Engine Mechanical (1GR-FE): Overhaul Toyota 4Runner IV

OVERHAUL

HINT

1. Thoroughly clean all parts to be assembled.
2. Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
3. Replace all gaskets, O-rings and oil seals with new parts.

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1. REMOVE ENGINE HANGER NO.1 Remove the 2 bolts and engine hanger No. 1.
2. REMOVE ENGINE HANGER NO. 2 Remove the 2 bolts and engine hanger No. 2.
3. REMOVE OIL LEVEL GAUGE GUIDE Remove the bolt and pull out the oil level gauge guide. Remove the O-ring from the oil level gauge guide.
4. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Remove the 2 water drain cocks.
5. REMOVE VVT SENSOR Remove the 2 bolts and 2 VVT sensors.
6. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and crankshaft position sensor.
7. REMOVE OIL CONTROL VALVE FILTER Remove the plug, filter and gasket from each cylinder head.
8. REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
9. REMOVE CYLINDER HEAD COVER SUB-ASSY LH Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket. Remove the ventilation valve from the cylinder head cover.
10. REMOVE CRANKSHAFT PULLEY Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above. Using SST, hold the crankshaft pulley and loosen the pulley set bolt. SST 09213-54015 (91651-60855), 09330-00021 Using the pulley set bolt and SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
11. REMOVE OIL PAN DRAIN PLUG Remove the drain plug and gasket.
12. REMOVE OIL PAN SUB-ASSY NO. 2 Remove the 10 bolts and 2 nuts. Insert the blade of SST between the oil pan and oil pan No. 2, cut off applied sealer and remove the oil pan No. 2. SST 09032-00100 NOTE: Be careful not to damage the contact surface of the oil pan and oil pan No. 2. Be careful not to damage the oil pan No. 2 flange.
13. REMOVE OIL STRAINER SUB-ASSY Remove the 2 nuts, oil strainer and gasket.
14. REMOVE OIL PAN SUB-ASSY Remove 17 bolts and 2 nuts. Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown. NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. Remove the O-ring from the oil pump.
15. REMOVE WATER PUMP ASSY Remove the 17 bolts, water pump and gasket.
16. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY Remove the 15 bolts and 2 nuts. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. Remove the O-ring from the LH cylinder head.
17. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the oil pump assembly. Wrap a tip of the screwdriver with tape.
18. REMOVE CHAIN TENSIONER ASSY NO.1 NOTE: Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration. While turning the stopper plate of the tensioner downward, insert a bar of his 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Remove the 2 bolts and chain tensioner.
19. REMOVE CHAIN TENSIONER SLIPPER
20. REMOVE IDLE GEAR NO.1 Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1.
21. REMOVE CHAIN VIBRATION DAMPER NO. 2 Remove the 2 chain vibration damper No. 2.
22. REMOVE CHAIN SUB-ASSY
23. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
24. REMOVE CHAIN VIBRATION DAMPER NO.1 Remove the 2 bolts and chain vibration damper No. 1.
25. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (RH BANK) While raising up the chain tensioner No. 2, insert a pin of (]) 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly.
26. REMOVE CHAIN TENSIONER ASSY NO. 2 Remove the bolt and chain tensioner No. 2.
27. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (LH BANK) While pushing down the chain tensioner No. 3, insert a pin of slash 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly.
28. REMOVE CHAIN TENSIONER ASSY NO. 3 Remove the bolt and chain tensioner No. 3.
29. REMOVE CAMSHAFTS NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Remove the camshafts of the RH bank. Rotate the camshafts counterclockwise using the wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration. Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 8 bearing caps and 2 camshafts. Remove the camshafts of the LH bank. Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 8 bearing caps and 2 camshafts.
30. REMOVE CAMSHAFT BEARING NO.1
31. REMOVE CAMSHAFT BEARING NO. 2
32. REMOVE CYLINDER HEADS Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence as shown in the illustration. Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 16 cylinder head bolts and plate washers. NOTE: Be careful not to drop the plate washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in incorrect order. Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench. NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. Remove the RH and LH cylinder head gaskets.
33. REMOVE WATER OUTLET PIPE NO.1 Separate the knock sensor wire. Remove the bolt, 2 nuts and water outlet pipe.
34. REMOVE KNOCK SENSOR Disconnect the knock sensor connectors. Remove the 2 bolts and 2 knock sensors.
35. REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 5 bolts and 2 nuts. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.
36. REMOVE ENGINE REAR OIL SEAL Using a screwdriver and hammer, tap out the oil seal.
37. INSPECT CAMSHAFTS Inspect camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the runout at the center journal. Maximum runout: 0.06 mm (0.0024 in.) If the runout is greater than maximum, replace the camshaft. Inspect cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 44.168-44.268 mm (1.7389-1.7428 in.) Exhaust 44.580-44.680 mm (1.7551-1.7591 in.) Minimum cam lobe height: Intake 44.018 mm (1.7330 in.) Exhaust 44.430 mm (1.7492 in.) If the cam lobe height is less than minimum, replace the camshaft. Inspect camshaft journals. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971-35.985 mm (1.4162-1.4167 in.) Other journal diameter: 22.959-22.975 mm (0.9039-0.9045 in.) If the journal diameter is not as specified, check the oil clearance.
38. INSPECT CAMSHAFT TIMING GEAR ASSY Fix the intake camshaft with a vise. NOTE: Be careful not to damage the camshaft. Align the knock pin hole in the camshaft timing gear assembly with the knock pin of the camshaft, and install the camshaft timing gear assembly with the bolt. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf) Confirm the camshaft timing gear assembly is locked. Release lock pin. Cover 4 oil paths of cam journal with a masking tape as shown in the illustration. HINT: The one of the 2 grooves on the cam journal is for retards (upper) and the rest is for advances (lower). Each groove has the 2 oil paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with the tape. Prick the tape for the advances oil path and for the retards oil path in the opposite side from the advances as shown in the illustration. Put air pressure into two broken paths (the advance side path and the retard side path) with about 200 kPa (2.0 kgf/cm 2 ). NOTE: Cover the paths with shop rag to avoid oil splashing. Confirm if the camshaft timing gear assembly rotates in the timing advance direction when reducing the air pressure of the timing retard path. HINT: When the lock pin is released, camshaft timing gear rotates in the advance direction. When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, take out that of timing advance side path. NOTE: Camshaft timing assembly gear occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released first. It often results in the breakage of the lock pin. Check smooth revolution. Except the position where the lock pin meets at the most retard angle, let the camshaft timing gear assembly turn back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 31° NOTE: Be sure to perform this check by hand, instead of air pressure. Check the lock in the most retarded position. Confirm that the camshaft timing gear assembly is locked at the most retarded position. Remove the set bolt and camshaft timing gear assembly. NOTE: Be sure not to remove the other 3 bolts.
39. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the thread outside diameter of the bolt. Standard outside diameter: 10.85-11.00 mm (0.4272-0.4331 in.) Minimum outside diameter: 10.7 mm (0.421 in.)
40. INSPECT CHAIN SUB-ASSY Using a spring scale, pull the chain sub assembly with 147 N (15.0 kgf, 33.1 lbf) and measure the length of the chain sub assembly by a vernier caliper. Maximum chain elongation: 146.8 mm (5.780 in.) NOTE: Perform the same measurements by pulling at random 3 or more places to obtain an average length. If the elongation is greater than maximum, replace the chain.
41. INSPECT NO. 2 CHAIN SUB-ASSY Using a spring scale, pull the chain sub assembly with 147 N (15.0 kgf, 33.1 lbf) and measure the length of the chain sub assembly by a vernier caliper. Maximum chain elongation: 146.8 mm (5.780 in.) NOTE: Perform the same measurements by pulling at random 3 or more places to obtain an average length. If the elongation is greater than maximum, replace the chain.
42. INSPECT CAMSHAFT TIMING GEAR ASSY Put the No. 1 chain on the larger gear of camshaft timing gear assembly. Using a vernier caliper, measure the timing gear with the chain. Minimum gear diameter (w/ chain): 115.5 mm (4.547 in.) NOTE: Vernier caliper must contact the chain rollers for the measuring. If the diameter is less than minimum, replace the No. 1 chain and camshaft timing gear assembly. Put the No. 2 chain on the smaller gear of camshaft timing gear assembly. Using a vernier caliper, measure the timing gear with the chain. Minimum gear diameter (w/ chain): 73.1 mm (2.878 in.) NOTE: Vernier caliper must contact the chain rollers for the measuring. If the diameter is less than minimum, replace the No. 2 chain and camshaft timing gear assembly.
43. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET Put the No. 2 chain on the camshaft timing gear. Using a vernier caliper, measure the camshaft timing gear diameter with the chain. Minimum gear diameter (w/ chain): 73.1 mm (2.878 in.) NOTE: Vernier caliper must contact the chain rollers for the measuring. If the diameter is less than minimum, replace the No. 2 chain and the camshaft timing gear.
44. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET Put the No. 1 chain on the crankshaft timing gear. Using a vernier caliper, measure the crankshaft timing gear diameter with the chain. Minimum gear diameter (w/ chain): 61.0 mm (2.402 in.) NOTE: Vernier caliper must contact the chain rollers for the measuring. If the diameter is less than minimum, replace the No. 1 chain and crankshaft timing gear.
45. INSPECT IDLE GEAR NO.1 Put the No. 1 chain on the idle gear. Using a vernier caliper, measure the idle gear with the chain. Minimum gear diameter (w/ chain): 61.0 mm (2.402 in.) NOTE: Vernier caliper must contact the chain rollers for the measuring. If the diameter is less than minimum, replace the No. 1 chain and idle gear.
46. INSPECT IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the idle gear shaft diameter. Idle gear shaft diameter: 22.987-23.000 mm (0.9050-0.9055 in.) Using a caliper gauge, measure the inside diameter of the idle gear. Idle gear inside diameter: 23.02-23.03 mm (0.9063-0.9067 in.) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement. Standard oil clearance: 0.020-0.043 mm (0.0008-0.0017 in.) Maximum oil clearance: 0.093 mm (0.0037 in.)
47. INSPECT CHAIN TENSIONER ASSY NO.1 Check that the plunger moves smoothly when the ratchet pawl is raised with finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushing with finger.
48. INSPECT CHAIN TENSIONER ASSY NO. 2 Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than maximum, replace the chain tensioner No. 2.
49. INSPECT CHAIN TENSIONER ASSY NO. 3 Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than maximum, replace the chain tensioner No. 3.
50. INSPECT CHAIN TENSIONER SLIPPER Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than maximum, replace the chain tensioner slipper.
51. INSPECT CHAIN VIBRATION DAMPER NO.1 Measure the worn depth of the chain vibration damper No. 1. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than maximum, replace the chain vibration damper No. 1.
52. INSPECT CHAIN VIBRATION DAMPER NO. 2 Measure the worn depth of the chain vibration damper No. 2. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than maximum, replace the chain vibration damper No. 2.
53. INSTALL ENGINE REAR OIL SEAL Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-78010 Apply MP grease to the oil seal lip.
54. INSTALL ENGINE REAR OIL SEAL RETAINER Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block. Apply a continuous bead of the seal packing (diameter 2-3 mm (0.08-0.12 in.)) to the oil seal retainer as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied. Install the oil seal retainer with the 5 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
55. INSTALL KNOCK SENSOR Install the 2 knock sensors with the 2 bolts as shown in the illustration. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) Connect the knock sensor connectors.
56. INSTALL WATER OUTLET PIPE NO.1 Install the water outlet pipe with the bolt and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
57. INSTALL CYLINDER HEAD GASKET Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. Apply a continuous bead of the seal packing (diameter 2.5-3 mm (0.098-0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp is upward. NOTE: Be careful of the installation direction. Place the cylinder head carefully in order to not damage the gasket with the bottom part of the head.
58. INSTALL CYLINDER HEAD SUB-ASSY Place the RH cylinder head on the cylinder head gasket. Install the 8 cylinder head bolts. HINT: The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTE: Do not drop the washers into the cylinder head. Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts by 180° revolution as shown. Check that the painted marks are now at 180° opposite to the engine front.
59. INSTALL CYLINDER HEAD GASKET NO. 2 Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. Apply a continuous bead of the seal packing (diameter 2.5-3 mm (0.098-0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp is upward. NOTE: Be careful of the installation direction. Place the cylinder head carefully in order to not damage the gasket with the bottom part of the head.
60. INSTALL CYLINDER HEAD LH Place the LH cylinder head on the cylinder head gasket. Install the 8 cylinder head bolts. HINT: The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTE: Do not drop the washers into the cylinder head. Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts by 180° revolution as shown. Check that the painted marks are now at 180° opposite to the engine front. Install the 2 cylinder head bolts. Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the 2 cylinder head bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
61. INSTALL CAMSHAFT BEARING NO.1 Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing. NOTE: Install the bearing while aligning it with the oil hole in the bearing cap. Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
62. INSTALL CAMSHAFT BEARING NO. 2 Install the camshaft bearing No. 2 to the cylinder head. NOTE: Clean the backside of the bearing and the bearing surface of the cylinder head and let not stick the oils and fats.
63. INSTALL CAMSHAFTS NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Set the crankshaft position. Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position. NOTE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle. Apply new engine oil to the thrust portion and journal of the camshafts. Install the camshaft of the RH bank. Place the 2 camshafts onto the RH cylinder head with the cam lobes of No. 1 cylinder face each direction as shown in the illustration. Install the 8 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head Turn the camshafts clockwise with the wrench until the camshaft knock pin comes 90° position to the cylinder head. Install the camshafts of the LH bank. Place the 2 camshafts onto the LH cylinder head with the cam lobes of No. 2 cylinder faced as shown in the illustration. Install the 8 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head
64. INSTALL CHAIN TENSIONER ASSY NO. 2 While pushing in the tensioner, insert a pin of his 1.0 mm (0.039 in.) into the hole to fix it. Install the chain tensioner No. 2 with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
65. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (RH BANK) Align the mark links (yellow) with the timing marks (1 dot mark) of camshaft timing gears as shown in the illustration. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts. Temporarily install the 2 camshaft timing gear bolts. NOTE: Do not push camshaft timing gear assembly to the camshaft forcibly when installing it. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf) Remove the pin from the chain tensioner No. 2.
66. INSTALL CHAIN TENSIONER ASSY NO. 3 While pushing in the tensioner, insert a pin of his 1.0 mm (0.039 in.) into the hole to hold it. Install the chain tensioner No. 3 with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
67. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (LH BANK) Align the mark links (yellow) with the timing marks (1 dot mark and 2 dot marks) of camshaft timing gears as shown in the illustration. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts. Temporarily install the 2 camshaft timing gear bolts. NOTE: Do not push camshaft timing gear assembly to the camshaft forcibly when installing it. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf) Remove the pin from the chain tensioner No. 3.
68. INSTALL CHAIN VIBRATION DAMPER NO.1 Install the chain vibration damper No. 1 with the 2 bolts. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
69. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET Align the timing gear set key with the key groove of the timing gear. Install the timing gear onto the crankshaft with the gear side facing inward.
70. INSTALL CHAIN TENSIONER SLIPPER
71. INSTALL CHAIN TENSIONER ASSY NO.1 While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. While turning the stopper plate of the tensioner counterclockwise, insert a bar of his 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
72. INSTALL CHAIN SUB-ASSY Set the No. 1 cylinder to TDC/ compression. Align the timing marks of the camshaft timing gears and bearing caps. Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. Align the mark link (yellow) with the timing mark of the crankshaft timing gear. Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
73. INSTALL CHAIN VIBRATION DAMPER NO. 2 Instal the 2 chain vibration damper No. 2.
74. INSTALL IDLE GEAR NO.1 Apply a light coat of engine oil to rotating surface of the idle gear shaft No. 1. Temporarily install the idle gear shaft No. 1 and idle gear No. 1 with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block. NOTE: Be careful of the idle gear direction. Using a 10 mm hexagon wrench, tighten the idle gear shaft No. 2. Torque: 60 N.m (612 kgf.cm, 44 ft.lbf) Remove the bar from the chain tensioner.
75. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09226-10010 Apply MP grease to the oil seal lip.
76. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Install a new O-ring to the LH cylinder head as shown in the illustration. Apply a continuous bead of the seal packing (diameter 3-4 mm (0.12-0.16 in.)) to 4 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Apply a continuous bead of the seal packing (diameter 3-4 mm (0.12-0.16 in.)) to the timing chain cover as shown in the illustration. Seal packing: Water pump part: Part No. 08826-00100 or equivalent Other part: Part No. 08826-00080 or equivalent NOTE: Install the timing chain cover within 3 minutes after applying seal packing. After installing it, timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Do not apply seal packing to the "A" as shown in the illustration. Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place. Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) NOTE: Pay attention not to wrap the chain and slipper over the timing chain cover seal line. After installing the timing chain cover, must install the water pump within 15 minutes. HINT: Each bolt length as follows: A 25 mm (0.98 in.) B 55 mm (2.17 in.)
77. INSTALL WATER PUMP ASSY Install a new gasket and the water pump with the 17 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 23 N.m (235 kgf.cm, 17 ft.lbf) for 12 mm (0.47 in.) head
78. INSTALL OIL PAN SUB-ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan. Install the 4 stud bolts. Torque: 4.0 N.m (41 kgf.cm, 35 in..lbf) Install a new O-ring to the oil pump. Apply a continuous bead of the seal packing (diameter 3-4 mm (0.12-0.16 in.)) to the oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the oil pan within 3 minutes after applying seal packing. After installing it, oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 19 N.m (194 kgf.cm, 14 ft.lbf) for 12 mm (0.47 in.) head HINT: Each bolt length as follows: A 25 mm (0.98 in.) B 40 mm (1.57 in.) C 14 mm (0.55 in.)
79. INSTALL OIL STRAINER SUB-ASSY Install a new gasket and the oil strainer with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
80. INSTALL OIL PAN SUB-ASSY NO. 2 Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No. 2. Apply a continuous bead of the seal packing (diameter 3-4 mm (0.12-0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the oil pan No. 2 within 3 minutes after applying seal packing. After installing it, oil pan No. 2 bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the oil pan No. 2 with the 10 bolts and 2 nuts, tighten the bolts and nuts uniformly in several steps. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
81. INSTALL OIL PAN DRAIN PLUG Install the drain plug with a new gasket. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)
82. INSTALL CRANKSHAFT PULLEY Using SST, install the pulley set bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 250 N.m (2, 549 kgf.cm, 184 ft.lbf)
83. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
84. INSPECT VALVE CLEARANCE (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
85. ADJUST VALVE CLEARANCE (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
86. INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. Install the gasket to the cylinder head cover. Apply a continuous bead of the seal packing (diameter 2-3 mm (0.08-0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the seal washers to the bolts. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
87. INSTALL CYLINDER HEAD COVER SUB-ASSY LH Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. Apply adhesive on the threads of the ventilation valve. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the ventilation valve to the cylinder head cover. Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) Install the gasket to the cylinder head cover. Apply a continuous bead of the seal packing (diameter 2-3 mm (0.08-0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the seal washers to the bolts. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
88. INSTALL OIL CONTROL VALVE FILTER Check that no foreign objects on the mesh part of the 2 filters. Install 2 new gaskets to each new plug. Insert the filters to the plugs. Apply adhesive to 2 or 3 threads of the plugs. Adhesive: Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent Install the plugs to each cylinder head. Torque: 62 N.m (632 kgf.cm, 46 ft.lbf)
89. INSTALL CRANKSHAFT POSITION SENSOR Install the crankshaft position sensor with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
90. INSTALL VVT SENSOR Apply a light coat of engine oil to the O-ring of each VVT sensor. Install the 2 VVT sensors with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
91. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Apply adhesive to 2 or 3 threads of the drain cocks end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent After reached the specified torque, rotate the drain cocks clockwise as shown in the illustration. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) NOTE: Do not rotate the drain cocks more than 1 complete revolution (360°) after tightening the drain cocks with the specified torque. Do not loosen the drain cocks after setting it correctly.
92. INSTALL OIL LEVEL GAUGE GUIDE Install a new O-ring to the oil level gauge guide. Apply a light coat of engine oil to the O-ring. Push in the oil level gauge guide end into the guide hole of the oil pan. Install the oil level gauge guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
93. INSTALL ENGINE HANGER NO. 2 Install the engine hanger with the 2 bolts. Torque: 33 N.m (336 kgf.cm, 24 ft.lbf)
94. INSTALL ENGINE HANGER NO.1 Install the engine hanger with the 2 bolts. Torque: 33 N.m (336 kgf.cm, 24 ft.lbf)

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1. REMOVE VALVE LIFTER HINT: Arrange the valve lifter in the correct order.
2. REMOVE VALVE HINT: Arrange the valves, inner compression springs, valve spring retainers and valve spring retainer rocks in the correct order. Place the cylinder head on the wooden block. Using SST, compress the inner compression spring and remove the 2 valve spring retainer rocks. SST 09202-70020 (09202-00010) Remove the valve, inner compression spring, valve spring and valve spring retainer.
3. REMOVE VALVE SPRING SEAT Using compressed air and a magnetic finger, remove the valve spring seat by blowing air.
4. REMOVE VALVE STEM OIL O SEAL OR RING Using a needle-nose plier, remove the valve stem oil seal.
5. CLEAN CYLINDER HEAD SUB-ASSY Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTE: Be careful not to scratch the cylinder block contact surface. Using a wire brush, remove all the carbon from the combustion chambers. NOTE: Be careful not to scratch the combustion chambers. Using a valve guide bushing brush and solvent, clean all the valve guide bushes. Using a soft brush and solvent, thoroughly clean the cylinder head.
6. INSPECT CYLINDER HEAD SUB-ASSY Inspect flatness. Using a precision straight edge and feeler gauge, measure flatness the surfaces contacted the cylinder block and manifolds. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head. Inspect cranks. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. CLEAN VALVE Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve.
7. INSPECT VALVE Inspect valve stem diameter. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter VALVE STEM DIAMETER SPECIFICATION Intake 5.470-5.485 mm (0.2154-0.2159 in) Exhaust 5.465-5.480 mm (0.2152-0.2158 in) Inspect valve face angle. Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° Inspect valve head margin thickness. Using vernier calipers, check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. Inspect overall length. Using vernier calipers, check the overall length. Standard overall length VALVE STANDARD OVERALL LENGTH SPECIFICATION Intake 106.95 mm (4.2106 in.) Exhaust 105.80 mm (4.1654 in.) Minimum overall length VALVE MINIMUM OVERALL LENGTH SPECIFICATION Intake 106.40 mm (4.1890 in.) Exhaust 105.30 mm (4.1457 in.) If the overall length is less than minimum, replace the valve. Inspect valve stem tip. Check the surface of the valve stem tip for wear. NOTE: Do not grind off more than minimum length. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.
8. CLEAN VALVE SEAT Using a 45° carbide cutter, resurface the valve seats. Clean the valve seats.
9. INSPECT VALVE SEAT Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against the valve seat. NOTE: Do not rotate the valve. Check the valve face and seat according to the following procedure. If the blue appears 360° around the face, the valve is center. If not, replace the valve. If the blue appears 360° around the valve seat, the guide and face are center. If not, resurface the valve seat. Check that the seat contacts the middle of the valve face with these width. Standard width: 1.0-1.4 mm (0.039-0.055 in.)
10. REPAIR VALVE SEAT NOTE: Take off a cutter gradually to make the intake valve seat smooth. If the seating is too high to the valve face, use 30° and 45° cutters to correct the seat. Intake side: If the seating is too low to the valve face, use 60° and 45C cutters to correct the seat. Exhaust side: If the seating is too low to the valve face, use 75° and 45C cutters to correct the seat. Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat.
11. INSPECT INNER COMPRESSION SPRING Inspect squareness. Using a steel square, measure the squareness of the inner compression spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the inner compression spring. Inspect free length. Using vernier calipers, measure the free length of the inner compression spring. Free length: 47.80 mm (1.8819 in.) If the free length is not as specified, replace the inner compression spring. Inspect tension. Using a spring tester, measure the tension of the inner compression spring at the specified installed length. Installed tension: 186.2-205.8 N (19.0-21.0 kgf, 41.9-46.3 lbf) at 33.3 mm (1.311 in.) If the installed tension is not specified, replace the inner compression spring.
12. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Inside diameter: 5.51-5.53 mm (0.2169-0.2177 in.) Subtract the valve stem diameter measurement (Step 7 ) from the valve guide bush inside diameter measurement. Standard oil clearance STANDARD OIL CLEARANCE SPECIFICATION Intake 0.025-0.060 mm (0.0010-0.0024 in) Exhaust 0.030-0.065 mm (0.0012-0.0026 in) Maximum oil clearance MAXIMUM OIL CLEARANCE SPECIFICATION Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in..) If the oil clearance is greater than maximum, replace the valve and valve guide bush.
13. REMOVE VALVE GUIDE BUSH Gradually heat the cylinder head to 80-100°C (176-212°F). Place the cylinder head on the wooden block. Using SST, tap out the valve guide bush. SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)
14. INSTALL VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Bush bore diameter: 10.295-10.315 mm (0.4053-0.4061 in.) If the bush bore diameter of the cylinder head is greater than 10.315 mm (0.4061 in.), machine the bush bore to the dimension of 10.345-10.365 mm (0.4073-0.4081 in.). Valve guide bush diameter VALVE GUIDE BUSH DIAMETER SPECIFICATION STD 10.333-10.344 mm (0.4068-0.4072 in.) O/S 0.05 10.383-10.394 mm (0.4088-0.4092 in.) Gradually heat the cylinder head to 80-100°C (176-212°F). Place the cylinder head on the wooden block. Using SST, tap in a new valve guide bush to the specified protrusion height. SST 09201-10000, 09201-01055, 09950-70010 (09951-07100) Protrusion height: 9.3-9.7 mm (0.366-0.382 in.) Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem. Standard oil clearance STANDARD OIL CLEARANCE SPECIFICATION Intake 0.025-0.060 mm (0.0010-0.0024 in.) Exhaust 0.030-0.065 mm (0.0012-0.0026 in.)
15. INSPECT VALVE LIFTER Using a micrometer measure the valve lifter diameter. Valve lifter diameter: 30.966-30.976 mm (1.2191-1.2195 in.)
16. INSPECT VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009-31.025 mm (1.2208-1.2215 in.) Subtract the valve lifter diameter measurement (Step 15 ) from the lifter bore diameter measurement. Standard oil clearance: 0.033-0.059 mm (0.0013-0.0023 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the valve lifter. If necessary, replace the cylinder head.
17. INSPECT CAMSHAFT OIL CLEARANCE Clean the camshaft bearing caps, camshaft bearings and camshaft journals. Install the camshaft bearing. (See «OVERHAUL»(ref-235151-S27619466712006061400000) ) Place the camshaft on the cylinder head. Lay a strip of Plastigage across each of the camshaft journals. Install the camshaft bearing caps. (See «OVERHAUL»(ref-235151-S27619466712006061400000) ) NOTE: Do not turn the camshafts. Remove the camshaft bearing caps. (See «OVERHAUL»(ref-235151-S27619466712006061400000) ) Measure the Plastigage at its widest point. Standard oil clearance (Cylinder head RH) STANDARD OIL CLEARANCE SPECIFICATION (CYLINDER HEAD RH) No. 1 (Intake) 0.008-0.038 mm (0.0003-0.0015 in) No. 1 (Exhaust) 0.040-0.079 mm (0.0016-0.0031 in) Others 0.025-0.062 mm (0.0010-0.0024 in) Standard oil clearance (Cylinder head LH) STANDARD OIL CLEARANCE SPECIFICATION (CYLINDER HEAD LH) No. 1 0.040-0.079 mm (0.0016-0.0031 in) Others 0.025-0.062 mm (0.0010-0.0024 in) Maximum oil clearance (Cylinder head RH) MAXIMUM OIL CLEARANCE SPECIFICATION (CYLINDER HEAD RH) No. 1 (Intake) 0.07 mm (0.0028 in.) Others 0.10 mm (0.0039 in.) Maximum oil clearance (Cylinder head LH): 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft bearings and/or camshaft. If necessary, replace the camshaft bearing caps and cylinder head together. Reference REFERENCE Cylinder head journal bore diameter 40.009-40.017 mm (1.5752-1.5755 in.) Camshaft bearing center wall thickness (Mark "2") 2.004-2.008 mm (0.0789-0.0791 in.) Camshaft journal diameter 35.971-35.985 mm (1.4165-1.4167 in.) Remove the Plastigage completely. Remove the camshafts. Remove the camshaft bearing.
18. INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. (See «OVERHAUL»(ref-235151-S27619466712006061400000) ) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.04-0.09 mm (0.016-0.035 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than maximum, replace the camshafts. If necessary, replace the camshaft bearing caps and cylinder head as a set.
19. INSTALL RING PIN Using a plastic-faced hammer, tap in the new ring pins until it is reached to the specified protrusion height. Specified protrusion height: 2.7-3.3 mm (0.106-0.130 in.)
20. INSTALL STRAIGHT PIN Using a plastic-faced hammer, tap in the new straight pins until it is reached to the specified protrusion height. Specified protrusion height SPECIFIED PROTRUSION HEIGHT REFERENCE A 17.5-19.5 mm (0.689-0.768 in.) B 7.5-8.5 mm (0.295-0.335 in.) C 7.0-9.0 mm (0.276-0.354 in.)
21. INSTALL STUD BOLT Using the TORX socket wrench E5 and E7, install the stud bolts. Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf) for stud bolt A 9.0 N.m (92 kgf.cm, 80 in.lbf) for stud bolt B
22. INSTALL UNION Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using a deep socket wrench 12, install the unions. Torque: 15 N.m (150 kgf.cm, 11 ft.lbf)
23. INSTALL TIGHT PLUG Apply adhesive around tight plug. Using SST, tap in the tight plugs until the specified depth. SST 09950-60010 (09951-00250), 09950-70010 (09951-07150) Specified depth: 1.5 mm (0.059 in.)
24. INSTALL W/ HEAD STRAIGHT SCREW PLUG Using a straight hexagon wrench 14, install a new gasket and straight screw plug. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf)
25. INSTALL VALVE STEM OIL O SEAL OR RING HINT: The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray. Apply a light coat of engine oil to the valve guide bush. Using SST, push in a new valve stem oil seal. SST 09201-41020
26. INSTALL VALVE SPRING SEAT
27. INSTALL VALVE Apply the engine oil to the valve as shown in the illustration. Place the cylinder head on the wooden block. Install the valve, inner compression spring and valve spring retainer. Using SST, compress the inner compression spring and place the 2 valve spring retainer rocks around the valve stem. SST 09202-70020 (09202-00010) Using a pin punch 5, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the valve stem tip.
28. INSTALL VALVE LIFTER Apply the engine oil to the valve stem end and valve lifter, and install the valve lifter to the valve stem. Check that the valve lifter rotates smoothly by hand.

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1. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15-0.30 mm (0.0059-0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.)
2. INSPECT CONNECTING ROD OIL CLEARANCE Check the match marks on the connecting rod and cap are aligned to ensure correct reassembling. Using SST, remove the 2 connecting rod cap bolts. SST 09011-38121 Clean the crank pin, bearing and connecting rod. Check the crank pin and bearing for pits and scratches. Lay a strip of plastigage across the crank pin. Check that the protrusion of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil on the threads of the connecting rod cap bolts. Using SST, tighten the bolts alternately with the specified torque. SST 09011-38121 Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) Mark the front side of the each connecting cap bolt with paint. Retighten the cap bolts until 90° as shown in the illustration. NOTE: Do not turn the crankshaft. Remove the 2 bolts, connecting rod cap and lower bearing. Measure the plastigage at its widest point. Standard oil clearance: 0.026-0.046 mm (0.0010-0.0018 in.) Maximum oil clearance: 0.066 mm (0.0025 in.) NOTE: Completely remove the plastigage. If replace the bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1 ", "2", "3" and "4" accordingly. HINT: Standard bearing center wall thickness BEARING CENTER WALL THICKNESS SPECIFICATION Mark mm (in.) "1" 1.484-1.487 (0.0584-0.0585) "2" 1.487-1.490 (0.0585-0.0587) "3" 1.490-1.493 (0.0587-0.0588) "4" 1.493-1.496 (0.0588-0.0589)
3. REMOVE PISTON SUB-ASSY W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push in the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, 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 oil ring by hand.
6. REMOVE PISTON PIN HOLE SNAP RING Using a small screwdriver, pry out the 2 snap rings.
7. REMOVE W/PIN PISTON SUB-ASSY Gradually heat the piston to approx. 80°C(176°F). Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
8. INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04-0.24 mm (0.0016-0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the pair of the thrust washers or a crankshaft. HINT: Thrust washer thickness 1.93-1.98 mm (0.0760-0.0780 in.)
9. REMOVE CRANKSHAFT Using several steps, loosen and remove the 8 main bearing cap bolts and seal washers uniformly in the sequence as shown in the illustration. Using several steps, loosen and remove the 16 main bearing cap bolts uniformly in the sequence as shown in the illustration. Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps and lower bearings. NOTE: Pull up the main bearing cap little by little to the right and the left by turns. Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
10. REMOVE CRANKSHAFT THRUST WASHER SET
11. REMOVE CRANKSHAFT BEARING
12. REMOVE SUB-ASSY OIL NOZZLE NO.1 Using a 5 mm socket hexagon wrench, remove the 3 oil nozzles.
13. INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure flatness for the contact surface of the cylinder head gasket. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder block.
14. 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: 94.000-94.012 mm (3.7008-3.7013 in.) Maximum diameter: 94.132mm (3.7060 in.) If the average diameter of 4 positions is greater than maximum, replace the cylinder block.
15. INSPECT W/PIN PISTON SUB-ASSY Using a micrometer, measure the piston diameter at right angle to the piston pin center line, 27.7 mm (1.091 in.) from the piston head. Piston diameter: 93.910-93.920 mm (3.6972-3.6976 in.)
16. INSPECT PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.080-0.102 mm (0.0031-0.0040 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
17. INSPECT CONNECTING ROD SUB-ASSY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for out-of-alignment. Maximum out-of alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out-of alignment is greater than maximum, replace the connecting rod assembly. Check twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly.
18. INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston pin hole inside diameter: 22.001-22.010 mm (0.8662-0.8665 in.) HINT: Piston pin hole inside diameter PISTON PIN HOLE INSIDE DIAMETER SPECIFICATION Mark mm (in.) A 22.001-22.004 (0.8662-0.8663) B 22.005-22.007 (0.8663-0.8664) C 22.008-22.010 (0.8665-0.8665) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997-22.006 mm (0.8660-0.8664 in.) HINT: Piston pin diameter PISTON PIN DIAMETER SPECIFICATION Mark mm (in.) A 21.997-22.000 (0.8660-0.8661) B 22.001-22.003 (0.8661-0.8663) C 22.004-22.006 (0.8663-0.8664) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005-22.014 mm (0.8663-0.8667 in.) HINT: Bushing inside diameter CONNECTING ROD BUSHING INSIDE DIAMETER SPECIFICATION Mark mm (in.) A 22.005-22.008 (0.8663-0.8665) B 22.009-22.011 (0.8665-0.8666) C 22.012-22.014 (0.8666-0.8667) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement. Standard oil clearance: 0.001-0.007 mm (0.00004-0.00028 in.) Maximum oil clearance: 0.040 mm (0.0016 in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin together. Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005-0.011 mm (0.0002-0.0004 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together.
19. REMOVE CONNECTING ROD SMALL END BUSH Using SST and a press, press out the bushing. SST 09222-30010
20. INSTALL CONNECTING ROD SMALL END BUSH Align the oil holes of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin. Standard oil clearance: 0.005-0.011 mm (0.0002-0.0004 in.) HINT: Check that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.
21. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: No. 1 0.02-0.07 mm (0.0008-0.0028 in.) No. 2 0.02-0.06 mm (0.0008-0.0024 in.) Oil 0.07-0.15 mm (0.0028-0.0060 in.)
22. INSPECT 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: No. 1 0.30-0.40 mm (0.0118-0.0157 in.) No. 2 0.40-0.50 mm (0.0157-0.0197 in.) Oil (Side rail) 0.10-0.40 mm (0.0039-0.0157 in.) Maximum end gap: No. 1 1.0 mm (0.039 in.) No. 2 1.1 mm (0.043 in.) Oil (Side rail) 1.0 mm (0.039 in.)
23. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.2-7.3 mm (0.283-0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than minimum, replace the bolt.
24. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 10.0-10.2 mm (0.393-0.402 in.) If the diameter is less than minimum, replace the bolt.
25. INSPECT CRANKSHAFT Using a dial indicator and V-blocks, measure the runout as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) Using a micrometer, measure the diameter of each main journal. Diameter: 71.988-72.000 mm (2.8342-2.8346 in.) Check each main journal for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) Using a micrometer, measure the diameter of each crank pin. Diameter: 55.992-56.000 mm (2.2044-2.2047 in.) Check each crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
26. INSPECT CRANKSHAFT OIL CLEARANCE HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. Clean each main journal and bearing. Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTE: Do not apply engine oil to the bearing and its contact surface. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 bottom bearings. NOTE: Do not apply engine oil to the bearing and its contact surface. HINT: A number marked on each main bearing cap indicates the installation position. Place the crankshaft on the cylinder block. Lay a strip of plastigage across each journal. Examine the front marks and numbers and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads of bearing cap bolts. Temporarily install the 8 main bearing cap bolts to the inside positions. Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes under 6 mm (0.23 in.). Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil on the threads of main bearing cap bolts. Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 61 N.m (622 kgf.cm, 45 ft.lbf) Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts until 90° in the sequence as shown. Check that the painted mark is now at a 90° angle to the front. NOTE: Do not turn the crankshaft. Install the 8 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) Remove the main bearing caps. Measure the Plastigage at its widest point. Standard oil clearance: 0.018-0.030 mm (0.0007-0.0012 in.) Maximum clearance: 0.046 mm (0.0018 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: Completely remove the plastigage. If using a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 size of standard bearings, marked "1", "2", "3", "4" and "5" accordingly Journal bearings BEARING NUMBER REFERENCE Cylinder block (A) + Crankshaft 0-5 6-11 12-17 18-23 24-28 Use Bearing "1" "2" "3" "4" "5" HINT: EXAMPLE Cylinder block "11" (A) + Crankshaft "06" (B) =Total number 17 (Use bearing "3")
27. INSTALL STUD BOLT Install the stud bolts as shown in the illustration. Torque: Stud bolt A: 11 N.m (112 kgf.cm, 8.1 ft.lbf) Stud bolt B: 4.5 N in (46 kgf.cm, 40 in.lbf) Stud bolt C: 4.0 N.m (41 kgf.cm, 35 in.lbf)
28. INSTALL STRAIGHT PIN Using a plastic-faced hammer, tap into the straight pin. Standard protrusion: Pin A: 22.5-23.5 mm (0.886-0.925 in.) Pin B: 10.5-11.5 mm (0.413-0.453 in.) Pin C: 8.5-9.5 mm (0.335-0.374 in.) Pin D: 5.5-6.5 mm (0.217-0.256 in.)
29. INSTALL TIGHT PLUG Apply adhesive around tight plugs. Adhesive: part No. 08833-00070, THREE BOND 1324 or equivalent. Using SST, install the tight plugs as shown in the illustration. SST 09950-60010 (09951-00350), 09950-70010 (09951-07150) Standard depth: 0.2-1.2 mm (0.008-0.047 in.)
30. INSTALL OIL JET Using a screw driver and hemmer, tap in a oil jet.
31. INSTALL SUB-ASSY OIL NOZZLE NO.1 Using a 5 mm socket hexagon wrench, install the 3 oil nozzles. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
32. INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring at one side of the piston pin hole. HINT: Check that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston.
33. INSTALL W/PIN PISTON SUB-ASSY Gradually heat the piston to about 80°C (176°F). Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with thumb.
34. INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring on the other side of the piston pin hole. HINT: Be sure that an end of gap of the snap ring is not overlapped to the pin hole cutout portion of the piston.
35. INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings. NOTE: Install the compression ring No. 2 with the painted mark facing upward. Position the piston rings so that the ring ends are as shown.
36. INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting cap. NOTE: Clean the backside of the bearing and the bearing surface of the connecting rod and let not stick the oils and fats.
37. INSTALL CRANKSHAFT BEARING HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. Clean each main journal and bearing. Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTE: Do not apply engine oil to the bearing and its contact surface. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings. NOTE: Do not apply engine oil to the bearing and its contact surface. HINT: A number marked on each main bearing cap indicates the installation position.
38. INSTALL CRANKSHAFT Apply engine oil to upper bearing and install the crankshaft on the cylinder block. Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block. Push the crankshaft toward the front (rear) side. Install the 2 upper thrust washers with the oil grooves facing outward. Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward. Examine the front marks and numbers and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads of bearing cap bolts. Temporarily install the 8 main bearing cap bolts to the inside positions. Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes under 6 mm (0.23 in.). Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil on the threads of main bearing cap bolts. Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 61 N.m (622 kgf.cm, 45 ft.lbf) Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts 90° in the sequence as shown, (m) Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
39. INSTALL PISTON SUB-ASSY W/CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. Check the position of the piston ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTE: Clean the backside of the bearing and the bearing surface of the connecting rod cap and let not stick the oils and fats. Match the numbered connecting rod cap with the connecting rod. Check that the protrusion of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil on the threads of the connecting rod cap bolts. Using SST, tighten the bolts alternately with the specified torque. SST 09011-38121 Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) Mark the front side of the each connecting cap bolt with paint. Retighten the cap bolts 90° as shown. Check that the crankshaft turns smoothly.

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