Engine Mechanical (2UZ-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 4 bolts and engine hangers.
2. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Remove the 2 water drain cocks.
3. REMOVE SPARK PLUG
4. REMOVE OIL FILLER CAP SUB-ASSY
5. REMOVE OIL FILLER CAP HOUSING Remove the 2 nuts and oil filler cap housing.
6. REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
7. REMOVE CYLINDER HEAD COVER SUB-ASSY LH Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
8. REMOVE IDLER PULLEY SUB-ASSY NO. 2 Remove the pulley bolt, cover plate and idler pulley.
9. REMOVE TIMING BELT COVER SUB-ASSY NO. 2 Remove the 2 bolts and timing belt cover.
10. REMOVE V-RIBBED BELT TENSIONER ASSY Remove the bolt, 2 nuts and belt tensioner.
11. REMOVE FAN BRACKET SUB-ASSY Remove the 2 bolts, 2 nuts and fan bracket.
12. REMOVE CRANKSHAFT DAMPER SUB-ASSY Using SST, loosen the pulley bolt. SST 09213-7001 1 (90105-08076), 09330-00021 Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)
13. REMOVE TIMING BELT NO. 1 COVER Remove the 4 bolts and timing belt cover.
14. REMOVE TIMING GEAR COVER SPACER
15. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
16. SET NO. 1 CYLINDER TO TDC/COMPRESSION If re-using the timing belt, check the installation marks on the timing belt. Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration. If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Check that the timing marks of the camshaft timing pulleys and timing belt plates aligned. If not, turn the crankshaft 1 revolution (360°).
17. REMOVE TIMING BELT Set the No. 1 cylinder to approx. 50° BTDC/compression. Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx.50°. NOTE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle. Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley counterclockwise. SST 09960-10010 (09962-01000, 09963-00350) Disconnect the timing belt from the timing belt idler No. 1, and remove the timing belt.
18. INSPECT TIMING BELT NOTE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water or steam. Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects, as shown in the illustrations, check these points: Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation. If the belt teeth are cracked or damaged, check to see if either camshaft is locked. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt.
19. INSPECT CHAIN TENSIONER ASSY NO. 1 Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. NOTE: Never hold the tensioner push rod facing downward. Measure the protrusion of the push rod from the housing end. Protrusion: 9.5-10.5 mm (0.374-0.413 in.) If the protrusion is not as specified, replace the tensioner.
20. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the 2 bolt and 2 timing pulleys. SST 09960-10010 (09962-01000, 09963-01000)
21. REMOVE TIMING BELT IDLER SUB-ASSY NO. 1 Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.
22. REMOVE TIMING BELT IDLER SUB-ASSY NO. 2 Remove the bolt and idler.
23. INSPECT TIMING BELT IDLER Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. Check that the idler pulley turns smoothly. If necessary, replace the idler.
24. REMOVE CRANKSHAFT TIMING PULLEY Using SST, remove the timing pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) NOTE: Do not turn the timing pulley.
25. REMOVE TIMING BELT PLATE RR RH Remove the 3 bolts, stud bolt and timing belt plate RR RH.
26. REMOVE TIMING BELT PLATE RR LH Remove the 3 bolts and timing belt plate RR LH.
27. REMOVE CAMSHAFTS NOTE: Since 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 receiving 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. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a service bolt. Recommended service bolt: RECOMMENDED SERVICE BOLT Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16-20 mm (0.63-0.79 in.) HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown. Remove the oil feed pipe, 9 bearing caps, camshaft housing plug and 2 camshafts. Remove the camshafts of the LH bank. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a service bolt. Recommended service bolt: RECOMMENDED SERVICE BOLT Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16-20 mm (0.63-0.79 in.) HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown. Remove the oil feed pipe, 9 bearing caps, camshaft housing plug and 2 camshafts. HINT: Arrange the bearing caps in correct order.
28. REMOVE SEMICIRCULAR PLUG
29. REMOVE CAMSHAFT SETTING OIL SEAL
30. REMOVE CYLINDER HEAD SUB-ASSY Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown, then do the other side as shown. Remove the 20 cylinder head bolts and plate washers. NOTE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. 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. The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly. HINT: If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver.
31. INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 9.810-9.960 mm (0.3862-0.3921 in.) Minimum outside diameter: 9.700 mm (0.3819 in.)
32. REMOVE WATER PUMP ASSY Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. Remove the O-ring from the water bypass pipe.
33. REMOVE OIL PAN SUB-ASSY NO. 2 Remove the 17 bolts and 2 nuts. Insert the blade of SST between the No. 1 and No. 2 oil pans, cut off applied sealer and remove the No. 2 oil pan. SST 09032-00100 NOTE: Be careful not to damage the No. 2 oil pan contact surface of the No. 1 oil pan. Be careful not to damage the No. 2 oil pan flange.
34. REMOVE OIL PAN BAFFLE PLATE Remove the 2 bolts, 2 nuts and baffle plate.
35. REMOVE OIL PAN SUB-ASSY Remove the 18 bolts and 2 nuts. Using a screwdriver, remove the No. 1 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 No. 1 oil pan.
36. REMOVE OIL STRAINER SUB-ASSY Remove the 2 bolts, 2 nuts, oil strainer and gasket.
37. REMOVE OIL PUMP ASSY Remove the 7 bolts and stud bolt. HINT: Use a 6 mm hexagon wrench for the hexagon head bolt. Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block. NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pump. Remove the O-ring from the cylinder block.
38. REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 7 bolts. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap. Remove the O-ring.
39. REMOVE SPARK PLUG TUBE GASKET Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more. Using a screwdriver, pry out the gasket. NOTE: Be careful not to damage the cylinder head cover. Tape the screwdriver tip.
40. INSTALL SPARK PLUG TUBE GASKET Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09950-60010 (09951-00240, 09951-00440, 09952-06010), 09950-70010 (09951-07100) NOTE: Be careful of the installation direction. Apply a light coat of MP grease to the gasket lip. Return the 4 ventilation case claws to its original position.
41. REMOVE CAMSHAFT SUB GEAR Mount the hexagon wrench head portion of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, turn the sub gear clockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) Recommended service bolt: RECOMMENDED SERVICE BOLT Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16-20 mm (0.63-0.79 in.) Using snap ring pliers, remove the snap ring. Remove the wave washer, sub gear and gear bolt washer. HINT: Arrange the driven sub gears and gear bolt washers (RH and LH sides).
42. INSPECT CAMSHAFTS Inspect camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in) If the circle runout is greater than maximum, replace the camshaft. Inspect cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: intake 41.94-42.04 mm (1.6512-16.551 in.) Exhaust 41.96-42.06 mm (1.6520-1.6559 in.) Minimum cam lobe height: intake 41.79 mm (1.6453 in.) Exhaust 41.81 mm (1.6461 in.) If the cam lobe height is less than minimum, replace the camshaft. Inspect camshaft journals. Using a micrometer, measure the journal diameter. Journal diameter: 26.954-26.970 mm (1.0612-1.0618 in) If the journal diameter is not as specified, check the oil clearance.
43. INSPECT CAMSHAFT TIMING GEAR BOLT WASHER Using vernier calipers, measure the free distance between the washer ends. Free distance: 18.2-18.8 mm (0.717-0.740 in.) If the free distance is not as specified, replace the washer.
44. INSTALL CAMSHAFT SUB GEAR Install the gear bolt washer (1), sub gear (2) and wave washer (3). HINT: Attach the pins on the gears to the gear bolt washer ends. Using snap ring pliers, install the snap ring. Mount the hexagon wrench head portion of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt. Recommended service bolt: RECOMMENDED SERVICE BOLT Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16-20 mm (0.63-0.79 in.)
45. REMOVE OIL PUMP SEAL Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the oil pump body. Tape the screwdriver tip.
46. INSTALL OIL PUMP SEAL Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09316-6001 1 (09316-00011) Apply MP grease to the oil seal lip.
47. REMOVE ENGINE REAR OIL SEAL Using a screwdriver and hammer, tap out the oil seal.
48. 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 09223-56010 Apply MP grease to the oil seal lip.
49. 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. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the oil seal retainer as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 3-4 mm (0.12-0.16 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install a new O-ring to the cylinder block. Install the oil seal retainer with the 7 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
50. INSTALL OIL PUMP ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the oil pump as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Avoid applying an excessive amount to the surface. Be particularly careful near oil passage. Install a nozzle that has been cut to a 2-3 mm (0.08-0.12 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install a new O-ring to the cylinder block. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft. Install the oil pump with a new stud bolt and the 7 bolts. Uniformly tighten the bolts diagonally. NOTE: Do not reuse the stud bolt. HINT: Use a 6 mm hexagon wrench for the hexagon head bolt. The following chart is the reference to the oil pump bolt length. OIL PUMP BOLT LENGTH Bolt Size of Bolt Head Length A 12 mm 50 mm (1.97 in.) B 14 mm Stud Bolt 102.8 mm (4.047 in.) C 12 mm 35 mm (1.38 in.) D 14 mm 44 mm (1.73 in.) E 6 mm Hexagon 28 mm (1.10 in.) Torque: 16 N.m (158 kgf.cm, 11 ft.lbf) for bolt A, B, C and E 31 N.m (311 kgf.cm, 23 ft.lbf) for bolt D
51. INSTALL OIL STRAINER SUB-ASSY Install a new gasket and the oil strainer with the 2 bolts and 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) HINT: Use bolts 12 mm (0.47 in.) in length.
52. INSTALL STUD BOLT
53. 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 No. 1 oil pan, cylinder block, oil pump and rear oil seal retainer. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the No. 1 oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 3-5 mm (0.12-0.20 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Temporarily install the oil pan with the 18 bolts and 2 nuts. HINT: The following chart is the reference to the oil pump bolt length. OIL PUMP BOLT LENGTH Bolt Size of Bolt Head Length A 10 mm 20 mm (0.79 in.) B 12 mm 25 mm (0.98 in.) C 12 mm 60 mm (2.36 in.) D 10 mm 35 mm (1.38 in.) Set the oil pan as shown in the illustration. NOTE: Make sure the clearance between the rear end of the oil pan and cylinder block is 0.2 mm (0.008 in.) or less. If the clearance is more than 0.2 mm (0.008 in.), the oil pan will be stretched. Uniformly tighten the bolts and nuts diagonally. Torque: 7.5 N.m (76 kgf.cm, 66 in lbf) for bolt A and D 28 N in (286 kgf.cm, 21 ft.lbf) for bolt B, C and nut
54. INSTALL OIL PAN BAFFLE PLATE Install the baffle plate with the 2 bolts and 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) HINT: Use bolts 12 mm (0.47 in.) in length.
55. INSTALL OIL PAN SUB-ASSY NO. 2 Remove any oil packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No, 1 and No. 2 oil pans. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. NOTE: Do not use a solvent which will affect the painted surfaces. Apply seal packing to the No. 2 oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 3-5 mm (0.12-0.20 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the No. 2 oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) HINT: Use bolts 14 mm (0.55 in.) in length.
56. INSTALL WATER PUMP ASSY Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes. Torque: Bolt 21 N.m (214 kgf.cm, 15 ft.lbf) Stud bolt and nut 18 N.m (184 kgf.cm, 13 ft.lbf) HINT: Use bolts 35 mm (1.38 in.) in length.
57. INSTALL CYLINDER HEAD SUB-ASSY Place 2 new cylinder head gaskets in position on the cylinder block. HINT: On the rear side of the cylinder head gasket are marks to distinguish the LH and RH banks, a "2UR" mark for the RH bank and a "2UL" mark for the LH bank. NOTE: Be careful of the installation direction. Place the 2 cylinder heads in position on the cylinder head gaskets. Install the cylinder head bolts. HINT: The cylinder head bolts are tightened in 2 progressive 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 and under the heads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown, then do the other side as shown. Torque: 32 N.m (326 kgf.cm, 24 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 plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90° in the numerical order shown. Retighten the cylinder head bolts by an additional 90°. Check that the painted mark is now at a 180° angle to front.
58. INSTALL CAMSHAFTS NOTE: Since 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 receiving 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 damper bolt, turn the crankshaft, and set the set key of the crankshaft at the position of 90° counterclockwise from the timing mark (dot) of the oil pump body. 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. Install the camshafts of the RH bank. Apply MP grease to the thrust portion of the intake and exhaust camshafts. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts. Set the timing mark (1 dot mark) of the camshaft drive and driven main gears at approx. 10° angle. Apply seal packing to the camshaft housing plug. Remove the old packing (FIPG) material. Apply seal packing to the housing plug. Seal packing: Part No. 08826-00080 or equivalent Install the camshaft housing plug to the cylinder head as shown in the illustration. NOTE: Be careful of the installation direction. Apply seal packing to the front bearing cap. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove. Thoroughly clean all components to remove all the loose material. Using a non- residue solvent, clean both sealing surfaces. Apply seal packing to the bearing cap as shown in the illustration. Install a nozzle that has been cut to a 1.5-2.0 mm (0.059-0.079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Seal packing: Part No. 08826-00080 or equivalent NOTE: Do not apply seal packing to the front bearing cap grooves. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the other bearing caps in the sequence shown with the arrow mark facing forward. Push in a new camshaft setting oil seal. Install a new seal washer to the bearing cap bolt (A and B). Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E). NOTE: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). HINT: Each bolt length is indicated in the illustration. Bolt length: 94 mm (3.70 in.) for A with seal washer 72 mm (2.83 in.) for B with seal washer 25 mm (0.98 in.) for C 55 mm (2.17 in.) for D 40 mm (1.57 in.) for E Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) for bolt C 16 N.m (163 kgf.cm, 12 ft.lbf) for others Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. Remove the service bolt. Install the camshafts of the LH bank. Apply MP grease to the thrust portion of the camshafts. Align the timing marks (2 dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts. Apply seal packing to the camshaft housing plug. Remove the old packing (FIPG) material. Apply seal packing to the housing plug. Seal packing: Part No. 08826-00080 or equivalent Install the camshaft housing plug to the cylinder head as shown in the illustration. NOTE: Be careful of the installation direction. Apply seal packing to the front bearing cap. Remove any old packing (FIPG) material and be care not to drop any oil on the contact surfaces of the bearing cap and cylinder head. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove. Thoroughly clean all components to remove all the loose material. Using a non- residue solvent, clean both sealing surfaces. Apply seal packing to the bearing cap as shown in the illustration. Install a nozzle that has been cut to a 1.5-2.0 mm (0.059-0.079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Seal packing: Part No. 08826-00080 or equivalent NOTE: Do not apply seal packing to the front bearing cap grooves. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the other bearing cap in the sequence shown with the arrow mark facing forward. Push in a new camshaft setting oil seal. Install a new seal washer to the bearing cap bolt (A and B). Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E). NOTE: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). HINT: Each bolt length is indicated in the illustration. Bolt length: 94 mm (3.70 in.) for A with seal washer 72 mm (2.83 in.) for B with seal washer 25 mm (0.98 in.) for C 55 mm (2.17 in.) for D 40 mm (1.57 in.) for E Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) for bolt C 16 N.m (163 kgf.cm, 12 ft.lbf) for others Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. Remove the service bolt.
59. INSTALL TIMING BELT PLATE RR RH Install the timing belt plate with 3 the bolts and stud bolt. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
60. INSTALL TIMING BELT PLATE RR LH Install the timing belt plate with the 3 bolts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
61. INSTALL CRANKSHAFT TIMING PULLEY Align the timing pulley set key with the key groove of the pulley. Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-4601 1
62. INSTALL TIMING BELT IDLER SUB-ASSY NO. 2 Install the idler with the bolt. Torque: 35 N.m (352 kgf.cm, 25 ft.lbf) Check that the idler moves smoothly.
63. INSTALL TIMING BELT IDLER SUB-ASSY NO. 1 Apply adhesive 2 or 3 threads of the pivot bolt. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt. Torque: 35 N.m (352 kgf.cm, 25 ft.lbf) Check that the idler bracket moves smoothly.
64. INSTALL CAMSHAFT TIMING PULLEYS Align the camshaft knock pin with the knock pin grove of the timing pulley, and side on the timing pulley. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 N.m (1, 101 kgf.cm, 80 ft.lbf)
65. INSTALL TIMING BELT NOTE: The engine should be cold. Set the No. 1 cylinder to TDC/compression. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates aligned. HINT: Setting positions of the camshaft timing pulleys by turning them slightly clockwise makes it easy to install the timing belt: Camshaft timing pulley of LH bank: 1/2 teeth Camshaft timing pulley of RH bank: 1 tooth Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Install the timing belt. Remove any oil or water on the each pulley, and keep them clean. NOTE: Only wipe the pulleys; do not use any cleansing agent. Face the front mark (arrow) on the timing belt forward. Connect the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. Connect the timing belt to the idler No. 2. Connect the timing belt to the camshaft timing pulley LH. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. Connect the timing belt to the water pump pulley. Connect the timing belt to the camshaft timing pulley (RH bank). Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. Connect the timing belt to the idler No. 1. Set the belt tensioner. Using a press, slowly press in the push rod using 981-9, 807 N (100-1, 000 kgf, 220-2, 205 lbf) of pressure. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. Release the press. Install the dust boot to the belt tensioner. Install the belt tensioner. Temporarily install the belt tensioner with the 2 bolts. Alternately tighten the 2 bolts. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner. Check the valve timing. Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTE: Always turn the crankshaft pulley clockwise. Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it.
66. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 Install the sensor plate, facing the cup side outward.
67. INSTALL TIMING GEAR COVER SPACER Install the gasket to the cover spacer. Install the cover spacer.
68. INSTALL TIMING BELT NO. 1 COVER Install the timing belt cover with the 4 bolts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
69. INSTALL CRANKSHAFT DAMPER SUB-ASSY Using SST and a hammer, tap in the crankshaft damper. SST 09223-4601 1 Using SST, install the damper bolt. SST 09213-7001 1 (90105-08076), 09330-00021 Torque: 245 N.m (2, 498 kgf.cm, 181 ft.lbf) Align the pulley set key with the key groove of the crankshaft damper.
70. INSPECT VALVE CLEARANCE (See «ADJUSTMENT»(ref-235152-S17461996472006061400000) )
71. ADJUST VALVE CLEARANCE (See «ADJUSTMENT»(ref-235152-S17461996472006061400000) )
72. INSTALL FAN BRACKET SUB-ASSY Install the idler pulley with the 2 bolts and 2 nuts. Torque: 16 N.m (163 kgf.cm, 12 ft.lbf) for 12 mm head 32 N.m (326 kgf.cm, 24 ft.lbf) for 14 mm head HINT: Each bolt length is indicated in the illustration. Bolt Length: 106 mm (4.17 in.) for 12 mm head (A) 114 mm (4.49 in.) for 14 mm head (B)
73. INSTALL V-RIBBED BELT TENSIONER ASSY Install the belt tensioner with the bolt and 2 nuts. Torque: 16 N.m (158 kgf.cm, 11 ft.lbf) HINT: Use a bolt 106 mm (4.17 in.) in length.
74. INSTALL TIMING BELT COVER SUB-ASSY NO. 2 Fit the timing belt cover, matching the claws and pin with each part. Install the timing belt cover with the 2 bolts. Torque: 16 N.m (163 kgf.cm, 12 ft.lbf) HINT: Use bolts 106 mm (4.17 in.) in length.
75. INSTALL IDLER PULLEY SUB-ASSY NO. 2 Install the idler pulley and cover plate with the bolt. Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
76. INSTALL SEMICIRCULAR PLUG Remove any old packing (FIPG) material. Apply seal packing to the semicircular plug grooves. Seal packing: Part No. 08826-00080 or equivalent Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.
77. INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the seal washer to the bolt. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes. Torque: 6.0 N.m (61 kgf.cm, 53 in..lbf)
78. INSTALL OIL FILLER CAP HOUSING Install a new gasket and the oil filler cap housing with the 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
79. INSTALL OIL FILLER CAP SUB-ASSY
80. INSTALL SPARK PLUG Torque: 18 N.m (178 kgf.cm, 13 ft.lbf)
81. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Apply seal packing to 2 or 3 threads. Seal packing: Part No. 08826-00100 or equivalent Install the 2 drain unions. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.
82. INSTALL ENGINE HANGER NO. 1 Install the 2 engine hangers with 4 bolts. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)

Scheme 724

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 VALVE LIFTER Remove the valve lifter and adjusting shim. HINT: Arrange the valve lifters and shims in correct order.
2. REMOVE INTAKE VALVE Using SST, compress the compression spring and remove the 2 keepers. SST 09202-70020 (09202-01010) Remove the spring retainer, compression spring, valve and spring seat. HINT: Arrange the valves, compression springs, spring seats and spring retainers in correct order.
3. REMOVE EXHAUST VALVE Using SST, compress the compression spring and remove the 2 keepers. SST 09202-70020 (09202-00010) Remove the spring retainer, compression spring, valve and spring seat. HINT: Arrange the valves, compression springs, spring seats and spring retainers in correct order.
4. REMOVE VALVE STEM OIL O SEAL OR RING Using needle-nose pliers, remove the oil seal.
5. INSPECT CYLINDER HEAD SUB-ASSY Clean the cylinder head. 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 cylinder block contact surface. Using a valve guide bushing brush and solvent, clean all the guide bushes. Using a soft brush and solvent, thoroughly clean the cylinder head. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head. Inspect for cracks. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
6. INSPECT VALVE Clean the valves. Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.470-5.485 mm (0.2154-0.2159 in.) Exhaust 5.465-5.480 mm (0.2152-0.2157 in.) Check the 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° Check the valve head margin thickness. Standard margin thickness: Intake 1.25 mm (0.049 in.) Exhaust 1.4 mm (0.055 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. Check the valve overall length. Standard overall length: Intake 95.05 mm (3.7421 in.) Exhaust 95.10 mm (3.7441 in.) Minimum overall length: Intake 94.55 mm (3.7224 in.) Exhaust 94.60 mm (3.7244 in.) If the overall length is less than minimum, replace the valve. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTE: Do not grind off more than minimum.
7. INSPECT INNER COMPRESSION SPRING Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. Using vernier calipers, measure the free length of the valve spring. Free length: 54.1 mm (2.130 in.) If the free length is not as specified, replace the valve spring. Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 210-226 N (21.4-23.0 kgf, 47.2-50.7 lbf) at 35.0 mm (1.378 in.) If the installed tension is not as specified, replace the valve spring.
8. INSPECT VALVE GUIDE BUSH Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510-5.530 mm (0.2169-0.2177 in.) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: 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: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bush.
9. REMOVE VALVE GUIDE BUSH Gradually heat the cylinder head to 80-100°C (176-212°F). Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01060), 09950-70010 (09951-07100)
10. INSTALL VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Select a new guide bush (STD or O/S 0.05). GUIDE BUSH REFERENCE Bush bore diameter Bush size 10.285-10.306 mm (0.4049-0.4057 in) Use STD 10.335-10.356 mm (0.4069-0.4077 in) Use O/S 0.05 If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to this dimension of 10.335-10.356 mm (0.4069-0.4077 in.). If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. HINT: Different the bushes are used for the intake and exhaust. Gradually heat the cylinder head to 80-100°C (176-212°F). Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01060), 09950-70010 (09951-07100) Protrusion height: Intake 9.2-9.8 mm (0.362-0.386 in.) Exhaust 8.2-8.8 mm (0.323-0.346 in.) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.
11. INSPECT VALVE SEAT Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. Check the valve seating position. Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. Check the valve face and seat for the following: 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 these width: Width: 1.0-1.4 mm (0.039-0.055 in.)
12. REPAIR VALVE SEAT 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 60° and 45° 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.
13. INSPECT VALVE LIFTER Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000-31.016 mm (1.2205-1.2211 in.) Using a micrometer, measure the lifter diameter at the 12.3-12.7 mm (0.484-0.500 in.) from the top surface. Lifter diameter: 30.968-30.976 mm (1.2192-1.2195 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024-0.050 mm (0.0009-0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.
14. INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. Place the camshafts on the cylinder head. Lay a strip of plastigage across each of the camshaft journals. Install the bearing caps. (See «OVERHAUL»(ref-235152-S39920773902006061400000) ) Torque: 16 N.m (163 kgf.cm, 12 ft.lbf) NOTE: Do not turn the camshaft. Remove the bearing caps. Measure the plastigage at its widest point. Standard oil clearance: 0.030-0.071 mm (0.0012-0.0028 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Completely remove the plastigage. Remove the camshafts.
15. INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. (See «OVERHAUL»(ref-235152-S39920773902006061400000) ) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: Intake 0.040-0.090 mm (0.0016-0.0035 in.) Exhaust 0.030-0.075 mm (0.0012-0.0030 in.) Maximum thrust clearance: Intake 0.12 mm (0.0047 in.) Exhaust 0.1 mm (0.0039 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Remove the camshafts.
16. INSPECT CAMSHAFT GEAR BACKLASH Install the camshafts without installing the exhaust cam-sub-gear and front bearing cap. (See «OVERHAUL»(ref-235152-S39920773902006061400000) ) Using a dial indicator, measure the backlash. Standard backlash: 0.020-0.200 mm (0.0008-0.0079 in.) Maximum backlash: 0.30 mm (0.0118 in.) If the backlash is greater than maximum, replace the camshafts. Remove the camshafts.
17. INSTALL TIGHT PLUG NO. 1 Apply adhesive to the tight plug. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using SST and a hammer, tap in a new tight plug as shown in the illustration. SST 09950-60010 (09951-00300), 09950-70010 (09951-07100)
18. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
19. INSTALL STUD BOLT
20. INSTALL VALVE STEM OIL O SEAL OR RING Using SST, push in a new oil seal. HINT: The oil seal for intake is brown and the oil seal for exhaust is gray. SST 09201-41020
21. INSTALL VALVE Install these parts: Valve Spring seat Valve spring Spring retainer Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00010) Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to assure proper fit. NOTE: Be careful not do damage the valve stem tip.
22. INSTALL VALVE LIFTER Install the valve lifter and shim. Check that the valve lifter rotates smoothly by hand.

Scheme 771

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. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160-0.290 mm (0.0063-0.0114 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly (s). If necessary, replace the crankshaft. Connecting rod thickness: 22.880-22.920 mm (0.9008-0.9024 in.)
2. INSPECT CONNECTING ROD OIL CLEARANCE Check the matchmarks on the connecting rod and cap ensure correct reassembly. Remove the 2 connecting rod cap bolts. Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of plastigage across the crank pin. Match the numbered connecting rod cap with the connecting rod. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap. Check that the outside mark of the connecting rod cap is facing in correct direction. HINT: The connecting rod cap bolts are tightened in 2 progressive steps. If any one of the connecting rod cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) NOTE: Do not turn the crankshaft. If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. Mark the front of the connecting cap bolts with paint. Retighten the cap bolts 90° as shown. Check that the painted mark is now at a 90° angle to the front. Remove the 2 bolts, connecting rod cap and lower bearing. Measure the plastigage at its widest point. Standard oil clearance: 0.027-0.053 mm (0.0011-0.0021 in.) Maximum oil clearance: 0.065 mm (0.0026 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a standard 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 connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7". EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4") Reference Connecting rod big end inside diameter: CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATION Mark "1" 55.000-55.006 - mm (2.1654-2.1656 in.) Mark "2" 55.006-55.012 - mm (2.1656-2.1658 in.) Mark "3" 55.012-55.018 - mm (2.1658-2.1661 in.) Mark "4" 55.018-55.024 - mm (2.1661-2.1663 in.) Crankshaft crank pin diameter: CRANKSHAFT CRANK PIN DIAMETER SPECIFICATION Mark "1" 51.994-52.000 mm (2.0470-2.0472 in.) Mark "2" 51.988-51.994 mm (2.0468-2.0470 in.) Mark "3" 51.982-51.988 mm (2.0465-2.0468 in.) Standard sized bearing center wall thickness: STANDARD SIZED BEARING CENTER WALL THICKNESS SPECIFICATION Mark "2" 1.484-1.487 mm (0.0584-0.0585 in.) Mark "3" 1.487-1.490 mm (0.0585-0.0587 in.) Mark "4" 1.490-1.493 mm (0.0587-0.0588 in.) Mark "5" 1.493-1.496 mm (0.0588-0.0589 in.) Mark "6" 1.496-1.499 mm (0.0589-0.0590 in.) Mark "7" 1.499-1.502 mm (0.0590-0.0591 in.) Completely remove the plastigage.
3. REMOVE PISTON AND 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 bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in correct order.
4. REMOVE PISTON Check fit between the piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. HINT: Arrange the piston rings in correct order only. Using a small screwdriver, pry out the 2 snap rings. Gradually heat the piston to approx. 60°C (140°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 correct order.
5. 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: 0.020-0.220 mm (0.0008-0.0087 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. Thrust washer thickness: THRUST WASHER THICKNESS SPECIFICATION STD 2.440-4.490 mm (0.0961-0.0980 in.) O/S0.125 2.503-2.553 mm (0.0985-0.1005 in.)
6. INSPECT CRANKSHAFT OIL CLEARANCE Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several passes, in the sequence shown. Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only). NOTE: Be careful not to damage the cylinder block. HINT: Keep the lower bearing and crankshaft bearing cap together. Arrange the crankshaft bearing caps and lower thrust washers in correct order. Lift out the crankshaft. Remove the 2 upper thrust washers. HINT: Arrange the upper thrust washers in correct order. Keep the upper bearings together with the cylinder block. Clean each crankshaft journal and bearing. Check each crankshaft journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Place the crankshaft on the cylinder block, (h) Lay a strip of plastigage across each journal. Install the 5 crankshaft bearing caps in their proper locations. HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any one of the main bearing cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts. Install and uniformly tighten the 10 crankshaft bearing cap bolts in several passes, in the sequence shown. Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) NOTE: Do not turn the crankshaft. If any one of the crankshaft bearing cap bolts does not meet the torque specification, replace the crankshaft bearing cap bolt. Mark the front of the crankshaft n bearing cap bolt with paint. Retighten the crankshaft bearing cap bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. Remove the crankshaft bearing caps. Measure the plastigage at its widest point. Standard clearance: STANDARD CLEARANCE SPECIFICATION No.1 and No.5 0.028-0.046 mm (0.0011-0.0018 in.) Others 0.040-0.058 mm (0.0016-0.0023 in.) Maximum clearance: MAXIMUM CLEARANCE SPECIFICATION No.1 and No.5 0.065 mm (0.0026 in.) Others 0.065 mm (0.0026 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a standard 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 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For others position bearings, use bearings marked "1", "2", "3", "4" and "5". No. 1, No. 5: EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5") Others: EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3") Reference Cylinder block crankshaft journal bore diameter (A): CYLINDER BLOCK CRANKSHAFT JOURNAL BORE DIAMETER (A) REFERENCE Mark "00" 72.000 mm (2.8347 in.) Mark "01" 72.001 mm (2.8347 in.) Mark "02" 72.002 mm (2.8347 in.) Mark "03" 72.003 mm (2.8348 in.) Mark "04" 72.004 mm (2.8348 in.) Mark "05" 72.005 mm (2.8348 in.) Mark "06" 72.006 mm (2.8349 in.) Mark "07" 72.007 mm (2.8349 in.) Mark "08" 72.008 mm (2.8350 in.) Mark "09" 72.009 mm (2.8350 in.) Mark "10" 72.010 mm (2.8350 in.) Mark "11" 72.011 mm (2.8351 in.) Mark "12" 72.012 mm (2.8351 in.) Mark "13" 72.013 mm (2.8352 in.) Mark "14" 72.014 mm (2.8352 in.) Mark "15" 72.015 mm (2.8352 in.) Mark "16" 72.016 mm (2.8353 in.) Crankshaft journal diameter (B): CRANKSHAFT JOURNAL DIAMETER (B)REFERENCE Mark "00" 67.000 mm (2.6378 in.) Mark "01" 66.999 mm (2.6378 in.) Mark "02" 66.998 mm (2.6377 in.) Mark "03" 66.997 mm (2.6377 in.) Mark "04" 66.996 mm (2.6376 in.) Mark "05" 66.995 mm (2.6376 in.) Mark "06" 66.994 mm (2.6376 in.) Mark "07" 66.993 mm (2.6375 in.) Mark "08" 66.992 mm (2.6375 in.) Mark "09" 66.991 mm (2.6374 in.) Mark "10" 66.990 mm (2.6374 in.) Mark "11" 66.989 mm (2.6374 in.) Mark "12" 66.988 mm (2.6373 in.) Standard bearing center wall thickness: No. 1 and No. 5 STANDARD BEARING CENTER WALL THICKNESS SPECIFICATION (NO. 1 AND 5) Mark "3" 2.487-2.490 mm (0.0979-0.0980 in.) Mark "4" 2.490-2.493 mm (0.0980-0.0982 in.) Mark "5" 2.493-2.496 mm (0.0982-0.0983 in.) Mark "6" 2.496-2.499 mm (0.0983-0.0984 in.) Mark "7" 2.499-2.502 mm (0.0984-0.0985 in.) Others STANDARD BEARING CENTER WALL THICKNESS SPECIFICATION (OTHERS) Mark "1" 2.481-2.484 mm (0.0977-0.0978 in.) Mark "2" 2.484-2.487 mm (0.0978-0.0979 in.) Mark "3" 2.487-2.490 mm (0.0979-0.0980 in.) Mark "4" 2.490-2.493 mm (0.0980-0.0982 in.) Mark "5" 2.493-2.496 mm (0.0982-0.0983 in.) Completely remove the plastigage.
7. REMOVE CRANKSHAFT Lift up the crankshaft. Remove the 5 upper crankshaft bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the crankshaft bearing caps, bearings and thrust washers in correct order.
8. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY
9. CLEAN CYLINDER BLOCK SUB-ASSY Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
10. INSPECT CYLINDER BLOCK SUB-ASSY Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and crankshaft bearing cap for warpage. Maximum warpage: 0.07 mm (0.0028 in.) If warpage is greater than maximum, replace the cylinder block sub-assy. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block. Inspect the cylinder bore diameter. HINT: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: CYLINDER BORE STANDARD DIAMETER SPECIFICATION STD Mark "1" 94.002-94.010 mm (3.7009-3.7012 in.) STD Mark "2" 94.010-94.023 mm (3.7012-3.7017 in.) STD Mark "3" 94.023-94.031 mm (3.7017-3.7020 in.) Maximum diameter: 94.230 mm (3.5917 in.) CYLINDER BORE MAXIMUM DIAMETER SPECIFICATION STD 94.231 mm (3.7099 in.) O/S 0.50 94.731 mm (3.7296 in.) If the diameter is greater than maximum, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block. Remove the cylinder ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
11. INSPECT PISTON Clean the piston. Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush. Inspect the piston oil clearance. HINT: There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. Piston diameter: PISTON DIAMETER SPECIFICATION STD Mark "1" 93.902-93.912 mm (3.6969-3.6973 in.) STD Mark "2" 93.912-93.920 mm (3.6973-3.6976 in.) STD Mark "3" 93.920-93.930 mm (3.6976-3.6980 in.) O/S 0.50 94.402-94.430 mm (3.7168-3.7177 in.) Measure the cylinder bore diameter in the thrust directions. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.090-0.111 mm (0.0035-0.0044 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than maximum, replace all the 8 pistons and rebore all the 8 cylinders. If necessary, replace the cylinder block. HINT: Use a new cylinder block: Use a piston with the same number mark as the cylinder diameter marked on the cylinder block. The shape of the piston varies for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R". Inspect the piston pin fit. At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb. Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997-22.009 mm (0.8660-0.8664 in.)
12. INSPECT PISTON RING SET Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: RING GROOVE CLEARANCE SPECIFICATION No.1 0.030-0.080 mm (0.0012-0.0032 in.) No. 2 0.030-0.070 mm (0.0012-0.0028 in.) If the clearance is not as specified, replace the piston. Inspect the piston ring end gap. Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap: STANDARD RING END GAP SPECIFICATION No. 1 0.300-0.400 mm (0.0118-0.0158 in.) No. 2 0.400-0.550 mm (0.0158-0.0217 in.) Oil (Side rail) 0.130-0.380 mm (0.0051-0.0150 in.) Maximum end gap: MAXIMUM END GAP SPECIFICATION No. 1 1.10 mm (0.0433 in.) No. 2 1.20 mm (0.0472 in.) Oil (Side rail) 1.15 mm (0.0453 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, rebore all the 8 cylinders or replace the cylinder block sub-assy.
13. INSPECT CONNECTING ROD SUB-ASSY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod sub-assy. Check for 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. Inspect the piston pin oil clearance. 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.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997-22.009 mm (0.8660-0.8664 in.) 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: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the connecting rod sub-assy. If necessary, replace the piston and piston pin as a set.
14. INSPECT CONNECTING ROD BOLT Using vernier calipers, measure the tension portion of the connecting rod bolt. Standard diameter: 7.200-7.300 mm (0.2835-0.2874 in.) Minimum diameter: 7.00 mm (0.2756 in.) If the diameter is less than minimum, replace the bolt.
15. INSPECT CRANKSHAFT BEARING CAP BOLT Using vernier calipers, measure the thread outside diameter of the crankshaft bearing cap bolt. Standard diameter: 10.760-10.970 mm (0.4236-0.4319 in.) Minimum diameter: 10.40 mm (0.4094 in.) If the diameter is less than minimum, replace the cap bolt.
16. INSPECT CRANKSHAFT Inspect for circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in.) If the circle runout is greater than maximum, replace the crankshaft. Inspect the crankshaft journals and crank pins. Using a micrometer, measure the diameter of each crankshaft journal and crank pin. Crankshaft journal diameter: 66.988-67.000 mm (2.6373-2.6378 in.) Crank pin diameter: 51.982-52.000 mm (2.0465-2.0472 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crankshaft journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than maximum, replace the crankshaft.
17. INSTALL TIGHT PLUG Apply adhesive to the tight plug. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using SST and a hammer, tap in a new tight plug as shown in the illustration. SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
18. INSTALL STUD BOLT
19. INSTALL STRAIGHT PIN
20. INSTALL RING PIN
21. INSTALL PISTON Using a small screwdriver, install a new snap ring on one side of the piston pin hole. Gradually heat the piston to about 60°C (140°F). Coat the piston pin with engine oil. Position the piston front mark with respect to the outside mark on the connecting rod as shown in the illustration. NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R". Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
22. 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 with the code mark facing upward. Code mark: COMPRESSION RING CODE MARK REFERENCE No. 1 1R No. 2 2R Position the piston rings so that the ring ends are as shown. NOTE: Do not align the ring ends.
23. INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting cap. Install the bearings in the connecting rod and connecting rod cap.
24. INSTALL CRANKSHAFT BEARING HINT: Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions. Upper bearings have an oil groove and oil holes; lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings. HINT: A number is marked on each bearing cap to indicate the installation position.
25. INSTALL CRANKSHAFT THRUST WASHER SET Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
26. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
27. INSTALL CRANKSHAFT Place the crankshaft on the cylinder block. Install the 5 crankshaft bearing caps in their proper locations. HINT: Place the bearing caps level and let them return to their original position by their own weight. NOTE: Do not install the bearing cap by tapping it. Install the crankshaft bearing cap bolts. HINT: The bearing cap bolts are tightened in 2 progressive steps. If any one of the bearing cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts. Install and uniformly tighten the 10 crankshaft bearing cap bolts in several passes, in the sequence shown. Torque: 27 Nm (275 kgfcm, 20 ft-lbf) If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt. Mark the front of the crankshaft bearing cap bolt with paint. Retighten the crankshaft bearing cap bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. Install a new seal washer to the crankshaft bearing cap bolt. Check that the crankshaft turns smoothly.
28. INSTALL PISTON AND CONNECTING ROD 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: The shape of the piston varies for the LH and RH banks. The LH piston is marked with "LH" and "2R", the RH piston with "RH" and "2R. Place the connecting rod cap on the connecting rod. Match the numbered connecting rod cap with the connecting rod. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap. Check that the outside mark of the connecting rod cap is facing in correct direction. Install the connecting rod cap bolts. HINT: The connecting rod cap bolts are tightened in 2 progressive steps. If any one of the connecting rod cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. Mark the front of the connecting cap bolt with paint. Retighten the cap bolts 90° as shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.

Scheme 850

Scheme 851

Scheme 852

Scheme 853

Scheme 854

Scheme 855

Scheme 856

Scheme 857

Scheme 858

Scheme 859

Scheme 860

Scheme 861

Scheme 862

Scheme 863

Scheme 864

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Scheme 866

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Scheme 868

Scheme 869

Scheme 870

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Scheme 872

Scheme 873

1. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S38479857142006061400000) )
2. SEPARATE BATTERY NEGATIVE TERMINAL
3. REMOVE THROTTLE BODY COVER SUB-ASSY Remove the 2 cap nuts and throttle body cover sub-assy.
4. REMOVE AIR CLEANER HOSE ASSY
5. REMOVE RADIATOR SUPPORT SEAL UPPER Remove the 11 clips and radiator support seal upper.
6. REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235152-S25929235362006061400000) )
7. REMOVE FAN W/ FLUID COUPLING Unfasten each clip the 2 hose clamps, and then separate the 2 oil cooler hoses from fan shroud. Remove the 3 bolts and separate the fan shroud from radiator. Remove the 4 nuts and separate the fan w/ fluid coupling from engine. Remove the fan shroud and fan w/ fluid coupling from the vehicle at the same time.
8. SEPARATE VANE PUMP ASSY Disconnect the vacuum hose. Remove the nut, 2 bolts and vane pump assy. HINT: Hand up the hoses instead of detaching.
9. REMOVE GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
10. SEPARATE COMPRESSOR Remove the nut, 3 bolts compressor stay and compressor. HINT: Hang up the hoses instead of detaching.
11. REMOVE IDLER PULLEY SUB-ASSY NO. 2 Remove the bolt and idler pulley sub-assy.
12. REMOVE OIL COOLER PIPE Disconnect the 3 hoses. Remove the bolt, nut and oil cooler pipe.
13. REMOVE TIMING BELT COVER SUB-ASSY NO. 3 LH Remove the grommet and separate the cam position sensor connector and cam position sensor wire from timing belt cover sub-assy No. 3 LH. Disconnect the 3 wire harness clamps. Remove the 4 bolts and timing belt cover sub-assy No. 3 LH.
14. REMOVE TIMING CHAIN OR BELT COVER NO. 2 Remove the nut, 3 bolts and timing belt cover No. 2.
15. REMOVE TIMING BELT COVER SUB-ASSY NO. 2 Remove the 2 bolts and timing belt cover sub-assy No. 2.
16. REMOVE V-RIBBED BELT TENSIONER ASSY Remove the bolt 2 nuts and v-ribbed belt tensioner.
17. REMOVE FAN BRACKET SUB-ASSY Remove the 2 nuts, 2 bolts and fan bracket sub-assy with fan pulley.
18. REMOVE CRANKSHAFT DAMPER SUB-ASSY Using SST, remove the pulley bolt. SST 09213-7001 1 (09213-70020), 09330-00021 Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)
19. REMOVE TIMING BELT NO. 1 COVER Remove the 4 bolts and timing belt cover.
20. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
21. REMOVE TIMING BELT If re-using the timing belt, check the installation marks on the timing belt. Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration. If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part. Set the No. 1 cylinder to approx. 50° BTDC/compression. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Check that the timing marks of the camshaft timing pulleys and timing belt plates aligned. If not, turn the crankshaft 1 revolution (360°). Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 50°. NOTE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle. Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise. SST 09960-10010 (09962-01000, 09963-01000) Disconnect the timing belt from the timing belt idler No. 1, and remove the timing belt.
22. INSTALL TIMING BELT Check the timing belt idler No. 1 and No. 2. Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler. Check that the idler turns smoothly. If necessary, replace the idler. Check the water pump. Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump and timing belt. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, idler No. 1 and idler No. 2, and keep them clean. NOTE: Only wipe the pulleys; do not use any cleansing agent. Set the No. 1 cylinder to TDC/compression. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates aligned. HINT: Setting positions of the camshaft timing pulleys by turning them slightly clockwise makes it easy to install the timing belt: Camshaft timing pulley of LH bank: 1/2 teeth Camshaft timing pulley of RH bank: 1 tooth Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Install the timing belt. Remove any oil or water on the each pulley, and keep them clean. NOTE: Only wipe the pulleys; do not use any cleansing agent. Face the front mark (arrow) on the timing belt forward. Connect the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. Connect the timing belt to the idler No. 2. Connect the timing belt to the camshaft timing pulley (LH.bank). Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. Connect the timing belt to the water pump pulley. Connect the timing belt to the camshaft timing pulley (RH bank). Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. Connect the timing belt to the idler No.1. Set the belt tensioner. Using a press, slowly press in the push rod using 981-9, 807 N (100-1, 000 kgf, 220-2, 205 lbf) of pressure. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. Release the press. Install the dust boot to the belt tensioner. Install the belt tensioner. Temporarily install the belt tensioner with the 2 bolts. Alternately tighten the 2 bolts. Torque: 26 N.m (270 kgf.cm, 19 ft.lbf) Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner. Check the valve timing. Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTE: Always turn the crankshaft pulley clockwise. Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it. Remove the crankshaft damper bolt.
23. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 Install the crank angle sensor plate as shown in the illustration. NOTE: Take care not to install it in the wrong direction.
24. INSTALL TIMING BELT NO. 1 COVER Install the timing belt cover with the 4 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)
25. INSTALL CRANKSHAFT DAMPER SUB-ASSY Using SST and a hammer, tap in the crankshaft damper. SST 09223-4601 1 Using SST, install the damper bolt. SST 09213-7001 1 (09213-70020), 09330-00021 Torque: 245 N.m (2, 500 kgf.cm, 181 ft.lbf) Align the damper set key with the key groove of the crankshaft damper.
26. INSTALL FAN BRACKET SUB-ASSY Install the fan bracket with the 2 bolts and 2 nuts. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) for 12 mm head 32 N.m (330 kgf.cm, 24 ft.lbf) for 14 mm head
27. INSTALL V-RIBBED BELT TENSIONER ASSY Install the belt tensioner with the bolt and 2 nuts. Torque: Bolt 16 N.m (160 kgf.cm, 12 ft.lbf) Nut 16 N.m (160 kgf.cm, 12 ft.lbf)
28. INSTALL TIMING BELT COVER SUB-ASSY NO. 2 Fit the timing belt cover, matching the claws and pin with each part. Install the timing belt cover with the 2 bolts. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf)
29. INSTALL TIMING BELT COVER SUB-ASSY NO. 3 LH Install the timing belt cover sub-assy with 4 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf) Install the cam position sensor connector and grommet to the timing belt cover.
30. INSTALL TIMING CHAIN OR BELT COVER NO. 2 Install the timing chain or belt cover with the nut and 3 bolts. Torque: Bolt 7.5 N.m (80 kgf.cm, 66 in..lbf) Nut 7.5 N.m (80 kgf.cm, 66 in..lbf)
31. INSTALL OIL COOLER PIPE Install the oil cooler pipe with bolt and nut. Torque: Bolt 7.5 N.m (80 kgf.cm, 66 in..lbf) Nut 7.5 N.m (80 kgf.cm, 66 in..lbf) Connect the 3 hoses.
32. INSTALL IDLER PULLEY SUB-ASSY NO. 2 Install the idler pulley with the bolt. Torque: 39 N.m (400 kgf.cm, 24 ft.lbf)
33. INSTALL COMPRESSOR Install the compressor with stay, nut and 3 bolts. Torque: Bolt 47 N.m (475 kgf.cm, 34 ft.lbf) Nut 25 N.m (255 kgf.cm, 18 ft.lbf)
34. INSTALL GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
35. INSTALL VANE PUMP ASSY Install the vane pump assy with nut and 2 bolts. Torque: Bolt 43 N.m (438 kgf.cm, 32 ft.lbf) Nut 43 N.m (438 kgf.cm, 32 ft.lbf)
36. INSTALL FAN W/ FLUID COUPLING Put the fan w/ fluid coupling and fan shroud into the engine room at the same time. Install the fan shroud with 3 bolts. Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) Install the fan w/ fluid coupling with 4 nuts. Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)
37. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235152-S25929235362006061400000) )
38. INSTALL RADIATOR SUPPORT SEAL UPPER
39. INSTALL AIR CLEANER HOSE ASSY
40. INSTALL THROTTLE BODY COVER SUB-ASSY Install the throttle body cover sub-assy with 2 nuts. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)
41. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S38479857142006061400000) )
42. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-235178-S31831565622006061400000) )

Scheme 874

Scheme 875

Scheme 876

Scheme 877

Scheme 878

Scheme 879

Scheme 880

Scheme 881

Scheme 882

Scheme 883

Scheme 884

Scheme 885

Scheme 886

Scheme 887

Scheme 888

Scheme 889

Scheme 890

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See «FUEL SYSTEM PRECAUTION»(ref-191947-S33659745172005091500000) )
2. REMOVE TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
3. REMOVE CAMSHAFT (RH BANK) (See «REPLACEMENT»(ref-235152-S30166134142006061400000) )
4. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY Remove the bolt and transmission oil filler tube.
5. REMOVE OIL LEVEL GAGE GUIDE Remove the bolt and oil level gage guide.
6. DISCONNECT FUEL HOSE
7. DISCONNECT FUEL HOSE NO. 2
8. DISCONNECT FUEL VAPOR FEED HOSE ASSY
9. SEPARATE ENGINE WIRE Disconnect 8 fuel injector connectors. Remove the 3 bolts and separate engine wire harness.
10. DISCONNECT WATER BY PASS HOSE NO. 7
11. DISCONNECT WATER BY PASS HOSE
12. REMOVE INTAKE MANIFOLD ASSY Remove the 6 bolts and 4 nuts. Remove the intake manifold assy and 2 gaskets.
13. REMOVE WATER INLET HOUSING Remove the 2 bolts. Remove the water inlet housing and gasket from engine.
14. REMOVE WATER BY PASS JOINT FR Remove the 4 nuts. Remove the water by pass joint and 2 gaskets.
15. REMOVE WATER BY PASS PIPE SUB-ASSY Remove the bolt and water by pass.
16. REMOVE WATER BY PASS JOINT RR Remove the 4 nuts, water by pass joint and 2 gaskets.
17. DISCONNECT ENGINE WIRE Remove the 2 bolts as shown in the illustration.
18. SEPARATE FRONT EXHAUST PIPE Remove the 2 bolts and separate the front exhaust pipe.
19. REMOVE CYLINDER HEAD SUB-ASSY Uniformly loosen and remove the sequence shown. Remove the 10 cylinder head bolts and plate washers. NOTE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. Right the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
20. REMOVE CYLINDER HEAD GASKET
21. CLEAN CYLINDER BLOCK SUB-ASSY Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. Using a gasket scraper, remove all the gasket material from the cylinder block surface. Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air.
22. INSPECT CYLINDER BLOCK FOR FLATNESS Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage. Maximum warpage: 0.07 mm (0.0028 in.) If warpage is greater than maximum, replace the cylinder block.
23. CLEAN CYLINDER HEAD SUB-ASSY Using a gasket scraper, remove all the gasket material form the cylinder block contact surface. NOTE: Be careful not to scratch the cylinder block contact surface.
24. INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head.
25. INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 9.810-9.960 mm (0.3862-0.3921 in.) Minimum outside diameter: 9.700 mm (0.3819 in.) If the diameter is less than minimum, replace the bolt.
26. INSTALL CYLINDER HEAD GASKET Place new cylinder head gasket in position on the cylinder block. HINT: On the rear side of the cylinder head gasket are marks to distinguish the LH and RH banks, a "2UR" mark for the RH bank and a "2UL" mark for the LH bank. NOTE: Be careful of the installation direction. Place the cylinder head in position on the cylinder head gasket.
27. INSTALL CYLINDER HEAD SUB-ASSY HINT: The cylinder head bolts are tightened in 2 progressive steps. If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the sequence shown. Torque: 32 N.m (325 kgf.cm, 24 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 plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90° in the numerical order shown. Retighten the cylinder head bolts by an additional 90°. Check that the painted mark is now at a 180° angle to front.
28. INSTALL FRONT EXHAUST PIPE Place the new gasket to the front exhaust pipe. Install the 2 nuts and front exhaust pipe. Torque: 62 N.m (632 kgf.cm, 46 ft.lbf)
29. CONNECT ENGINE WIRE Connect the engine wire with bolt as shown in the illustration.
30. INSTALL WATER BY PASS JOINT RR (See «REPLACEMENT»(ref-235152-S37425579712006061400000) )
31. INSTALL WATER BY PASS JOINT FR (See «REPLACEMENT»(ref-235152-S37425579712006061400000) )
32. INSTALL WATER INLET HOUSING Install the new gasket and water inlet housing with 2 bolts. Torque: 18 N.m (185 kgf.cm, 13 in..lbf)
33. INSTALL WATER BY PASS PIPE SUB-ASSY Install a new O-ring to the water by pass pipe. Apply soapy water to the O-ring. Push in the water by pass pipe end into the pipe hole of the water pump. Install the water by pass pipe with the bolt. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
34. INSTALL INTAKE MANIFOLD ASSY Install the 2 new gaskets to cylinder head. Install the intake manifold assy with the 6 bolts and 2 nuts. Torque: Bolt 18 N.m (185 kgf.cm, 13 ft.lbf) Nut 18 N.m (185 kgf.cm, 13 ft.lbf)
35. CONNECT WATER BY PASS HOSE
36. CONNECT WATER BY PASS HOSE NO. 7
37. INSTALL ENGINE WIRE Torque: 8.2 N.m (83 kgf.cm, 72 in..lbf)
38. CONNECT FUEL VAPOR FEED HOSE ASSY
39. CONNECT FUEL HOSE NO. 2
40. CONNECT FUEL HOSE
41. INSTALL OIL LEVEL GAGE GUIDE Install the new O-ring to the oil level gage guide. Install the oil level gage guide with the bolt. Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
42. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY Install the transmission oil filler tube sub-assy with the bolt.
43. INSTALL CAMSHAFT (RH BANK) (See «REPLACEMENT»(ref-235152-S30166134142006061400000) )
44. INSTALL TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )

Scheme 891

Scheme 892

Scheme 893

Scheme 894

Scheme 895

Scheme 896

Scheme 897

Scheme 898

Scheme 899

Scheme 900

Scheme 901

Scheme 902

Scheme 903

Scheme 904

Scheme 905

Scheme 906

Scheme 907

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See «FUEL SYSTEM PRECAUTION»(ref-191947-S33659745172005091500000) )
2. REMOVE TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
3. REMOVE CAMSHAFT (LH BANK) (See «REPLACEMENT»(ref-235152-S02049091912006061400000) )
4. DISCONNECT FUEL HOSE
5. DISCONNECT FUEL HOSE NO. 2
6. DISCONNECT FUEL VAPOR FEED HOSE ASSY
7. SEPARATE ENGINE WIRE Disconnect 8 fuel injector connectors. Remove the 3 bolts and separate engine wire harness.
8. DISCONNECT WATER BY PASS HOSE NO. 7
9. DISCONNECT WATER BY PASS HOSE
10. REMOVE INTAKE MANIFOLD ASSY Remove the 6 bolts and 4 nuts. Remove the intake manifold assy and 2 gaskets.
11. REMOVE WATER INLET HOUSING Remove the 2 bolts. Remove the water inlet housing and gasket from engine.
12. REMOVE WATER BY PASS JOINT FR Remove the 4 nuts. Remove the water by pass joint and 2 gaskets.
13. REMOVE WATER BY PASS PIPE SUB-ASSY Remove the bolt and water by pass.
14. REMOVE WATER BY PASS JOINT RR Remove the 4 nuts, water by pass joint and 2 gaskets.
15. DISCONNECT ENGINE WIRE Remove the 2 bolts as shown in the illustration.
16. SEPARATE FRONT EXHAUST PIPE Remove the 2 bolts and separate the front exhaust pipe.
17. REMOVE CYLINDER HEAD SUB-ASSY Uniformly loosen and remove the sequence shown. Remove the 10 cylinder head bolts and plate washers. NOTE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
18. REMOVE CYLINDER HEAD GASKET NO. 2
19. CLEAN CYLINDER BLOCK SUB-ASSY Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. Using a gasket scraper, remove all the gasket material from the cylinder block surface. Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air.
20. INSPECT CYLINDER BLOCK FOR FLATNESS Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage. Maximum warpage: 0.07 mm (0.0028 in.) If warpage is greater than maximum, replace the cylinder block.
21. CLEAN CYLINDER HEAD SUB-ASSY Using a gasket scraper, remove all the gasket material form the cylinder block contact surface. NOTE: Be careful not to scratch the cylinder block contact surface.
22. INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head.
23. INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 9.810-9.960 mm (0.3862-0.3921 in.) Minimum outside diameter: 9.700 mm (0.3819 in.) If the diameter is less than minimum, replace the bolt.
24. INSTALL CYLINDER HEAD GASKET Place new cylinder head gasket in position on the cylinder block. HINT: On the rear side of the cylinder head gasket are marks to distinguish the LH and RH banks, a "2UR" mark for the RH bank and a "2UL" mark for the LH bank. NOTE: Be careful of the installation direction. Place the cylinder head in position on the cylinder head gasket.
25. INSTALL CYLINDER HEAD SUB-ASSY HINT: The cylinder head bolts are tightened in 2 progressive steps. If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the sequence shown. Torque: 32 N.m (325 kgf.cm, 24 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 plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90° in the numerical order shown. Retighten the cylinder head bolts by an additional 90°. Check that the painted mark is now at a 180° angle to front.
26. INSTALL FRONT EXHAUST PIPE Place the new gasket to the front exhaust pipe. Install the 2 nuts and front exhaust pipe. Torque: 62 N.m (632 kgf.cm, 46 ft.lbf)
27. CONNECT ENGINE WIRE Connect the engine wire with 2 bolts as shown in the illustration.
28. INSTALL WATER BY PASS JOINT RR (See «REPLACEMENT»(ref-235152-S37425579712006061400000) )
29. INSTALL WATER BY PASS JOINT FR (See «REPLACEMENT»(ref-235152-S37425579712006061400000) )
30. INSTALL WATER INLET HOUSING Install the new gasket and water inlet housing with 2 bolts. Torque: 18 N.m (185 kgf.cm, 13 in..lbf)
31. INSTALL WATER BY PASS PIPE SUB-ASSY Install a new O-ring to the water by pass pipe. Apply soapy water to the O-ring. Push in the water by pass pipe end into the pipe hole of the water pump. Install the water by pass pipe with the bolt. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
32. INSTALL INTAKE MANIFOLD ASSY Install the 2 new gaskets to cylinder head. Install the intake manifold assy with the 6 bolts and 2 nuts. Torque: Bolt 18 N.m (185 kgf.cm, 13 ft.lbf) Nut 18 N.m (185 kgf.cm, 13 ft.lbf)
33. CONNECT WATER BY PASS HOSE
34. CONNECT WATER BY PASS HOSE NO. 7
35. INSTALL ENGINE WIRE Torque: 8.2 N.m (83 kgf.cm, 72 in..lbf)
36. CONNECT FUEL VAPOR FEED HOSE ASSY
37. CONNECT FUEL HOSE NO. 2
38. CONNECT FUEL HOSE
39. INSTALL CAMSHAFT (LH BANK) n (See «REPLACEMENT»(ref-235152-S02049091912006061400000) )
40. INSTALL TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )

Scheme 908

Scheme 909

Scheme 910

Scheme 911

Scheme 912

Scheme 913

Scheme 914

Scheme 915

Scheme 916

Scheme 917

Scheme 918

Scheme 919

Scheme 920

Scheme 921

Scheme 922

Scheme 923

Scheme 924

Scheme 925

Scheme 926

Scheme 927

Scheme 928

Scheme 929

Scheme 930

Scheme 931

Scheme 932

Scheme 933

Scheme 934

Scheme 935

Scheme 936

1. REMOVE TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
2. REMOVE CAMSHAFT TIMING PULLEY Using SST, remove the bolt and timing pulley. Remove the timing pulley. SST 09960-10010 (09962-01000, 09963-01000)
3. REMOVE TIMING BELT PLATE RR RH Remove the 3 bolts, stud bolt and timing belt plate RR RH.
4. REMOVE IGNITION COIL ASSY Disconnect the 4 ignition coil assy connectors. Remove the 4 bolts and 4 ignition coil assy.
5. REMOVE CYLINDER HEAD COVER Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. Remove the cylinder head cover.
6. REMOVE CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be levelled while it is being removed. If the camshaft is not being levelled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. Having the crankshaft pulley at the wrong angle can cause damages due to the piston head and valve head come into contact with each other while you remove the camshaft. Always be sure to set the crankshaft pulley at the correct angle as shown in the illustration. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a service bolt. Recommended service bolt Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16-20 mm HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown. Remove the oil feed pipe, 9 bearing caps, cam shaft timing oil control valve and camshafts. HINT: Arrange the bearing caps in correct order. Mount the hexagon wrench head portion of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, turn the sub-gear clockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) Using snap ring pliers, remove the snap ring. Remove these parts: Wave washer Camshaft sub-gear Camshaft gear spring HINT: Arrange the camshaft sub-gears and gear spring (RH and LH sides). NOTE: Be careful not to damage the camshaft timing tube. Remove the oil seal from the intake camshaft.
7. REMOVE CAMSHAFT HOUSING PLUG
8. REMOVE SEMICIRCULAR PLUG
9. INSTALL CAMSHAFT HOUSING PLUG Remove any old packing (FIPG) material. Apply seal packing to the camshaft housing plug grooves. Seal packing: Part No. 08826-00080 or equivalent Install the camshaft housing plug to the cylinder heads.
10. INSTALL CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be levelled while it is being installed. If the camshaft is not being levelled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. Having the crankshaft pulley at the wrong angle can cause damage due to the piston head and valve head come into contact with each other when you install the camshaft. Always, be sure to set the crankshaft pulley at the correct angle as shown in the illustration. Install these parts: Camshaft gear spring Camshaft sub-gear HINT: Attach the pins on the gears to the gear spring ends. Wave washer Using snap ring pliers, install the snap ring. Mount the hexagon wrench head portion of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt. Apply MP grease to the thrust portion of the intake and exhaust camshafts. Place the intake and exhaust camshafts. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle. Remove any old packing (FIPG) material from front bearing cap. Apply seal packing to the front bearing cap as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 1.5-2.0 mm (0.059-0.0079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. NOTE: Do not apply seal packing to the front bearing cap grooves. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the other bearing cap in the sequence shown with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Push in the new camshaft oil seal. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). Install the oil feed pipe and the 22 bearing cap bolts as shown. HINT: Each bolt length is indicated in the illustration. Bolt length: 94 mm (3.70 in.) for A 72 mm (2.83 in.) for B 25 mm (0.98 in.) for C 52 mm (2.05 in.) for D 38 mm (1.50 in.) for E Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Torque: Bolt C 7.5 N.m (80 kgf.cm, 66 in..lbf) Others 16 N.m (160 kgf.cm, 12 ft.lbf) Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. Remove the service bolt.
11. INSPECT VALVE CLEARANCE (See «ADJUSTMENT»(ref-235152-S17461996472006061400000) ) Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.
12. INSTALL SEMICIRCULAR PLUG Remove any old packing (FIPG) material. Apply seal packing to the semi-circular plug grooves. Seal packing: Part No. 08826-00080 or equivalent Install the 2 semi-circular plugs to the cylinder heads.
13. INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the seal washer to the bolt. Install the cylinder head cover with the 18 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers. Torque: 6.0 N.m (60 kgf.cm, 53 in..lbf)
14. INSTALL IGNITION COIL ASSY Install 4 bolts and ignition coil assy. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)
15. INSTALL TIMING BELT PLATE RR RH Install the timing belt plate with 3 the bolts and stud bolt. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
16. INSTALL CAMSHAFT TIMING PULLEY Using SST, install the timing pulley with the bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 N.m (1100 kgf.cm, 80 ft.lbf)
17. INSTALL TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )

Scheme 937

Scheme 938

Scheme 939

Scheme 940

Scheme 941

Scheme 942

Scheme 943

Scheme 944

Scheme 945

Scheme 946

Scheme 947

Scheme 948

Scheme 949

Scheme 950

Scheme 951

Scheme 952

Scheme 953

Scheme 954

Scheme 955

Scheme 956

Scheme 957

Scheme 958

Scheme 959

Scheme 960

Scheme 961

Scheme 962

Scheme 963

Scheme 964

Scheme 965

1. REMOVE TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
2. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSY LH Using SST, remove the bolt and timing pulley. Remove the timing pulley. SST 09960-10010 (09962-01000, 09963-01000)
3. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt, stud bolt and camshaft position sensor.
4. REMOVE TIMING BELT PLATE RR LH Remove the 3 bolts and timing belt plate RR LH.
5. REMOVE IGNITION COIL ASSY Disconnect the 4 ignition coil assy connectors. Remove the 4 bolts and 4 ignition coil assy.
6. REMOVE CYLINDER HEAD COVER Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. Remove the cylinder head cover.
7. REMOVE CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be levelled while it is being removed. If the camshaft is not being levelled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. Having the crankshaft pulley at the wrong angle can cause damages due to the piston head and valve head come into contact with each other while you remove the camshaft. Always be sure to set the crankshaft pulley at the correct angle as shown in the illustration. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a service bolt. Bolt Specification Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16-20 mm HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown. Remove the oil feed pipe, 9 bearing caps and camshafts. HINT: Arrange the bearing caps in correct order. Mount the hexagon wrench head portion of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, turn the sub-gear clockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) Using snap ring pliers, remove the snap ring. Remove these parts: Wave washer Camshaft sub-gear Camshaft gear spring HINT: Arrange the camshaft sub-gears and gear spring (RH and LH sides). NOTE: Be careful not to damage the camshaft timing tube. Remove the oil seal from the intake camshaft.
8. REMOVE CAMSHAFT HOUSING PLUG
9. REMOVE SEMICIRCULAR PLUG
10. INSTALL CAMSHAFT HOUSING PLUG Remove any old packing (FIPG) material. Apply seal packing to the camshaft housing plug grooves. Seal packing: Part No. 08826-00080 or equivalent Install the camshaft housing plug to the cylinder heads.
11. INSTALL CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be levelled while it is being installed. If the camshaft is not being levelled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. Having the crankshaft pulley at the wrong angle can cause damage due to the piston head and valve head come into contact with each other when you install the camshaft. Always, be sure to set the crankshaft pulley at the correct angle as shown in the illustration. Install these parts: Camshaft gear spring Camshaft sub-gear HINT: Attach the pins on the gears to the gear spring ends. Wave washer Using snap ring pliers, install the snap ring. Mount the hexagon wrench head portion of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt. Apply MP grease to the thrust portion of the intake and exhaust camshafts. Place the intake and exhaust camshafts. Engage the intake to the exhaust gear by meeting the timing marks (2 dot marks) on each gear. Remove any old packing (FIPG) material. Apply seal packing to the front bearing cap. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 1.5-2.0 mm (0.059-0.079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. NOTE: Do not apply seal packing to the front bearing cap grooves. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the other bearing cap in the sequence shown with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Push in the new camshaft oil seal. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). Install the oil feed pipe and the 22 bearing cap bolts as shown. HINT: Each bolt length is indicated in the illustration. Bolt length: 94 mm (3.70 in.) for A 72 mm (2.83 in.) for B 25 mm (0.98 in.) for C 52 mm (2.05 in.) for D 38 mm (1.50 in.) for E Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Torque: Bolt C 7.5 N.m (80 kgf.cm, 66 in..lbf) Others 16 N.m (160 kgf.cm, 12 ft.lbf) Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. Remove the service bolt.
12. INSPECT VALVE CLEARANCE (See «ADJUSTMENT»(ref-235152-S17461996472006061400000) ) Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.
13. INSTALL SEMICIRCULAR PLUG Remove any old packing (FIPG) material. Apply seal packing to the semi-circular plug grooves. Seal packing: Part No. 08826-00080 or equivalent Install the 4 semi-circular plugs to the cylinder heads.
14. INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the seal washer to the bolt. Install the cylinder head cover with the 18 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers. Torque: 6.0 N.m (60 kgf.cm, 53 in..lbf)
15. INSTALL IGNITION COIL ASSY Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf)
16. INSTALL TIMING BELT PLATE RR LH Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
17. INSTALL CAMSHAFT POSITION SENSOR Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
18. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSY LH Using SST, install the timing pulley with the bolt. SST 09960-10010 (09962-01000, 09963-01000)
19. INSTALL TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )

Scheme 966

Scheme 967

Scheme 968

Scheme 969

1. REMOVE TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )
2. REMOVE CRANKSHAFT TIMING PULLEY Using SST, remove the timing pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) NOTE: Do not turn the timing pulley.
3. REMOVE OIL PUMP SEAL Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
4. INSTALL OIL PUMP SEAL Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09316-6001 1 (09316-00011)
5. INSTALL CRANKSHAFT TIMING PULLEY Align the timing pulley set key with the key groove of the pulley. Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-4601 1
6. INSTALL TIMING BELT (See «REPLACEMENT»(ref-235152-S20839505222006061400000) )

Scheme 970

Scheme 971

Scheme 972

Scheme 973

Scheme 974

Scheme 975

Scheme 976

Scheme 977

1. REMOVE AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )
2. REMOVE AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )
3. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY Using SST, hold the crankshaft. SST 09213-7001 1, 09330-00021 Remove the 8 bolts, front spacer, drive plate and rear spacer.
4. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
5. INSTALL ENGINE REAR OIL SEAL Apply multipurpose grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010
6. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY Using SST, hold the crankshaft. SST 09213-7001 1, 09330-00021 Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the front spacer, drive plate and rear spacer on the crankshaft. Install and uniformly tighten 8 new mounting bolts in several passes in the sequence shown. Torque: 30 N.m (301 kgf.cm, 22 ft.lbf) If any of the mounting bolts does not meet the torque specification, replace the mounting bolt. Mark the mounting bolt with paint. Retighten the mounting bolts by 90° in the sequence shown. Check that the painted mark is now at a 90° angle to step e .
7. INSTALL AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )
8. INSTALL AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «OVERHAUL - A750E & A750F»(ref-153920) )