Lexus SC300 / Lexus SC400. Service manual — part 439

4.

INSTALL NO. 4 TIMING BELT COVER
Install the No. 4 timing belt cover with four bolts.

Torque:

8.8 N

⋅

m (90 kgf

⋅

cm, 78 in.

⋅

lbf)

5.

INSTALL CAMSHAFT TIMING PULLEYS
(a) Align the camshaft knock pin with the groove in the

pulley, and slide on the pulley.

(b) Temporarily install the timing pulley bolt.
(c) Hold

the hexagon portion of the camshaft with a wrench,

and tighten the timing pulley bolt.

Torque:

79 N

⋅

m (810 kgf

⋅

cm, 59 ft

⋅

lbf)

6. INSTALL NO. 3 NO. 1 AND NO. 2 CYLINDER HEAD

COVERS
(a) Remove any oil packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the

illustration.

Seal packing:

Part No. 08826–00080 or equivalent

(c) Install the gaskets to the No. 1 and No. 2 cylinder head

covers.

(d) Install the cylinder head cover with the 12 bolts and four

nuts.

Torque:

5.4 N

⋅

m (55 kgf

⋅

cm, 48 in.

⋅

lbf)

7. INSTALL

INTAKE

MANIFOLD

(a) Install a new gasket and the intake manifold with the six

bolts and two nuts.

Torque:

21 N

⋅

m (210 kgf

⋅

cm, 15 ft

⋅

lbf)

(b) Install the intake manifold stay with the two bolts.

Torque:

39 N

⋅

m (400 kgf

⋅

cm, 29 ft

⋅

lbf)

EM–58

–

ENGINE MECHANICAL

Cylinder Head

8.

CONNECT ENGINE WIRE TO INTAKE MANIFOLD
(a) Install the harness protector to the intake manifold with

the two bolts.

(b) Install the three clamp bolts and two nuts.

(c) Connect the following connectors:

(1) Engine coolant temperature sensor connector
(2) Engine coolant temperature sender gauge connec-

tor

(3) Two knock sensor connectors
(4) Oil pressure switch connector
(5) Oil level sensor connector
(6) A/C compressor connector

9.

INSTALL NO. 1 AND NO. 2 FUEL PIPES

Torque:

8.8 N

⋅

m (90 kgf

⋅

cm, 78 in.

⋅

lbf)

10. INSTALL DELIVERY PIPE AND INJECTORS

(See steps 1, 3, 6 and 7 on pages FI–33 and 34)

Torque: 21

N

⋅

m (210 kgf

⋅

cm, 15 ft

⋅

lbf)

11. INSTALL AIR INTAKE CHAMBER

(a) Install

a

new gasket and the intake chamber with the five

bolts and two nuts.

Torque:

21 N

⋅

m (210 kgf

⋅

cm, 15 ft

⋅

lbf)

(b) Install the check connector and harness protector to the

air intake chamber with the two bolts.

(c) Connect the following hoses:

(1) Vacuum hose to brake booster union
(2) Vacuum hose (to ACIS vacuum tank)
(3) Vacuum sensing hose
(4) Air hose (to PS air control valve)

–

ENGINE MECHANICAL

Cylinder Head

EM–59

(d) Install the intake chamber stay with the bolt and nut.

Install the No. 1 and No. 2 stay.

Torque: 18

N

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

HINT: The No. 1 stay is marked ”F” and No. 2 stay is marked
with ”R”.

12. INSTALL OIL DIPSTICK GUIDES FOR ENGINE AND

TRANSMISSION (A/T)
(a) Install a new O–ring on the dipstick guide.
(b) Apply soapy water on the O–ring.
(c) Connect the dipstick guide end to the tube of the oil pan.
(d) Install the dipstick guide with a bolt.
(e) Connect the fuel return hose to the engine oil dipstick

guide.

13. INSTALL VACUUM CONTROL VALVE SET AND NO. 2

VACUUM PIPE
(a) Install the vacuum control valve set and vacuum pipe

with the four nuts.

Torque: 21

N

⋅

m (210 kgf

⋅

cm, 15 ft

⋅

lbf)

(b) Connect the following hoses:

(1) Vacuum hose to ACIS vacuum tank
(2) Three vacuum hoses to VSV

(c) Connect the two connectors to the VSV.

14. INSTALL WATER OUTLET AND NO. 1 BY–PASS HOSE

(a) Insert the No. 1 by–pass hose to the intake manifold,

and connect the hose to the clamp.

(b) Install the water outlet with the two nuts and bolt.

Torque: 21

N

⋅

m (210 kgf

⋅

cm, 15 ft

⋅

lbf)

15. INSTALL WATER BY–PASS OUTLET AND NO. 1 WATER

BY–PASS PIPE
(a) Install

two new O–rings to the No. 1 water by–pass pipe.

(b) Install a new O–ring and the water by–pass outlet with

the two bolts.

Torque: 8.8

N

⋅

m (90 kgf

⋅

cm, 78 in.

⋅

lbf)

EM–60

–

ENGINE MECHANICAL

Cylinder Head

16. INSTALL EXHAUST MANIFOLD

(a) Install a new gasket and the exhaust manifold with the

four nuts. Install the No. 1 and No. 2 exhaust manifolds.

Torque: 39

N

⋅

m (400 kgf

⋅

cm, 29 ft

⋅

lbf)

(b) Install the manifold heat insulator with the four nuts.

Torque: 18

N

⋅

m (185 kgf

⋅

cm, 13 ft

⋅

lbf)

(c) Connect the two oxygen sensor connectors.

17. INSTALL NO. 2 FRONT EXHAUST PIPE

(See step 5 on page EM–105)

18. INSTALL TIMING BELT

(See steps 8 to 14 on pages EM–30 to 33)

19. INSTALL RADIATOR AND WATER PUMP PULLEY

(See steps 15, 16, 19 and 24 on pages EM–110 to 112)

20. INSTALL SPARK PLUGS (See step 6 on page IG–9)

Torque: 18

N

⋅

m (180 kgf

⋅

cm, 13 ft

⋅

lbf)

21. CONNECT HIGH–TENSION CORDS TO SPARK PLUGS

(See steps 14 to 21 on pages EM–17 to 21)

22. FILL ENGINE WITH COOLANT (See page CO–5)

Capacity (w/ Heater):

M/T

8.5 liters (9.0 US qts, 7.5 lmp. qts)

A/T

8.4 liters (8.9 US pts, 7.4 lmp. qts)

23. START ENGINE AND CHECK FOR LEAKS

24. (A/T)

CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
(See page MA–11)
NOTICE: Do not overfill.

25. CHECK IGNITION TIMING (See page IG–14)

Ignition timing:

10

°

BTDC @ idle

(w/ Terminals TE1 and E1 connected)

26. PERFORM ROAD TEST

Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.

27. RECHECK ENGINE COOLANT LEVEL

–

ENGINE MECHANICAL

Cylinder Head

EM–61