switch
(A/T only).
(e) Make sure the engine is clear of all wiring, hoses and cables.
(f) Place the engine and transmission assembly onto the
stand.
EM±72
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COMPONENTS FOR SEPARATION AND
ASSEMBLY OF ENGINE AND
TRANSMISSION
SEPARATION OF ENGINE AND
TRANSMISSION
1. (A/T)REMOVE OIL DIPSTICK GUIDE FOR TRANSMISSION
2. (A/T) REMOVE OIL COOLER PIPES FOR TRANSMISSION
3. DISCONNECT ENGINE WIRE FROM TRANSMISSION
4. REMOVE STARTER
5. SEPARATE ENGINE AND TRANSMISSION
6. (M/T) REMOVE CLUTCH COVER AND DISC
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COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY OF CYLINDER BLOCK
EM±74±
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COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY OF CYLINDER BLOCK
(Cont'd)
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ENGINE MECHANICAL Cylinder BlockEM±75
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PREPARATION FOR DISASSEMBLY
(See Components on pages EM±74 and 75)1. (M/T) REMOVE FLYWHEEL
2. (A/T) REMOVE DRIVE PLATE
Remove the eight bolts, two spacers and drive plate.
3. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
4. REMOVE GENERATOR
5. REMOVE THROTTLE BODY WITH INTAKE AIR CONNECTOR (See pages EM±10 to 11)
6. REMOVE TIMING BELT AND PULLEYS (See pages EM±24 to 26)
7. REMOVE WATER PUMP AND BY±PASS HOSE
8. REMOVE FUEL PRESSURE PULSATION DAMPER
9. REMOVE CYLINDER HEAD (See pages EM±36 to 40)
10. REMOVE FUEL PIPE SUPPORT
11. REMOVE OIL PRESSURE SWITCH AND KNOCK SENSORS
SST 09816±30010
12. REMOVE LH ENGINE MOUNTING BRACKET
13. REMOVE RH ENGINE MOUNTING BRACKET
14. REMOVE OIL FILTER BRACKET (a) Remove the union bolt and oil filter bracket.
(b) Remove the gasket from the union bolt.
(c) Remove the O±ring from the oil filter bracket.
15. REMOVE OIL PUMP (See page LU±10)
EM±76
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DISASSEMBLY OF CYLINDER BLOCK
(See Components on page EM±75)
1. REMOVE REAR OIL SEAL RETAINER (a) Remove the six bolts.
(b) Remove the oil seal retainer by prying the area between
the oil seal retainer and main bearing cap with a
screwdriver.
2. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while
moving the two connecting rods back and forth.
Standard thrust clearance: 0.250±0.402 mm
(0.0098±0.0158 in.)
Maximum thrust clearance: 0.50 mm (0.0197 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
Connecting rod thickness: 25.898±25.950 mm (1.0196±1.0217 in.)
3. REMOVE CONNECTING ROD CAPS AND CHECK OILCLEARANCE
(a) Check the matchmarks on the connecting rod and cap.
(b) Remove the connecting rod cap bolts.
(c) Using the two removed connecting rod bolts, removethe 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.
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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±98 and 99)
Torque: 1st 29 N Vm (300 kgf Vcm, 22 ft Vlbf)
2nd turn 90 5
HINT: Do not turn the crankshaft.
(h) Remove the two bolts, connecting rod cap and lower
bearing. (See procedures (b) and (c) above)
(i) Measure the Plastigage at widest point.
Standard oil clearance: STD size 0.035±0.053 mm (0.0014±0.0021 in.)
U/S 0.25 0.040±0.078 mm (0.0016±0.0031 in.)
Maximum oil clearance:
STD size 0.08 mm (0.0031 in.)
U/S 0.25 0.09 mm (0.0035 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, replace the crankshaft.
EM±78
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