Engine Mechanical: Removal & Installation Toyota Celica T230 рестайлинг

REPLACEMENT

Note. There are 2 methods (A and B) to replace the oil seal which are as follows

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1. If timing chain cover is removed from cylinder block. Using a screwdriver and a hammer, tap out the oil seal. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010 Apply MP grease to the oil seal lip.
2. If timing chain cover is installed to the cylinder block. Using a knife, cut off the oil seal lip. NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Using a screwdriver, pry out the oil seal. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010

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1. Install valve timing controller assembly and camshaft timing sprocket . Apply engine oil in the range from the tip of the intake camshaft to 16 mm from that tip. NOTE: Do not push valve timing controller assembly to the camshaft forcibly when installing it. Align the timing mark on the value timing controller assembly with the knock pin, and install the value timing controller assembly to the cam shaft. Align the knock pin hole in the cam shaft timing sprocket with the knock pin of the cam shaft, and exhaust the sprocket to the cam shaft. Temporarily install the timing sprocket bolt. Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the timing sprocket bolt. Torque: 1ZZ-FE 45 N.m (460 kgf.cm, 33 ft.lbf) 2ZZ-GE 54 N.m (551 kgf.cm, 40 ft.lbf)
2. Set No. 1 cylinder to TDC/compression : Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets. Using a crankshaft pulley bolt, Turn the crankshaft and set the set key on the crankshaft upward.
3. Install chain vibration damper with the 2 bolts. Torque: 1ZZ-FE 11 N.m (113 kgf.cm, 8 ft.lbf) 2ZZ-GE 20.5 N.m (209 kgf.cm, 15 ft.lbf)
4. Install timing chain and crankshaft timing sprocket : NOTE: If necessary, install the sprocket with SST. SST 09223--22010 Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on the crankshaft timing sprocket. 1ZZ-FE: Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on the camshaft timing sprockets. 2ZZ-GE: Install the timing chain on the camshaft timing sprockets with the orange color links aligned with the timing marks on the camshaft timing sprockets. Check that the tension between the intake camshaft timing sprocket and crankshaft timing sprocket.
5. Install chain tensioner slipper : NOTE: DO not turn the crankshaft. Install the slipper with the bolt. Torque: 1ZZ-FE 18.5 N.m (189 kgf.cm, 14 ft.lbf) 2ZZ-GE 20.5 N.m (209 kgf.cm, 15 ft.lbf) Check that the slipper moves is caught on the cylinder head stopper.
6. Install the crank angle sensor plate with the"F" mark facing forward.
7. 1ZZ-FE: Install timing chain cover and water pump : Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Using a razor blade and a gasket scraper, remove all the old 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 timing chain cover as shown in the illustration. Seal packing: Part No. 08826 -- 00100 or equivalent Install a nozzle that has been cut to a 1.5 mm (0.16 -- 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826 -- 00080 or equivalent Install a nozzle that has been cut to a 1.5 mm (0.16 -- 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the timing chain cover, O-ring and water pump with the 17 bolts and nut. Uniformly tighten the bolts and nut in several passes. Torque: 10 mm head: 9 N.m (92 kgf.cm, 80 in.lbf) for C 13 N.m (133 kgf.cm, 10 ft.lbf) for A 11 N.m (113 kgf.cm, 8 ft.lbf) for others 12 mm head: 18.5 N.m (189 kgf.cm, 14 ft.lbf) NOTE: Pay attention not to wrap the chain and slipper over the chain cover seal line. After installing the chain cover, must install the mounting bracket and water pump within 15 minutes. Each bolt length in indicated in the illustration. Bolt "A" 45 mm (1.77 in.). Bolt "B" 35 mm (1.38 in.). Bolt "C" 30 mm (1.18 in.). Bolt "D" 25 mm (0.98 in.). Using a torx wench socket (E8), install the stud bolt. Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
8. 2ZZ-GE: Install timing chain cover and water pump : Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Using a razor blade and a gasket scraper, remove all the old 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 timing chain cover as shown in the illustration. Seal packing: Part No. 08826-00100 or equivalent Install a nozzle that has been cut to a 1.5 mm opening. Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the 2 gasket to the timing chain cover as shown in the illustration. Apply seal packing to 4 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 4 -- 5 mm (0.16 -- 0.20 in.) opening. Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the timing chain cover, O-ring and water pump with the 19 bolts. Uniformly tighten the bolts in several passes. Each bolt length in indicated in the illustration. Torque: A: 21 N.m (214 kgf.cm, 15 ft.lbf) B: 11 N.m (113 kgf.cm, 8 ft.lbf) C: 9.0 N.m (92 kgf.cm, 80 in.lbf) D: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: Pay attention not to wrap the chain and slipper over the chain cover seal line. After install the chain cover, must install the mounting bracket and water pump within 15 minutes. Using a torx wrench socket (E8), install the stud bolt. Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
9. 1ZZ-FE: Install RH engine mounting bracket : NOTE: Do not apply seal packing to 2 or 3 threads of the bolt end. Apply seal packing to threads of the mounting bolt. Seal packing: Part No. 08826 -- 00080 or equivalent Install the mounting bracket with the 3 bolts. Torque: 47 N.m (479 kgf.cm, 35 ft.lbf)
10. 2ZZ-GE: Install RH engine mounting bracket with the 4 bolts. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
11. Install drive belt tensioner : Check the appearance before installing the drive belt tensioner. If in case of having the oil leakage, crack, and etc., replace the drive belt tensioner. Install the drive belt tensioner. Torque: Bolt 1ZZ-FE 69 N.m (704 kgf.cm, 51 ft.lbf) 2ZZ-GE 100 N.m (1,020 kgf.cm, 74 ft.lbf) Nut 29 N.m (296 kgf.cm, 21 ft.lbf) NOTE: Take 3 seconds or more for 1 full stroke. Hook the tool on the hexagonal portion of the drive belt tensioner bracket and operate drive belt tensioner 3 times with full stroke.
12. Install crankshaft position sensor : Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
13. Install crankshaft pulley : Clean the crankshaft pulley inside. Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST and 2 nuts (width: 10 mm (0.25 in.), install the pulley bolt. SST 09213-70011, 09330-00021 Torque: 1ZZ-FE 138 N.m (1,409 kgf.cm, 102 ft.lbf) 2ZZ-GE 120 N.m (1,200 kgf.cm, 87 ft.lbf)
14. Install chain tensioner : Check the chain tensioner. See 2 . Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. NOTE: In the case that the hook is released while pushing in, apply the hook again and push the tensioner in. Pay attention not to catch the O-ring as it is built in the chain tensioner previously. Insert the O-ring with your hand until it reaches to the chamfering position and install nut temporally. Then, by tightening the nut, insert the chain tensioner to the installation position. Tighten the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
15. Set chain tension : Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. NOTE: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
16. Check valve timing : Turn the crankshaft pulley, and align its groove with timing mark"0" of the timing chain cover. NOTE: Always turn the crankshaft clockwise. Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
17. 1ZZ-FE: Install cylinder head cover : Remove any old packing (FIPG) material. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826 -- 00080 or equivalent Install the gasket to the cylinder head cover. HINT: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied. Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown. Torque: W/O washer 11 N.m (113 kgf.cm, 8 ft.lbf) W/washer 9.0 N.m (92 kgf.cm, 80 in.lbf) Connect the 2 PCV hoses to the cylinder head cover. Install the ignition coil (See page lG-7). . See «REMOVAL & INSTALLATION»(ref-133226-S41582560472002021900000) .
18. 2ZZ-GE: Install cylinder head cover : Remove any old packing (FIPG) material. HINT: When FIPG on the head cover gasket side cannot be eliminated completely, replace the gasket. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. HINT: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied. Install a new O-ring to the cylinder head cover. Install the cylinder head cover and wire harness protector with the9 bolts. Uniformly tighten the bolts, in the several passes, in the sequence shown. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) Connect the 2 PCV hoses to the cylinder head cover. Install a new gasket and No. 1 ventilation pipe with 2 nuts and bolt. Torque: Nut 10 N.m (100 kgf.cm, 7 ft.lbf) Bolt 25 N.m (255 kgf.cm, 18 ft.lbf) Connect the No. 3 ventilation hose to the No. 1 ventilation pipe. Install the ignition coil. See «REMOVAL & INSTALLATION»(ref-133226-S41582560472002021900000) .
19. Install RH engine mounting insulator : 1ZZ-FE: Install the RH engine mounting insulator with the 4 bolts and 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 2ZZ-GE: Install the RH engine mounting insulator with the 5 bolts and 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
20. Install PS pump : Install the PS pump with the 2 through bolts and nuts. Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) Install the PS pump pulley with the pulley nut. Connect the PS oil pressure switch connector.
21. Install generator and drive belt . See «INSTALLATION»(ref-173160-S08158168092005031000000) .
22. Install RH engine under cover .
23. Install RH front wheel .
24. Fill with engine coolant . See «REPLACEMENT»(ref-171346-S41444811672005020100000) .
25. Install front fender apron seal and upper radiator support seal .
26. Start engine and check for coolant leaks .

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1. Remove battery .
2. Remove ECU box . See «REMOVAL»(ref-163200-S32859062662005020100000) .
3. Drain engine coolant .
4. Disconnect engine coolant reservoir .
5. Remove air cleaner assembly .
6. Disconnect accelerator cable .
7. Remove drive belt and alternator . See «REMOVAL»(ref-173160-S23088450822005031000000) .
8. Remove exhaust pipe . See «REMOVAL»(ref-163200-S32859062662005020100000) .
9. 1ZZ-FE: Remove exhaust manifold : Remove the 3 bolts and exhaust manifold stay. Remove the 6 bolts and upper heat insulator. Remove the 5 nuts, exhaust manifold and gasket. Remove the 3 bolts and lower heat insulator.
10. 2ZZ-GE: Remove exhaust manifold : Remove the 4 bolts and exhaust manifold stay. Remove the 5 bolts and upper heat insulator. Remove the 3 bolts, 2 nuts, exhaust manifold and gasket. Remove the 4 bolts and lower heat insulator.
11. Remove ignition coil . See «REMOVAL & INSTALLATION»(ref-133226-S41582560472002021900000) .
12. Remove spark plug .
13. Remove PCV hoses .
14. Remove throttle body .
15. Remove injector .
16. 1ZZ-FE: Disconnect engine wire from cylinder head : Disconnect the ECT sensor connector. Disconnect the camshaft position sensor connector. Disconnect the oil control valve for VVT connector. Disconnect the 2 ground wires. Disconnect the 2 clamps and engine wire protector from the intake manifold.
17. 2ZZ-GE: Disconnect engine wire from cylinder head : Disconnect the ECT sensor connector. Disconnect the camshaft position sensor connector. Disconnect the oil control valve for VVT connectors. Disconnect the oil control valve for VVTL connectors. Disconnect the oil pressure switch connector. Disconnect the 2 ground wires. Remove the 2 bolts, and disconnect the engine wire, Remove the intake manifold No. 2 insulator.
18. 1ZZ-FE: Remove intake manifold : Disconnect the EVAP hose for ORVR. Disconnect the brake booster vacuum hose. Remove the 4 bolts, 2 nuts, intake manifold, 2 wire harness stays and gasket.
19. 2ZZ-GE: Remove intake manifold : Disconnect the EVAP hose for ORVR. Disconnect the brake booster vacuum hose. Remove the bolt and disconnect the No. 1 ventilation pipe and oil dipstick and guide. Remove the 2 bolts, nut and stay. Remove the 4 bolts, 2 nuts, intake manifold and gasket. Remove the intake manifold insulator.
20. Remove camshaft position sensor .
21. Remove ECT sensor .
22. Remove PCV valve and grommet .
23. Remove oil filler cap .
24. Remove camshaft timing sprockets .
25. 1ZZ-FE: Remove camshaft : Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts.
26. 2ZZ-GE: Remove camshaft : Uniformly loosen and remove the 20 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps intake and exhaust camshaft.
27. Remove cylinder head : Disconnect the upper radiator hoses from the water hose union. Disconnect the heater water hose from the water hose union. CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. Remove the bolt holding the water bypass pipe to the cylinder head. CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. NOTE: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. Lift the cylinder from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench.

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1. Remove oil control valve for VVT : Remove the bolt and cam timing oil control valve.
2. Remove oil control valve filter : Remove the bolt, gasket and oil control valve filter.
3. 2ZZ-GE: Remove oil control valve housing : Remove the bolt and oil control valve for VVTL. Using SST, remove the oil pressure switch. SST 09816-30010 Remove the 3 bolts, 2 nuts, oil control valve housing and gasket. Remove the oil control valve filter.
4. 2ZZ-GE: Remove valve rocker arm : Remove the 2 bolts, rocker No. 1 and No. 2 shafts. Remove the 8 valve rocker arm. HINT: Arrange the rocker arms in the correct order.
5. Remove valve lifters .
6. Remove valves : Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00020) Remove the spring retainer. Remove the valve spring. Remove the valve. Using needle-nose pliers, remove the oil seal. NOTE: Arrange the valves, valve springs, spring seats, and spring retainers in the correct order. Using compressed air and magnetic finger, remove the spring seat by blowing air.

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1. Clean top surfaces of pistons and cylinder block : Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston surface. Using a gasket scraper, remove all the gasket material from the cylinder block surface. WARNING: Protect your eyes when using high pressure compressed air. Using compressed air, blow carbon and oil from the bolt holes.
2. Remove gasket material : Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
3. Clean combustion chambers : Using a wire brush, remove all the carbon from the combustion chambers.
4. Clean cylinder head : Using a soft brush and solvent, thoroughly clean the cylinder head.
5. Clean valve guide bushings : Using a valve guide bushing brush and solvent, clean all the guide bushings.
6. Inspect for flatness : Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder head.
7. Inspect for cracks : Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
8. Clean valves : Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve.
9. Inspect valve stems and guide bushings : Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 1ZZ-FE 5.510 -- 5.530 mm (0.2169 -- 0.2177 in.) 2ZZ-GE 5.500 -- 5.518 mm (0.2165 -- 0.2172 in.) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 1ZZ-FE Intake 5.470 -- 5.485 mm (0.2154 -- 0.2159 in.) Exhaust 5.465 -- 5.480 mm (0.2152 -- 0.2157 in.) 2ZZ-GE Intake 5.460 -- 5.475 mm (0.21496 -- 0.21555 in.) Exhaust 5.445 -- 5.470 mm (0.21437 -- 0.21535 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: 1ZZ-FE Intake 0.025 -- 0.060 mm (0.0010 -- 0.0024 in.) Exhaust 0.030 -- 0.065 mm (0.0012 -- 0.0026 in.) 2ZZ-GE Intake 0.025 -- 0.058 mm (0.00098 -- 0.00228 in.) Exhaust 0.030 -- 0.063 mm (0.00118 -- 0.00248 in.) Maximum oil clearance: 1ZZ-FE Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) 2ZZ-GE 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing.
10. Inspect valves : Check the valve is ground to the correct valve face angle. Valve face angle: 44.5° Check that the surface of the valve for wear. If the valve face is worn, replace the valve. Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.7 mm (0.028 in.) If the margin thickness is less than minimum, replace the valve. Check the valve overall length. Standard overall length: 1ZZ-FE Intake 88.65 mm (3.4902 in.) Exhaust 88.69 mm (3.4917 in.) 2ZZ-GE Intake 111.3 mm (4.382 in.) Exhaust 111.7 mm (4.398 in.) Minimum overall length: 1ZZ-FE Intake 88.35 mm (3.4783 in.) Exhaust 88.39 mm (3.4799 in.) 2ZZ-GE Intake 110.9 mm (4.366 in.) Exhaust 111.3 mm (4.382 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, replace the valve.
11. Inspect and clean valve seats : Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. After resurfacing the valve seat 45°, measure the residuary width of the valve seat 45° Minimum residuary length: intake 3.3 mm (0.130 in.) Exhaust 3.2 mm (0.126 in.) If the valve seat 45° residuary width less than minimum, replace the cylinder head. 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 the following width: 1.0 -1.4 mm (0.039 -- 0.055 in.) If not, correct the valve seats as follows: If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat. Inspect valve springs : Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than maximum, replace the valve spring. Using vernier calipers, measure the free length of the valve spring. Free length: 1ZZ-FE 45.90 mm (1.8070 in.) 2ZZ-GE Intake 46.4 mm (1.830 in.) Exhaust 46.5 mm (1.831 in.) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 1ZZ-FE 139.6 -- 154.4 N (14.2 -- 15.8 kgf, 31.3 -- 34.8 lbf) at 33.6 mm (1.323 in.) 2ZZ-GE Intake 220.2 -- 243.8 N (22.5 -- 24.7 kgf, 49.6 -- 55.5 lbf) at 38.5 mm (1.516 in.) Exhaust 208.2 -- 229.8 N (21.2 -- 23.4 kgf, 47.6 -- 52.6 lbf) at 38.5 mm (1.516 in.) Maximum working tension: 1ZZ-FE 244.9 -- 276.1 N (25.5 -- 28.1 kgf, 56.2 -- 61.9 lbf) at 24.6 mm (0.969 in.) 2ZZ-GE Intake 533 -- 589 N (54.4 -- 60.1 kgf, 119.9 -- 132.5 lbf) at 27.3 mm (1.075 in.) Exhaust 495.5 -- 548.5 N (50.5 -- 55.9 kgf, 111.3 -- 123.2 lbf) at 28.5 mm (1.122 in.) If the installed tension is not as specified, replace the valve spring 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: 0.03 mm (0.0012 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: 1ZZ-FE: Intake 44.333 -- 44.433 mm (1.7454 -- 1.7493 in.) Exhaust 43.761 -- 43.861 mm (1.7229 -- 1.7268 in.) 2ZZ-GE: INTAKE No. 1 40.607 -- 40.707 mm (1.59586 -- 1.59979 in.) No. 2 38.769 -- 38.869 mm (1.52362 -- 1.52755 in.) 2ZZ-GE: EXHAUST No. 1 40.019 -- 40.119 mm (1.57275 -- 1.57668 in.) No. 2 38.863 -- 38.963 mm (1.52732 -- 1.53125 in.) Minimum cam lobe height: 1ZZ-FE: Intake 44.18 mm (1.7394 in.) Exhaust 43.61 mm (1.7169 in.) 2ZZ-GE: Intake No.1 40.45 mm (1.5925 in.) No.2 38.61 mm (1.5201 in.) Exhaust No.1 39.86 mm (1.5693) No.2 38.71 mm (1.5240) If the cam lobe height is less than minimum, replace the camshaft. Inspect camshaft journals : Using a micrometer, measure the journal diameter. 1ZZ-FE: No.1 journal diameter: 34.449 -- 34.465 mm (1.3563 -- 1.3569 in.) Others journal diameter: 22.949 -- 22.965 mm (0.9035 -- 0.9041 in.) 2ZZ-GE: No.1 journal diameter: 34.449 -- 34.465 mm (1.35626 -- 1.35689 in.) Other journal diameter: 27.949 -- 27.965 mm (1.10035 -- 1.10098 in.) If the journal diameter is not as specified, check the oil clearance. Inspect camshaft journal clearance : Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. Install the bearing caps. See «INSTALLATION»(ref-163200-S02167951622005020100000) . Torque: 1ZZ-FE: No.1 23 N.m (235 kgf.cm, 17 ft.lbf) No.3 13 N.m (133 kgf.cm, 10 ft.lbf) 2ZZ-GE: 18.5 N.m (189 kgf.cm, 14 ft.lbf) NOTE: Do not turn the camshaft. Remove the bearing caps. Measure the plastigage at its widest point. 1ZZ-FE: Standard oil clearance: 0.035 -- 0.072 mm (0.0014 -- 0.0028 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) 2ZZ-GE: Standard oil clearance: No. 1 journal 0.035 -- 0.076 mm (0.00138 -- 0.00299 in.) Other journal 0.035 -- 0.072 mm (0.00138 -- 0.00283 in.) Maximum oil clearance: 0.10 mm (0.039 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. Inspect camshaft thrust clearance : Install the camshafts. See «INSTALLATION»(ref-163200-S02167951622005020100000) . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. 1ZZ-FE: Standard thrust clearance: 0.040 -- 0.095 mm (0.0016 -- 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) 2ZZ-GE: Standard thrust clearance: 0.04 -- 0.14 mm (0.0016 -- 0.0055 in.) Maximum thrust clearance: 0.15 mm (0.0059 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. Inspect valve timing controller assembly : NOTE: Do not apply tape in the range from the tip of the camshaft to 18 mm from that tip. Apply vinyl tape to all the ports except the one indicated by the arrow in the illustration. NOTE: Do not push valve timing controller assembly to the camshaft forcibly when installing it. Install the valve timing controller assembly. Torque: 47 N.m (480 kgf.cm, 35 ft.lbf) Check that the valve timing controller assembly will not turn. NOTE: When the oil splashes, wipe it off with a shop rag and the likes. Perform this in order to release the lock pin for the maximum delay angle locking. Wind tape around the tip of the air gun and apply air of approximatley 100 kPa (1 kgf/cm 2 , 14 psi) to the port of the camshaft. NOTE: Depending on the air pressure, the valve timing controller assembly will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released. Under the condition of (d), turn the valve timing controller assembly to the advance angel side (the arrow marked direction in the illustration) with your hand. Standard: Must turn Except the position where the lock pin meets at the maximum delay angle, let the valve timing controller assembly turn back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 30° . Turn the valve timing controller assembly with your hand and lock it at the maximum delay angel position. 1ZZ-FE: Inspect valve lifters and lifter bores : Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 -- 31.025 mm (1.2205 -- 1.2215 in.) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 -- 30.976 mm (1.2191 -- 1.2195 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 -- 0.059 mm (0.0009 -- 0.0023 in.) Maximum oil clearance: 0.079 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. Inspect intake manifold : Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the manifold. Inspect exhaust manifold : Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If warpage is greater than maximum, replace the manifold. Inspect cylinder head bolts : Standard outside diameter: 9.0 -- 9.2 mm (0.354 -- 0.362 in.) Minimum outside diameter: 9.0 mm (0.354 in.) If the outer diameter is less than minimum, replace the bolt.

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1. Gradually heat the cylinder head to 110 -- 130 °C (230 -- 266 °F).
2. Using SST and a hammer, tap out the guide bushing. SST 09201-01055, 09950-70010 (09951-07100)
3. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
4. 1ZZ-FE: Select the new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bushing bore to the following dimension: 10.335 -- 10.356 mm (0.4068 -- 0.4077 in.) If the bushing bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.
5. 1ZZ-FE: Gradually heat the cylinder head to 80 -- 100 °C (176 -- 212 °F).
6. 2ZZ-GE: Select the new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.506 mm (0.4136 in.), machine the bushing bore to the following dimension: 10.538 -- 10.556 mm (0.4149 -- 0.4156 in.) If the bushing bore diameter of the cylinder head is greater than 10.556 mm (0.4156 in.), replace the cylinder head.
7. 2ZZ-GE: Gradually heat the cylinder head to 110 -- 130 °C (230 -- 266 °F).
8. Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201-01055, 09950-70010 (09951-07100) Protrusion height: 1ZZ-FE 8.7 -- 9.1 mm (0.342 -- 0.358 in.) 2ZZ-GE 15.3 -- 15.7 mm (0.602 -- 0.618 in.)
9. Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance. For inpectioon procedure between the guide bushing and valve stem, See «INSPECTION»(ref-163200-S10952047122005020100000) .

INSTALLATION

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones.

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1. Place cylinder head on cylinder block : NOTE: Be careful of the installation direction. Place a new cylinder head gasket on the cylinder block surface with the Lod No. stamp upward. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
2. Install cylinder head bolts : Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown. Torque: 1ZZ-FE: 49 N.m (500 kgf.cm, 36 ft.lbf) 2ZZ-GE: 35 N.m (375 kgf.cm, 26 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. Mark the front of the cylinder head bolt with paint. 1ZZ-FE: Retighten the cylinder head bolts 90° in the numerical order shown. 2ZZ-GE: Retighten the cylinder head bolts 180° in the numerical order shown. 1ZZ-FE: Check that the paint mark is now at a 90° angle to the front. 2ZZ-GE: Check that the paint mark is now at a 180° angle to the front. Install the bolt holding the water bypass pipe to the cylinder head. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) Connect the upper radiator hose to the water hose unions. Connect the heater hose to the water hose unions.
3. Install camshafts : Place the 2 camshafts on the cylinder head with the No. 1 can lobes facing as shown the illustration. Install the bearing caps in their proper locations. HINT: 1ZZ-FE: No. 3 camshaft bearing cap has a number and front mark. 2ZZ-GE: No. 2, No.3 camshaft bearing cap has a number and front mark. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. 1ZZ-FE: Install and uniformly tighten the 19 bearing cap bolts. After tightening the No. 1 camshaft bearing cap, tighten then in several passes, in the sequence shown. Torque: No. 1 23 N.m (235 kgf.cm, 17 ft.lbf) No. 3 13 N.m (133 kgf.cm, 10 ft.lbf) 2ZZ-GE: Install and uniformly tighten the 20 bearing cap bolts. After tightening the No. 1 camshaft bearing cap, tighten then in several passes, in the sequence shown. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf)
4. Check and adjust valve clearance . See «VALVE CLEARANCE»(ref-163200-S14004949002005020100000) .
5. Install camshaft timing sprockets and valve timing controller assembly , See «INSTALLATION»(ref-163200-S33740329352005020100000) .
6. Install oil filter cap .
7. Install grommet and PCV valve .
8. Install ECT sensor .
9. Install camshaft position sensor .
10. 1ZZ-FE: Install Intake Manifold Install a new gasket, the intake manifold with the 4 bolts and 2 nuts. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) Connect the brake booster vacuum hose. Connect the EVAP hose for ORVR.
11. 2ZZ-GE: Install Intake Manifold Install the intake manifold insulator to the cylinder block. Install a new gasket, the intake manifold with the 4 bolts and 2 nuts. Torque: A: 27 N.m (275 kgf.cm, 20 ft.lbf) B: 46 N.m (469 kgf.cm, 34 ft.lbf) Install the stay with the 2 bolts and nut. Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) Install the oil dipstick and guide with the bolt. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) Connect the brake booster vacuum hose. Connect the EVAP hose for ORVR.
12. 1ZZ-FE: Connect engine wire to cylinder head : Connect the 2 clamps of engine wire to the intake manifold. Connect the 2 ground cables. Connect the oil control valve for VVT connector. Connect the camshaft position sensor connector. Connect the ECT sensor connector.
13. 2ZZ-GE: Connect engine wire to cylinder head : Install the intake manifold insulator No. 2. Connect the 2 ground cables. Connect the oil pressure switch connector. Connect the oil control valve for VVT connector. Connect the oil control valve for VVTL connector. Connect the camshaft position sensor connector. Connect the ECT sensor connector. Install the accelerator cable bracket with the 2 bolts.
14. Install injectors . See «INSTALLATION»(ref-133226-S24949108462002021900000) .
15. Install Throttle Body . See «INSTALLATION»(ref-133226-S24226164282002021900000) .
16. Instal PCV hoses .
17. INSTALL SPARK PLUGS . See «IGNITION»(ref-206133) .
18. Install ignition coil . See «REMOVAL & INSTALLATION»(ref-133226-S41582560472002021900000) .
19. 1ZZ-FE: Install exhaust manifold : Install the lower heat insulator with the 3 bolts. Torque: 12 N.m (123 kgf.cm, 9 ft.lbf) Install a new gasket, and the exhaust manifold with the 5 nuts. Uniformly tighten the nuts in several passes. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) Install the upper heat insulator with the 6 bolts. Torque: 12 N.m (123 kgf.cm, 9 ft.lbf) Install the exhaust manifold stay with the 3 bolts. Torque: 49 N.m (500 kgf.cm, 37 ft.lbf)
20. 2ZZ-GE: Install Exhaust Manifold : Install the lower heat insulator with the 4 bolts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) Install the exhaust manifold with the 3 bolts and 2 nuts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) Install the upper heat insulator with the 5 bolts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) Install the exhaust manifold stay withe 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
21. Install exhaust pipe . See «INSTALLATION»(ref-163200-S27673295712005020100000) .
22. Install generator and drive belt . See «INSTALLATION»(ref-173160-S08158168092005031000000) .
23. Connect accelerator cable .
24. Install air cleaner assembly .
25. Install ECM box . See «INSTALLATION»(ref-163200-S27673295712005020100000) .
26. Install battery .
27. Fill with engine coolant . See «REPLACEMENT»(ref-171346-S41444811672005020100000) .
28. Start engine and check for leaks .
29. Recheck engine coolant level and oil level .

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1. Remove battery and tray .
2. Remove hood .
3. Remove engine under covers .
4. Drain engine coolant .
5. Drain engine oil .
6. Drain transaxle oil .
7. Remove bumper cover and head light .
8. Remove air cleaner cap . Disconnect the MAF meter connector. Disconnect the VSV for EVAP Disconnect the 2 hoses. Disconnect the 3 clamps, and disconnect the air cleaner cap from the air cleaner case. Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body.
9. Remove air cleaner case : Remove the air filter. Disconnect the hose from the VSV for Canister Closed VALVE (CVC). Disconnect the hose from the intake air control valve. Remove the 2 bolts, and disconnect the air cleaner case. Disconnect the 2 hoses from the air cleaner case.
10. Remove ECM box : Remove the 2 bolts and ECM cover. Disconnect the 4 connectors from the ECM, Disconnect the 2 connectors from the ECM box. Remove the ECM from the ECM box, Disconnect the clamp from the ECM box. Disconnect the 2 engine wires from the ECM box. Remove the 3 bolts and ECM box. Remove the 2 nuts, bolt and ECM box stay.
11. Disconnect engine wire from engine compartment relay box : Remove the relay box upper cover. Disconnect the 3 connectors. Disconnect the 7 claws and J/B from the relay box. Disconnect the 3 connectors. Disconnect the engine wire from the relay box.
12. W/ Cruise Control System: Disconnect cruise control actuator : Disconnect the actuator connector. Remove the 3 bolts and disconnect the actuator from the body.
13. Remove radiator assembly . See «REMOVAL»(ref-171346-S40145393822005020100000) .
14. Remove drive belt and generator . See «REMOVAL»(ref-173160-S23088450822005031000000) .
15. W/A/C: Disconnect A/C compressor : Disconnect the A/C compressor connector. NOTE: Suspend the A/C compressor securely. Remove the 3 bolts, and disconnect the A/C compressor from the engine.
16. Disconnect tube and hose : Disconnect the fuel tube from the fuel pipe on vehicle side. Disconnect the 2 heater hoses from the engine side. Disconnect the brake booster vacuum hose.
17. M/T: Disconnect clutch release cylinder : Remove the 3 bolts, and disconnect the brackets from the transaxle. Remove the 2 bolts, and disconnect the release cylinder from the transaxle.
18. Disconnect transaxle control cable(s) .
19. Disconnect 2 ground cables .
20. Remove drive shaft . See «REMOVAL»(ref-163195-S08024892472004062200000) .
21. Remove exhaust pipe : Disconnect the 2 heated oxygen sensor. Remove the 4 bolts and springs. Disconnect the 2 O-rings, and remove the exhaust pipe and 2 gaskets.
22. 1ZZ-FE: Remove exhaust manifold : Remove the 6 bolts and upper heat insulator. Remove the 3 bolts and exhaust manifold stay. Remove the 5 nuts, exhaust manifold and gasket.
23. 2ZZ-GE: Remove exhaust manifold : Remove the 5 bolts and upper heat insulator. Remove the 4 bolts and exhaust manifold stay. Remove the 2 nuts, 3 bolts, exhaust manifold and gasket.
24. Disconnect PS pump : Disconnect the PS oil pressure switch connector. NOTE: Put aside the pump and suspend it to the cowl with a string. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine.
25. Remove Stabilizer Bar Bracket . See «STABILIZER BAR»(ref-164588-S36736889532004081000000) .
26. Disconnect PS gear : Remove the 4 bolts, and disconnect the PS gear from the suspension member.
27. Remove suspension member : Remove the 9 bolts, 3 nuts and suspension member.
28. Attach engine sliding device to engine hanger : Remove the 4 bolts and No. 2 cylinder head cover. Disconnect the PCV hoses from the cylinder head cover. Install the 2 engine hangers in the correct direction. Engine hanger part No.: 1ZZ-FE Front: 12281--22021 Rear: 12281--15040 or 12281--15050 Bolt: 91512-B1016 2ZZ-GE Front: 12281--88600 Rear: 12282--88600 Bolt: 91512--61020 Torque: 38 N.m (388 kgf.cm, 28 ft.lbf) CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. Attach the engine sling device to the engine hangers.
29. Remove rear engine mounting : Remove the through bolt and rear engine mounting insulator. Remove the 3 bolts and rear engine mounting bracket.
30. Remove engine and transaxle assembly : Remove the LH engine mounting through bolt and nut. 1ZZ-FE: Remove the 4 bolts, 2 nuts and RH engine mounting insulator. 2ZZ-GE: Remove the 5 bolts, 2 nuts and RH engine mounting insulator. Lower the engine out of vehicle slowly and carefully, and raise the vehicle. HINT: Make sure the engine is clear of all wiring, hoses and cables. Place the engine and transaxle assembly onto the stand.
31. Separate engine and transaxle : (C56 M/T: . See «REMOVAL & INSTALLATION»(ref-157691) . (C60 M/T: . See «REMOVAL & INSTALLATION»(ref-157691) . (U240E A/T: . See «REMOVAL & INSTALLATION»(ref-157691) . (U341E A/T: . See «REMOVAL & INSTALLATION»(ref-157691) .

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1. Assembly engine and transaxle : (C56 M/T: . See «REMOVAL & INSTALLATION»(ref-157691) . (C60 M/T: . See «REMOVAL & INSTALLATION»(ref-157691) . (U240E A/T: . See «REMOVAL & INSTALLATION»(ref-157691) . (U341E A/T: . See «REMOVAL & INSTALLATION»(ref-157691) .
2. Install engine and transaxle assembly in vehicle : Attach the engine sling device to the engine hangers. Slowly lower the vehicle, and raise the engine into the engine compartment. Keep the engine level, and align RH and LH mountings with the body bracket. 1ZZ-FE: Install the RH engine mounting insulator with the 4 bolts and 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 2ZZ-GE: Install the RH engine mounting insulator with the 5 bolts and 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) Install the LH engine mounting through bolt and nut. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf)
3. Remove engine sling device
4. Install rear engine mounting : Install the rear engine mounting bracket with the 3 bolts. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) Temporarily install the rear engine mounting insulator with the through bolt.
5. Install suspension member : Install the suspension member with the 9 bolts and 3 nuts. Torque: A 52 N.m (530 kgf.cm, 32 ft.lbf) B 52 N.m (530 kgf.cm, 32 ft.lbf) C 157 N.m (1,600 kgf.cm, 116 ft.lbf) D 157 N.m (1,600 kgf.cm, 116 ft.lbf) E 39 N.m (400 kgf.cm, 29 ft.lbf) Nut 52 N.m (530 kgf.cm, 32 ft.lbf) Tighten the rear engine mounting through bolt. Torque: 87 N.m (887 kgf.cm, 64 ft.lbf)
6. Connect PS gear : Install the PS gear with the 4 bolts. Torque: 45 N.m (460 kgf.cm, 33 ft.lbf)
7. Install stabilizer bar bracket . See «STABILIZER BAR»(ref-164588-S36736889532004081000000) .
8. Connect PS pump : Install the PS pump with the 2 through bolts and nuts. See «INSTALLATION»(ref-171187-S32904091012005013100000) . Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) Connect the PS oil pressure switch connector.
9. 1ZZ-FE: Install exhaust manifold : Install the gasket and exhaust manifold with the 5 nuts. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) Install the exhaust manifold stay with the 3 bolts. Torque: 49 N.m (500 kgf.cm, 37ft.lbf) Install the upper heat insulator with the 6 bolts. Torque: 12 N.m (123 kgf.cm, 9 ft.lbf)
10. 2ZZ-GE: Install exhaust manifold Install the gasket and exhaust manifold with the 2 nuts and 3 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) Install the exhaust manifold stay with the 4 bolts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) Install the upper heat insulator with the 5 bolts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
11. Install exhaust pipe : Install the 2 gaskets and exhaust pipe. Connect the 2 O-rings. Install the 4 springs and bolts. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) Connect the 2 heated oxygen sensor.
12. Install drive shaft . See «INSTALLATION»(ref-163195-S18625847272004062200000) .
13. Connect 2 ground cables .
14. Connect transaxle control cable(s) .
15. M/T: Connect clutch release cylinder : Install the release cylinder with the 2 bolts. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) Install the brackets with the 3 bolts. Torque: Bolt A 12 N.m (120 kgf.cm, 9 ft.lbf) Bolt B 4.9 N.m (50 kgf.cm, 43 in.lbf)
16. Connect tube and hose : Connect the brake booster vacuum hose. Connect the 2 heater hoses to the engine side. Connect the fuel tube to the fuel pipe on vehicle side.
17. W/ A/C: install A/C compressor : Install the A/C compressor with the 3 bolts. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) Connect the A/C compressor connector.
18. Install generator and drive belt . See «INSTALLATION»(ref-173160-S08158168092005031000000) .
19. Install radiator assembly . See «INSTALLATION»(ref-171346-S08542454652005020100000) .
20. W/ Cruise Control System: Install cruise control actuator : Install the actuator with the 3 bolts. Connect the actuator connector.
21. Connect engine wire to engine compartment relay box : Install the engine wire to the relay box. Connect the 3 connectors. Connect the J/B to the relay box. Connect the 3 connectors. Install the relay box upper cover.
22. INSTALL ECM BOX Install the ECM box stay with the 2 nuts and bolt. Torque: Nut 12 N.m (120 kgf.cm, 9 ft.lbf) Bolt 18 N.m (185 kgf.cm, 13 ft.lbf) Instal the ECM box with the 3 bolts. Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf) Connect the 2 engine wire to the ECM box. Connect the clamp to the ECM box. Install the ECM to the ECM box. Connect the 2 connectors to the ECM box. Connect the 4 connectors to the ECM Install the ECM cover with the 2 bolts. Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf)
23. Install air cleaner case : Connect the 2 hoses to the air cleaner case. Install the air cleaner case with the 2 bolts. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) Connect the hose to the intake air control valve. Connect the hose to the VSV for canister closed valve (CVC). Install the air filter.
24. Install air cleaner cap : Install the air cleaner hose to the throttle body with the hose clamp. Connect the air cleaner cap to the air cleaner case with the 3 clamps. Connect the 2 hoses. Connect the VSV for EVAP. Connect the MAF meter connector.
25. Install headlight and bumper cover .
26. Install battery and tray .
27. Fill with transaxle oil .
28. Fill with engine oil .
29. Fill with engine coolant . See «REPLACEMENT»(ref-171346-S41444811672005020100000) .
30. Start engine and check for leads .
31. Perform engine adjustment .
32. Check front wheel alignment .
33. Install engine under covers .
34. Install engine hood .
35. Road test vehicle . Check for abnormal noises, shock slippage, correct shift points and smooth operation.
36. Recheck engine coolant and oil levels .

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1. M/T: Remove flywheel .
2. A/T: Remove drive plate .
3. Install engine to engine stand for disassembly .
4. Remove timing chain and sprockets . See «REMOVAL»(ref-163200-S28314870632005020100000) .
5. Remove engine wire .
6. Remove cylinder head . See «REMOVAL»(ref-163200-S13032368722005020100000) .
7. 1ZZ-FE: Remove oil dipstick and guide : Remove the bolt and oil dipstick and guide. Remove the O-ring from the dipstick.
8. Remove water bypass pipe : Remove the 2 nuts, bolts and water bypass pipe.
9. Remove thermostat . See «REMOVAL»(ref-171346-S19640175992005020100000) .
10. Remove knock sensor .
11. Remove engine coolant drain union .
12. Remove oil pump. See «REMOVAL»(ref-171349-S15616776402005020200000) . .
13. 2ZZ-GE: Remove ventilation case : Remove the 3 nuts, ventilation case and gasket. Remove the clip and No. 3 ventilation hose.
14. Remove oil filter . See «REPLACEMENT»(ref-171349-S35711467732005020200000) .
15. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union.
16. Remove oil pan : 1ZZ-FE: Remove the 14 bolts and 2 nuts. 2ZZ-GE: Remove the 12 bolts and 4 nuts. NOTE: Be careful not to the damage the oil pan contact surface of the bearing cap sub-assembly. Be careful not to damage the oil pan flange. Insert the blade of SST between the bearing cap sub-assembly and oil pan, and cut off applied sealer and remove the oil pan. SST 09032-00100
17. 1ZZ-FE: Remove oil strainer : Remove the 2 nuts, bolt, oil strainer and gasket.
18. 2ZZ-GE: Remove oil strainer and oil pan baffle : Remove the 2 nuts, bolt, oil strainer and gasket. Remove the 4 bolts, 2 nuts and oil pan baffle.
19. Check connecting rod thrust clearance : Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 -- 0.342 mm (0.0063 -- 0.0135 in.) Maximum thrust clearance: 0.342 mm (0.0135 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 19.788 -- 19.840 mm (0.7791 -- 0.7811 in.)
20. Remove Connecting Rod Caps And Check Oil Clearance Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. NOTE: Keep the lower bearing inserted with the connecting rod cap. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. 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 the crank pin. Install the connecting rod cap with the 2 bolts. See «REASSEMBLY»(ref-163200-S04607564012005020100000) . Torque: 1st: 1ZZ-FE: 20 N.m (204 kgf.cm, 15 ft.lbf) 2ZZ-GE: 30 N.m (306 kgf.cm, 22 ft.lbf) 2nd: Turn extra 90° NOTE: Do not turn the crankshaft. Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) Measure the Plastigage at its widest point. Standard oil clearance: 1ZZ-FE: 0.028 -- 0.060 mm (0.0011 -- 0.0024 in.) 2ZZ-GE: 0.028 -- 0.052 mm (0.0011 -- 0.0020 in.) Maximum oil clearance; 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. NOTE: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked"1","2" and"3" accordingly. Reference Standard bearing center wall thickness Completely remove the Plastigage.
21. Remove Piston And Connecting Rod Assemblies Using a ridge reamer, remove all the carbon from the top of the cylinder. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
22. Remove bearing cap sub-assembly and crankshaft rear oil seal, and check oil clearance : 2ZZ-GE: Remove the 4 screw plugs from the bearing cap sub-assembly. Remove the 10 hexagon head bearing cap sub-assembly bolts. Uniformly loosen and remove the 10 bearing cap sub-assembly bolts, in several passes, in the sequence shown. CAUTION: Be careful not to damage the contact surfaces of the cylinder block and bearing cap sub-assembly. Keep the lower bearing and bearing cap sub-assembly together. Using a screwdriver, remove the bearing cap sub-assembly by prying the portions between the cylinder block and bearing cap sub-assembly. Remove the 5 lower main bearings. Remove the crankshaft rear oil seal. NOTE: Keep the upper bearings together with the cylinder block. Lift out the crankshaft. Clean each main journal and bearing. Check each main 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. Lay a strip of Plastigage across each journal. Install the bearing cap sub-assembly. See «REASSEMBLY»(ref-163200-S04607564012005020100000) . NOTE: Do not turn the crankshaft. Remove the bearing cap sub-assembly (See procedures (a) to (e) above). Measure the Plastigage at its widest point. Standard oil clearance: 1ZZ-FE: 0.015 -- 0.032 mm (0.0006 -- 0.0013 in.) 2ZZ-GE: 0.016 -- 0.032 mm (0.0006 -- 0.0013 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater then maximum, replace the bearings. If necessary, replace the crankshaft. 1ZZ-FE: 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 selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked"1","2","3" and"4" accordingly. EXAMPLE: Cylinder block"4" (A) + Crankshaft"3" (B) = Total number 7 (Use bearing"3") 2ZZ-GE: If using standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, refer to the following table to select bearing. EXAMPLE: Cylinder block"4", Crank shaft"3", Use bearing"3" Completely remove the Plastigage.
23. Check crankshaft thrust clearance : Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 -- 0.24 mm (0.0016 -- 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 2.430 -- 2.480 mm (0.0957 -- 0.0976 in.)
24. Remove crankshaft : Lift out the crankshaft. NOTE: Arrange the main bearings and thrust washers in the correct order. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
25. Check fit between 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.
26. Remove piston rings : 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 the correct order only.
27. Disconnect connecting rod from piston : Using a small screwdriver, pry out the 2 snap rings. 1ZZ-FE: Gradually heat the piston to 80 -- 90°C (176 -- 194°F). NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. 1ZZ-FE: Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. 2ZZ-GE: Remove the pin and connecting rod from the piston.

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1. Remove gasket material : Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block : Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness : Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder block.
4. Inspect cylinder bore diameter : Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter : Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 1ZZ-FE 79.000 -- 79.013 mm (3.1102 -- 3.1107 in.) 2ZZ-GE 82.000 -- 82.013 mm (3.2283 -- 3.2289 in.) Maximum diameter: 1ZZ-FE 79.013 mm (3.1107 in.) 2ZZ-GE 82.013 mm (3.2289 in.) If the diameter is greater than maximum, replace the cylinder block.
6. Remove Cylinder Ridge If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
7. Inspect 12 pointed head bearing cap sub-assembly bolts : Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.3 -- 7.5 mm (0.287 -- 0.295 in.) Minimum diameter: 7.3 mm (0.287 in.) If the diameter is less than minimum, replace the bolt.
8. Clean 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. NOTE: Do not use a wire brush. Using solvent and a brush, thoroughly clean the piston.
9. Inspect piston oil clearance : 1ZZ-FE: Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 25.6 mm (1.008 in.) from the piston head. 2ZZ-GE: Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 12.0 mm (0.048 in.) from the piston bottom. Piston diameter: 1ZZ-FE: 78.925 -- 78.935 mm (3.1073 -- 3.1077 in.) 2ZZ-GE: 81.975 -- 81.993 mm (3.2274 -- 3.2281 in.) Measure the cylinder bore diameter in the thrust directions (See procedure in step 5 ). Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 1ZZ-FE: 0.065 -- 0.088 mm (0.0026 -- 0.0035 in.) 2ZZ-GE: 0.007 -- 0.038 mm (0.0003 -- 0.0015 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.
10. Inspect piston ring end gap : Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: 0.030 -- 0.070 mm (0.0012 -- 0.0028 in.) If the clearance is not as specified, replace the piston.
11. Inspect 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, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.25 -- 0.35 mm (0.0098 -- 0.0138 in.) No. 2 0.35 -- 0.50 mm (0.0138 -- 0.0197 in.) Oil (Side rail) 0.15 -- 0.40 mm (0.0059 -- 0.0157 in.) Maximum end gap: No. 1 1.05 mm (0.0413 in.) No. 2 1.20 mm (0.0472 in.) Oil (Side rail) 1.05 mm (0.0413 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
12. Inspect piston pin fit : At 80 -- 90°C (176 -- 194°F), you should be able to push the piston pin into the piston pin hole with your thumb.
13. Inspect connecting rod alignment : Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for out-of-alignment Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out-of alignment is greater than maximum, replace the connecting rod assembly. Check for twist Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly.
14. Inspect piston pin oil clearance : Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 1ZZ-FE 20.012 -- 20.021 mm (0.7879 -- 0.7882 in.) 2ZZ-GE 20.011 -- 20.023 mm (0.7878 -- 0.7883 in.) 2ZZ-GE: Using caliper gauge, measure the inside diameter of the piston bushing. Bushing inside diameter: 20.013 -- 20.025 mm (0.7879 -- 0.7884 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 1ZZ-FE 20.004 -- 20.013 mm (0.7876 -- 0.7879 in.) 2ZZ-GE 20.004 -- 20.016 mm (0.7876 -- 0.7880 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 1ZZ-FE 0.005 -- 0.011 mm (0.0002 -- 0.0004 in.) 2ZZ-GE Piston x Piston pin 0.005 -- 0.013 mm (0.0002 -- 0.0005 in.) Piston pin x Connecting rod 0.005 -- 0.009 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 bushing. If necessary, replace the piston and piston pin as a set.
15. Inspect connecting rod bolts : Using a vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 6.6 -- 6.7 mm (0.260 -- 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than minimum, replace the bolt.
16. Inspect crankshaft for circle runout : Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the crankshaft.
17. Inspect main journals and crank pins : Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 47.988 -- 48.000 mm (1.8893 -- 1.8898 in.) Crank pin diameter: 1ZZ-FE: 43.992 -- 44.000 mm (1.7320 -- 1.7323 in.) 2ZZ-GE: 44.992 -- 45.000 mm (1.7713 -- 1.7717 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main 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.

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1. Replace connecting rod bushings : Using SST and a press, press out the bushing. SST 09222-30010 Align the oil hoses of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance, See «INSPECTION»(ref-163200-S19256860002005020100000) , between the bushing and piston pin. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
2. Replace crankshaft rear oil seal : If rear oil seal is installed to cylinder block. Using a knife cut off the oil seal lip. CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver tip. Using a screwdriver, pry out the oil 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 rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100)