engine LEXUS SC400 1991 Service Repair Manual

3. INSPECT TIMING BELT TENSIONER(a) Visually check tensioner for oil leakage.
HINT: If there is only the faintest trace of oil on the seal on the
push rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
(b) Hold the tensioner in both hands and push the push rodstrongly against the floor or wall to check that it doesn't
move.
If the push rod moves, replace the tensioner.
(c) Measure the protrusion of the push rod from the housing
end.
Protrusion: 10.5±11.5 mm (0.413±0.453 in.)
If the protrusion is not as specified, replace the tensioner.
INSTALLATION OF TIMING BELT
(See Components pages EM±33 and 34)
1. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key on the crankshaft with the keygroove of the timing pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the flange side rearward.
SST 09223±46011
2. INSTALL NO. 1 IDLER PULLEY (a) Apply adhesive to two or three threads of the pulley boltend.
Adhesive: Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 OR equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer
and idler pulley with the pulley bolt. Torque the pulley
bolt.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
(c) Check that the pulley bracket moves smoothly.
EM±46
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3. INSTALL NO. 2 IDLER PULLEY(a) Install the idler pulley with the pulley bolt. Torque thepulley bolt.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft andalign the timing marks of the crankshaft timing pulley
and oil pump body.
(b) Remove any oil or water on the crankshaft timing pulley,
No. 1 idler pulley and No. 2 idler pulley, and keep them
clean.
(c) Align the installation mark on the timing belt with the dot
mark of the crankshaft timing pulley.
(d) Install the timing belt on the crankshaft timing pulley, No.
1 idler pulley and No. 2 idler pulley.
5. INSTALL TIMING BELT GUIDE (NO. 1 CRANK ANGLE SENSOR PLATE)
Install the belt guide, facing the cup side forward.
6. INSTALL TIMING BELT COVER SPACER (a) Install the gasket to the spacer.
(b) Install the spacer.
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7. INSTALL NO.1 TIMING BELT COVER(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the four bolts.
8. INSTALL HYDRAULIC PUMP (a) Install the hydraulic pump and solenoid valve connectorclamp and engine speed sensor wire clamp with the two
bolts and two nuts.
Torque:
12 mm heads 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
Others 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
A 106 mm (4.17 in.) for 12 mm head
B 114 mm (4.49 in.) for 14 mm head
(b) Connect the solenoid valve connector.
9. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key on the crankshaft with the keygroove of the pulley.
(b) Using SST and a hammer, tap in the pulley.
SST 09223±46011
(c) Using SST, install and torque the pulley bolt.
SST 09213±70010 and 09330±00021
Torque: 245 N Vm (2,500 kgf Vcm, 181 ft Vlbf)
10. INSTALL RH 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 ºRº 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)
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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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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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19. INSTALL DRIVE BELT TENSIONERInstall the tensioner with the bolt and two nuts.
Torque: 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
HINT: Use bolt 106 mm (4.17 in.) in length.
20. INSTALL ALTERNATOR (a) Install the alternator and A/T oil cooler pipe bracket withthe bolt and nut.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
(b) Connect the alternator connector.
(c) Connect the alternator wire with the nut and cap.
21. INSTALL RH DISTRIBUTOR HOUSING (a) Install the distributor housing with the three bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT:
w The RH distributor housing is marked with ºRº.
w Each bolt length is indicated in the illustration.
Bolt length: A 38 mm (1.50 in.)
B 96 mm (3.78 in.)
(b) Connect the cam position sensor connector.
22. INSTALL LH DISTRIBUTOR HOUSING (a) Install the distributor housing with the three bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT:
w The LH distributor housing is marked with ºLº.
w Each bolt length is indicated in the illustration.
Bolt length: A 38 mm (1.50 in.)
B 80 mm (3.15 in.)
23. INSTALL DISTRIBUTOR ROTORS (a) Align the protrusion of the distributor rotor with thegroove of the camshaft timing pulley.
(b) Install the distributor rotor with the two bolts. Install the two distributor rotors.
Torque: 3.8 N Vm (39 kgf Vcm, 34 in. Vlbf)
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24. INSTALL DISTRIBUTOR CAPSInstall the distributor cap with the three bolts. Install the two
distributor caps.
Torque: 3.8 N Vm (39 kgf Vcm, 34 in. Vlbf)
25. INSTALL RH NO.2 TIMING BELT COVER
(a) Install the four gaskets to the timing belt cover.
(b) Install the connector grommet to the timing belt cover.
(c) Install the timing belt cover with the five bolts.
Torque (12 mm head bolt):
16 NVm (160 kgf Vcm, 12 ft Vlbf)
HINT (12 mm head bolt): Use bolts 106 mm (4.17 in.) in
length.
(d) Install the wire clamp to the timing belt cover.
(e) Install the cam position sensor connector to the ignition
coil bracket.
26. INSTALL LH NO.2 TIMING BELT COVER (a) Install the two gaskets to the timing belt cover.
(b) Run the cam po sition sensor wire through the timing belt
cover hole.
(c) Install the timing belt cover and connector bracket with the three bolts.
(d) Connect the cam position sensor connector.
(e) Install cam position sensor c onnector to connector
bracket.
(f) Install the connector grommet to the timing belt cover hole.
27. INSTALL DRIVE BELT IDLER PULLEY Install the idler pulley and cover plate with the pulley bolt.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
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28. INSTALL HIGH±TENSION CORDS, HIGH±TENSIONCORD CLAMP AND LOWER HIGH±TENSION CORD
COVER ASSEMBLY
(a) Install the lower high±tension cord cover with the bolt.
(b) Connect the high±tension cord to RH ignition coil.
(c) Connect the four high±tension cord to the RH sparkplugs.
(d) Install the RH rear and front high±tension cord clamps
with the two bolts.
HINT: Place the front and rear ends of the front hightension
cord clamp on the rear high±tension cord clamp and lower
high±tension cord cover.
(e) Connect the four high±tension cord to the LH spark plugs.
(f) Install the LH rear and front high±tension cord clamps
with the two bolts.
HINT: Place the front and rear ends of the front hightension
cord clamp on the rear high±tension cord clamp and lower
high±tension cord cover.
(g) Fit the high±tension cords to the high±tension cord clamp. (See page IG±16)
29. INSTALL RH NO.3 TIMING BELT COVER (a) Install the three gaskets to the timing belt cover.
(b) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(c) Install the timing belt cover with the three bolts.
30. INSTALL VSV FOR EVAP SYSTEM Install the VSV with the two bolts.
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31. INSTALL LH NO.3 TIMING BELT COVER(a) Install the three gaskets to the timing belt cover.
(b) Install the cord grommet to the high±tension cord.
(c) Install the cord grommet to the timing belt cover.
(d) Fit portion A of the timing belt cover, matching it with the
lower high±tension cord cover.
(e) Install the timing belt cover with the four bolts.
32. INSTALL RH ENGINE WIRE COVER (a) Fit portions A and B of the engine wire cover, matchingthem with the lower high±tension cord cover and No. 3
timing belt cover.
(b) Install the engine wire cover with the bolt.
33. INSTALL LH ENGINE WIRE COVER (a) Connect portions A and B of the engine wire cover to the
wire cover brackets.
(b) Set the VSV (for Fuel pressure control system) wire in original position.
(c) Fit portions C and D of the engine wire cover, matching them with the lower high±tension cord cover and No.3
timing belt cover.
(b) Install the engine wire cover with the two bolts.
34. INSTALL UPPER HIGH±TENSION CORD COVER (a) Fit portion A of the upper high±tension cover, matchingit with the top of the lower high±tension cord cover.
(b) Push the front side of the high±tension cord cover, and connect the front side claw groove of the upper
high±tension cord cover to the claw of the lower
high±tension cord cover.
(c) Install the upper high±tension cord cover with the two bolts.
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