1991 LEXUS SC400 engine

2. REPLACE CRANKSHAFT REAR OIL SEALHINT: There are two methods, A and B, to replace the oil seal
as follows:
A. If rear oil seal retainer is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until itssurface is flush with the rear oil seal retainer edge.
SST 09223±15030, 09608±30022 (09608±05010)
(c) Apply MP grease to the oil seal lip.
B. If rear oil seal retainer is installed on cylinder block: (a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until itssurface is flush with the rear oil seal retainer edge.
SST 09223±15030, 09608±30022 (09608±05011)
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ENGINE MECHANICAL Cylinder BlockEM±93
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ASSEMBLY OF PISTON AND
CONNECTING ROD ASSEMBLIES
1. ASSEMBLE PISTON AND CONNECTING ROD(a) Install a new snap ring at one end of the piston pin hole.
HINT: Be sure that end gap of the snap ring is not aligned with
the pin hole cutout portion of the piston.
(b) Gradually heat the piston to about 80
C (176
F).
(c) Coat the piston pin with engine oil..
(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
(e) Install a new snap ring at the other end of the piston pin hole.
HINT: Be sure that end gap of the snap ring is not aligned with
the pin hole cutout portion of the piston.
2. INSTALL PISTON RINGS (a) Install the oil ring expander and two side rails by hand.
EM±94
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(b) Using a piston ring expander, install the twocompression rings with the code mark facing up.
Code mark: No.1 1T
No.2 2T
(c) Position the piston rings so that the ring ends are asshown.
NOTICE: Do not align the piston ring ends.
3. INSTALL BEARINGS (a) Align the bearing claw with the groove of the connectingrod and connecting cap.
(b) I n s t a l l t h e b e a r i n g s i n t h e c onnecting rod and
connecting rod cap.
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ASSEMBLY OF CYLINDER BLOCK
(See Components on page EM±75)HINT:
wThoroughly 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.
NOTICE: Apply a generous amount of oil on the sliding
surface of the b earing, and not on the back of it or on the
surface to which it is installed.
1. INSTALL MAIN BEARINGS HINT: The No. 1 main bearing is different from the rest of the
bearing.
(a) Align the bearing claw with the claw groove of the mainbearing cap or cylinder block.
NOTICE: Install the bearing with the oil hole in the cylin-
der block.
(b) Instal the bearings in the cyli nder block and main
bearing caps.
2. INSTALL UPPER THRUST WASHERS Install the thrust washers under the No. 4 main journal posi-
tion of the block with the oil grooves facing outward.
EM±96
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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 lower thrust washers on the No. 4 mainbearing with the grooves facing outward.
(b) Install the main bearing caps in numerical order with the arrows facing forward.
B. Install main bearing cap bolts HINT:
wThe main bearing cap bolts are tightened in two
progressive steps (steps (b) and (d)).
w If any of the main bearing bolts break or deform, replace
them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) First, install and uniformly tighten the 14 main bearing
cap bolts in several passes in the sequence shown.
Torque: 44 N Vm (450 kgf Vcm, 33 ft Vlbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.
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(c) Mark the front of the main bearing cap bolt head withpaint.
(d) Second, retighten the main bearing cap bolts 90
in the
numerical order shown above.
(e) Check that the painted mark is now at a 90
angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance. (See step 5 on page EM±80)
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.
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) Install the connecting rod cap by aligning the dowel pin to the corrosponding hole.
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 of the connecting rod bolts break or deform,
replace them.
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(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) At first, install and alternately tighten the bolts of the connecting rod cap in several passes.
Torque: 29 N Vm (300 kgf Vcm, 22 ft Vlbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the connecting rod cap bolt with paint.
(d) Retighten the connecting rod cap bolts 905 in the
numerical 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±77)
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 debris.
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
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) Install the retainer with the six bolts.
Torque: 5.9 NVm (60 kgf Vcm, 52 in. Vlbf)
POST ASSEMBLY
(See Components on page EM±75)
1. INSTALL OIL PUMP (See page LU±15)
2. INSTALL OIL FILTER BRACKET
(a) Place a new O±ring in position on the oil filter bracket.
(b) Install a new gasket to the union bolt.
(c) Install the oil filter bracket with the union bolt.
Torque: 88 N Vm (900 kgf Vcm, 65 ft Vlbf)
3. INSTALL LH ENGINE MOUNTING BRACKET
Install the mounting bracket with the four bolts.
Torque: 58 N Vm (590 kgf Vcm, 43 ft Vlbf)
HINT: The LH mounting bracket is marked ºLF±Zº.
4. INSTALL RH ENGINE MOUNTING BRACKET Install the mounting bracket with the four bolts.
Torque: 58 N Vm (590 kgf Vcm, 43 ft Vlbf)
HINT: The RH mounting bracket is marked ºRR±Zº.
EM±100
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