1991 LEXUS SC300 timing belt

41. INSTALL TIMING BELT REAR PLATESInstall the rear plate with the two bolts. Install the two rear
plates.
Torque: 7.8 N Vm (80 kgf Vcm, 69 in. Vlbf)
42. INSTALL WATER INLET AND INLET HOUSING
(a) Remove any old packing (FIPG) material.w Using a razor blade and gasket scraper, remove all
the old packing (FIPG) materials from the gasket
surfaces and sealing groove.
w Thoroughly clean all components to remove all the
loose materials.
w Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the sealing groove of the water inlet housing 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 a new O±ring to the water inlet housing.
(d) Apply soapy water to the O±ring.
(e) Push the water inlet housing end into the water pump hole.
(f) Install the water inlet and housing assembly with the two
bolts. Alternately tighten the bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
HINT: Use bolts 25 mm (0.98 in.) in length.
(g) Connect the water by±pass hose to the ISC valve.
±
ENGINE MECHANICAL Cylinder HeadsEM±113
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PREPARATION FOR DISASSEMBLY
(See Components on page EM±131)
1. REMOVE DRIVE PLATE Remove the eight bolts, two spacers and drive plate.
2. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
3. REMOVE TIMING BELT AND PULLEYS (See pages EM±36 to 44)
4. REMOVE Cylinder Block (See pages EM±61 to 75)
5. REMOVE RH ENGINE MOUNTING BRACKET Remove the four bolts and mounting bracket.
6. REMOVE LH ENGINE MOUNTING BRACKET (a) Remove the clamp bolt, and disconnect the engine wirefrom the engine mounting bracket.
(b) Remove the four bolts and mounting bracket.
7. REMOVE STARTER (a) Remove the two bolts, and disconnect the starter fromthe cylinder block.
EM±132
±
ENGINE MECHANICAL Cylinder Block
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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)
±
ENGINE MECHANICAL Cylinder BlockEM±165
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31. INSTALL THROTTLE BODY COVERInstall the throttle body cover and hose clamp with the two
bolts and cap nut.
32. INSTALL DRIVE BELT Install the drive belt by turning the drive belt tensioner coun-
terclockwise.
HINT: The pulley bolt for the belt tensioner has a left±hand
thread.
33. INSTALL BATTERY
34. FILL WITH ENGINE COOLANT (See page CO±7)
35. FILL COOLING FAN RESERVOIR TANK WITH FLUID (See page CO±23)
36. FILL WITH ENGINE OIL (See page LU±7)
Capacity:
Drain and refill
w/Oil filter change4.8 liters (5.1 US qts, 4.2 lmp. qts)
w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 lmp. qts)
Dry fill 6.0 liters (6.3 US qts, 5.3 lmp. qts)
37. START ENGINE AND CHECK FOR LEAKS
38. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
39. CHECK IGNITION TIMING (See page IG±28)
Ignition timing:
8±125 BTDC @ idle
(w/ Terminals TE1 and E1 connected)
40. INSTALL ENGINE UNDER COVER
41. INSTALL HOOD
42. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
32. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS
±
ENGINE MECHANICAL Cylinder BlockEM±177
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SERVICE SPECIFICATIONS
SERVICE DATA
 Engine tune±up Battery specific gravity  1.27±1.29 g  (when fully charged at 205C (68 5F))  High±tension cord resistance Limit 25 k
per cord  Valve clearance Intake 0.15 ± 0.25 mm 0.006 ± 0.010 in.   Exhaust 0.25 ± 0.35 mm 0.010 ± 0.014 in.
  Ignition timing 8±12 5 BTDC @ idle
   (w/ Terminals TE1 and E1 connected)
  Idle speed 700 + 50 rpm
 


Intake
manifold 


at Idle speed 


 


60 kPa 450 mmHg 17.7 in.Hg
vacuum vacuum  
Compressionat 250 rpmSTD1,226 kPa (12.5 kgf/cm, 178 psi) or more pressure  Limit 981 kPa 10.0 kgf/cm 142 psi  Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm, 14 psi) or less Timing belt ten- Protrusion from housing end 10.5 ± 11.5 mm 0.413 ± 0.453 in. g
sioner g  
 Cylinder head Warpage Cylinder block side Limit 0.10 mm 0.0039 in.
 
y
 Manifold side Limit 0.10 mm 0.0039 in.
  Valve seat Refacing angle 30
5, 45 5, 75 5
  Contacting angle 455
Contacting width1.0 ± 1.4 mm0.039 ± 0.055 in.  Cylinder head bolt thread outside diam4eter 
   STD 9.770 ± 9.960 mm 0.3846 ± 0.3921 in.   Limit 9.60 mm 0.3780 in. Valve guide Inside diameter 6.010 ± 6.030 mm 0.2366 ± 0.2374 in.
 
g
bushing Outside diameter (for repair part) STD 11.048 ± 11.059 mm 0.4350 ± 0.4354 in.
 
g
  O/S 0.05 11.098 ± 11.109 mm 0.4369 ± 0.4374 in.
 Valve Valve overall length STD Intake 94.95 mm 3.7382 in.
    Exhaust 96.90 mm 3.8150 in.
LimitIntake94.45 mm3.7185 in.    Exhaust 96.40 mm 3.7953 in.  Valve face angle   44.5 5  Stem diameter  Intake 5.970 ± 5.985 mm 0.2350 ± 0.2356 in.    Exhaust 5.965 ± 5.980 mm 0.2356 ± 0.2354 in.
  Stem oil clearance STD Intake 0.025 ± 0.060 mm 0.0010 ± 0.0024 in.
    Exhaust 0.030 ± 0.065 mm 0.0012 ± 0.0026 in.
   Limit Intake 0.08 mm 0.0031 in.
Exhaust0.10 mm0.0039 in.  Margin thickness  STD 1.0 mm 0.039 in.    Limit 0.5 mm 0.020 in. Valve spring Squareness Limit 2.0 mm 0.079 in. g Free length  43.6 mm 1.717 in.
  Installed tension at 32.9 mm (1.295 in.) 186±206 N 
    (19.0 ± 21.0 kgf, 41.9 ± 46.3 lbf)
 Valve lifter Lifter diameter 30.966±30.976 mm 1.2191±1.2195 in.
  Lifter bore diameter  31.000±31.016 mm 1.2205±1.2211 in.
Oil clearanceSTD0.024±0.050 mm0.0009±0.0020 in.   Limit 0.07 mm 0.0028 in.
EM±178±
ENGINE MECHANICAL Service Specifications
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TORQUE SPECIFICATIONS
\
 \
Part tightened NVm kgf Vcm ft Vlbf
 No.1 idler pulley X Cylinder block  34 350 25
No.2 idler pulley X Cylinder block3435025 Hydraulic pump X Cylinder block 12 mm head 16 160 12  14 mm head 30 310 22
 Crankshaft pulley X Crankshaft  245 2,500 181
Camshaft timing pulley X Camshaft1081,10080 Timing belt tensioner X Oil pump  26 270 20 Spark plug X Cylinder head  18 180 13
 Drive belt tensioner X Cylinder block  16 160 12
Alternator X Alternator bracket3738027 Alternator X Cylinder block  37 380 27 Distributor housing X Cylinder head  18 185 13
 Distributor rotor X Distributor housing   3.8 39  34 in. Vlbf
Distributor cap X Camshaft timing pulley 3.839 34 in. Vlbf\
 \
RH No.2 timing belt cover X Cylinder block (for 12 mm head) 16 160 12 Drive belt idler pulley X Hydraulic pump  37 380 27
 A/C compressor X Hydraulic pump  49 500 36
A/C compressor X Cylinder block4950036 A/C compressor stay X Oil filter bracket  29 300 22 Exhaust manifold X Cylinder head  39 400 29
 Main oxygen sensor X Exhaust manifold  44 450 33
Cylinder head X Cylinder block1st3940029  2nd Turn 90 5  
 Camshaft bearing cap X Cylinder head  16 160 12
 Cylinder head cover X Cylinder head   5.9 60  52 in. Vlbf
Engine hanger X Cylinder head3738027 EGR pipe X Exhaust manifold  18 185 13 Rear water by±pass joint X Cylinder head  18 185 13
 Front water by±pass joint X Cylinder head  18 185 13
Intake manifold X Cylinder head1818513 Delivery pipe X Intake manifold  18 185 13\
 \
Fuel return pipe X RH delivery pipe(for union bolt) 35 360 26
 Fuel inlet hose X LH delivery pipe  39 400 29
for SST3334024 Cold start injector X Air intake chamber   7.8 80  69 in. Vlbf Air intake chamber X Intake manifold  18 185 13
 EGR pipe X Air intake chamber  18 185 13
EGR pipe X RH cylinder head1818513 Cold start injector tube X RH delivery pipe  15 150 11 Brake booster union X Air intake chamber  29 300 22
 Throttle body X Air intake chamber  18 185 13
ISC valve X Air intake chamber1818513 EGR valve adapter X Air intake chamber  18 185 13 EGR valve X EGR valve adapter  18 185 13
 Timing belt rear plate X Cylinder head   7.8 80  69 in. Vlbf
Water inlet housing X Water pump1818513\
 \
Catalytic converter (main) X Exhaust manifold 62 630 46\
 \
Catalytic converter (main) X Front exhaust pipe 43 440 32
\
 \
Front exhaust pipe support bracket X Transmission 43 440 32
PS pump X RH cylinder headBolt3940029  Nut 43 440 32 Main bearing cap X Cylinder block Nut 1st 27 275 20
  2nd Turn 90 5  
Bolt4950036
±
ENGINE MECHANICAL Service SpecificationsEM±181
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6. REMOVE UPPER HIGH±TENSION CORD COVER(a) Remove the two mounting bolts.
(b) Disconnect the front side claw groove of the cord coverfrom the claw of the lower cover, and remove the cord
cover.
7. REMOVE RH ENGINE WIRE COVER Remove the bolt and wire cover.
8. REMOVE LH ENGINE WIRE COVER Remove the two bolts and wire cover.
9. REMOVE VSV FOR EVAP SYSTEM Remove the two bolts, and disconnect the VSV from cylinder
head and timing belt cover.
10. REMOVE RH NO.3 TIMING BELT COVER Remove the three bolts and timing belt cover.
FI±28
EFI SYSTEM
± Fuel System (Cold Start Injector)
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11. REMOVE LH NO.3 TIMING BELT COVER(a) Remove the four mounting bolts.
(b) Disconnect the cord grommet from the timing belt cover,
and remove the timing belt cover.
(c) Remove the cord grommet from the high±tension cord.
12. REMOVE LOWER HIGH±TENSION CORD COVER (a) Disconnect the high±tension cord from the RH ignitioncoil.
(b) D i s c onnect the high±tension cords from the
high±tension cord cover.
(c) Remove the bolt and cord cover.
13. REMOVE THROTTLE BODY (a) Disconnect the following connectors:(1) Throttle position sensor connector
(2) (w/ TRAC) Sub±throttle position sensor connector
(3) (w/ TRAC) Sub±throttle actuator connector
(b) Disconnect the following hoses: (1) Heater water hose from heater water valve FI±29
EFI SYSTEM
± Fuel System (Cold Start Injector)
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