Engine Mechanical: Removal & Installation Scion tC I

REPLACEMENT

Note. When disconnecting the battery negative terminal, initialize the following system(s) after the terminal is reconnected.

INITIALIZATION SYSTEM DESCRIPTION

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «FUEL - FUEL SYSTEM (2AZ-FE)»(ref-224766-S02956210462006031100000) )
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
7. REMOVE ENGINE COVER SUB-ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
8. DRAIN ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
9. DRAIN AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE) (See «REPLACEMENT»(ref-224780-S03150983572006031100000) )
10. DRAIN MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
11. DISCONNECT RADIATOR HOSE INLET
12. DISCONNECT RADIATOR HOSE OUTLET
13. DISCONNECT OIL COOLER INLET TUBE NO. 1 (AUTOMATIC TRANSAXLE)
14. DISCONNECT OIL COOLER OUTLET TUBE NO. 1 (AUTOMATIC TRANSAXLE)
15. REMOVE RADIATOR ASSY (See «REPLACEMENT»(ref-224770-S06269267862006031100000) )
16. REMOVE AIR CLEANER ASSY Remove the air cleaner cap (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) ). Remove the air cleaner filter element (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) ). Disconnect the clamp of the engine wire. Remove the 3 bolts from the air cleaner case. Disconnect the air cleaner case from the air cleaner inlet No. 1.
17. REMOVE BATTERY
18. REMOVE BATTERY TRAY
19. REMOVE BATTERY CARRIER Disconnect the clamp of the engine wire. Remove the 4 bolts, then remove the battery carrier.
20. DISCONNECT FUEL TUBE SUB-ASSY (See «REPLACEMENT»(ref-224766-S16305639062006031100000) ) SST 09268-21010
21. DISCONNECT UNION TO CONNECTOR TUBE HOSE Disconnect the union to connector tube hose from the booster vacuum tube.
22. DISCONNECT HEATER WATER INLET HOSE A Disconnect the heater water inlet hose from the air conditioner tube.
23. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) Disconnect the heater water outlet hose from the air conditioner tube.
24. SEPARATE TRANSMISSION CONTROL CABLE ASSY (AUTOMATIC TRANSAXLE) (See «REPLACEMENT»(ref-224780-S03150983572006031100000) )
25. SEPARATE TRANSMISSION CONTROL CABLE ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
26. SEPARATE CLUTCH RELEASE CYLINDER ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
27. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
28. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
29. SEPARATE W/PULLEY COMPRESSOR ASSY (See «REPLACEMENT»(ref-224785-S18279915692006031100000) ) HINT: Separate the compressor together with the low-pressure and high-pressure hoses, then secure it to the vehicle side using a rope.
30. REMOVE GLOVE COMPARTMENT DOOR ASSY (See «INSTRUMENT PANEL SUB-ASSY LOWER»(ref-224792-S32836266652006031100000) )
31. DISCONNECT ENGINE WIRE Disconnect the engine wire from the ECM and junction block. Pull out the engine wire. Remove the engine room relay block cover. Remove the 2 claws and 2 connectors, and push the engine wire harness up. Remove the 2 clamps of the engine wire. Remove the nut from the battery positive terminal to disconnect the engine wire. Remove the bolt, then disconnect the ground terminal.
32. REMOVE EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
33. REMOVE COLUMN HOLE COVER SILENCER SHEET
34. SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO. 2 (See «OVERHAUL»(ref-224784-S12474833262006031100000) )
35. REMOVE FRONT AXLE HUB LH NUT (See «OVERHAUL»(ref-224777-S00379100242006031100000) ) SST 09930-00010
36. REMOVE FRONT AXLE HUB RH NUT SST 09930-00010 HINT: Perform the same procedure as above on the opposite side.
37. SEPARATE FRONT STABILIZER LINK ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
38. SEPARATE FRONT STABILIZER LINK ASSY RH HINT: Perform the same procedure as above on the opposite side.
39. SEPARATE SPEED SENSOR FRONT LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
40. SEPARATE SPEED SENSOR FRONT RH HINT: Perform the same procedure as above on the opposite side.
41. SEPARATE TIE ROD END SUB-ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) ) SST 09628-0001 1
42. SEPARATE TIE ROD END SUB-ASSY RH SST 09628-0001 1 HINT: Perform the same procedure as above on the opposite side.
43. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
44. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH HINT: Perform the same procedure as above on the opposite side.
45. SEPARATE FRONT AXLE ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
46. SEPARATE FRONT AXLE ASSY RH HINT: Perform the same procedure as above on the opposite side.
47. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Disconnect the oil reservoir to pump hose No. 1. Disconnect the return tube. Set the engine lifter. Remove the bolt and 2 nuts, then separate the engine mounting bracket No. 2 RH. Remove the through bolt and nut, then separate the engine mounting insulator LH. Remove the 8 bolts and front suspension member brace rear RH and LH. Remove the 2 bolts and 2 nuts shown in the illustration. Carefully remove the engine with transaxle from the vehicle. Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) PARTS NO. : PARTS DESCRIPTION Engine hanger No. 1 12281-28010 Engine hanger No. 2 12282-28010 Bolt 91512-61020 Attach the sling device and hang the engine with the chain block.
48. SEPARATE VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) )
49. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER Remove the through bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR. Remove the through bolt, then separate the engine mounting insulator RR from the engine mounting bracket RR. Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
50. REMOVE FRONT DRIVE SHAFT ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) ) SST 09520-01010, 09520-24010 (09520-32040)
51. REMOVE FRONT DRIVE SHAFT ASSY RH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
52. REMOVE STARTER ASSY (See «STARTER ASSY (2AZ-FE)»(ref-224773-S21441689822006031100000) )
53. REMOVE AUTOMATIC TRANSAXLE ASSY (AUTOMATIC TRANSAXLE) (See «REPLACEMENT»(ref-224780-S03150983572006031100000) )
54. REMOVE MANUAL TRANSAXLE ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
55. REMOVE CLUTCH COVER ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) )
56. REMOVE CLUTCH DISC ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) )
57. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (AUTOMATIC TRANSAXLE) (See «ENGINE REAR OIL SEAL (2AZ-FE)»(ref-224768-S39672838162006031100000) ) SST 09213-54015 (91651-60855), 09330-00021
58. REMOVE FLYWHEEL SUB-ASSY (MANUAL TRANSAXLE) (See «ENGINE REAR OIL SEAL (2AZ-FE)»(ref-224768-S39672838162006031100000) ) SST 09213-54015 (91651-60855), 09330-00021
59. REMOVE DRIVE SHAFT BEARING BRACKET Remove the 3 bolts and drive shaft bearing bracket.
60. REMOVE OIL LEVEL GAGE SUB-ASSY
61. REMOVE OIL LEVEL GAGE GUIDE (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
62. REMOVE MANIFOLD STAY (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
63. REMOVE MANIFOLD STAY NO. 2 (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
64. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
65. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
66. REMOVE WATER INLET (See «REPLACEMENT»(ref-224770-S30444153672006031100000) )
67. REMOVE THERMOSTAT
68. REMOVE WATER BY-PASS PIPE NO. 1 Remove the bolt and 2 nuts, then remove the water bypass pipe. Remove the gasket from the cylinder block.
69. REMOVE INTAKE MANIFOLD (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
70. REMOVE INTAKE MANIFOLD INSULATOR NO. 1
71. REMOVE V-RIBBED BELT TENSIONER ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
72. REMOVE IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
73. REMOVE FUEL DELIVERY PIPE SUB-ASSY (See «REPLACEMENT»(ref-224766-S16305639062006031100000) )
74. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See «CAMSHAFT TIMING OIL CONTROL VALVE ASSY (2AZ-FE)»(ref-224765-S32397363092006031100000) )
75. REMOVE KNOCK SENSOR (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
76. REMOVE RADIO SETTING CONDENSER Remove the bolt and condenser.
77. REMOVE ENGINE OIL PRESSURE SWITCH ASSY (See «LUBRICATION SYSTEM (2AZ-FE)»(ref-224771-S40337973372006031100000) )
78. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (See «ENGINE COOLANT TEMPERATURE SENSOR (2AZ-FE)»(ref-224765-S42923728762006031100000) ) SST 09817-33190
79. REPLACE PARTIAL ENGINE ASSY
80. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (See «ENGINE COOLANT TEMPERATURE SENSOR (2AZ-FE)»(ref-224765-S42923728762006031100000) ) SST 09817-33190
81. INSTALL ENGINE OIL PRESSURE SWITCH ASSY (See «LUBRICATION SYSTEM (2AZ-FE)»(ref-224771-S40337973372006031100000) )
82. INSTALL RADIO SETTING CONDENSER Install the condenser with the bolt. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
83. INSTALL KNOCK SENSOR (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
84. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See «CAMSHAFT TIMING OIL CONTROL VALVE ASSY (2AZ-FE)»(ref-224765-S32397363092006031100000) )
85. INSTALL FUEL DELIVERY PIPE SUB-ASSY (See «REPLACEMENT»(ref-224766-S16305639062006031100000) )
86. INSTALL IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
87. INSTALL V-RIBBED BELT TENSIONER ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
88. INSTALL INTAKE MANIFOLD INSULATOR NO. 1
89. INSTALL INTAKE MANIFOLD (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
90. INSTALL WATER BY-PASS PIPE NO. 1 Install a new gasket and the water by-pass pipe with the bolt and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
91. INSTALL THERMOSTAT (See «REPLACEMENT»(ref-224770-S30444153672006031100000) )
92. INSTALL WATER INLET (See «REPLACEMENT»(ref-224770-S30444153672006031100000) )
93. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
94. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
95. INSTALL MANIFOLD STAY NO. 2 (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
96. INSTALL MANIFOLD STAY (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
97. INSTALL OIL LEVEL GAGE GUIDE (See «REPLACEMENT»(ref-224768-S36196097092006031100000) )
98. INSTALL OIL LEVEL GAGE SUB-ASSY
99. INSTALL DRIVE SHAFT BEARING BRACKET Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
100. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (AUTOMATIC TRANSAXLE) (See «ENGINE REAR OIL SEAL (2AZ-FE)»(ref-224768-S39672838162006031100000) ) SST 09213-54015 (91651-60855), 09330-00021
101. INSTALL FLYWHEEL SUB-ASSY (MANUAL TRANSAXLE) (See «ENGINE REAR OIL SEAL (2AZ-FE)»(ref-224768-S39672838162006031100000) ) SST 09213-54015 (91651-60855), 09330-00021
102. INSTALL CLUTCH DISC ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) ) SST 09301-00220
103. INSTALL CLUTCH COVER ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) )
104. INSTALL AUTOMATIC TRANSAXLE ASSY (AUTOMATIC TRANSAXLE) (See «REPLACEMENT»(ref-224780-S03150983572006031100000) )
105. INSTALL MANUAL TRANSAXLE ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
106. INSTALL STARTER ASSY (See «STARTER ASSY (2AZ-FE)»(ref-224773-S21441689822006031100000) )
107. INSTALL FRONT DRIVE SHAFT ASSY RH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
108. INSTALL FRONT DRIVE SHAFT ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
109. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member. Install the through bolt, which is used to secure the engine mounting insulator RR, into the engine mounting bracket RR. Torque: 87 N.m (887 kgf.cm, 64 ft.lbf) Install the bolt, which is used to secure the engine mounting insulator FR, into the engine mounting bracket FR. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
110. INSTALL VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) )
111. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Set the engine assembly with transaxle on the engine lifter. Temporarily install the suspension crossmember with the 2 bolts and 2 nuts. Install the engine mounting insulator LH with the through bolt and nut. Torque: 87 N.m (887 kgf.cm, 64 ft.lbf) Install the engine mounting insulator RH with the 4 bolts and 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) Tighten the 2 bolts and 2 nuts. Torque: 45 N.m (459 kgf.cm, 33 ft.lbf) for bolt 133 N.m (1,356 kgf.cm, 98 ft.lbf) for nut Install the front suspension member brace rear RH and LH with the 8 bolts. Torque: 133 N.m (1,356 kgf.cm, 98 ft.lbf) for bolt A 80 N.m (816 kgf.cm, 59 ft.lbf) for bolt B. NOTE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other. Connect the return tube. Connect the oil reservoir to pump hose No. 1.
112. INSTALL FRONT AXLE ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
113. INSTALL FRONT AXLE ASSY RH HINT: Perform the same procedure as above on the opposite side.
114. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
115. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH HINT: Perform the same procedure as above on the opposite side.
116. INSTALL TIE ROD END SUB-ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
117. INSTALL TIE ROD END SUB-ASSY RH HINT: Perform the same procedure as above on the opposite side.
118. INSTALL SPEED SENSOR FRONT LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
119. INSTALL SPEED SENSOR FRONT RH HINT: Perform the same procedure as above on the opposite side.
120. INSTALL FRONT STABILIZER LINK ASSY LH (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
121. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Perform the same procedure as above on the opposite side.
122. INSTALL FRONT AXLE HUB LH NUT (See «OVERHAUL»(ref-224777-S00379100242006031100000) )
123. INSTALL FRONT AXLE HUB RH NUT HINT: Perform the same procedure as above on the opposite side.
124. CONNECT STEERING INTERMEDIATE SHAFT ASSY NO. 2 (See «OVERHAUL»(ref-224784-S12474833262006031100000) )
125. INSTALL COLUMN HOLE COVER SILENCER SHEET
126. INSTALL EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
127. CONNECT ENGINE WIRE
128. INSTALL GLOVE COMPARTMENT DOOR ASSY
129. INSTALL W/PULLEY COMPRESSOR ASSY (See «REPLACEMENT»(ref-224785-S18279915692006031100000) )
130. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
131. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
132. INSTALL CLUTCH RELEASE CYLINDER ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
133. INSTALL TRANSMISSION CONTROL CABLE ASSY (AUTOMATIC TRANSAXLE) (See «REPLACEMENT»(ref-224780-S03150983572006031100000) )
134. INSTALL TRANSMISSION CONTROL CABLE ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
135. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
136. CONNECT HEATER WATER INLET HOSE A
137. CONNECT UNION TO CONNECTOR TUBE HOSE
138. CONNECT FUEL TUBE SUB-ASSY (See «REPLACEMENT»(ref-224766-S16305639062006031100000) )
139. INSTALL BATTERY CARRIER Install the battery carrier with the 4 bolts. Torque: 12.8 N.m (131 kgf.cm, 9 ft.lbf) Connect the clamp of the engine wire.
140. INSTALL BATTERY TRAY
141. INSTALL BATTERY
142. INSTALL AIR CLEANER ASSY Connect the air cleaner case to the air cleaner inlet No. 1. Install the air cleaner case with the 3 bolts. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) Connect the clamp of the engine wire. Install the air cleaner filter element (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) ). Install the air cleaner cap (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) ).
143. INSTALL RADIATOR ASSY (See «REPLACEMENT»(ref-224770-S06269267862006031100000) )
144. CONNECT OIL COOLER OUTLET TUBE NO. 1 (AUTOMATIC TRANSAXLE)
145. CONNECT OIL COOLER INLET TUBE NO. 1 (AUTOMATIC TRANSAXLE)
146. CONNECT RADIATOR HOSE OUTLET
147. CONNECT RADIATOR HOSE INLET
148. INSTALL FRONT WHEELS Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
149. BLEED POWER STEERING FLUID
150. ADD AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE)
151. ADD MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE)
152. INSPECT MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE) (See «MANUAL TRANSAXLE OIL (MTM)»(ref-224781-S12061915642006031100000) )
153. ADD ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
154. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
155. CHECK FOR FLUID LEAKAGE
156. CHECK FOR ENGINE COOLANT LEAKAGE (See «COOLING SYSTEM (2AZ-FE)»(ref-224770-S17497212542006031100000) )
157. CHECK FOR FUEL LEAKAGE
158. CHECK FOR EXHAUST GAS LEAKAGE
159. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See «FRONT WHEEL ALIGNMENT»(ref-224774-S02083852832006031100000) )
160. CHECK ABS SPEED SENSOR SIGNAL (See «PRECAUTION»(ref-224755-S38822527172006031100000) )
161. CHECK IGNITION TIMING (See «ENGINE (2AZ-FE)»(ref-224768-S26228873732006031100000) ) SST 09843-18040
162. INSPECT ENGINE IDLING SPEED (See «ENGINE (2AZ-FE)»(ref-224768-S26228873732006031100000) ) SST 09843-18030
163. INSPECT CO/HC (See «ENGINE (2AZ-FE)»(ref-224768-S26228873732006031100000) )
164. INSTALL ENGINE COVER SUB-ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
165. INSTALL FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
166. INSTALL ENGINE UNDER COVER LH
167. INSTALL ENGINE UNDER COVER RH

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1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE VENTILATION VALVE SUB-ASSY
5. REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the 8 bolts and 2 nuts, then remove the cylinder head cover.
6. REMOVE CYLINDER HEAD COVER GASKET
7. REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter. SST 09228-06501
8. REMOVE OIL FILTER UNION Using a socket hexagon wrench 12, remove the oil filter union.
9. REMOVE CAMSHAFT POSITION SENSOR
10. REMOVE CRANKSHAFT POSITION SENSOR
11. REMOVE WATER PUMP PULLEY Using SST, remove the 4 bolts and water pump pulley. SST 09960-10010 (09962-01000, 09963-00700)
12. REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts, bracket and water pump.
13. REMOVE OIL PAN DRAIN PLUG Remove the oil pan drain plug and gasket.
14. REMOVE OIL PAN SUB-ASSY Remove the 12 bolts and 2 nuts. Insert the blade of SST between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan. SST 09032-00100 NOTE: Be careful not to damage the contact surface of the crank case, chain cover and oil pan.
15. REMOVE CRANKSHAFT PULLEY Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) and align the timing marks as above. Using SST, fix the pulley and loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Using SST and pulley bolt, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
16. REMOVE CHAIN TENSIONER ASSY NO. 1 Remove the 2 nuts, chain tensioner and gasket. NOTE: Do not turn the crankshaft without the chain tensioner.
17. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY Remove the 14 bolts and 2 nuts. Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
18. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver and hammer, tap out the oil seal.
19. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
20. REMOVE TIMING CHAIN GUIDE Remove the bolt and timing chain guide.
21. REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and chain tensioner slipper.
22. REMOVE CHAIN SUB-ASSY
23. REMOVE CHAIN VIBRATION DAMPER NO. 1 Remove the 2 bolts and chain vibration damper.
24. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
25. REMOVE NO. 2 CHAIN SUB-ASSY Turn the crankshaft counterclockwise by 90° to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then remove the nut. Remove the bolt, then remove the chain tensioner plate and spring. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.
26. REMOVE OIL PUMP ASSY Remove the 3 bolts, then remove the oil pump and gasket.
27. REMOVE CAMSHAFTS Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration. Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.
28. REMOVE CAMSHAFT BEARING NO. 1 Remove the camshaft bearing No. 1 from the camshaft bearing cap No. 1.
29. REMOVE CAMSHAFT BEARING NO. 2 Remove the camshaft bearing No. 2 from the cylinder head.
30. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET Clamp the camshaft in a vise, then remove the bolt and camshaft timing gear. NOTE: Be careful not to damage the camshaft.
31. REMOVE CAMSHAFT TIMING GEAR ASSY Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate. Cover all the oil ports with vinyl tape except the advance side port shown in the illustration. Apply air pressure to the oil port of 100 kPa (1.0 kgf/cm 2 14 psi), then turn the camshaft timing gear to the advance direction (counterclockwise) by hand. CAUTION: Cover the paths with a shop rag to avoid oil splashes. HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released. Remove the fringe bolt of the camshaft timing gear. NOTE: Be sure not to remove the other 4 bolts. When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.
32. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY Remove the bolt, then remove the camshaft timing oil control valve. Remove the O-ring from the camshaft timing oil control valve.
33. REMOVE CYLINDER HEAD SUB-ASSY Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers. NOTE: Be careful not to drop the plate washers into the cylinder head. Head warpage or cracking could result from removing the bolts in the wrong order.
34. REMOVE CYLINDER HEAD GASKET
35. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
36. REMOVE OIL CONTROL VALVE FILTER Using a socket hexagon wrench 6, remove the plug and gasket. Remove the oil control valve filter.
37. REMOVE W/HEAD TAPER SCREW PLUG NO. 1 Remove the plug from the cylinder block.
38. INSPECT BALANCESHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth. Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 in.) Maximum thrust clearance: 0.09 mm (0.0035 in.) If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft.
39. CHECK BALANCESHAFT OIL CLEARANCE Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. Remove the balanceshaft housing from the crankcase. HINT: Keep the lower bearing and balanceshaft housing together. Lift out the No. 1 and No. 2 balances hafts. HINT: Keep the upper bearing with the crankcase. Clean each bearing and journal. Check each bearing and journal for pitting and scratches. If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft. Place the No. 1 and No. 2 balanceshafts onto the crankcase. Lay a strip of Plastigage across each journal. Install the balanceshaft housing. Apply a light coat of engine oil on the threads and under the heads of the bolts. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 21.6 N.m (220 kgf.cm, 16 ft.lbf) Mark the front of the bolts with paint. Retighten the bolts 90° as shown in the illustration. Check that the painted mark is now at a 90° angle to the front. Remove the balanceshaft housing from the crankcase. Measure the Plastigage at its widest point. Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 in.) Maximum oil clearance: 0.049 mm (0.0019 in.) NOTE: Remove the Plastigage completely after the measurement. If the oil clearance is greater than maximum, replace the bearing. If necessary, replace the balanceshaft. HINT: If replacing a bearing, select a new one with the same number. BALANCESHAFT HOUSING JOURNAL BORE DIAMETER: BALANCESHAFT HOUSING JOURNAL BORE DIAMETER Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.) Balanceshaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 in.) STANDARD BEARING CENTER WALL THICKNESS: STANDARD BEARING CENTER WALL THICKNESS Mark 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.) Mark 2 1.490 to 1.492 mm (0.0587 to 0.0587 in.) Mark 3 1.493 to 1.495 mm (0.0588 to 0.0589 in.)
40. REMOVE BALANCESHAFT
41. REMOVE BALANCESHAFT BEARING NO. 1
42. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver with its tip wrapped with tape, pry out the oil seal. NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
43. REMOVE STIFFENING CRANKCASE ASSY Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. Remove the crankcase by prying the portions between the crankcase and cylinder block. NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. Remove the O-ring from the cylinder block.
44. INSPECT CHAIN TENSIONER ASSY NO. 1 Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
45. INSPECT CHAIN SUB-ASSY Using vernier calipers, measure the length of the 16 links with the chain fully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) If the chain elongation is greater than maximum, replace the chain. HINT: Take the same measurements by pulling at 3 or more places selected at random.
46. INSPECT CHAIN TENSIONER SLIPPER Using vernier calipers, measure the tensioner slipper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the tensioner slipper.
47. INSPECT CHAIN VIBRATION DAMPER NO. 1 Using vernier calipers, measure the vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the vibration damper.
48. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing gear. Using vernier calipers, measure the timing gear diameter with the chain. Minimum gear diameter (w/ chain): 51.6 mm (2.031 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and timing gear.
49. INSPECT OIL PUMP DRIVE GEAR Wrap the chain around the drive gear. Using vernier calipers, measure the drive gear diameter with the chain. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and drive gear.
50. INSPECT OIL PUMP DRIVE SHAFT GEAR Wrap the chain around the drive shaft gear. Using vernier calipers, measure the drive shaft gear diameter with the chain. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and drive shaft gear.
51. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing gear. Using vernier calipers, measure the timing gear diameter with the chain. Minimum gear diameter (w/chain): 97.3 mm (3.831 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and timing gear.
52. INSPECT CAMSHAFT Check the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: 46.495 to 46.595 mm (1.8305 to 1.8345 in.) Minimum cam lobe height: 46.385 mm (1.8262 in.) If the cam lobe height is less than minimum, replace the camshaft. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance.
53. INSPECT NO. 2 CAMSHAFT Check the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: 45.983 to 46.083 mm (1.8104 to 1.8143 in.) Minimum cam lobe height: 45.873 mm (1.8060 in.) If the cam lobe height is less than minimum, replace the camshaft. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameters: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance.
54. INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the length of the head bolts from the seat to the end. Standard bolt length: 161.3 to 162.7 mm (6.350 to 6.406 in.) Maximum bolt length: 164.2 mm (6.465 in.) If the bolt length is greater than maximum, replace the bolt.
55. INSTALL BALANCESHAFT BEARING NO. 1 Install the bearings onto the crankcase and balanceshaft housing. Apply a light coat of engine oil to the bearings.
56. INSTALL BALANCESHAFT Rotate the driven gear No. 1 of balanceshaft No. 1 in the rotating direction until it hits the stopper. Confirm that the matchmarks on driven gear No. 1 and No. 2 are aligned. Align the matchmarks of the No. 1 and No. 2 balance-shafts as shown in the illustration. Place the No. 1 and No. 2 balanceshafts onto the crank case. Apply a light coat of engine oil to the threads and under the heads of the bolts. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 21.6 N.m (224 kgf.cm, 16 ft.lbf) Mark the front of the bolts with paint. Retighten the bolts 90° as shown in the illustration. Check that the painted mark is now at a 90° angle to the front.
57. INSTALL STIFFENING CRANKCASE ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase. Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the crankcase within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the crankcase. Place a new O-ring on the cylinder block as shown in the illustration. With the No. 1 crank pin of the crankshaft placed at 6 o'clock, install the No. 1 and No. 2 balanceshaft and the adjusting hole as shown in the illustration. Temporarily install the crank case with the 11 bolts. HINT: Bolt length: 112 mm (4.41 in.) for A of 12 mm head 35 mm (1.38 in.) for B of 12 mm head Uniformly tighten the bolts. Torque: 32.5 N.m (331 kgf.cm, 24 ft.lbf) Confirm that the timing marks of the balanceshafts are aligned when the key groove is placed at 6 o'clock position, as shown in the illustration.
58. INSTALL ENGINE REAR OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip free of foreign objects. Using SST and a hammer, tap the oil seal in until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTE: Wipe any extra grease off the crankshaft.
59. INSTALL W/HEAD TAPER SCREW PLUG NO. 1 Apply adhesive to 2 or 3 threads of the plug, and install it. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent NOTE: Install the plug within 3 minutes of applying adhesive. Do not put in coolant for at least an hour after installing the plug.
60. INSTALL OIL CONTROL VALVE FILTER Check that there is no foreign objects on the mesh part of the oil control valve filter. Using a socket hexagon wrench 6, install a new gasket and the oil control valve filter with the plug. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
61. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Apply adhesive to 2 or 3 threads of the drain cock. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent After tightening the drain cock to the specified torque, turn the drain cock clockwise as shown in the illustration. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) NOTE: Install the drain cock within 3 minutes of applying adhesive. Do not put in coolant for at least an hour after installing the drain cock. Do not turn the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque. Do not loosen the drain cock after setting it correctly.
62. INSTALL CYLINDER HEAD GASKET Place a new gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Remove any oil from contact surface. Be careful of the installation direction. Place the cylinder head gently in order to avoid damaging the gasket with the bottom part of the head.
63. INSTALL CYLINDER HEAD SUB-ASSY NOTE: The cylinder head bolts are tightened in 2 successive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Torque: 78.5 N.m (800 kgf.cm, 58 ft.lbf) Mark the front of the cylinder head bolts with paint. Retighten the cylinder head bolts 90° in the same sequence as step ( c ). Check that the painted mark is now at a 90° angle to the front.
64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve. Install the camshaft timing oil control valve with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
65. INSTALL CAMSHAFT TIMING GEAR ASSY Put the camshaft timing gear and camshaft together with the straight pin off the key groove. Turn the camshaft timing gear in the left as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove. CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle). Check that there is no clearance between the gear fringe and camshaft. Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
66. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET Clamp the camshaft in a vise, then install the camshaft timing gear with the bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) NOTE: Be careful not to damage the No. 2 camshaft.
67. INSTALL CAMSHAFT BEARING NO. 2 Clean the contact surfaces of the bearing and the cylinder head. Install the camshaft bearing No. 2 onto the cylinder head. NOTE: Do not apply engine oil to the bearing and its contact surface.
68. INSTALL CAMSHAFT BEARING NO. 1 Clean the contact surfaces of the bearing and the bearing cap No. 1. Align the bearing claw with the claw groove of bearing cap No. 1, and push in the bearing. NOTE: Do not apply engine oil to the bearing and its contact surface.
69. INSTALL CAMSHAFTS Apply a light coat of engine oil to the journal portion of the camshaft. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 1 and No. 2 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 NOTE: Tighten the bolts after deciding the position in the thrust direction of the camshaft by the bearing cap No. 1 and No. 2. Install the camshaft with its timing mark of the camshaft timing gear on the top.
70. INSTALL OIL PUMP ASSY Install a new gasket and oil pump with the 3 bolts. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
71. INSTALL NO. 2 CHAIN SUB-ASSY Set the crankshaft key in the left horizontal position. Turn the cutout of the drive shaft to the top. Align the yellow mark links with the timing marks of the each gear as shown in the illustration. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped. Temporarily tighten the oil pump drive shaft gear with the nut. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then tighten the nut. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
72. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
73. INSTALL CHAIN VIBRATION DAMPER NO. 1 Install the chain vibration damper with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
74. INSTALL CHAIN SUB-ASSY Set the No. 1 cylinder to TDC/compression. Turn the camshafts with a wrench on the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward. Install the chain onto the crankshaft timing gear with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear. Using SST, tap in the crankshaft timing gear. SST 09309-37010 Align the gold or yellow mark links with each timing mark located on the camshaft timing gears, then install the chain.
75. INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
76. INSTALL TIMING CHAIN GUIDE Install the timing chain guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
77. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 Install the sensor plate with the "F" mark facing forward.
78. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip free of foreign objects. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010
79. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Apply a continuous bead of seal packing (Diameter 2.0 mm (0.079 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Apply a continuous bead of seal packing as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N in (92 kgf.cm, 80 in.lbf) for bolt A 25 N.m (255 kgf.cm, 18 ft.lbf) for bolt B 55 N.m (561 kgf.cm, 41 ft.lbf) for bolt C 43 N.m (438 kgf.cm, 32 ft.lbf) for bolt D 11 N.m (112 kgf.cm, 8 ft.lbf) for nut HINT: Bolt length: BOLT SPECIFICATION Bolt A 30 mm (1.18 in.) length for 10 mm head Bolt B 30 mm (1.18 in.) length for 12 mm head Bolt C 40 mm (1.57 in.) length for 14 mm head Bolt D 65 mm (2.56 in.) length for 14 mm head
80. INSTALL CHAIN TENSIONER ASSY NO. 1 Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position. Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
81. INSTALL CRANKSHAFT PULLEY Using SST, fix the pulley and tighten the bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 180 N.m (1,835 kgf.cm, 133 ft.lbf) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, then check that the plunger is extended.
82. INSTALL OIL PAN SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the oil pan. Install the oil pan to the cylinder block. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
83. INSTALL OIL PAN DRAIN PLUG Place a new gasket on the oil pan drain plug, then install it onto the oil pan. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)
84. INSTALL WATER PUMP ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and water pump. Apply a continuous bead of seal packing (Diameter 2.2 to 2.5 mm (0.087 to 0.098 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the water pump within 3 minutes of applying seal packing. Do not put in coolant for at least 2 hours after installing the water pump. Install the water pump with the 4 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: Tighten the outside bolt and nut with the clamp.
85. INSTALL WATER PUMP PULLEY Using SST, install the water pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) NOTE: Be careful that the O-ring is not cracked or jammed when installing.
86. INSTALL CRANKSHAFT POSITION SENSOR Apply a light coat of engine oil to the O-ring of the crankshaft position sensor. Install the crankshaft position sensor with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: Be careful that the O-ring is not cracked or jammed when installing. Confirm that the wire harness of the sensor is placed as shown.
87. INSTALL CAMSHAFT POSITION SENSOR Apply a light coat of engine oil to the O-ring of the camshaft position sensor. Install the camshaft position sensor with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: Be careful that the O-ring is not cracked or jammed when installing.
88. INSTALL OIL FILTER UNION Using a socket hexagon wrench 12, install the oil filter union. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf)
89. INSTALL OIL FILTER SUB-ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, then tighten it until the gasket comes into contact with the seat. Using SST, tighten it an additional 3/4 turn. SST 09228-06501 Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
90. INSPECT VALVE CLEARANCE Set the No. 1 cylinder to TDC/compression. Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above. Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.) for intake 0.30 to 0.40 mm (0.0118 to 0.0158 in.) for exhaust Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression. Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.) for intake 0.30 to 0.40 mm (0.0118 to 0.0158 in.) for exhaust Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
91. ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the TDC/compression. Place paint marks on the chain and camshaft timing gears. Remove the 2 nuts, chain tensioner and gasket. NOTE: Do not turn the crankshaft without the chain tensioner. Remove the No. 2 camshaft. While holding the camshaft with a wrench, loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the valve lifter. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. While holding the No. 2 camshaft by hand, remove the camshaft timing gear set bolt. Remove the camshaft timing gear from the No. 2 camshaft with the timing chain wrapped. Remove the camshaft timing gear from the timing chain. Remove the camshaft. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. Remove the camshaft and camshaft timing gear while holding the timing chain by hand. Tie the timing chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover. Remove the valve lifters. Using a micrometer, measure the thickness of the removed valve lifters. Calculate the thickness of a new lifter so that the valve clearance comes within the specified values. VALVE CLEARANCE A Thickness of new lifter B Thickness of used lifter C Measured valve clearance Valve clearance: Intake A = B + (C - 0.24 mm (0.0095 in.)) Exhaust A = B + (C - 0.35 mm (0.0138 in.)) Example (Intake): Measured intake valve clearance = 0.40 mm (0.0158 in.) 0.40 mm (0.0158 in.) - 0.24 mm (0.0095 in.) = 0.16 mm (0.0063 in.) (Measured - Specification = Excess clearance) Used lifter measurement = 5.250 mm (0.2067 in.) 0.16 mm (0.0063 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.) (Excess clearance + Used lifter = Ideal new lifter) Closest new lifter = 5.410 mm (0.2130 in.) Select No. 42 lifter HINT: Select a new lifter with a thickness as close to the calculated values as possible. Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). Refer to New Lifter Thickness, see "Valve Lifter Selection Chart (Intake)" & " Valve Lifter Selection Chart (Exhaust)". Install the camshaft. Apply a light coat of engine oil to the journal portion of the camshaft. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 1 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 Install the No. 2 camshaft. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing gear. While holding the No. 2 camshaft by hand, temporally tighten the camshaft timing gear set bolt. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 2 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 While holding the camshaft with a wrench, tighten the camshaft timing gear set bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) NOTE: Be careful not to damage the valve lifter. Check that the paint marks on the chain and camshaft timing gears are aligned. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover. Install the chain tensioner. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position. Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, then check that the plunger is extended.
92. INSTALL CYLINDER HEAD COVER GASKET Install the gasket onto the cylinder head cover.
93. INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing material from the contact surface. Apply seal packing to the 2 locations shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the cylinder head cover. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) for bolt A 14 N.m (143 kgf.cm, 10 ft.lbf) for bolt B 11 N.m (112 kgf.cm, 8 ft.lbf) for nut
94. INSTALL VENTILATION VALVE SUB-ASSY Apply adhesive to the threads of the ventilation valve. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
95. INSTALL OIL FILLER CAP GASKET
96. INSTALL OIL FILLER CAP SUB-ASSY
97. INSTALL SPARK PLUG Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)

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Note. When disconnecting the battery negative terminal, initialize the following system(s) after the terminal is reconnected.

INITIALIZATION SYSTEM DESCRIPTION

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE HOOD SUB-ASSY
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
7. REMOVE ENGINE COVER SUB-ASSY NO. 1 Remove the 2 nuts, then remove the engine cover No. 1.
8. DRAIN ENGINE OIL (See «OIL FILTER SUB-ASSY (2AZ-FE)»(ref-224771-S15692372992006031100000) )
9. REMOVE EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
10. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
11. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
12. SEPARATE VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
13. REMOVE ENGINE MOUNTING INSULATOR RH Remove the bolt and radiator reserve tank. Separate the vane pump oil reservoir from the oil reservoir bracket No. 1. NOTE: Do not disconnect the 2 hoses. Remove the 2 bolts, then separate the return tube. Remove the 2 bolts and oil reservoir bracket No. 1. Remove the bolt, then separate the wire harness protector. Disconnect the 2 clamps of the engine wire. Place a transmission jack underneath the engine, then put a wooden block on the jack. Remove the bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR. Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH. NOTE: Do not apply excessive force to the return tube when removing the engine mounting insulator RH. HINT: Keep clearance by lowering the engine using the transmission jack when removing the engine mounting insulator RH.
14. REMOVE IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
15. REMOVE CYLINDER HEAD COVER SUB-ASSY Disconnect the 2 ventilation hoses from the cylinder head cover. Disconnect the clamp of the engine wire. Remove the bolt, then disconnect the engine wire. Remove the 8 bolts and 2 nuts, then remove the cylinder head cover.
16. REMOVE V-RIBBED BELT TENSIONER ASSY Lift the engine upward using the transmission jack, then remove the bolt and nut shown in the illustration. NOTE: Do not lift the engine more than necessary. Remove the V-ribbed belt tensioner.
17. REMOVE CRANKSHAFT POSITION SENSOR (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
18. REMOVE OIL PAN SUB-ASSY Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) PARTS NO. : PARTS DESCRIPTION Engine hanger No. 1 12281-28010 Engine hanger No. 2 12282-28010 Bolt 91512-61020 Using a chain block and sling device, hold the engine. Remove the 12 bolts and 2 nuts. Insert the blade of SST between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan. SST 09032-00100 NOTE: Be careful not to damage the contact surface of the crank-case, chain cover and oil pan.
19. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.
20. REMOVE CRANKSHAFT PULLEY Using SST, fix the pulley and loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Using SST and the pulley bolt, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
21. REMOVE CHAIN TENSIONER ASSY NO. 1 Remove the bolt. Disconnect the wire harness protector clamp. Remove the 2 nuts, chain tensioner and gasket. NOTE: Do not turn the crankshaft without the chain tensioner.
22. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY Using a Torx socket E10, remove the stud bolt for the V-ribbed belt tensioner. Remove the 14 bolts and 2 nuts. Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
23. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver and hammer, tap out the oil seal.
24. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
25. REMOVE TIMING CHAIN GUIDE Remove the bolt and timing chain guide.
26. REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and chain tensioner slipper.
27. REMOVE CHAIN SUB-ASSY
28. REMOVE CHAIN VIBRATION DAMPER NO. 1 Remove the 2 bolts and chain vibration damper.
29. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
30. REMOVE NO. 2 CHAIN SUB-ASSY Turn the crankshaft by 90° counterclockwise to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pomp. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then remove the nut. Remove the bolt, then remove the chain tensioner plate and spring. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.
31. INSTALL NO. 2 CHAIN SUB-ASSY Set the crankshaft key in the left horizontal position. Turn the cutout of the drive shaft to the top. Align the yellow mark links with the timing marks of the each gear as shown in the illustration. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped. Temporarily tighten the oil pump drive shaft gear with the nut. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then tighten the nut. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
32. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
33. INSTALL CHAIN VIBRATION DAMPER NO. 1 Install the chain vibration damper with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
34. INSTALL CHAIN SUB-ASSY Set the No. 1 cylinder to TDC/compression. Turn the camshafts with a wrench on the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward. Install the chain onto the crankshaft timing gear with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear. Using SST, tap in the crankshaft timing gear. SST 09309-37010 Align the gold or yellow mark links with each timing mark located on the camshaft timing gears, then install the chain.
35. INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
36. INSTALL TIMING CHAIN GUIDE Install the timing chain guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
37. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 Install the sensor plate with the "F" mark facing forward.
38. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip free of foreign objects. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010
39. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Apply a continuous bead of seal packing (Diameter 2.0 mm (0.079 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Apply a continuous bead of seal packing as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N in (92 kgf.cm, 80 in.lbf) for bolt A 25 N.m (255 kgf.cm, 18 ft.lbf) for bolt B 55 N.m (561 kgf.cm, 41 ft.lbf) for bolt C 43 N.m (438 kgf.cm, 32 ft.lbf) for bolt D 11 N.m (112 kgf.cm, 8 ft.lbf) for nut HINT: Bolt length: BOLT SPECIFICATION Bolt Length A 30 mm (1.18 in.) length for 10 mm head B 30 mm (1.18 in.) length for 12 mm head C 40 mm (1.57 in.) length for 14 mm head D 65 mm (2.56 in.) length for 14 mm head Using a Torx socket E10, install the stud bolt for the V-ribbed belt tensioner. Torque: 21.5 N.m (219 kgf.cm, 16 ft.lbf)
40. INSTALL CHAIN TENSIONER ASSY NO. 1 Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position. Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
41. INSTALL CRANKSHAFT PULLEY Using SST, fix the pulley and tighten the bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 180 N.m (1,835 kgf.cm, 133 ft.lbf) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, then check that the plunger is extended. Connect the wire harness protector clamp. Install the bolt. Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf)
42. INSTALL OIL PAN SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes of applying seal packing. Do not put into engine oil for at least 2 hours after installing the oil pan. Install the oil pan to the cylinder block. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) Place a transmission jack underneath the engine, then put a wooden block on the jack. Remove the chain block and sling device. Remove the engine hanger No. 1 and No. 2.
43. INSTALL CRANKSHAFT POSITION SENSOR (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
44. INSTALL V-RIBBED BELT TENSIONER ASSY Install the V-ribbed belt tensioner with the bolt and nut. Torque: 59.5 N.m (607 kgf.cm, 44 ft.lbf) NOTE: Do not lift the engine more than necessary.
45. INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing material from the contact surface. Apply seal packing to the 2 locations shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the cylinder head cover. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) for bolt A 14 N.m (143 kgf.cm, 10 ft.lbf) for bolt B 11 N.m (112 kgf.cm, 8 ft.lbf) for nut Install the engine wire with the bolt. Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) Connect the clamp of the engine wire. Connect the 2 ventilation hoses to the cylinder head cover.
46. INSTALL IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
47. INSTALL ENGINE MOUNTING INSULATOR RH Install the engine mounting insulator RH with the 4 bolts and 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) Install the engine mounting insulator FR with the bolt and nut. Torque: 52 N m (530 kgf.cm, 38 ft.lbf) Connect the 2 clamps of the engine wire. Install the wire harness protector with the bolt. Install the oil reservoir bracket No. 1 with the 2 bolts. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) Install the return tube with the 2 bolts. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) Install the vane pump oil reservoir onto the oil reservoir bracket No. 1. Install the radiator reserve tank with the bolt. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
48. INSTALL VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
49. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
50. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
51. INSTALL EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
52. ADD ENGINE OIL (See «OIL FILTER SUB-ASSY (2AZ-FE)»(ref-224771-S15692372992006031100000) )
53. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
54. CHECK FOR ENGINE OIL LEAKAGE
55. CHECK FOR EXHAUST GAS LEAKAGE
56. INSTALL ENGINE COVER SUB-ASSY NO. 1 Install the engine cover No. 1 with the 2 nuts. Torque: 7.0 N.m (70 kgf.cm, 62 in.lbf)
57. INSTALL FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
58. INSTALL ENGINE UNDER COVER LH
59. INSTALL ENGINE UNDER COVER RH
60. INSTALL FRONT WHEEL RH Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
61. INSTALL HOOD SUB-ASSY (See «HOOD»(ref-224796-S19869784622006031100000) )

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Note. When disconnecting the battery negative terminal, initialize the following system(s) after the terminal is reconnected.

INITIALIZATION SYSTEM DESCRIPTION

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1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
6. REMOVE ENGINE COVER SUB-ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
7. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
8. SEPARATE VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
9. REMOVE ENGINE MOUNTING INSULATOR RH (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
10. REMOVE IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
11. REMOVE CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
13. REMOVE NO. 2 CAMSHAFT Place paint marks on the chain and camshaft timing gears. Remove the bolt. Disconnect the wire harness protector clamp. Remove the 2 nuts, chain tensioner and gasket. NOTE: Do not turn the crankshaft without the chain tensioner. While holding the camshaft with a wrench, loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the valve lifter. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. While holding the No. 2 camshaft by hard, remove the camshaft timing gear set bolt. Remove the camshaft timing gear from the No. 2 camshaft with the timing chain wrapped. Remove the camshaft timing gear from the timing chain.
14. REMOVE CAMSHAFT Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. Remove the camshaft and camshaft timing gear while holding the timing chain by hand. Tie the timing chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover.
15. REMOVE CAMSHAFT TIMING GEAR ASSY Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate. Cover all the oil ports with vinyl tape except the advance side port shown in the illustration. Apply air pressure to the oil path of 100 kPa (1.0 kgf/cm 2 14 psi), then turn the camshaft timing gear to the advance direction (counterclockwise) by hand. CAUTION: Cover the paths with a shop rag to avoid oil splashes. HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released. Remove the fringe bolt of the camshaft timing gear. NOTE: Be sure not to remove the other 4 bolts. When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.
16. INSTALL CAMSHAFT TIMING GEAR ASSY Put the camshaft timing gear and camshaft together with the straight pin off the key groove. Turn the camshaft timing gear in the left as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove. CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle). Check that there is no clearance between the gear fringe and camshaft. Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
17. INSTALL CAMSHAFT Apply a light coat of engine oil to the journal portion of the camshaft. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 1 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3
18. INSTALL NO. 2 CAMSHAFT Apply a light coat of engine oil to the journal portion of the No. 2 camshaft. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing gear. While holding the No. 2 camshaft by hand, temporally tighten the camshaft timing gear set bolt. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 2 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 While holding the camshaft with a wrench, tighten the camshaft timing gear set bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) NOTE: Be careful not to damage the valve lifter. Check that the paint marks on the chain and camshaft timing gears are aligned. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover. Install the chain tensioner. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position. Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, then check that the plunger is extended. Connect the wire harness protector clamp. Install the bolt. Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf)
19. CHECK VALVE CLEARANCE (See «VALVE CLEARANCE (2AZ-FE)»(ref-224768-S17236351722006031100000) )
20. ADJUST VALVE CLEARANCE (See «VALVE CLEARANCE (2AZ-FE)»(ref-224768-S17236351722006031100000) )
21. INSTALL CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
22. INSTALL IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
23. INSTALL ENGINE MOUNTING INSULATOR RH (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
24. INSTALL VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
25. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
26. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
27. CHECK FOR ENGINE OIL LEAKAGE
28. INSTALL ENGINE COVER SUB-ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
29. INSTALL FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
30. INSTALL ENGINE UNDER COVER LH
31. INSTALL ENGINE UNDER COVER RH
32. INSTALL FRONT WHEEL RH Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Note. When disconnecting the battery negative terminal, initialize the following system(s) after the terminal is reconnected.

INITIALIZATION SYSTEM DESCRIPTION

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

1. DISCHARGE FUEL SYSTEM PRESSURE (See «FUEL - FUEL SYSTEM (2AZ-FE)»(ref-224766-S02956210462006031100000) )
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE HOOD SUB-ASSY
4. REMOVE FRONT WHEEL RH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
8. REMOVE ENGINE COVER SUB-ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
9. REMOVE FRONT WIPER ARM HEAD CAP (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
10. REMOVE FR WIPER ARM LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
11. REMOVE FR WIPER ARM RH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
12. REMOVE HOOD TO COWL TOP SEAL (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
13. REMOVE COWL TOP VENTILATOR LOUVER LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
14. REMOVE WIPER LINK ASSY (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
15. REMOVE COWL TOP PANEL SUB-ASSY OUTER (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
16. REMOVE COWL BODY MOUNTING BRACKET LOWER LH (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
17. DRAIN ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
18. DRAIN ENGINE OIL (See «OIL FILTER SUB-ASSY (2AZ-FE)»(ref-224771-S15692372992006031100000) )
19. REMOVE AIR CLEANER CAP SUB-ASSY (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) )
20. REMOVE THROTTLE BODY ASSY (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) )
21. REMOVE FUEL DELIVERY PIPE SUB-ASSY (See «REPLACEMENT»(ref-224766-S16305639062006031100000) ) SST 09268-21010
22. REMOVE INTAKE MANIFOLD (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
23. REMOVE INTAKE MANIFOLD INSULATOR NO. 1
24. REMOVE EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
25. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
26. REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
27. SEPARATE VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
28. REMOVE ENGINE MOUNTING INSULATOR RH (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
29. REMOVE IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
30. REMOVE CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
31. REMOVE V-RIBBED BELT TENSIONER ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
32. REMOVE CRANKSHAFT POSITION SENSOR (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
33. REMOVE OIL PAN SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) ) SST 09032-00100
34. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
35. REMOVE CRANKSHAFT PULLEY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) ) SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
36. REMOVE CHAIN TENSIONER ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
37. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
38. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
39. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
40. REMOVE TIMING CHAIN GUIDE (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
41. REMOVE CHAIN TENSIONER SLIPPER (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
42. REMOVE CHAIN SUB-ASSY
43. REMOVE CHAIN VIBRATION DAMPER NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
44. REMOVE OIL LEVEL GAGE SUB-ASSY
45. REMOVE OIL LEVEL GAGE GUIDE Remove the bolt, then remove the oil level gage guide. Remove the O-ring from the oil level gage guide.
46. REMOVE MANIFOLD STAY Remove the bolt and nut, then remove the manifold stay.
47. REMOVE MANIFOLD STAY NO. 2 Remove the bolt and nut, then remove the manifold stay No. 2.
48. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 Disconnect the air fuel ratio sensor connector. Remove the 3 bolts and nut, then remove the exhaust manifold heat insulator.
49. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY Remove the 5 nuts, then remove the exhaust manifold converter. Remove the gasket from the cylinder head.
50. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See «CAMSHAFT TIMING OIL CONTROL VALVE ASSY (2AZ-FE)»(ref-224765-S32397363092006031100000) )
51. REMOVE CAMSHAFTS Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration. Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.
52. REMOVE CAMSHAFT BEARING NO. 2 Remove the camshaft bearing No. 2 from the cylinder head.
53. REMOVE CYLINDER HEAD SUB-ASSY Disconnect the radiator hose inlet. Disconnect the radio setting condenser connector. Disconnect the engine oil pressure switch connector. Disconnect the engine coolant temperature sensor connector. Disconnect the camshaft position sensor connector. Remove the bolt, then disconnect the engine earth. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers. NOTE: Be careful not to drop the plate washers into the cylinder head. Head warpage or cracking could result from removing the bolts in the wrong order.
54. REMOVE CYLINDER HEAD GASKET
55. INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the length of the head bolts from the seat to the end. Standard bolt length: 161.3 to 162.7 mm (6.350 to 6.406 in.) Maximum bolt length: 164.2 mm (6.465 in.) If the bolt length is greater than maximum, replace the bolt.
56. INSTALL CYLINDER HEAD GASKET Place a new gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Remove any oil from contact surface. Be careful of the installation direction. Place the cylinder head gently in order to avoid damaging the gasket.
57. INSTALL CYLINDER HEAD SUB-ASSY NOTE: The cylinder head bolts are tightened in 2 successive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Torque: 78.5 N.m (800 kgf.cm, 58 ft.lbf) Mark the front of the cylinder head bolts with paint. Retighten the cylinder head bolts by 90° in the same sequence as step ( c ). Check that the painted mark is now at a 90° angle to the front. Connect the engine earth with the bolt. Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) Connect the camshaft position sensor connector. Connect the engine coolant temperature sensor connector. Connect the engine oil pressure switch connector. Connect the radio setting condenser connector. Connect the heater water inlet hose. Connect the radiator hose inlet.
58. INSTALL CAMSHAFT BEARING NO. 2 Clean the contact surfaces of the bearing and the cylinder head. Install the camshaft bearing No. 2 onto the cylinder head. NOTE: Do not apply engine oil to the bearing and its contact surface.
59. INSTALL CAMSHAFTS Apply a light coat of engine oil to the journal portion of the camshaft. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 1 and No. 2 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 NOTE: Tighten the bolts after deciding the position in the thrust direction of the camshaft by the bearing cap No. 1 and No. 2. Install the camshaft with its timing mark of the camshaft timing gear on top. 60.
60. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See «CAMSHAFT TIMING OIL CONTROL VALVE ASSY (2AZ-FE)»(ref-224765-S32397363092006031100000) )
61. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY Install a new gasket onto the cylinder head. Temporarily tighten the exhaust manifold converter with the 5 nuts. Tighten the 5 nuts in the sequence shown in the illustration. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
62. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 Install the exhaust manifold heat insulator with the 3 bolts and nut. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Connect the air fuel ratio sensor connector.
63. INSTALL MANIFOLD STAY NO. 2 Install the manifold stay No. 2 with the bolt and nut. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
64. INSTALL MANIFOLD STAY Install the manifold stay with the bolt and nut. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
65. INSTALL OIL LEVEL GAGE GUIDE Apply a light coat of engine oil to a new O-ring and install it onto the oil level gage guide. Install the oil level gage guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
66. INSTALL OIL LEVEL GAGE SUB-ASSY
67. INSTALL CHAIN VIBRATION DAMPER NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
68. INSTALL CHAIN SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) ) SST 09309-37010
69. INSTALL CHAIN TENSIONER SLIPPER (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
70. INSTALL TIMING CHAIN GUIDE (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
71. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
72. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (See «REPLACEMENT»(ref-224768-S11554739982006031100000) ) SST 09223-22010
73. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
74. INSTALL CHAIN TENSIONER ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
75. INSTALL CRANKSHAFT PULLEY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) ) SST 09213-54015 (91651-60855), 09330-00021
76. INSTALL OIL PAN SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
77. INSTALL CRANKSHAFT POSITION SENSOR (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
78. INSTALL V-RIBBED BELT TENSIONER ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
79. INSTALL CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
80. INSTALL IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
81. INSTALL ENGINE MOUNTING INSULATOR RH (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
82. INSTALL VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
83. INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
84. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
85. INSTALL EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
86. INSTALL INTAKE MANIFOLD INSULATOR NO. 1
87. INSTALL INTAKE MANIFOLD (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
88. INSTALL FUEL DELIVERY PIPE SUB-ASSY (See «REPLACEMENT»(ref-224766-S16305639062006031100000) )
89. INSTALL THROTTLE BODY ASSY (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) )
90. INSTALL AIR CLEANER CAP SUB-ASSY (See «THROTTLE BODY ASSY (2AZ-FE)»(ref-224765-S18214347842006031100000) )
91. ADD ENGINE COOLANT (See «ENGINE COOLANT (2AZ-FE)»(ref-224770-S13931103942006031100000) )
92. ADD ENGINE OIL (See «OIL FILTER SUB-ASSY (2AZ-FE)»(ref-224771-S15692372992006031100000) )
93. CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
94. CHECK FOR FUEL LEAKAGE
95. CHECK FOR ENGINE COOLANT LEAKAGE (See «COOLING SYSTEM (2AZ-FE)»(ref-224770-S17497212542006031100000) )
96. CHECK FOR ENGINE OIL LEAKAGE
97. CHECK FOR EXHAUST GAS LEAKAGE
98. CHECK IGNITION TIMING (See «ENGINE (2AZ-FE)»(ref-224768-S26228873732006031100000) ) SST 09843-18040
99. INSPECT ENGINE IDLING SPEED (See «ENGINE (2AZ-FE)»(ref-224768-S26228873732006031100000) ) SST 09843-18030
100. INSPECT COMPRESSION (See «ENGINE (2AZ-FE)»(ref-224768-S26228873732006031100000) ) SST 09992-00500
101. INSPECT CO/HC (See «ENGINE (2AZ-FE)»(ref-224768-S26228873732006031100000) )
102. INSTALL COWL BODY MOUNTING BRACKET LOWER LH (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
103. INSTALL COWL TOP PANEL SUB-ASSY OUTER (See «REPLACEMENT»(ref-224765-S16938301462006031100000) )
104. INSTALL WIPER LINK ASSY (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
105. INSTALL COWL TOP VENTILATOR LOUVER LH
106. INSTALL HOOD TO COWL TOP SEAL
107. INSTALL FR WIPER ARM RH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
108. INSTALL FR WIPER ARM LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
109. INSTALL FRONT WIPER ARM HEAD CAP
110. INSTALL ENGINE COVER SUB-ASSY NO. 1 (See «REPLACEMENT»(ref-224768-S11554739982006031100000) )
111. INSTALL FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
112. INSTALL ENGINE UNDER COVER LH
113. INSTALL ENGINE UNDER COVER RH
114. INSTALL FRONT WHEEL RH Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
115. INSTALL HOOD SUB-ASSY (See «HOOD»(ref-224796-S19869784622006031100000) )

Scheme 321

Scheme 322

1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
3. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
4. REMOVE CRANKSHAFT PULLEY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) ) SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
5. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver with its tip wrapped with tape, pry out the oil seal. NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
6. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip off foreign objects. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 NOTE: Wipe any extra grease off the crankshaft.
7. INSTALL CRANKSHAFT PULLEY (See «REPLACEMENT»(ref-224768-S11554739982006031100000) ) SST 09213-54015 (91651-60855), 09330-00021
8. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
9. CHECK FOR ENGINE OIL LEAKAGE
10. INSTALL FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
11. INSTALL FRONT WHEEL RH Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Scheme 332

1. REMOVE MANUAL TRANSAXLE ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )
2. REMOVE AUTOMATIC TRANSAXLE ASSY (AUTOMATIC TRANSAXLE) (See «REPLACEMENT»(ref-224780-S03150983572006031100000) )
3. REMOVE CLUTCH COVER ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) )
4. REMOVE CLUTCH DISC ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) )
5. REMOVE FLYWHEEL SUB-ASSY (MANUAL TRANSAXLE) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 Remove the 8 bolts and flywheel.
6. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (AUTOMATIC TRANSAXLE) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 Remove the 8 bolts, rear spacer, drive plate and front spacer.
7. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver with its tip wrapped with tape, pry out the oil seal. NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
8. INSTALL ENGINE REAR OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip free of foreign objects. Using SST and a hammer, tap in the new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTE: Wipe any extra grease off the crankshaft.
9. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (AUTOMATIC TRANSAXLE) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 Clean the 8 bolts and 8 bolt holes. Apply adhesive to 2 or 3 threads of the 8 bolts. Adhesive: Part No. 08833-00070, THREE BOND or equivalent Install the front spacer, drive plate and rear spacer onto the crankshaft. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 98 N.m (1,000 kgf.cm, 72 ft.lbf)
10. INSTALL FLYWHEEL SUB-ASSY (MANUAL TRANSAXLE) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 Clean the 8 bolts and 8 blot holes. Apply adhesive to 2 or 3 threads of the 8 bolts. Adhesive: Part No. 08833-00070 THREE BOND or equivalent Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 130 N.m (1,326 kgf.cm, 96 ft.lbf)
11. INSTALL CLUTCH DISC ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) ) SST 09301-00220
12. INSTALL CLUTCH COVER ASSY (MANUAL TRANSAXLE) (See «CLUTCH UNIT (MTM)»(ref-224782-S01438104112006031100000) )
13. INSTALL AUTOMATIC TRANSAXLE ASSY (AUTOMATIC TRANSAXLE) (See «REPLACEMENT»(ref-224780-S03150983572006031100000) )
14. INSTALL MANUAL TRANSAXLE ASSY (MANUAL TRANSAXLE) (See «REPLACEMENT»(ref-224781-S07346935602006031100000) )

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1. REMOVE VALVE LIFTER HINT: Arrange the valve lifters in the correct order.
2. REMOVE INTAKE VALVE Place the cylinder head on wooden blocks. Using SST, compress the spring, then remove the 2 retainer locks. SST 09202-70020 (09202-00010) Remove the retainer, spring and valve from the cylinder head. HINT: Arrange the removed parts in the correct order.
3. REMOVE EXHAUST VALVE Place the cylinder head on wooden blocks. Using SST, compress the spring, then remove the 2 retainer locks. SST 09202-70020 (09202-00010) Remove the retainer, spring and valve from the cylinder head. HINT: Arrange the removed parts in the correct order.
4. REMOVE VALVE STEM OIL O SEAL OR RING Using needle-nose pliers, remove the 16 oil seals.
5. REMOVE VALVE SPRING SEAT
6. REMOVE STUD BOLT Using Torx socket wrenches E5 and E7, remove the 11 stud bolts.
7. CHECK CYLINDER HEAD FOR WARPAGE Using a precision straight edge and a feeler gauge, measure the surface that is in contact with the cylinder block and the manifolds for warpage. Maximum warpage: 0.08 mm (0.0032 in.) If the warpage is greater than maximum, replace the cylinder head.
8. CHECK CYLINDER HEAD FOR CRACKS Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
9. INSPECT VALVE SEATS Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. NOTE: Do not turn the valve. Check the valve face and seat in accordance with the following procedure. If blue appears 360° around the face, the valve is concentric. If not, replace the valve. If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with a width of between 1.0 to 1.4 mm (0.039 to 0.055 in.).
10. REPAIR VALVE SEATS NOTE: Releasing the seat cutter pressure gradually helps to make the valve seat faces smoother. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. Lap the valve and valve seat by hand with an abrasive compound. Recheck the valve seating position.
11. CHECK CAMSHAFT THRUST CLEARANCE Install the 2 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) for intake 0.080 to 0.135 mm (0.0032 to 0.0053 in.) for exhaust Maximum thrust clearance: 0.110 mm (0.0043 in.) for intake 0.150 mm (0.0059 in.) for exhaust If the thrust clearance is greater than maximum, replace the cylinder head. If damages are found on the camshaft thrust surfaces, replace the camshaft.
12. CHECK CAMSHAFT OIL CLEARANCE Clean the 10 bearing caps and camshaft journals. Place the 2 camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. Install the 10 bearing caps (See «OVERHAUL»(ref-224768-S27225882122006031100000) ). NOTE: Do not turn the camshaft. Remove the 10 bearing caps (See «OVERHAUL»(ref-224768-S27225882122006031100000) ). Measure the Plastigage at its widest point. STANDARD OIL CLEARANCE: ITEM SPECIFICATION Item Specification Intake No. 1 journal 0.007 to 0.038 mm (0.0003 to 0.0015 in.) Exhaust No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journal 0.025 to 0.062 mm (0.0010 to 0.0024 in.) MAXIMUM OIL CLEARANCE: ITEM SPECIFICATION Item Specification Intake No. 1 journal 0.07 mm (0.0028 in.) Other journal 0.10 mm (0.0039 in.) NOTE: Completely remove the Plastigage after the measurement. If the oil clearance is greater than maximum, replace the cylinder head or the camshaft. If the oil clearance on the No.1 journal is greater than maximum, choose a new bearing and install it. HINT: CYLINDER HEAD JOURNAL BORE DIAMETER: CYLINDER HEAD JOURNAL BORE DIAMETER Mark 1 40.000 to 40.008 mm (1.5748 to 1.5751 in.) Mark 2 40.009 to 40.017 mm (1.5752 to 1.5755 in.) Mark 3 40.018 to 40.025 mm (1.5755 to 1.5758 in.) Standard bearing center wall thickness: STANDARD BEARING CENTER WALL THICKNESS Mark 1 2.000 to 2.004 mm (0.0787 to 0.0789 in.) Mark 2 2.005 to 2.008 mm (0.0789 to 0.0791 in.) Mark 3 2.009 to 2.012 mm (0.0791 to 0.0792 in.) Camshaft journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
13. INSPECT VALVE LIFTER Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) If the diameter is not as specified, replace the valve lifter.
14. CHECK VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the valve lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) If the diameter is not as specified, replace the cylinder head. Subtract the valve lifter diameter measurement from the valve lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.079 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the valve lifter. If necessary, replace the cylinder head.
15. INSPECT INNER COMPRESSION SPRING Using vernier calipers, measure the free length of the valve spring. Free length: 45.7 mm (1.799 in.) If the length is not as specified, replace the compression spring. Using a steel square, measure the deviation of the inner compression spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (Reference): 2° If the deviation is greater than maximum, replace the compression spring.
16. INSPECT INTAKE VALVE Using vernier calipers, measure the valve overall length. Standard overall length: 101.71 mm (4.0043 in.) Minimum overall length: 101.21 mm (3.9846 in.) If the overall length is less than minimum, replace the valve. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) If the diameter is not as specified, replace the valve. Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than minimum, replace the valve.
17. INSPECT EXHAUST VALVE Using vernier calipers, measure the valve overall length. Standard overall length: 101.15 mm (3.9823 in.) Minimum overall length: 100.70 mm (3.9646 in.) If the overall length is less than minimum, replace the valve. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2158 in.) If the diameter is not as specified, replace the valve. Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than minimum, replace the valve.
18. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) If the inside diameter is not as specified, replace the valve guide bush. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: ITEM SPECIFICATION Item Specification Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) MAXIMUM OIL CLEARANCE: ITEM SPECIFICATION Item Specification Intake 0.08 mm (0.0032 in.) Exhaust 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the valve and valve guide bush.
19. REMOVE INTAKE VALVE GUIDE BUSH Using SST, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
20. REMOVE EXHAUST VALVE GUIDE BUSH Using SST, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
21. INSTALL INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4058 in.) Install the STD bush if the diameter is within the specified diameter. Standard diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.) Using SST, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.6 to 10 mm (0.3780 to 0.3937 in.) Using a sharp 5.5 mm reamer, ream the valve guide bush to the standard specified clearance between the valve guide bush and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
22. INSTALL EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4058 in.) Install the STD bush if the diameter is within the specified diameter. Standard diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.) Using SST, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.6 to 10.0 mm (0.3780 to 0.3937 in.) Using a sharp 5.5 mm reamer, ream the valve guide bush to the standard specified clearance between the valve guide bush and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
23. INSTALL RING W/HEAD PIN Using a plastic-faced hammer, tap in new 4 ring pins to the specified protrusion height. Protrusion height: 3.0 mm (0.12 in.)
24. INSTALL STUD BOLT Using Torx socket wrenches E5 and E7, install the 11 stud bolts. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt A 5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt B 9.5 N.m (97 kgf.cm, 84 in.lbf) for bolt C 9.5 N.m (97 kgf.cm, 84 in.lbf) for bolt D
25. INSTALL VALVE STEM OIL O SEAL OR RING Apply a light coat of engine oil to a new oil seals. NOTE: Pay close attention when installing the intake and exhaust oil seals. Mixing up the two seals can cause installation problems. HINT: The intake valve stem oil seal is gray and exhaust valve stem oil seal is black. Using SST, push in the 16 oil seals by hand. SST 09201-41020
26. INSTALL INTAKE VALVE Place the cylinder head on wooden blocks. Install the valve, spring and retainer onto the cylinder head. Using SST, compress the spring, and place the 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) Using a plastic-faced hammer and discarded valve (its tip is wrapped with tape), lightly tap the installed valve to fit into place. NOTE: Be careful not to damage the valve stem tip.
27. INSTALL EXHAUST VALVE Place the cylinder head on wooden blocks. Install the valve, spring and retainer onto the cylinder head. Using SST, compress the spring, and place the 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) Using a plastic-faced hammer and discarded valve (its tip is wrapped with tape), lightly tap the installed valve to fit into place. NOTE: Be careful not to damage the valve stem tip.
28. INSTALL VALVE LIFTER Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied. NOTE: Install the valve lifters in their original places.

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1. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than maximum, replace the connecting rod. If necessary, replace the crankshaft.
2. CHECK CONNECTING ROD OIL CLEARANCE NOTE: Do not turn the crankshaft during the measurement. Using marking paint, write the matched cylinder number on each connecting rod and cap. HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly. Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. Check that the front mark of the connecting rod cap is facing in the correct direction. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts. Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) Mark the front of the connecting rod bolts with paint. Retighten the cap bolts 90° as shown in the illustration. Check that the crankshaft turns smoothly. Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap. Measure the Plastigage at its widest point. Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 in.) Maximum oil clearance: 0.08 mm (0.0032 in.) NOTE: Remove the Plastigage completely after the measurement. If the oil clearance is greater than maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.
3. REMOVE PISTON SUB-ASSY W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
4. REMOVE CONNECTING ROD BEARING
5. REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and expander by hand.
6. REMOVE PISTON PIN HOLE SNAP RING Using a small screwdriver, pry out the 2 snap rings.
7. REMOVE PISTON Gradually heat the piston up to 80 to 90°C (176 to 194°F). Using a plastic hammer and brass bar, lightly tap out the piston pin, then remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the piston, pin, ring, connecting rod and bearings in the correct order.
8. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0095 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. HINT: The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).
9. REMOVE CRANKSHAFT Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps from the cylinder block. Remove the crankshaft from the cylinder block.
10. REMOVE CRANKSHAFT THRUST WASHER UPPER
11. REMOVE CRANKSHAFT BEARING HINT: Arrange the bearings in the correct order.
12. REMOVE CRANKSHAFT BEARING NO. 2 HINT: Arrange the bearings in the correct order.
13. REMOVE STUD BOLT Remove the 8 stud bolts.
14. CHECK CYLINDER BLOCK FOR WARPAGE Using a precision straight edge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than maximum, replace the cylinder block.
15. INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 88.500 to 88.513 mm (3.4843 to 3.4848 in.) Maximum diameter: 88.633 mm (3.4895 in.) If the average diameter of the 4 positions is greater than maximum, replace the cylinder block.
16. INSPECT PISTON Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 30.3 mm (1.193 in.) from the piston head. Piston diameter: 88.439 to 88.449 mm (3.4819 to 3.4822 in.) If the diameter is not as specified, replace the piston.
17. CHECK PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.051 to 0.074 mm (0.0020 to 0.0029 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace all the pistons. If necessary, replace the cylinder block.
18. CHECK RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between the new piston ring and wall of the ring groove. RING GROOVE CLEARANCE: ITEM SPECIFICATION Item Specification No. 1 ring 0.17 to 0.22 mm (0.0067 to 0.0087 in.) No. 2 ring 0.17 to 0.21 mm (0.0067 to 0.0083 in.) Oil ring 0.21 to 0.29 mm (0.0083 to 0.0114 in.) If the groove clearance is not as specified, replace the piston.
19. CHECK PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. STANDARD END GAP: ITEM SPECIFICATION Item Specification No. 1 ring 0.22 to 0.32 mm (0.0087 to 0.0126 in.) No. 2 ring 0.50 to 0.60 mm (0.0197 to 0.0236 in.) Oil ring 0.10 to 0.35 mm (0.0039 to 0.0138 in.) MAXIMUM END GAP: ITEM SPECIFICATION Item Specification No. 1 ring 0.89 mm (0.0350 in.) No. 2 ring 1.35 mm (0.0531 in.) Oil ring 0.73 mm (0.0287 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
20. CHECK PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the piston pin bore diameter. Piston pin bore diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.) SPECIFIED CONDITION Mark Specified Condition A 22.001 to 22.004 mm (0.8662 to 0.8663 in.) B 22.005 to 22.007 mm (0.8663 to 0.8664 in.) C 22.008 to 22.010 mm (0.8665 to 0.8665 in.) If the diameter is not as specified, replace the piston. Using a micrometer, measure the piston pin outer diameter. Piston pin outer diameter: 21.997 TO 22.006 MM (0.8660 TO 0.8664 IN.) SPECIFIED CONDITION Mark Specified Condition A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) C 22.004 to 22.006 mm (0.8663 to 0.8664 in.) If the diameter is not as specified, replace the piston pin. Using a caliper gauge, measure the connecting rod small end bore diameter. Connecting rod small end bore diameter: 22.005 TO 22.014 MM (0.8663 TO 0.8667 IN.) SPECIFIED CONDITION Mark Specified Condition A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) C 22.012 to 22.014 mm (0.8666 to 0.8667 in.) If the diameter is not as specified, replace the connecting rod. Subtract the piston pin outer diameter measurement from the piton pin bore diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.00004 to 0.0003 in.) Maximum oil clearance: 0.013 mm (0.0005 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.017 mm (0.0007 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
21. INSPECT CONNECTING ROD SUB-ASSY Using a connecting rod aligner and feeler gauge, check the connecting rod alignment. Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the misalignment is greater than maximum, replace the connecting rod. Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than maximum, replace the connecting rod.
22. INSPECT CONNECTING ROD BOLT Using vernier calipers, measure the tension portion diameter of the bolts. Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Maximum diameter: 7.0 mm (0.276 in.) If the diameter is less than minimum, replace the connecting rod bolt.
23. INSPECT CRANKSHAFT Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration (Scheme 400) Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the crankshaft. Using a micrometer, measure the diameter of each main journal. Diameter: 54.988 to 55.000 mm (2.1649 to 2.1654 in.) If the diameter is not as specified, check the crankshaft oil clearance. Check each main journal for taper and distortion as shown in the illustration. Maximum taper and distortion: 0.003 mm (0.0001 in.) If the taper and distortion are greater than maximum, replace the crankshaft. DIAMETER (REFERENCE): SPECIFIED CONDITION Mark Specified Condition 0 54.999 to 55.000 mm (2.1653 to 2.1654 in.) 1 54.997 to 54.998 mm (2.1652 to 2.1653 in.) 2 54.995 to 54.996 mm (2.1652 to 2.1652 in.) 3 54.993 to 54.994 mm (2.1651 to 2.1651 in.) 4 54.991 to 54.992 mm (2.1650 to 2.1650 in.) 5 54.988 to 54.990 mm (2.1649 to 2.1650 in.) Using a micrometer, measure the diameter of each crank pin. Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.) If the diameter is not as specified, check the connecting rod oil clearance. Check each crank pin for taper and distortion as shown in the illustration. Maximum taper and distortion: 0.003 mm (0.0001 in.) If the taper and distortion are greater than maximum, replace the crankshaft.
24. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using vernier calipers, measure the tension portion diameter of the bolts. Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.) Minimum diameter: 7.5 mm (0.295 in.) If the diameter is less than minimum, replace the bolt.
25. CHECK CRANKSHAFT OIL CLEARANCE NOTE: Do not turn the crankshaft during the measurement. Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. Install the upper bearing with an oil groove onto the cylinder block. NOTE: Do not apply engine oil to the bearing or its contact surface. Install the lower bearing onto the bearing cap. NOTE: Do not apply engine oil to the bearing or its contact surface. Place the crankshaft onto the cylinder block. Lay a strip of Plastigage across each journal. Examine the front marks and numbers and install the bearing caps onto the cylinder block in the sequence order shown in the illustration. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly Install and tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) Mark the front of the bearing cap bolts with paint. Retighten the bearing cap bolts 90° in the same sequence as step ( i ). Check that the painted marks are at a 90° angle to the front. Remove the bearing caps. Measure the Plastigage at its widest point. Standard oil clearance: 0.017 to 0.040 mm (0.0007 to 0.0016 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) NOTE: Remove the Plastigage completely after the measurement. If the oil clearance is greater than maximum, replace the crankshaft bearing. If necessary, replace the crankshaft. HINT: If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft, then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. STANDARD BEARINGS SPECIFICATION Cylinder block + Crankshaft 0 to 2 3 to 5 6 to 8 9 to 11 Use bearing "1" "2" "3" "4" HINT: EXAMPLE Imprinted number on the cylinder block is 3 Imprinted number on the crankshaft is 4 3 + 4 = 7 Select the bearing marked "7"
26. INSTALL TIGHT PLUG Apply adhesive around the new tight plugs. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. Using SST, install 2 tight plugs. SST 09950-60010 (09951-00200), 09950-70010 (09951-07100) STANDARD DEPTH: TIGHT PLUG STANDARD DEPTH SPECIFICATION Item Specification A 1.7 to 2.7 mm (0.07 to 0.11 in.) B 2.2 to 3.2 mm (0.09 to 0.13 in.)
27. INSTALL RING PIN Using a plastic hammer, install 12 new ring pins. PROTRUSION HEIGHT: RING PIN HEIGHT ITEM SPECIFICATION Item Specification A 6 mm (0.24 in.) B 5 mm (0.20 in.)
28. INSTALL STRAIGHT PIN Using a plastic hammer, install 8 new straight pins. PROTRUSION HEIGHT: STRAIGHT PIN HEIGHT SPECIFICATION Item Specification A 8 mm (0.31 in.) B 7.5 mm (0.30 in.) C 12 mm (0.47 in.) D 5 mm (0.20 in.)
29. INSTALL STUD BOLT Install 8 stud bolts into the cylinder block. TORQUE: STUD BOLT TORQUE SPECIFICATION Item Specification A 5.0 Nm (51 kgf.cm, 44 in.lbf) B 21.5 Nm (219 kgf.cm, 16 ft.lbf) C 5.0 Nm (51 kgf.cm, 44 in.lbf) D 9.5 Nm (97 kgf.cm, 84 in.lbf)
30. INSTALL PISTON Using a small screwdriver, install a new snap ring onto one end of the piston pin hole. HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston up to 80 to 90°C (176 to 194°F). Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin comes into contact with the snap ring. Using a small screwdriver, install a new snap ring onto other end of the piston pin hole. HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
31. INSTALL PISTON RING SET Install the expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the painted mark as shown in the illustration. NOTE: Install compression ring No. 2 with the code mark (2N) facing upward. Position the piston rings so that the ring ends are as shown in the illustration.
32. INSTALL CRANKSHAFT BEARING Install the upper bearing with an oil groove onto the cylinder block. NOTE: Do not apply engine oil to the bearing or its contact surface.
33. INSTALL CRANKSHAFT BEARING NO. 2 Install the lower bearing onto the bearing cap. NOTE: Do not apply engine oil to the bearing or its contact surface.
34. INSTALL CRANKSHAFT THRUST WASHER UPPER Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
35. INSTALL CRANKSHAFT Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block. Examine the front marks and numbers and install the bearing caps onto the cylinder block in the sequence order shown in the illustration. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly Install and tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) Mark the front of the bearing cap bolts with paint. Retighten the bearing cap bolts 90° in the same sequence as step ( d ). Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.
36. INSTALL CONNECTING ROD BEARING Align the bearing claw with the oil groove of the connecting rod or connecting rod cap. NOTE: Do not apply engine oil to the bearing or its contact surface.
37. INSTALL PISTON SUB-ASSY W/CONNECTING ROD Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings. Check the position of the piston ring ends. Using a piston ring compressor, correctly push the numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. Check that the front mark of the connecting rod cap is facing in the correct direction. NOTE: Match the numbered connecting rod cap with the connecting rod. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts. Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) Mark the front of the connecting rod bolts with paint. Retighten the cap bolts 90° as shown in the illustration. Check that the crankshaft turns smoothly.