engine LEXUS SC400 1991 Service Repair Manual

ASSEMBLY OF CYLINDER BLOCK
(See Components on page EM±131)
HINT:
w Thoroughly clean all parts to be assembled.
w Before installing the parts, apply new engine oil to all
sliding 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 caps. 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 claw with the claw groove of the cylinder block, and push in the five upper bearings.
(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the five lower bearings.
HINT: A number is marked on each main bearing cap indicat-
ing the installation position.
2. INSTALL UPPER THRUST WASHERS Install the two thrust washers under the No.3 journal position
of the block with the oil grooves facing outward.
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3. PLACE CRANKSHAFT ON CYLINDER BLOCK
4. INSTALL MAIN BEARING CAP AND LOWER THRUSTWASHERS
A. Place main bearing cap and lower thrust washers on cyl-
inder block
(a) Install the two thrust washers on the No.3 main bearing cap with the grooves facing outward.
(b) Install the main bearing caps in their proper location.
(c) Place the five bearing caps in position on cylinder block.
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 two
progressive steps (steps (b) and (d)).
w If any one of the main bearing cap stud bolts is broken
or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the main bearing caps.
(b) Install and uniformly tighten the twenty main bearing cap
nuts in several passes in the sequence shown.
Torque: 27 N Vm (275 kgf Vcm, 20 ft Vlbf)
If any one of the main bearing cap nuts does not meet the
torque specification, replace the main bearing cap stud bolt.
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(c) Mark the front of the main bearing cap nut with paint.
(d) R e t i g h t e n t h e m a i n b e a r i n g c a p n u t s 9 0 5 i n t h enumerical order shown.
(e) Check that the painted mark is now at a 905 angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance. (See step 5 on page EM±138)
C. Install main bearing cap bolts (a) Install a new seal washer to the main bearing cap bolt.
(b) Install the ten main bearing cap bolts.
Torque: 49 N Vm (500 kgf Vcm, 36 ft Vlbf)
5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
NOTICE: The shape of the piston varies for the RH and LH
banks. The RH piston is marked with ºRº, the LH piston
with ºLº.
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6. INSTALL CONNECTING ROD CAPS
A. Place connecting rod cap on connecting rod(a) Match the numbered c onnecting rod cap with the
connecting rod.
(b) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod
cap.
(c) Check that the outside mark on the connecting rod cap is facing in correct direction.
B. Install connecting rod cap bolts HINT:
wThe connecting rod cap bolts are tightened in two
progressive steps (steps (b) and (d)).
w If any one of the connecting rod bolts is broken or
deformed, replace it.
(a) Apply a light of engine oil on the threads and under the
heads of the connecting rod cap bolts.
(b) Usin g SS T, in sta ll an d alte rn a te ly tig h te n th e two connecting rod cap bolts in several passes.
SST 09011±38121
Torque: 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the connecting rod cap bolt.
(c) Mark the front of the connecting rod cap bolt with paint.
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(d) Retighten the connecting rod cap bolts 905 in thenumerical order shown.
(e) Check that the painted mark is now at a 905 angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance. (See step 2 on page EM±135)
7. INSTALL REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the retainer
and cylinder block.
w Using a razor blade and gasket scraper, remove all the
old packing (FIPG) material from the gasket surfaces
and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer as shown in the illustration.
Seal packing: Part No.08826±00080 or equivalent
wInstall a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
w Parts must be assembled within 3 minutes of
application. Otherwise the material must be removed
and reapplied.
w Immediately remove nozzle from the tube and reinstall
cap.
(c) Place a new O±ring in position on the cylinder block.
(d) Install the retainer with the seven bolts.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
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POST ASSEMBLY
(See Components on page EM±131)
1. INSTALL WATER SEAL PLATE (a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the seal
plate and cylinder block.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the seal plate as shown in the
illustration.
Seal packing: Part No.08826±00100 or equivalent
w Install a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
w Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
(c) Install the seal plate with the two nuts.
Torque: 14 N Vm (145 kgf Vcm, 10 ft Vlbf)
2. INSTALL ALTERNATOR BRACKET
Install the bracket with the bolt.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
3. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the oil
pump and cylinder block.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the
illustration.
Seal packing: Part No.08826±00080 or equivalent
w Install a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
w Parts must be assembled within 3 minutes of
application. Otherwise the material must be
removed and reapplied.
w Immediately remove nozzle from the tube and
reinstall cap.
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(c) Place a new O±ring in position on the cylinder block.
(d) Engage the spline teeth of the oil pump drive gear withthe large teeth of the crankshaft, and slide the oil pump.
(e) Install the oil pump with the eight bolts.
Torque: 12 mm head 16 N Vm (160 kgf Vcm, 12 ft Vlbf)
14 mm head 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
A 50 mm (1.97 in.) for 12 mm head
B 106 mm (4.17 in.) for 12 mm head
C 30 mm (1.18 in.) for 12 mm head
D 40 mm (1.57 in.) for 14 mm head
4. INSTALL NO. 1 OIL PAN AND NO. 2 OIL PANS (See steps 4 to 9 on pages LU±16 to 19)
5. INSTALL WATER PUMP (a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the water
pump and cylinder block.
w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose material.
w Using a non±residue solvent, clean both sealing
surfaces.
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(b) Apply seal packing to the sealing groove of the waterpump as shown in the illustration.
Seal packing: Part No.08826±00100 or equivalent
wInstall a nozzle that has been cut to a 2±3 mm
(0.08±0.12 in.) opening.
w Parts must be assembled within 5 minutes of
application. Otherwise the material must be removed
and reapplied.
w Immediately remove nozzle from the tube and reinstall
cap.
(c) Install the water pump with the five bolts, two stud bolts and nut.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 30 mm (1.18 in.) in length.
6. INSTALL ENGINE WIRE (a) Install the engine wire to the LH side of the cylinder block
with the two bolts.
(b) Install the wire cover with the three bolts.
(c) Connect the following connectors: (1) Oil level sensor connector
(2) Oil pressure switch connector
7. INSTALL WATER BY±PASS PIPE (a) Install a new O±ring to the by±pass pipe.
(b) Apply soapy water to the O±ring.
(c) Pull in the by±pass pipe end into the pipe hole of thewater pump.
(d) Install the water by±pass pipe with the two bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
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8. INSTALL KNOCK SENSORS(a) Using SST, install the two knock sensors.
SST 09816±30010
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
(b) Connect the two knock sensor connectors.
9. INSTALL STARTER (a) Install the wire clamp to the bracket on the starter.
(b) Connect the wire to the starter with the nut.
(c) Connect the connector to the starter.
(d) Install the starter with the two bolts.
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
10. INSTALL RH ENGINE MOUNTING BRACKET
Install the mounting bracket with the four bolts.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
HINT: The RH mounting bracket is marked with ºRº.
11. INSTALL LH ENGINE MOUNTING BRACKET (a) Install the mounting bracket with the four bolts.
Torque: 37 N Vm (380 kgf Vcm, 27 ft Vlbf)
HINT: The LH mounting bracket is marked with ºLº.
(b) Install the engine wire to the mounting bracket with the
bolt.
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12. INSTALL CYLINDER HEADS(See pages EM±92 to 115)
13. INSTALL TIMING PULLEYS AND BELT (See pages EM±48 to 57)
14. REMOVE ENGINE STAND FROM ENGINE
15. INSTALL DRIVE PLATE (a) Apply adhesive to two or three threads of the mountingbolt end.
Adhesive: Part No.08833±00070, THREE BOND 1324 or equiva-
lent
(b) Install the front spacer, drive plate and rear spacer on the crankshaft.
(c) Install and uniformly tighten the eight mounting bolts in
several passes in the sequence shown.
Torque: 98 N Vm (1,000 kgf Vcm, 72 ft Vlbf)
ASSEMBLY OF ENGINE AND
TRANSMISSION
(See Components on page EM±129)
1. ASSEMBLE ENGINE AND TRANSMISSION (See AT section)
2. INSTALL OIL COOLER PIPE (a) Temporarily install the two mounting bolts.
(b) Connect the two oil cooler pipes to the unions on thetransmission. Tighten the union nuts.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
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