Engine Mechanical - 2.4L: Overview Toyota Highlander I

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1. Inspect coolant (see «COOLANT (2AZ-FE)»(ref-179473-S18914038582005070800000) ) .
2. Inspect engine oil .
3. Inspect battery . Standard Specific Gravity: 1.25 - 1.29 At 20°C (68°F)
4. Inspect air cleaner filter element sub-assy .
5. Inspect spark plug (see INSPECT SPARK PLUG ) .
6. Inspect V-ribbed belt .
7. Inspect ignition timing . Warm up engine. When using TOYOTA hand-held tester . Connect the TOYOTA hand-held tester to the DLC3. Ignition timing: 8 - 12° BTDC NOTE: Please refer to the TOYOTA hand-held tester operator's manual for further details. When not using TOYOTA hand-held tester . Using SST, connect terminals 13 (TC) and 4 (CG) of DLC3. SST 09843-18040, 09843-18020 NOTE: Be sure not to connect incorrectly. It causes breakage of the engine. Turn OFF all electrical systems. Operate the inspection when the cooling fan motor is turned OFF. Remove the cylinder head cover No. 2. Pull out the wire harness as shown in the illustration. Connect the clip of the timing light to the engine. NOTE: Use a timing light which can detect the first signal. After checking, be sure to tape the wire harness. Inspect ignition timing at idle. Ignition timing: 8 - 12° BTDC NOTE: When checking the ignition timing, the transmission is at neutral position. NOTE: After engine RPM is kept at 1,000 - 1,300 r/min. for 5 seconds, check that it returns idle speed. Disconnect terminals 13 (TC) and 4 (CG) of DLC3. Inspect ignition timing at idle. Ignition timing: 5 - 15° BTDC Confirm that ignition timing moves to advanced angle side when the engine RPM is increased. Remove the timing light.
8. Inspect engine idle speed . Warm up engine. When using TOYOTA hand-held tester. Connect the TOYOTA hand-held tester to the DLC3. Idle speed: 600 - 700 r/min. NOTE: Check idle speed with cooling fan OFF. Switch off all accessories and air conditioning. NOTE: Please refer to the TOYOTA hand-held tester operator's manual for further details. When not using TOYOTA hand-held tester. Using SST, connect tachometer test prove to terminal 9 (TAC) of DLC3. SST 09843-18040 Check the idle speed. Idle speed: 600 - 700 r/min.
9. Inspect Compression Warm up and stop engine. Disconnect the injector connectors. Remove ignition coil. Remove spark plugs. Inspect cylinder compression pressure. SST 09992-00500 Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. Compression pressure: 1.360 MPa (13.9 kgf/cm 2 , 198 psi) Minimum pressure: 0.98 MPa (10 kgf/cm 2 , 142 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm 2 , 14 psi) NOTE: Always use a fully charged battery to obtain engine speed of 250 RPM or more. Check other cylinder's compression pressure in the same way. This measurement must be done in as short a time as possible. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. NOTE: If adding oil increases the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating improperly, or there may be leakage past the gasket.
10. Inspect CO/HC Start the engine. Race engine at 2,500 RPM for approx. 180 seconds. Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into tailpipe during idling. Immediately check CO/HC concentration at idle and/or 2,500 r/min. NOTE: Complete the measuring within 3 minutes. When doing the 2 mode (idle and 2,500 r/min.) test, these measuring orders are prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. Check heated oxygen sensor operation. (see HEATED OXYGEN SENSOR ) see the table below for possible causes, and then inspect and correct the applicable causes if necessary.

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1. Remove front wheel RH .
2. Remove front fender splash shield, front RH .
3. Remove front fender apron seal RH .
4. Remove engine mounting stay No. 2 RH .
5. Remove engine cover sub-assy No. 1 .
6. Remove engine moving control rod w/bracket . Remove the 3 bolts and engine mounting control rod w/bracket.
7. Remove engine mounting bracket No. 2 RH .
8. Remove fan and generator V belt . Turn the drive belt tensioner slowly clockwise, and remove the drive bolt by using SST. SST 09249-63010
9. Install fan and generator V belt . Turn the drive belt tensioner slowly clockwise, and install the drive bolt by using SST. SST 09249-63010
10. Install engine mounting bracket No. 2 RH . Torque: 52 N.m (531 kgf.cm, 38 ft.lbf)
11. Install engine moving control rod w/bracket . Install the engine mounting control rod with the 3 bolts w/bracket. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
12. Install engine mounting stay No. 2 RH . Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
13. Install front wheel RH . Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)

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1. Remove front wheel RH .
2. Remove front fender splash shield front RH .
3. Remove front fender apron seal RH .
4. Remove engine cover sub-assy No. 1 .
5. Remove ignition coil assy .
6. Separate ventilation hose .
7. Separate ventilation hose No. 2 .
8. Remove cylinder head cover sub-assy . Remove the bolt and disconnect the engine wire harness clamp. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.
9. Set No. 1 cylinder to TDC/compression . Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap as shown in the illustration.
10. Inspect valve clearance . NOTE: Inspect and adjust the valve clearance when the engine is cold. Check only the valve indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.19 - 0.29 mm (0.0075 - 0.0114 in.) Exhaust 0.30 - 0.40 mm (0.0118 - 0.0157 in.) Turn the crankshaft clockwise 1 revolution (360°) and set No. 4 cylinder to TDC/compression. Check only the valve indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.19 - 0.29 mm (0.0075 - 0.0114 in.) Exhaust 0.30 - 0.40 mm (0.0118 - 0.0157 in.)
11. Adjust valve clearance . NOTE: Be sure not to turn the crankshaft without the chain tensioner. Turn the crankshaft clockwise 1 revolution (360°) and set the No. 1 cylinder to the TDC/compression. Place matchmarks on the timing chain and camshaft timing gear. Remove the 2 bolts and chain tensioner. Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set blot. NOTE: Be careful not to damage the valve lifter. Loosen the camshaft bearing cap bolts on No. 2 camshaft in the sequence shown in the illustration in several passes, and remove the caps. Raising the camshaft, remove the set bolt. Remove the timing chain sprocket from the camshaft with timing chain. Remove the timing chain sprocket from the timing chain. Loosen the camshaft bearing cap bolts on camshaft in the sequence shown in the illustration in several passes, and remove the caps. Remove the intake camshaft. Tie the timing chain with a string. NOTE: Be careful not to drop anything inside the timing chain cover. Remove the valve lifters. Using a micrometer, measure the thickness of the removed lifter. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. Valve clearance: Intake A = B + (C - 0.24 mm (0.0094 in.)) Exhaust: A = B + (C - 0.35 mm (0.0138 in.)) NOTE: Select a new lifter with a thickness as close as possible to the calculated values. Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing sprockets. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration. Torque: Bearing cap No. 1 30 N.m (301 kgf.cm, 22 ft.lbf) Bearing cap No. 3 9.0 N.m (92 kgf.cm, 80 in.lbf) Put the camshaft No. 2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets. Raising the camshaft, tighten the set bolt temporarily. Examine the from marks and numbers and tighten the bolts in the sequence shown in the illustration. Torque: Bearing cap No. 2 30 N.m (301 kgf.cm, 22 ft.lbf) Bearing cap No. 3 9.0 N.m (92 kgf.cm, 80 in.lbf) Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) NOTE: Be careful not to damage the valve lifter. As shown in the illustration, check the matchmarks on the timing chain and camshaft timing sprockets and the alignment of the pulley groove with timing mark of the chain cover. Install chain tensioner. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Install a new gasket and chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the tensioner, set the hook again if the hook releases the plunger. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
12. Install cylinder head cover sub-assy . 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 NOTE: Remove any oil the contact surface. Install the cylinder head cover within 5 minutes after applying seal packing. Do not put into engine oil 2 hours after installing. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: Bolt A 11 N.m (110 kgf.cm, 8 ft.lbf) Bolt B 14 N.m (143 kgf.cm, 10 ft.lbf) Nut 11 N.m (110 kgf.cm, 8 ft.lbf)
13. Install ignition coil assy . Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
14. Install front wheel RH . Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
15. Inspect oil leak .

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1. Work for preventing gasoline from spilling out (see FUEL SYSTEM (2AZ-FE) ) .
2. Remove front wheel .
3. Remove engine under cover No. 1 .
4. Remove front fender splash shield front RH .
5. Remove front fender splash shield front LH .
6. Remove front fender apron seal RH .
7. Drain coolant (see «COOLANT (2AZ-FE)»(ref-179473-S18914038582005070800000) ) .
8. Drain automatic transaxle fluid . Using a 10 mm hexagon wrench, remove the drain plug and a gasket. Drain automatic transaxle fluid. Install a new gasket and the drain plug. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
9. Drain transfer oil (4WD drive type) . Install a new gasket and the drain plug after draining transfer oil. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
10. Remove battery .
11. Remove air cleaner assy .
12. Separate radiator hose inlet .
13. Separate radiator hose outlet .
14. Separate oil cooler inlet hose .
15. Separate oil cooler outlet hose .
16. Remove engine mounting stay No. 2 RH .
17. Remove engine moving control rod w/bracket . Remove the 3 bolts and the engine moving control rod w/ bracket.
18. Remove engine mounting bracket No. 2 RH .
19. Remove fan and generator V belt (see 8 Remove fan and generator V belt page) . SST 09249-63010
20. Separate vane pump oil reservoir assy .
21. Separate return tube sub-assy . Remove the 2 bolts and separate the return tube.
22. Separate union to check valve hose .
23. Separate accelerator control cable assy .
24. Separate floor shift transmission control cable assy (see «PARK/NEUTRAL POSITION SWITCH»(ref-142491-S39664561932002080800000) ) .
25. Separate heater inlet water hose .
26. Separate heater outlet water hose .
27. Separate fuel tube sub-assy (see FUEL SYSTEM (2AZ-FE) ) .
28. Separate engine room main wire . Separate the engine wire from engine ECU and junction block. Separate the engine wire from engine room junction block. Install the wire harness and remove a nut. Using a screwdriver, unlock the engine room junction block. Separate the engine wire by pulling it up-ward. Separate the connector. Pull out the engine wire. Separate B terminal of the generator. Remove the body ground.
29. Remove exhaust pipe assy front .
30. Remove propeller shaft (4WD drive type) . Place the matchmarks on both of the flanges. Remove the 4 nuts, bolts and washers. Insert SST after removing propeller shaft assembly. SST 09325-20010
31. Remove front stabilizer link assy LH . Using a 6 mm socket hexagon wrench to fix the stud bolt. Remove the nut and the stabilizer bar link.
32. Remove front stabilizer link assy RH . NOTE: Perform the same procedure as above on the opposite side.
33. Remove front axle hub LH nut . Using SST and a hammer, unstake the staked part of the lock nut. SST 09930-00010 NOTE: When removing the nut, unstake the staked part of it completely. Do not damage the threads of the drive shaft. Be sure not to sharpen the tip of the SST. Using a 30 mm socket wrench, remove the lock nut.
34. Remove front axle hub RH nut . SST 09930-00010 NOTE: Perform the same procedure as above on the opposite side.
35. Separate speed sensor front LH . NOTE: Keep the tip and connection part of speed sensor off foreign materials.
36. Separate speed sensor front RH . NOTE: Perform the same procedure as above on the opposite side.
37. Separate tie rod assy LH . Remove the cotter pin and a castle nut. Using SST, separate the tie rod end from the steering knuckle. SST 09628-62011 NOTE: Be careful not to damage the cover of the ball joint.
38. Separate tie rod assy RH . SST 09628-62011 NOTE: Perform the same procedure as above on the opposite side.
39. Separate front suspension arm sub-assy lower No. 1 LH . Remove the bolt and 2 nuts shown in the illustration. Using a plastic hammer, separate the drive shaft from the axle hub.
40. Separate front suspension arm sub-assy lower No. 1 RH . NOTE: Perform the same procedure as above on the opposite side.
41. Remove drive plate & torque converter clutch setting bolt . Fix the crankshaft and remove the 6 set bolts.
42. Separate steering intermediate shaft sub-assy . Loosen the sliding yoke bolt. Place matchmarks on the intermediate shaft and control valve shaft. Remove the bolt, and separate the steering intermediate shaft. To prevent from rotating the steering wheel, fix the wheel with seat belt. NOTE: The operation is useful to prevent the damage of the spiral cable.
43. Separate compressor and magnetic clutch . NOTE: Hung up the hoses instead of detaching.
44. Remove engine assembly with transaxle . Set the engine lifter. Remove the 6 bolts, frame side rail plate sub-assembly RH and LH. Remove the 6 bolts, front suspension member brace rear RH and LH. Carefully, remove the engine assembly from the vehicle. Install the 2 engine hangers as shown in the illustration. Parts No.: No. 1 engine hanger 12281-28010 No. 2 engine hanger 12282-28010 Bolt 91512-61020 Torque: 38 N.m (387 kgf.cm, 28 in.lbf) Using the chain block and engine sling device, hang the engine assembly.
45. Separate vane pump assy . Separate the PS oil pressure switch connector. Remove the 2 bolts and separate the vane pump from the engine.
46. Remove stabilizer bar front (4WD drive type) .
47. Remove rack & pinion power steering gear assy (4WD drive type) .
48. Remove front frame assy . Remove a nut installing the engine mounting insulator LH. Remove a nut installing the engine mounting insulator RH. Remove a nut installing the engine mounting insulator FR. Remove a nut installing the engine mounting insulator RR. (4WD) Raise the engine assembly and separate the front frame.
49. Remove front drive shaft assy RH (4WD drive type) (see «REMOVAL & INSTALLATION»(ref-157895) ) .
50. Remove transverse engine mounting bracket (4WD drive type) . Remove the 6 bolts and engine mounting bracket RR.
51. Remove transfer assy (4WD drive type) (see «OVERHAUL»(ref-153591) ) .
52. Remove front drive shaft assy LH (see «REMOVAL & INSTALLATION»(ref-157895) ) .
53. Remove front drive shaft assy RH (2WD drive type) (see «REMOVAL & INSTALLATION»(ref-157895) ) .
54. Remove starter assy (see «REMOVAL & INSTALLATION (HIGHLANDER & RAV4)»(ref-139867-S26306499222002051000000) ) .
55. Remove automatic transaxle assy (see «REMOVAL & INSTALLATION»(ref-157895) ) .
56. Remove drive plate & ring gear sub-assy . Fix the crankshaft with SST. SST 09213-54015 (91651-60855), 09330-00021 Remove the 8 bolts, rear spacer, drive plate and front spacer.
57. Install engine stand .
58. Remove Engine Cover Sub-Assy No. 1 .
59. Remove intake manifold . Remove the 5 bolts, 2 nuts, intake manifold and gasket.
60. Remove ventilation hose .
61. Remove ventilation hose No. 2 .
62. Remove engine wire .
63. Remove intake manifold insulator No. 1 .
64. Remove generator assy .
65. Remove oil level gauge sub-assy .
66. Remove oil level gauge guide .
67. Remove manifold converter insulator No. 1 .
68. Remove exhaust manifold converter sub-assy . Remove the 2 bolts, nuts No. 1 and No. 2 exhaust manifold stay. Remove the 5 nuts, exhaust manifold converter and gasket.
69. Remove water inlet .
70. Remove thermostat .
71. Remove Ignition Coil Assy .
72. Remove camshaft timing oil control valve assy .
73. Remove V-ribbed belt tensioner assy . Remove the bolt, nut and the drive belt tensioner.
74. Remove drive shaft bearing bracket (2WD drive type) .
75. Remove transverse engine mounting bracket .
76. Remove fuel delivery pipe w/injector (see FUEL SYSTEM ) .
77. Remove water by-pass pipe No. 1 .
78. Remove oil cooler pipe (w/oil cooler) .
79. Remove oil cooler hose (w/oil cooler) .
80. Remove oil cooler hose (w/oil cooler) .
81. Remove engine oil pressure switch assy . Remove the oil pressure switch.
82. Remove knock control sensor . Using SST, remove the knock control sensor. SST 09816-30010
83. Remove engine coolant temperature sensor . Remove the water temperature sensor.
84. Replace partial engine assy
85. Install engine coolant temperature sensor . Install a new gasket to the water temperature sensor. Install the water temperature sensor. Torque: 20 N.m (208 kgf.cm, 15 ft.lbf)
86. Install knock control sensor . Using SST, install the knock control sensor. SST 09816-30010 Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
87. Install engine oil pressure switch assy . Clean the threads of the oil pressure switch, apply adhesive there. Adhesive: Part No. 08833-00080 THREE BOND 1344 or equivalent Install the oil pressure switch. Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
88. Install oil cooler pipe (w/oil cooler) . Install a new gasket and the oil cooler pipe with the bolt and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
89. Install water by-pass pipe No. 1 . Install a new gasket and the water by-pass pipe No. 1 with the bolt and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
90. Install fuel delivery pipe w/injector (see FUEL SYSTEM ) .
91. Install transverse engine mounting bracket . Torque: 54 N.m (551 kgf.cm, 40 ft.lbf)
92. Install drive shaft bearing bracket (2WD drive type) . Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
93. Install V-ribbed belt tensioner assy . Install the drive belt tensioner with the bolt and the nut. Torque: 60 N.m (607 kgf.cm, 44 ft.lbf)
94. Install camshaft timing oil control valve assy . Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
95. Install ignition coil assy . Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
96. Install thermostat (see «THERMOSTAT (2AZ-FE)»(ref-179473-S32061798672005070800000) ) .
97. Install water inlet . Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
98. Install exhaust manifold converter sub-assy . Install a new gasket and the exhaust manifold converter with the 5 nuts. Torque: 37 N.m (378 kgf.cm, 27 ft.lbf) Install the No. 1 and No. 2 exhaust manifold stay with the 2 bolts and 2 nuts. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
99. Install manifold converter insulator No. 1 . Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
100. Install oil level gauge guide . Apply a light coat of engine oil to the O-ring, install it to the guide. Install the oil level gauge and guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
101. Install generator assy (see «GENERATOR ASSEMBLY»(ref-173287-S32066356372005042700000) ) .
102. Install intake manifold . Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
103. Install drive plate & ring gear sub-assy . Fix the crankshaft with SST. SST 09213-54015 (91651-60855), 09330-00021 Clean the bolt and the bolt hole. Apply Adhesive to 2 to 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND or equivalent. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown. Torque: 98 N.m (1000 kgf.cm, 72 ft.lbf)
104. Install automatic transaxle assy (see «REMOVAL & INSTALLATION»(ref-157895) ) .
105. Install starter assy . Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
106. Install front drive shaft assy RH (2WD drive type) (see «REMOVAL & INSTALLATION»(ref-157895) ) .
107. Install front drive shaft assy LH (see «REMOVAL & INSTALLATION»(ref-157895) ) .
108. Install transfer assy (4WD drive type) (see «OVERHAUL»(ref-153591) ) .
109. Install transverse engine mounting bracket (4WD drive type) . Install the mounting bracket with the 6 bolts. Torque: Bolt A 34 N.m (347 kgf.cm, 25 ft.lbf) Bolt B 64 N.m (653 kgf.cm, 47 ft.lbf)
110. Install front drive shaft assy RH (4WD drive type) (see «REMOVAL & INSTALLATION»(ref-157895) ) .
111. Install front frame assy . Install the engine mounting insulator LH with a nut. Torque: 95 N.m (969 kgf.cm, 70 ft.lbf) Install the engine mounting insulator RH with a nut. Torque: 95 N.m (969 kgf.cm, 70 ft.lbf) Install the engine mounting insulator FR with a nut. Torque: 87 N.m (888 kgf.cm, 64 ft.lbf) Install the engine mounting insulator RR with 2 nuts (4WD Drive Type). Torque: 75 N.m (765 kgf.cm, 55 ft.lbf)
112. Install rack & pinion power steering gear assy (4WD drive type) . Torque: 70 N.m (714 kgf.cm, 52 ft.lbf)
113. Install stabilizer bar front (4WD drive type) . Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
114. Install vane pump assy . Connect the vane pump to the engine with the 2 bolts. Torque: 43 N.m (439 kgf.cm, 31 ft.lbf)
115. Install engine assembly with transaxle . Set the engine assembly with transaxle on the engine lifter. Install the engine assembly to the vehicle. Install the frame side plate LH and RH with 6 bolts. Torque: Bolt A 85N.m (867 kgf.cm, 63 ft.lbf) Bolt B 32 N.m (326 kgf.cm, 24 ft.lbf) Install the front suspension member brace rear RH and LH with 6 bolts. Torque: Bolt C 85N.m (867 kgf.cm, 63 ft.lbf) Bolt D 32 N.m (326 kgf.cm, 24 ft.lbf)
116. Install compressor and magnetic clutch (see «AUTOMATIC A/C HEATER SYSTEMS»(ref-138672) ) .
117. Install steering intermediate shaft sub-assy . Align the matchmarks on the intermediate shaft and control valve shaft. Tighten the bolt. Torque: 35 N.m (357 kgf.cm, 26 ft.lbf)
118. Install drive plate & torque converter clutch setting bolt . Fix the crank shaft, and install the 6 set bolts. Torque: 41 N.m (418 kgf.cm, 30 ft.lbf)
119. Install front suspension arm sub-assy lower No. 1 LH . Install the drive shaft to steering knuckle. Install the suspension lower arm with the bolt and the 2 nuts. Torque: 127 N.m (1296 kgf.cm, 94 ft.lbf)
120. Install front suspension arm sub-assy lower No. 1 RH . NOTE: Perform the same procedure as above on the opposite side.
121. Install tie rod assy LH . Connect the tie rod end to the steering knuckle and install a new castle nut. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) NOTE: Prevent any lubricant from the thread and the taper portions. After tightening the castle nut, tighten it to the additional direction within 60° to put into a cotter pin. Insert a new cotter pin.
122. Install tie rod assy RH . NOTE: Perform the same procedure as above on the opposite side.
123. Install speed sensor front LH . Torque: 8.0 N.m (82 kgf.cm, 71 ft.lbf)
124. Install speed sensor front RH . Torque: 8.0 N.m (82 kgf.cm, 71 ft.lbf)
125. Install front axle hub LH nut . Using a 30 mm socket wrench, install a new hub nut. Torque: 294 N.m (3,000 kgf.cm, 217 ft.lbf) Using a chisel, stake the hub nut.
126. Install front axle hub RH nut . NOTE: Perform the same procedure as above on the opposite side.
127. Install front stabilizer link assy LH . Install the nut by using a 5 mm socket hexagon wrench to fix the stud bolt. Torque: 74 N.m (755 kgf.cm, 55 ft.lbf)
128. Install front stabilizer link assy RH . NOTE: Perform the same procedure as above on the opposite side.
129. Install propeller shaft (4WD drive type) . Align the matchmarks on both the flanges of the front propeller shaft and intermediate shaft, then install and tighten the 4 bolts, washers and nuts. Torque: 74 N.m (755 kgf.cm, 55 ft.lbf)
130. Install exhaust pipe assy front (see «EXHAUST»(ref-179444) ) .
131. Connect fuel tube sub-assy (see FUEL SYSTEM (2AZ-FE) ) .
132. Install return tube sub-assy . Install the return tube with 2 bolts. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
133. Install fan and generator V belt (see «DRIVE BELT (2AZ-FE)»(ref-159280-S33179642412005062900000) ) . SST 09249-63010
134. Install engine mounting bracket No. 2 RH . Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
135. Install engine moving control rod w/bracket . Install the engine mounting control rod w/bracket with 3 bolts. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
136. Install engine mounting stay No. 2 RH . Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
137. Install air cleaner assy . Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
138. Add transfer oil . Install a new gasket and the filler plug. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
139. Add automatic transaxle fluid .
140. Add engine oil .
141. Add coolant (see «COOLANT (2AZ-FE)»(ref-179473-S18914038582005070800000) ) .
142. Oil Leak
143. Check engine coolant leak (see «COOLANT (2AZ-FE)»(ref-179473-S18914038582005070800000) ) .
144. Inspect fuel leak (see FUEL SYSTEM (2AZ-FE) ) .
145. Install front wheel . torque: 103 n.m (1,050 kgf.cm, 76 ft.lbf)
146. Adjust front wheel alignment (see «SPECIFICATIONS & PROCEDURES»(ref-157296) ) .
147. Inspect check idle speed and ignition timing (see «ENGINE ASSY (2AZ-FE)»(ref-159280-S24369778602005062900000) ) .
148. Inspect CO/HC (see «ENGINE ASSY (2AZ-FE)»(ref-159280-S24369778602005062900000) ) .
149. Check ABS speed sensor signal (see «PRE-CHECK»(ref-177545-S42192344642005060100000) ) .

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1. Remove oil filler cap sub-assy.
2. Remove oil filler cap gasket.
3. Remove ventilation valve sub-assy.
4. Remove spark plug.
5. Remove oil filter sub-assy. Using SST, remove the oil filter. SST 09228-06501
6. Remove oil cooler assy (w/ oil cooler). Remove the flange nut. Remove the union bolt and oil cooler. Remove the O-ring from the oil cooler.
7. Remove oil filter union (w/o oil cooler). Using a 12 mm hexagon wrench, remove the oil filter union.
8. Remove cylinder head cover sub-assy Remove 8 bolts, 2 nuts, and cylinder head cover sub assembly.
9. Remove cylinder head cover gasket.
10. Remove crank position sensor.
11. Remove crankshaft pulley. Turn the crankshaft pulley, and align its groove with the timing mark "O" of the timing chain cover. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap as shown in the illustration. Using SST, fix the crankshaft pulley and loosen a pulley set bolt. SST 09213-54015 (91651-60855), 09330-00021 Using a pulley set bolt and SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
12. Remove chain tensioner assy No. 1. Remove the 2 nuts, timing chain tensioner and gasket. NOTE: Be sure not to turn the crankshaft without the chain tensioner.
13. Remove water pump pulley. Using SST, remove the water pump pulley. SST 09960-10010 (09962-01000, 09963-00700)
14. Remove water pump assy. Remove the 4 bolts, 2 nuts, bracket and water pump.
15. Remove camshaft position sensor.
16. Remove oil pan drain plug.
17. Remove oil pan sub-assy. Remove the 12 bolts and 2 nuts. Insert the blade of SST between the crank case and oil pan, cut off applied sealer and remove the oil pan. SST 09032-00100 NOTE: Be careful not to damage the contact surface of the cylinder block and oil pan.
18. Remove timing chain cover sub-assy (timing chain or belt cover sub-assy). Remove the 14 bolts and 2 nuts. Remove the timing chain cover by prying the portions between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.
19. Remove timing chain cover oil seal (timing gear case oil seal). Using a screwdriver, remove the oil seal.
20. Remove crankshaft position sensor plate No. 1.
21. Remove timing chain guide.
22. Remove chain tensioner slipper.
23. Remove chain vibration damper No. 1.
24. Remove chain sub-assy.
25. Remove crankshaft timing gear or sprocket.
26. Remove No. 2 chain sub-assy. Turn the crankshaft counterclockwise 90°, and align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Put a bar (4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove a nut. Remove bolt and a chain tensioner plate. Remove the oil pump drive gear, oil pump drive shaft gear and no. 2 chain sub assembly.
27. Remove oil pump assy. Remove 3 bolts and the oil pump assembly.
28. Remove No. 2 camshaft. Remove No. 1 and No. 2 camshaft bearing caps as the sequence shown in the illustration. Remove No. 2 camshaft.
29. Remove camshaft. Remove No. 1 and No. 3 camshaft bearing caps as the sequence shown in the illustration. Remove No. 1 camshaft.
30. Remove camshaft bearing No. 1.
31. Remove camshaft timing gear or sprocket. Fix the No. 2 camshaft with a vise, and remove the camshaft timing gear. NOTE: Be careful not to damage the camshaft.
32. Remove camshaft timing gear assy. Fix the No. 1 camshaft with a vise, and make sure the camshaft timing gear assembly does not move. Cover all the paths with vinyl tape except an advanced side path as shown in the illustration. Put air pressure into the oil path with 150 kPa (1.5 kgf/cm 2 21 psi), and turn the camshaft timing gear assembly to the advance direction (counterclockwise) by force. NOTE: Cover the paths with shop rag to avoid oil splashing. NOTE: Depending on the air pressure, the VVT timing sprocket 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 form the port, there may be the case that the lock pin could be hardly released. Remove a fringe bolt of camshaft timing gear assembly. NOTE: Be sure not to remove the other 4 bolts. In case of reusing the camshaft timing gear assembly, release the straight pin lock first, and then install the gear.
33. Remove camshaft bearing No. 2
34. Remove cylinder head sub-assy. 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. NOTE: Be careful not to drop washers into the cylinder head. Head warpage or cracking could result from removing bolts in and incorrect order.
35. Remove cylinder head gasket.
36. Remove cylinder block water drain cock sub-assy.
37. Remove union (w/oil cooler).
38. Remove oil control valve filter. Using a 6 mm socket hexagon wrench, remove a plug and oil control valve filter.
39. Remove w/head taper screw plug No. 1.
40. Inspect balance shaft thrust clearance. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth. Standard thrust clearance: 0.050 - 0.090 mm (0.0020 - 0.0035 in.) Maximum thrust clearance: 0.090 mm (0.0035 in.)
41. Inspect balance shaft oil clearance. Uniformly loosen and remove the 8 bolts in several passes, in the sequence shown. Lay a strip of plastigage across each journal, and install the balance shaft housing. Apply light coat of engine oil on the threads and under the heads of the balance shaft housing bolts. Temporarily tighten 8 bolts in the several passes, in the sequence shown, and fully tighten with specified torque. Torque: 22 n.m (220 kgf.cm, 16 ft.lbf) NOTE: The balance shaft housing bolts are tightened in 2 progressive steps. Mark the front side of each balance shaft housing bolt head with paint. Retighten the bolts 90° as the sequence shown. Check that the paint marks are now at a 90° angle to the front. Remove the balance shaft housing, and measure the plastigage at its widest point. Standard oil clearance: 0.004 - 0.031 mm (0.0002 - 0.0012 in.) Maximum oil clearance: 0.031 mm (0.0012 in.) NOTE: Completely remove the plastigage after the inspection. If the clearance is greater than maximum, replace the bearing. if necessary, replace the balance shaft. If using a standard bearing, replace it with one having the same number. Balance shaft housing journal bore diameter: Balance shaft journal diameter: Standard bearing center wall thickness
42. Remove balance shaft No. 1 and No. 2.
43. Remove balance shaft bearing No. 1.
44. Remove engine rear oil seal. Using a knife, cut off the oil seal lip. Using a screwdriver with its tip taped, pry out the oil seal. NOTE: After the removal, check the crankshaft is not damaged. if there is, mend it with a sandpaper (#400).
45. Remove stiffening crankcase assy. Uniformly loosen and remove the 11 bolts, in several passes, in the sequence shown. Using a screwdriver, remove the crankcase by prying the portions between the crankcase and cylinder block. NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. Remove the o-ring from the cylinder block.
46. Inspect oil pump drive gear. Wrap the chain around the drive gear. Using vernier calipers, measure the drive gear diameter with the chain. NOTE: Vernier calipers must contact the chain rollers for the measuring. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) If the diameter is less than minimum, replace the chain and drive gear.
47. Inspect oil pump drive shaft gear. Wrap the chain around the drive shaft gear. Using vernier calipers, measure the drive shaft gear diameter with the chain. NOTE: Vernier calipers must contact the chain rollers for the measuring. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) If the diameter is less than minimum, replace the chain and drive shaft gear.
48. Inspect crankshaft timing gear or sprocket. Wrap the chain around the timing gear. Using vernier calipers, measure the timing gear diameter with the chain. NOTE: Vernier calipers must contact the chain rollers for the measuring. Minimum gear diameter (w/chain): 51.6 mm (2.031 in.) If the diameter is less than minimum, replace the chain and timing gear.
49. Inspect chain tensioner slipper. Measure the chain tensioner slipper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the chain tensioner slipper.
50. Inspect chain vibration damper No. 1. Measure the chain vibration damper No. 1 wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the chain vibration damper No. 1.
51. Inspect cylinder head set bolt. Using vernier calipers, measure the length of head bolts from the seat to the end. Standard bolt length: 161.3 - 162.7 mm (6.350 - 6.406 in.) Maximum bolt length: 164.2 mm (6.465 in.) If the length is greater than maximum, replace the bolt.
52. Inspect chain tensioner assy No. 1. Check the plunger moves smoothly when the ratchet pawl is raised, and when the ratchet pawl is released, the plunger is locked in place. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with finger.
53. Inspect chain sub-assy. Using a spring scale, pull the chain sub assembly with 140 N (14.3 kgf, 315 lb) and measure the length of the chain sub assembly by a vernier calipers. Maximum chain elongation: 115.4 mm (4.543 in.) If the elongation is greater than maximum, replace the chain. NOTE: Make the same measurements pulling at 3 or more places selected at random, and average the length.
54. Inspect camshaft timing gear or sprocket. Wrap the chain around the timing sprocket. Using a vernier calipers, measure the timing sprocket diameter with the chain. Minimum sprocket diameter (w/chain): 97.3 mm (3.831 in.) NOTE: Vernier calipers must contact the chain rollers for the measuring.
55. Inspect camshaft. Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft. Inspect cam lobe height. Using a micrometer, measure the cam lobe height. Standard cam lobe height: 46.495 - 46.595 mm (1.8305 - 1.8345 in.) Minimum cam lobe height: 46.385 mm (1.8262 in.) If the cam lobe height is less than minimum, replace the camshaft. Inspect camshaft journal diameter. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 - 35.985 mm (1.4165 - 1.4167 in.) Other journal diameter: 22.959 - 22.975 mm (0.9039 - 0.9045 in.) If the journal diameter is not as specified, check the oil clearance.
56. Inspect No. 2 camshaft. 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 lobe height. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 45.983 - 46.083 mm (1.8104 - 1.8143 in.) Minimum cam lobe height: 45.873 mm (1.8060 in.) If the cam lobe height is less than minimum, replace the camshaft. (1) Inspect camshaft journal diameter. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 - 35.985 mm (1.4165 - 1.4167 in.) Other journal diameter: 22.959 - 22.975 mm (0.9039 - 0.9045 in.) If the journal diameter is not as specified, check the oil clearance.
57. Install engine rear oil seal. Apply MP grease to a new oil seal lip. NOTE: Keep the lip off the foreign materials. Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTE: Wipe off extra grease on the crank shaft.
58. Install balanceshaft bearing No. 1. Install the bearings in the crankcase and balance shaft housing. Apply a light coat of engine oil on the bearings.
59. Install Balance Shaft No. 1 & No. 2. Rotate driven gear No. 1 of balance shaft No. 1 for the rotating direction until it hits the stopper. Confirm the matchmarks on driven gear No. 1 and No. 2 are matched. Align the timing marks of the No. 1 and No. 2 balance shaft as shown in the illustration. Place the No. 1 and No. 2 balance shaft on the crank case. Apply a light coat of engine oil under the heads of the balance shaft housing bolts. Temporarily tighten 8 bolts in the several passes as the sequence shown, and fully tighten with specified torque. Torque: 22 N.m (220 kgf.cm, 16 ft.lbf) NOTE: The balance shaft housing bolts are tightened in 2 progressive steps. Mark the front side of each balance shaft housing bolt head with paint. Retighten the bolts by 90° as the sequence shown. Check that the painted marks are now at a 90° angle to the front.
60. Install Stiffening Crankcase Assy. Apply seal packing in the shape of bead (Diameter 2.5 mm - 3 mm (0.098 - 0.118 in.)) the places shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the crank case within 3 minutes after applying seal packing. Do not start the engine within 2 hours after installing. Install a new O-ring the place shown in the illustration. With the crank pin of the balance shaft, at 6 o'clock position, install the No. 1 and No. 2 balance shaft and the adjusting hole as shown in the illustration. Install the 11 bolts in the several passes as sequence shown in the illustration. Torque: 33 N.m (332 kgf.cm, 24 ft.lbf) Confirm that timing marks of the balance shaft are matched as shown in the illustration when the key groove is at 6 o'clock position.
61. Install w/head taper screw plug No. 1. Apply adhesive to the threads of the plug and install. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
62. Install oil control valve filter. Check that no foreign substance on the mesh part of the filter. Using a 6 mm socket hexagon wrench, install the oil control valve filter with a new gasket. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
63. Install cylinder block water drain cock sub-assy. Install the water drain cock sub assembly within the range shown in the illustration. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
64. Install union (w/ oil cooler). Torque: 40 N.m (408 kgf.cm, 29 ft.lbf)
65. Install cylinder head gasket. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Remove any oil from contact surface. Be careful of the installation direction. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
66. Install cylinder head sub-assy. NOTE: The cylinder head bolts are tightened in 2 progressive steps. Apply seal packing in the shape of bead (Diameter 2.5 - 3 mm (0.098 - 0.118 in.)) consequently as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from contact surface. Install the cylinder head within 3 minutes after applying seal packing. After installing the cylinder head, cylinder head bolt must be tightened within 15 minutes. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Install bolts and plate washers to the cylinder head. NOTE: Do not drop the washers into the cylinder head. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque. Torque: 79 N.m (806 kgf.cm, 58 ft.lbf) Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts by 90° in the sequence shown and tighten 90° more. Check that the painted marks are now at a 90° angle to the front.
67. Install camshaft bearing No. 2
68. Install camshaft timing gear assy. Put the camshaft timing gear assembly and the camshaft together with the straight pin of the key groove. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove. CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle). Check that there is no clearance between the gear's fringe and the camshaft. Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N.m (551 kgf.cm, 49 ft.lbf) Check that the camshaft timing gear assembly can move to the retard angle side (the right direction), and is locked at the most retarded position.
69. Install camshaft timing gear or sprocket. Fix the camshaft No. 2 to the vise, and install camshaft No. 2 timing gear. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf)
70. Install camshaft bearing No. 1.
71. Install camshaft. Tighten camshaft bearing cap No. 1 and No. 3 as the sequence shown in the illustration. Torque: Bearing cap No. 1 30 N.m (301 kgf.cm, 22 ft.lbf) Bearing cap No. 3 9N.m (92 kgf.cm, 80 in.lbf) NOTE: Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 1. Install the camshaft with its timing mark of camshaft timing gear on top.
72. Install No. 2 camshaft. Tighten camshaft bearing cap No. 2 and No. 3 as the sequence shown in the illustration. Torque: Bearing cap No. 2 30 N.m (301 kgf.cm, 22 ft.lbf) Bearing cap No. 3 9 N.m (92 kgf.cm, 80 in.lbf) NOTE: Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 2. Install the camshaft with its timing mark of camshaft timing gear on top.
73. Install oil pump assy. Install oil pump assembly with 3 bolts and a new gaskets. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
74. Install No. 2 chain sub-assy. Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top. Align the mark links (yellow colored links) with the timing marks of gear as shown in the illustration. Insert the gear with chain to the crankshaft and oil pump shaft. Temporarily tighten the oil pump drive shaft gear by a nut. Insert the damper spring into the adjusting hole, and install the chain tensioner plate by a bolt. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Align an adjusting hole of the sprocket with the groove of the oil pump. Put a bar (oslash 4mm) into the adjusting hole of the sprocket to lock in position, and assemble a nut. Torque: 30 N.m (301 kgf.cm, 22 ft.lbf) Rotate the crankshaft clockwise 90°, and align the crankshaft key with the top.
75. Install crankshaft timing gear or sprocket.
76. Install chain vibration damper No. 1. Install the chain vibration damper with the 2 bolts. Torque: 9 N.m (92 kgf.cm, 80 in.lbf)
77. Install chain sub-assy. Set No. 1 cylinder to TDC/compression. Align the timing marks of the camshaft timing sprockets and No. 1 bearing caps. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. Align the mark plate (blue or orange colored link) with the timing mark of the crankshaft timing gear. Using SST, install the sprocket. SST 09309-37010 Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear, and install the chain.
78. Install chain tensioner slipper. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
79. Install timing chain guide. Torque: 9 N.m (92 kgf.cm, 80 in.lbf)
80. Install crankshaft position sensor plate No. 1. Install crank angle sensor plate with the "F" mark facing forward.
81. Install timing chain cover oil seal (timing gear case oil seal). Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 Apply a light coat of MP grease to the lip of a new oil seal. NOTE: Keep the lip off foreign materials.
82. Installing timing chain cover sub-assy (timing chain or belt cover sub-assy). NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes after applying seal packing. Do not start the engine within 2 hours after installing. 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. Apply seal packing in the shape of bead (Diameter 2 mm (0.09 in.)) (Scheme 228) Seal packing: Part No. 08826-00080 or equivalent Apply seal packing in the shape of bead (Diameter 3-4 mm (0.118 - 0.157 in.)) (Scheme 229) Seal packing: Part No. 08826-00080 or equivalent Install the timing chain cover with the 14 bolts and 2 nuts. Torque: Bolt A 9.0 N.m (92 kgf.cm, 80 in.Ibf) Bolt B 21 N.m (214 kgf.cm, 15 ft.Ibf) Bolt C 43 N.m (438 kgf.cm, 32 ft.Ibf) Nut 9.0 N.m (92 kgf.cm, 80 in.Ibf)
83. Install oil pan sub-assy. NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine within 2 hours after installing. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. Apply seal packing in the shape of bead (Diameter 3 mm - 4 mm (0.157 in.)) (Scheme 231), and install the oil pan. Seal packing: Part No. 08826-00080 or equivalent Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.Ibf)
84. Install oil pan drain plug. Install an oil pan drain plug with a new gasket. Torque: 25 N.m (250 kgf.cm, 18 ft.Ibf)
85. Install water pump assy. Clean the contact surface of the cylinder block. Apply seal packing in the shape of bead (Diameter 2.2 - 2.5 mm) to the outside edge of the water pump. Seal packing: Part No. 08826-00100 or equivalent NOTE: Remove any oil from the contact surface. Install the water pump within 5 minutes after applying seal packing. Do not start the engine within 2 hours after installing. Install the water pump assembly with 4 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.Ibf) NOTE: Tighten the outside bolts and nuts with the clamp.
86. Install water pump pulley. Using SST, install the water pump pulley. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N.m (265 kgf.cm, 19 ft.Ibf)
87. Install crank position sensor. Install the bolt and crankshaft position sensor. Torque: 9.0 N.m (92 kgf.cm, 80 in.Ibf) Confirm the wire harness of the crank position sensor is placed (Scheme 236)
88. Install crankshaft pulley. Using SST, tighten the set bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 170 N.m (1,733 kgf.cm, 125 ft.Ibf)
89. Install chain tensioner assy (chain tensioner assy). Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Install a new gasket chain tensioner with 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.Ibf) NOTE: If the hook is released wile inserting, apply the hook again, and insert the chain tensioner. Turn the crankshaft counterclockwise, and check the plunger knock pin is disconnected from the hook. Turn the crankshaft clockwise, and check the plunger is pushed by the plunger.
90. Inspect valve clearance. Turn the crankshaft pulley, and align its groove with the timing mark "O" of the timing chain cover. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap (Scheme 242) Check only the valve indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Valve clearance (cold): Intake 0.19 - 0.29 mm (0.007 - 0.011 in.) Exhaust 0.30 - 0.40 mm (0.012 - 0.016 in.) Turn the crankshaft 1 revolution (360°) clockwise, and set No. 4 cylinder to TDC/compression. Check only the valve indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Valve clearance (cold): Intake 0.19 - 0.29 mm (0.007 - 0.011 in.) Exhaust 0.30 - 0.40 mm (0.012 - 0.016 in.)
91. Adjust valve clearance. NOTE: Do not turn the crankshaft without the chain tensioner. Turn the crankshaft 1 revolution (360°) clockwise, and Set No. 1 Cylinder To TDC/Compression. Place matchmarks on the timing chain and camshaft timing gear. Remove the 2 bolts and chain tensioner. Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the valve lifter. Loosen the camshaft bearing cap bolts on No. 2 camshaft in the sequence (Scheme 247)in several passes, and remove the caps. Raising the camshaft, remove the set bolt. Remove the timing chain sprocket from the camshaft with timing chain. Remove the timing chain sprocket from the timing chain. Loosen the camshaft bearing cap bolts on camshaft in the sequence (Scheme 249), in several passes, and remove the caps. Remove the intake camshaft. Tie the timing chain with a string. Using a micrometer, measure the thickness of the removed lifter. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. Valve clearance: Intake A = B + (C - 0.24 mm (0.0094 in.)) Exhaust A = B + (C - 0.35 mm (0.0138 in.)) NOTE: Select a new lifter with a thickness as close as possible to the calculated values. Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing sprockets. Examine the front marks and numbers and tighten the bolts in the order (Scheme 254) Torque: Bearing cap No. 1 30 N.m (301 kgf.cm, 22 ft.Ibf) Bearing cap No. 3 9.0N.m (92 kgf.cm, 80 in.Ibf) Put the camshaft No. 2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets. Raising the camshaft, tighten the set bolt temporarily. Examine the front marks and numbers and tighten the bolts in the sequence (Scheme 257) Torque: Bearing cap No. 2 30 N.m (301 kgf.cm, 22 ft.Ibf) Bearing cap No. 3 9.0N.m (92 kgf.cm, 80 in.Ibf) Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.Ibf) NOTE: Be careful not to damage the valve lifter. As shown in the illustration, check the matchmarks on the timing chain and camshaft timing sprockets and the alignment of the pulley groove with timing mark of the chain cover. NOTE: There are 7 links between the timing marks. Install chain tensioner. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Install a new gasket and chain tensioner with the 2 nuts. Torque: 9.0N.m (92 kgf.cm, 80 in.Ibf) NOTE: When installing the tensioner, set the hook again if the hook releases the plunger. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin form the hook. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
92. Install camshaft position sensor. Torque: 9.0 N.m (92 kgf.cm, 80 in. Ibf)
93. Install cylinder head cover gasket. Install the gasket to the cylinder head cover.
94. Install cylinder head cover sub-assy. Remove any old packing (FIPG) material. Apply seal packing to 2 locations (Scheme 264) Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 5 minutes after applying seal packing. Do not put into engine oil 2 hours after installing. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: Bolt A 11 N.m (112 kgf.cm, 8 ft.Ibf) Bolt B 14 N.m (143 kgf.cm, 10 ft.Ibf) Nut 11 N.m (112 kgf.cm, 8 ft.Ibf)
95. Install oil filter union (w/o oil cooler). Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N.m (306 kgf.cm, 22 ft.Ibf)
96. Install oil cooler assy (w/ oil cooler). Install a new O-ring to the oil cooler. Apply a light coat of engine oil on the threads and under the head of the union bolt. Install the oil cooler and union bolt. Torque: 78.5 N.m (800 kgf.cm, 58 ft.Ibf) Install the flange nut. Torque: 9.0 N.m (92 kgf.cm, 80 in.Ibf)
97. Install oil filter sub-assy. Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it an additional 3/4 turn. SST 09228-06501
98. Install spark plug. Torque: 19 N.m (194 kgf.cm, 14 ft.Ibf)
99. Install ventilation valve sub-assy. Apply adhesive on the threads of the ventilation valve. Torque: 19 N.m (194 kgf.cm, 14 ft.Ibf) Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
100. Install oil filler cap gasket. Install the gasket to the oil filter cap.
101. Install oil filler cap sub-assy.

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Scheme 313

1. Remove valve lifter . NOTE: Arrange the valve lifters in the correct order.
2. Remove intake valve . Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202-70020 (09202-00010) Remove the parts below from the cylinder head. NOTE: Arrange the removed parts in the correct order.
3. Remove exhaust valve . Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202-70020 (09202-00010) Remove the parts below from the cylinder head.
4. Remove valve stem oil seal or o-ring . Using needle-nose pliers, remove the oil seals.
5. Remove valve spring seat .
6. Remove stud bolt .
7. Inspect cylinder head for flatness . Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.08 mm (0.0031 in.) Exhaust manifold side 0.08 mm (0.0031 in.)
8. Inspect cylinder head for cracks . Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks.
9. Inspect valve seats . Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Check the valve face and seat according to the following procedure. If blue appears 360° around the face, the valve is concentric. If not, replace the valve. If blue appears 360° around the valve sat, the guide and face are concentric. If not, resurface the seat. Check that the sat contact is in the middle of the valve face with the width between 1.0 - 1.4 mm (0.039 - 0.055 in.).
10. Repair valve seats . NOTE: Take off a cutter gradually to make smooth seats. 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 sat with an abrasive compound. Check the valve seating position.
11. Inspect camshaft thrust clearance . Install the camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: Intake 0.040 - 0.095 mm (0.0016 - 0.0037 in.) Exhaust 0.080 - 0.135 mm (0.0032 - 0.0053 in.) Maximum thrust clearance: Intake 0.11 mm (0.0043 in.) Exhaust 0.15 mm (0.0059 in.) If the thrust clearance is greater than maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
12. Inspect camshaft oil 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. Torque: No. 1 30 N.m (301 kgf.cm, 22 ft.Ibf) No. 2 30 N.m (301 kgf.cm, 22 ft.Ibf) No. 3 9 N.m (92 kgf.cm, 80 in.Ibf) NOTE: Do not turn the camshaft. Remove the bearing cap, and measure the plastigage at its widest point. Standard oil clearance: Intake No. 1 journal bearing mark 1 0.007 - 0.038 mm (0.0028 - 0.00150 in.) Intake No. 1 journal bearing mark 3 0.008 - 0.038 mm (0.0031 - 0.00150 in.) Intake No. 1 journal bearing mark 3 0.008 - 0.038 mm (0.0031 - 0.00150 in.) Exhaust No. 1 journal 0.015 - 0.054 mm (0.0059 - 0.00213 in.) Other journals 0.025 - 0.062 mm (0.00098 - 0.00244 in.) Maximum oil clearance: Intake No. 1 journal 0.07 mm (0.0028 in.) Other journals 0.10 mm (0.0039 in.) NOTE: Completely remove the plastigage after the inspection. If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the cylinder head. If the oil clearance on No. 1 journal is greater than maximum, choose and replace the bearing. NOTE: Cylinder head journal bore diameter Standard bearing center wall thickness Camshaft journal diameter
13. Inspect inner compression spring . Check the free length. Using vernier calipers, measure the free length of the valve spring. Free length: 45.7 mm (1.799 in.) Check the deviation. Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2°
14. Inspect intake valve . Check the valve overall length. Using vernier calipers, measure the valve overall length. Standard overall length: 101.71 mm (4.0043in.) Minimum overall length: 101.21 mm (3.9846in.) Check the diameter of the valve stem. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 - 5.485 mm (0.2154 - 0.2159 in.) Check the valve head margin thickness. Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.05 - 1.45 mm (0.041 - 0.057 in.) Minimum margin thickness: 0.5 mm (0.020 in.)
15. Inspect exhaust valve . Check the valve overall length. Using vernier calipers, measure the valve overall length. Standard overall length: 101.15 mm (3.9823in.) Minimum overall length: 100.70 mm (3.9646 in.) Check the diameter of the valve stem. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 - 5.480 mm (0.2152 - 0.2157 in.) Check the valve head margin thickness. Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.2 - 1.6 mm 0.047 - 0.063 in.) Minimum margin thickness: 0.5 mm (0.020 in.)
16. Inspect intake valve guide bushing . Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Maximum oil clearance: 0.08 mm (0.0031 in.)
17. Inspect exhaust valve guide bushing . Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Maximum oil clearance: 0.10 mm (0.0039 in.)
18. Remove intake valve guide bushing . Using SST and a hammer, tap out the guide bushing. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
19. Remove exhaust valve guide bushing . Using SST and a hammer, tap out the guide bushing. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
20. Install intake valve guide bushing . Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Diameter: 10.285 - 10.306 mm (0.4049 - 0.4057 in.) Install the STD bushing if the diameter is within specified diameter. NOTE: Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. Protrusion height: 9.6 - 10.0 mm (0.3779 - 0.3937 in.) SST 09201-10000 (09201-01050), 09950-70010 (09951-07100), 23801 Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem. Standard oil clearance: 0.025 - 0.060 mm (0.00098 - 0.00236 in.)
21. Install exhaust valve guide bushing g. Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Diameter: 10.285 - 10.306 mm (0.4049 - 0.4057 in.) Install the STD bushing if the diameter is within specified diameter. NOTE: Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100), 23801 Protrusion height: 9.6 - 10.0 mm (0.3779 - 0.3937 in.) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem. Standard oil clearance: 0.030 - 0.065 mm (0.00118 - 0.00256 in.)
22. Inspect valve lifter . Check the lifter diameter. Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 in.) Check the valve lifter oil clearance. Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 - 31.025 mm (1.2208 - 1.2215 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 - 0.059 mm (0.0013 - 0.0023 in.) Maximum oil clearance: 0.07 mm (0.0028 in.)
23. Install ring w/head pin . Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 5.5 mm (0.2165 in.)
24. Install stud bolt . Torque: Bolt A 5 N.m (51 kgf.cm, 44 in. Ibf) Bolt B 5 N.m (51 kgf.cm, 44 in. Ibf) Bolt C 10 N.m (97 kgf.cm, 84 in. Ibf) Bolt D 10 N.m (97 kgf.cm, 84 in. Ibf)
25. Install valve spring seat .
26. Install valve stem oil seal or ring . Apply a light coat of engine oil on new valve stem seals. NOTE: Pay much attention assembling the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. NOTE: The intake valve oil seal is gray and the exhaust valve oil seal is black. Using SST, push in a the oil seal. SST 09201-41020
27. Install intake valve . Install the parts below to the cylinder head. Using SST and wooden blocks, compress and install 2 valve spring retainer locks. 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 ensure a proper fit. NOTE: Be careful not to damage the valve stem tip.
28. Install exhaust valve . Install the parts below to the cylinder head. Using SST and wooden blocks, compress and install 2 valve spring retainer locks. 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 ensure a proper fit. NOTE: Be careful not to damage the valve stem tip.
29. Install valve lifter . Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied. NOTE: Install the valve lifters originally placed.

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Scheme 376

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 - 0.362 mm (0.0063 - 0.0143 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
2. Inspect connecting rod oil clearance. NOTE: The connecting rod cap bolts are tightened in 2 progressive steps. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. NOTE: The matchmarks on the connecting rods and caps are for ensuring correct reassembly. Using a 12 mm socket wrench, remove the 2 connecting rod cap bolts. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. Lay a strip of plastigage on the crank pin. Check that the front mark of the connecting rod cap is facing in the correct direction. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using a 12 mm socket wrench, tighten the bolts in several passes by the specified torque. Torque: 25 N.m (250 kgf.cm, 18 ft.Ibf) Mark the front of the connecting rod cap bolts with paint. Retighten the cap bolts by 90° (Scheme 318) NOTE: Do not turn the crankshaft. Remove the 2 bolts, connecting rod cap and lower bearing. Measure the plastigage at its widest point. Standard oil clearance: 0.024 - 0.048 mm (0.0009 - 0.0019 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) NOTE: Completely remove the plastigage. 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. NOTE: Standard bearing center wall thickness.
3. Remove piston sub-assy w/connecting rod. Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
4. Remove connecting rod bearing.
5. Remove piston ring set. Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand.
6. Remove piston pin hole snap ring. Using a small screwdriver, pry out the 2 snap rings.
7. Remove piston. Gradually heat the piston to 80 - 90 °C (176 - 194 °F). Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
8. Inspect crankshaft thrust clearance. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.040 - 0.240 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: 1.930 - 1.980 mm (0.0760 - 0.0780 in.)
9. Remove crankshaft. Uniformly loosen and remove the 10 bearing cap sub-assembly bolts, in several passes, in the sequence shown. Remove the bearing cap and crankshaft.
10. Remove crankshaft thrust washer upper.
11. Remove crankshaft bearing. NOTE: Arrange the bearings in the correct order.
12. Remove crankshaft bearing No. 2. NOTE: Arrange the main bearings and thrust washers in the correct order.
13. Remove stud bolt.
14. Inspect 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.)
15. Inspect cylinder bore. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 88.500 - 88.513 mm (3.4843 - 3.4848 in.) Maximum diameter: 88.513 mm (3.4848 in.) If the diameter is greater than maximum, replace the cylinder block.
16. Inspect piston diameter. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.3 mm (1.193 in.) from the piston head. Piston diameter: 88.439 - 88.449 mm (3.4818 - 3.4822 in.)
17. Inspect piston clearance. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.051 - 0.074 mm (0.0020 - 0.0029 in.) Maximum oil clearance: 0.1 mm (0.0039 in.) If the clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.
18. Inspect ring groove clearance. Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove. Ring groove clearance: 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
19. Inspect piston ring end gap. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.22 - 0.32 mm (0.0087 - 0.0126 in.) No. 2 0.50 - 0.60 mm (0.0197 - 0.0236 in.) Oil (side rail) 0.10 - 0.35 mm (0.0039 - 0.0138 in.) Maximum end gap: No. 1 0.89 mm (0.0350 in.) No. 2 1.35 mm (0.0531 in.) Oil (side rail) 0.73 mm (0.0287 in.)
20. Inspect piston pin oil clearance. Using caliper gauge, measure the inside diameter of the piston bushing. Bushing inside diameter: 22.001 - 22.010 mm (0.8662 - 0.8665 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 in.) 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.) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement. Standard oil clearance: 0.001 - 0.007 mm (0.00004 - 0.00028 in.) Maximum oil clearance: 0.010 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. Subtract the piston pin diameter measurement form the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) Maximum oil clearance: 0.010 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
21. Inspect connecting rod sub-assy. Using a 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: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly.
22. Inspect connecting rod bolt. Using a vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 -- 7.3 mm (0.283 -- 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than minimum, replace the bolt.
23. Inspect crankshaft. Using a dial indicator and V--blocks, measure the circle runout, ash (Scheme 345) Maximum circle runout: 0.03 mm (0.0012 in.) Using a micrometer, measure the diameter of each main journal. Diameter: 54.988 - 55.000 (2.1648 - 2.06535 in.) Check each main journal for taper and out-of-round as shown. Maximum taper and out- of -round: 0.003 mm (0.0001 in.) Using a micrometer, measure the diameter of each crank pin. Diameter: 47.990 - 48.000 mm (1.8894 - 1.8898 in.) Check each crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.003 mm (0.0001 in.)
24. Inspect crankshaft bearing cap set bolt. 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: 7.2 mm (0.283 in.) If the diameter is less than minimum, replace the bolt.
25. Install ring pin. Using a plastic-faced hammer, tap into the ring pin. Standard protrusion: Ring pin A 6 mm (0.236 in.) Ring pin B 5 mm (0.197 in.)
26. Inspect crankshaft oil clearance. NOTE: Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats. The bearing cap bolts are tightened in 2 progressive steps. Clean each main journal and bearing. Install the upper bearing with an oil groove on cylinder block. Install the lower bearing on the bearing cap sub assembly. Place the crankshaft on the cylinder block. Lay a strip of plastigage across each journal. Examine the front marks and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads and under the bearing cap bolts. Tighten the bolts in several passes, in the sequence (Scheme 354), by the specified torque. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) Retighten the bolts in several passes, in the sequence (Scheme 354), by the specified torque. Torque: 40 N.m (408 kgf.cm, 29 ft.lbf) Mark the front of the bearing cap bolts with paint. Retighten the bearing cap bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. NOTE: Do not turn the crankshaft. Remove the bearing cap. Measure the plastigage at its widest point. Standard oil clearance: 0.017 - 0.040 mm (0.0007 - 0.0016 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) NOTE: Completely remove the plastigage. 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. NOTE: EXAMPLE Cylinder block "4" (A) + Crankshaft "3" (B) = Total number 7 (Use bearing "3") Reference
27. Install tight plug. Apply adhesive around tight plugs. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using SST, into the tight plugs (Scheme 360) SST 09950-60010 (09951-00200), 09950-70010 (09951-07100) Standard depth: Engine front 1.7 - 2.7 mm (0.067 - 0.106 in.) Engine rear 2.2 - 3.2 mm (0.087 - 0.126 in.)
28. Install stud bolt. Install the stud bolts as shown in the illustration. Torque: Stud bolt A 5.0 N.m (51 kgf.cm, 44 in.lbf) Stud bolt B 10N.m (97 kgf.cm, 84 in.lbf) Stud bolt C 5.0N.m (51 kgf.cm, 44 in.lbf)
29. Install straight pin. Using a plastic-faced hammer, tap into the straight pin. Standard protrusion: Pin A 7.5 mm (0.295 in.) Pin B 12 mm (0.472 in.)
30. Install piston. Using a small screwdriver, install a new snap ring at one end of the piston pin hole. Gradually hat the piston to 80 - 90°C (176 - 194° F). Align the front marks on the piston with connecting rod, and push in the piston with your thumb. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
31. 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 point mark facing right side. NOTE: Install the compression ring No. 2 with the code mark (2N) facing upward. Position the piston rings so that the ring ends are (Scheme 366)
32. Install crankshaft bearing. Install the upper bearing with an oil groove on cylinder block. NOTE: Clean the back side of the bearing and the bearing surface of the cylinder block and let not stick the oils and fats.
33. Installing crankshaft bearing no. 2. Install the lower bearing on bearing cap. NOTE: Clean the back side of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
34. Install crankshaft thrust washer upper. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
35. Install crankshaft. Apply engine oil to upper bearing and install the crankshaft on the cylinder block. Apply engine oil to lower bearing. Examine the front marks and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads and under the bearing cap bolts. Tighten the bolts in several passes, in the sequence shown, by the specified torque. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) Tighten the bolts in several passes, in the sequence shown, by the specified torque. Torque: 40 N.m (408 kgf.cm, 29 ft.lbf) Mark the front of the bearing cap bolts with paint. Retighten the bearing cap bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. Check the crankshaft turns smoothly.
36. Install connecting rod bearing. Align the bearing claw with the groove of the connecting rod or connecting cap. NOTE: Clean the back side of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
37. Install piston. NOTE: The connecting rod cap bolts are tightened in 2 progressive steps. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. Check the position of the piston ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTE: Match the numbered connecting rod cap with the connecting rod. Check that the protrusion of the connecting rod cap is facing in the correct direction. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using a 12 mm socket wrench, tighten the bolts in several passes by the specified torque. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) Mark the front of the connecting cap bolts with paint. Retighten the cap bolts by 90° as shown in the illustration. Check that the crankshaft turns smoothly.

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Scheme 382

Scheme 383

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Scheme 397

1. Work for preventing gasoline from spilling out (see FUEL SYSTEM (2AZ-FE) ).
2. Remove front suspension brace sub-assy upper center.
3. Remove chain sub-assy (see «TIMING CHAIN)»(ref-159280-S25394679782005062900000) ).
4. Drain coolant (see «COOLANT (2AZ-FE)»(ref-179473-S18914038582005070800000) ).
5. Drain transfer oil (4WD drive type). Install a new gasket and the drain plug after draining transfer oil. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
6. Separate radiator hose outlet.
7. Separate union to check valve hose.
8. Separate heater inlet water hose.
9. Separate fuel tube sub-assy (see FUEL SYSTEM (2AZ-FE) ).
10. Remove camshaft timing oil control valve assy.
11. Remove front drive shaft assy RH (4WD drive type) (see «REMOVAL»(ref-163861-S08884055992004071500000) ). SST 09520-01010, 09520-24010 (09520-32040)
12. Separate engine mounting insulator assy RR (4WD drive type). Remove the 2 bolts, and disconnect engine mounting insulator.
13. Separate transverse engine mounting bracket (4WD drive type). Remove the 6 bolts and engine mounting bracket.
14. Remove intake manifold. Disconnect the 2 water bypass hoses of the throttle body. Remove the 5 bolts, 2 nuts, intake manifold and gasket.
15. Separate engine wire.
16. Remove intake manifold insulator No. 1.
17. Remove exhaust manifold heat insulator No. 1.
18. Remove exhaust manifold converter sub-assy. Remove the 2 bolts, nuts No. 1 and No. 2 exhaust manifold stay. Remove the 5 nuts, exhaust manifold and gasket.
19. Remove No. 2 camshaft. Remove the No. 2 and No. 3 camshaft bearing cap in the sequence (Scheme 382) Remove the No. 2 camshaft.
20. Remove camshaft. Remove the No. 1 and No. 3 camshaft bearing cap in the sequence (Scheme 383) Remove the No. 1 camshaft.
21. Remove camshaft bearing No. 2.
22. Remove cylinder head sub-assy. 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. NOTE: Be careful not to drop washers into the cylinder head. Head warpage or cracking could result from removing bolts and installing incorrect order.
23. Remove cylinder head gasket.
24. Inspect cylinder head set bolt. Using a vernier calipers, measure the length of head bolts from the seat to the end. Standard bolt length: 161.3-162.3 mm (6.350-6.390 in.) Maximum bolt length: 164.2 mm (6.465 in) If the length is greater than maximum, replace the bolt.
25. Install cylinder head gasket. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Remove any oil from contact surface. Be careful of the installation direction. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
26. Install cylinder head sub-assy. NOTE: The cylinder head bolts are tightened in 2 progressive steps. Apply seal packing in the shape of bead (Diameter 2.5 - 3mm (0.098 - 0.118 in.)) consequently as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from contact surface. Install the cylinder head within 3 minutes after applying seal packing. After installing the cylinder head, cylinder head cylinder head bolts must be tightened within 15 minutes. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Install bolts and plate washers to the cylinder head. NOTE: Do not drop the washers into the cylinder head. 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: 79 N.m (806 kgf.cm, 58 ft.lbf) Mark the front side of the cylinder head bolt with paint. Retighten the cylinder head bolts by 90° in the sequence shown. Check that the paint mark is now at a 90° angle to the front.
27. Install camshaft. Tighten the camshaft bearing cap No. 1 and No. 3 as the sequence shown in the illustration. Torque: Bearing cap No. 1 30 N.m (301 kgf.cm, 22 ft.lbf) Bearing cap No. 3 9. N.m (92 kgf.cm, 80 in.lbf)
28. Install No. 2 camshaft. Tighten the camshaft bearing cap No. 2 and No. 3 as the sequence shown in the illustration. Torque: Bearing cap No. 2 30 N.m (301 kgf.cm, 22 ft.lbf) Bearing cap No. 3 9.0 N.m (92 kgf.cm, 80 in.lbf)
29. Install exhaust manifold converter sub-assy. Install a new gasket and the exhaust manifold with the 5 nuts. Torque: 37 N.m (378 kgf.cm, 27 ft.lbf) Install the No. 1 and No. 2 exhaust manifold stay with the 2 bolts and 2 nuts. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
30. Install exhaust manifold heat insulator No. 1. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
31. Install intake manifold. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
32. Install transverse engine mounting bracket (4WD drive type). Install the mounting bracket with the 6 bolts. Torque: Bolt A 34 N.m (347 kgf.cm, 25 ft.lbf) Bolt B 64 N.m (653 kgf.cm, 47 ft.lbf)
33. Install engine mounting insulator assy RR (4WD drive type). Install the mounting insulator with bolts. Torque: 75 N.m (765 kgf.cm, 55 ft.lbf)
34. Install front drive shaft assy RH (4WD drive type) (see «INSTALLATION»(ref-163861-S01074870952004071500000) ).
35. Install camshaft timing oil control valve assy. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
36. Connect fuel tube sub-assy (see FUEL SYSTEM (2AZ-FE) ).
37. Install chain sub-assy (see «TIMING CHAIN)»(ref-159280-S25394679782005062900000) ) SST 09309-37010
38. Install front suspension brace sub-assy upper center. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf)
39. Add engine oil.
40. Add coolant (see «COOLANT (2AZ-FE)»(ref-179473-S18914038582005070800000) ).
41. Add transfer oil (4WD drive type). Install a new gasket and the filler plug. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
42. Connect fuel tube sub-assy (see FUEL SYSTEM (2AZ-FE) ) Inspect oil leak.
43. Inspect check engine coolant leak (see «COOLANT (2AZ-FE)»(ref-179473-S18914038582005070800000) ).
44. Inspect fuel leak (see FUEL SYSTEM (2AZ-FE) ).
45. Inspect check idle speed and ignition timing (see «ENGINE ASSY (2AZ-FE)»(ref-159280-S24369778602005062900000) ).
46. Inspect CO/HC (see «ENGINE ASSY (2AZ-FE)»(ref-159280-S24369778602005062900000) ).
47. Check ABS speed sensor signal.
48. Inspect and adjust front wheel alignment.

Scheme 398

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Scheme 402

Scheme 403

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Scheme 407

Scheme 408

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

Scheme 421

Scheme 422

Scheme 423

Scheme 424

Scheme 425

Scheme 426

Scheme 427

Scheme 428

Scheme 429

Scheme 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

Scheme 435

Scheme 436

Scheme 437

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

1. Remove hood sub-assy.
2. Remove front wheel RH.
3. Remove engine under cover No. 1.
4. Remove front fender splash shield front RH.
5. Remove front fender apron seal RH.
6. Drain engine oil. Install a new gasket and the drain plug after draining engine oil. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
7. Remove exhaust pipe assy front.
8. Remove engine mounting stay No. 2 RH.
9. Remove engine moving control rod w/bracket. Remove the 3 bolts and engine moving control rod w/ bracket.
10. Remove engine mounting bracket No. 2 RH.
11. Remove fan and generator V belt (see «DRIVE BELT (2AZ-FE)»(ref-159280-S33179642412005062900000) ).
12. Remove generator assy.
13. Separate vane pump assy (see «VANE PUMP ASSY (2AZ-FE)»(ref-179717-S11694489652005071300000) ). NOTE: Do not disconnect the hose.
14. Remove engine cover sub-assy No. 1.
15. Remove ignition coil assy.
16. Separate ventilation hose.
17. Separate ventilation hose No. 2.
18. Remove cylinder head cover sub-assy. Remove the bolt and disconnect the engine wire harness clamp. Remove the 8 bolts and 2 nuts, and disconnect the cylinder head cover.
19. Set No. 1 cylinder to TDC/compression (see step 9 ) SET NO. 1 CYLINDER TO TDC/COMPRESSION.
20. Remove crankshaft pulley. Using SST, loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
21. Remove crank position sensor.
22. Remove oil pan sub-assy. Remove the 12 bolts and 2 nuts. Insert the blade of SST between the crank case and oil pan, cut off applied sealer and remove the oil pan. SST 09032-00100 NOTE: Be careful not to damage the contact surface of the cylinder block and oil pan.
23. Remove chain tensioner assy (chain tensioner assy No. 1). Remove the 2 nuts, timing chain tensioner and gasket. NOTE: Be sure not to revolve the crankshaft without the chain tensioner.
24. Remove V-ribbed belt tensioner assy. Remove the bolt, the bolt and drive belt tensioner.
25. Install engine hanger No. 1. Install the engine hanger No. 1, No. 2 and bolt as shown in the illustration. Torque: 38 N.m (387 kgf.cm, 30 ft.lbf) Parts No.: Engine hanger No. 1 12281-28010 Engine hanger No. 12282-28010 Bolt 91512-61020
26. Remove transverse engine mounting insulator. Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. Remove the 2 nuts, and disconnect the engine mounting insulator. Remove the 2 nuts, engine mounting insulator. (4WD Drive Type) Remove the bolt and disconnect the steering gear return hose clamp from the frame. Remove the 4 nuts from the engine mounting insulator RH. Raise the engine and remove the engine mounting insulator RH.
27. Remove transverse engine mounting bracket. Remove the 3 bolts and the engine mounting bracket RH.
28. Remove timing chain cover sub-assy (timing chain or belt cover sub-assy). Remove the stud bolt for drive belt tensioner from the cylinder block. Remove the 14 bolts and 2 nuts. Remove the timing chain cover with a screwdriver. NOTE: Be careful not to damage the contact surfaces of timing chain cover, cylinder block and cylinder head.
29. Remove crankshaft position sensor plate No. 1.
30. Remove chain tensioner slipper.
31. Remove chain vibration damper No. 1.
32. Remove chain sub-assy.
33. Remove crankshaft timing gear or sprocket.
34. Remove No. 2 chain sub-assy. Turn the crankshaft counterclockwise 90°, and align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Put a bar (° 4mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove a nut. Remove the bolt, chain tensioner plate and spring. Remove the chain tensioner, oil pump drive shaft gear and No. 2 chain.
35. Install No. 2 chain sub-assy. Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top. Align the mark links (yellow colored links) with the timing marks of the gear as shown in the illustration. Insert the gears with chain to the crankshaft and oil pump shaft. Temporarily tighten the oil pump drive shaft gear by a nut. Insert the damper spring into the adjusting hole, and install the chain tensioner plate by a nut. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Put a bar (oslash 4mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and assemble a nut. Torque: 30 N.m (301 kgf.cm, 22 ft.lbf) Rotate the crankshaft counterclockwise 90°, and align the crankshaft key to the top.
36. Install chain vibration damper No. 1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
37. Install chain sub-assy. Set No. 1 cylinder to TDC/compression. Align the timing marks of the camshaft timing sprockets with No. 1 bearing caps. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. Align the mark link (blue or orange colored link) with the timing mark of the crankshaft timing gear. Using a SST, install the sprocket. SST 09309-37010 Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear, and install the chain.
38. Install chain tensioner slipper. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
39. Install crankshaft position sensor plate No. 1. Install the crankshaft position sensor plate the "F" mark facing forward.
40. Install timing chain cover sub-assy (timing chain or belt cover sub-assy). NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes after applying seal packing. Do not start the engine 2 hours after installing. 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. Apply seal packing in the shape of bead (Diameter 2 mm (0.099 in.)) (Scheme 427) Seal packing: Part No. 08826-00080 or equivalent Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.118-0.157 in.)) (Scheme 428) Seal packing: Part No. 08826-00080 or equivalent Install the timing chain cover with the 14 bolts and 2 nuts. Torque: Bolt A 9.0 N.m (92 kgf.cm, 80 in.lbf) Bolt B 21 N.m (214 kgf.cm, 15 ft.lbf) Bolt C 43 N.m (438 kgf.cm 32 ft.lbt) Nut 9.0 N.m (92 kgf.cm, 80 in.lbf) Install the stud bolt to the drive belt tensioner. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
41. Install V-ribbed belt tensioner assy. Install the drive belt tensioner with the bolt and nut. Torque: 60 N.m (607 kgf.cm, 44 ft.lbf)
42. Install transverse engine mounting bracket. Install the engine mounting bracket RH with the 3 bolts. Torque: 52 N.m (531 kgf.cm, 38 ft.lbf)
43. Install transverse engine mounting insulator. Raise the engine and install the engine mounting insulator RH. Install the engine mounting insulator RH with the 4 nuts. Torque: Bolt A 95 N.m (969 kgf.cm, 70 ft.lbf) Bolt B 87 N.m (888 kgf.cm, 64 ft.lbf) Install the bolt and disconnect the steering gear return hose clamp from the frame. Torque: 8.0 N.m (80 kgf.cm, 69 in.lbf) Install the engine mounting insulator RR with the 2 nuts. (4WD DRIVE TYPE) Torque: 52 N.m (530 kgf.cm, 38 in.lbf) Install the engine mounting insulator FR with the 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 in.lbf)
44. Install oil pan sub-assy. NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine 2 hours after installing. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.157 in.)) as shown in the illustration, and install the oil pan. Seal packing: Part No. 08826-00080 or equivalent Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
45. Install chain tensioner assy (chain tensioner assy No. 1) (see step 17 INSTALL CHAIN TENSIONER ASSY No. 1.)
46. Install crank position sensor. Install the bolt and crankshaft position sensor. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) Confirm the wire harness of the crank position sensor is placed as shown in the illustration.
47. Install crankshaft pulley. Align the pulley set key with the key groove of the pulley, and side on the pulley. Using SST, install the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 170 N.m (1733 kgf.cm 125 in.lbf) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
48. Install cylinder head cover sub-assy (see step 8, REMOVE CYLINDER HEAD COVER SUB-ASSY.
49. Install ignition coil assy. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
50. Install vane pump assy (see «VANE PUMP ASSY (2AZ-FE)»(ref-179717-S11694489652005071300000).
51. Install generator assy (see «GENERATOR ASSEMBLY»(ref-173287-S32066356372005042700000) ).
52. Install fan and generator V belt (see «DRIVE BELT (2AZ-FE)»(ref-159280-S33179642412005062900000) ).
53. Install engine mounting bracket No. 2 RH. Torque: 52 N.m (531 kgf.cm, 38 ft.lbf)
54. Install engine moving control rod w/bracket. Install the engine mounting control rod w/bracket with 3 bolts. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
55. Install engine mounting stay No. 2 RH. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
56. Install exhaust pipe assy front (see «EXHAUST PIPE (2AZ-FE)»(ref-179444-S34136808292005070700000) ).
57. Install front wheel RH. Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
58. Install hood sub-assy. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
59. Add engine oil.
60. Inspect oil leak.

Scheme 443

Scheme 444

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Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

Scheme 457

Scheme 458

Scheme 459

Scheme 460

Scheme 461

Scheme 462

Scheme 463

Scheme 464

Scheme 465

Scheme 466

Scheme 467

1. Remove front wheel RH.
2. Remove front fender splash shield front RH.
3. Remove front fender apron seal RH.
4. Remove engine cover sub-assy No. 1.
5. Remove ignition coil assy.
6. Separate ventilation hose.
7. Separate ventilation hose No. 2.
8. Remove cylinder head cover sub-assy. Remove the bolt and disconnect the engine wire harness clamp. Remove the bolts, 2 nuts, cylinder head cover and gasket.
9. Set No. 1 cylinder to TDC/compression Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the bearing cap as shown in the illustration. Place match marks on the timing chain and camshaft timing sprocket.
10. Remove chain tensioner assy (chain tensioner assy No. 1) Remove the 2 nuts, timing chain tensioner and gasket. NOTE: Be sure not to revolve the crankshaft without the chain tensioner.
11. Remove No. 2 camshaft Fix the camshaft with a wrench and so on, then loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the valve lifter. Loosen the camshaft bearing cap bolts on No. 2 camshaft in the sequence (Scheme 447)in several passes, and remove the caps. Raising the camshaft, remove the set bolt. Remove the camshaft timing gear from the camshaft with timing chain. Remove the camshaft timing gear from the timing chain.
12. Remove camshaft. Loosen the camshaft bearing cap bolts on camshaft in the sequence (Scheme 449)in several passes, and remove the caps. Remove the intake camshaft. Tie the timing chain with a string. NOTE: Be careful not to drop anything inside the timing chain cover.
13. Remove camshaft timing gear assy. Fix the No. 1 camshaft with a vise, and make sure the camshaft timing gear assembly does not rotate. Cover all the paths with vinyl tape except an advanced side path (Scheme 451) Put air pressure into the oil path with 150 kpa (1.5 kgf/cm 2 21 psi), and turn the camshaft timing gear assembly to the advance direction (counterclockwise) by force. CAUTION: Cover the paths with shop rag to avoid oil splashing. NOTE: Depending on the air pressure, the VVT timing sprocket will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released. Remove a fringe bolt of camshaft timing gear assembly. NOTE: Be sure not to remove the other 4 bolts. In case of reusing the camshaft timing gear assembly, release the straight pin lock first, and then install the gear.
14. Install camshaft timing gear assy. Put the camshaft timing gear assembly and the a camshaft together with the straight pin off the key groove. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove. NOTE: Be sure not to turn the camshaft timing gear to the retard angle side (to the right direction). Check that there is no clearance between the gear's fringe and the camshaft. Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N.m (551 kgf.cm, 40 ft.Ibf) Check that the camshaft timing gear assembly can move to the retard angle side (to the right direction), and is locked at the most retarded position.
15. Install camshaft. Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing sprockets. Examine the front marks and numbers and tighten the bolts in the order (Scheme 455) Torque: Bearing cap No. 1 30 N.m (301 kgf.cm, 22 ft.Ibf) Bearing cap No. 3 9.0 N.m (92 kgf.cm, 80 in.Ibf)
16. Install No. 2 camshaft. Put the camshaft No. 2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets. Raising the camshaft, tighten the set bolt temporarily. Examine the from marks and numbers and tighten the bolts in the sequence shown in the illustration. Torque: Bearing cap No. 2 30 N.m (301 kgf.cm, 22 ft.Ibf) Bearing cap No. 3 9.0 N.m (92 kgf.cm, 80 in.Ibf) Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.Ibf) NOTE: Be careful not to damage the valve lifter. As shown in the illustration, check the match marks on the timing chain and camshaft timing sprockets and the alignment of the pulley groove with timing mark of the chain cover.
17. Install chain tensioner assy No. 1. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Install a new gasket and chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.Ibf) NOTE: When installing the tensioner, set the hook again if the hook releases the plunger. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
18. Install cylinder head cover sub-assy. 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 NOTE: Remove any oil the contact surface. Install the cylinder head cover within 5 minutes after applying seal packing. Do not put into engine oil 2 hours after installing. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: Bolt A 11 N.m (110 kgf.cm, 8 ft.Ibf) Bolt B 14 N.m (143 kgf.cm, 10 ft.Ibf) Nut 11 N.m (110 kgf.cm, 8 ft.Ibf)
19. Install ignition coil assy. Torque: 9.0 N.m (92 kgf.cm, 80 in.Ibf)
20. Install front wheel RH. Torque: 103 N.m (1050 kgf.cm, 76 ft.Ibf)
21. Inspect oil leak.

Scheme 468

Scheme 469

Scheme 470

Scheme 471

Scheme 472

Scheme 473

Scheme 474

1. Remove front wheel RH .
2. Remove front fender splash shield front RH .
3. Remove front fender apron seal RH .
4. Remove engine mounting stay No. 2 RH .
5. Remove engine cover sub-assy No. 1 .
6. Remove engine moving control rod w/bracket Remove the 3 bolts and engine moving control rod w/bracket.
7. Remove engine mounting bracket No. 2 RH
8. Remove fan and generator V belt (See «drive Belt (2AZ-FE)»(ref-159280-S33179642412005062900000) )
9. Remove crankshaft pulley Using SST, loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
10. Remove timing gear case or timing chain case oil seal Using a knife, cut off the oil seal lip. Using a screwdriver with taping tip, pry out the oil seal. NOTE: After the removal, check if the crankshaft is not damaged. If there is, mend it with a sandpaper (#400).
11. Install timing gear case or timing chain case oil seal . Apply MP grease to a new oil seal lip. NOTE: Keep the lip off foreign materials. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-22010 NOTE: Wipe off extra grease on the crankshaft.
12. Install crankshaft pulley . Align the pulley set key with the key groove of the pulley. Using SST, install the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 170 N.m (1,733 kgf.cm, 125 in.lbf)
13. Install fan and generator v belt (See «drive Belt (2AZ-FE)»(ref-159280-S33179642412005062900000) ) . SST 09249-63010
14. Install engine mounting bracket No. 2 RH Torque: 52 N.m (531 kgf.cm, 38 ft.lbf)
15. Install engine moving control rod w/bracket . Install the engine moving control rod w/bracket with 3 bolts. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
16. Install engine mounting stay No. 2 RH . Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
17. Install front wheel RH Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) .
18. Inspect oil leak .

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

1. Remove automatic transaxle assy (See «REMOVAL & INSTALLATION»(ref-157895) ) . NOTE: Remove and install the transaxle assembly after removing the engine assy w/transaxle.
2. Remove drive plate and ring gear sub-assy . Fix the crankshaft with SST. SST 09213-54015 (91651-60855), 09330-00021 Remove the 8 bolts, rear spacer, drive plate and front spacer.
3. Remove engine rear oil seal . Using a knife, cut off the oil seal lip. Using a screwdriver with taping its tip, pry out the oil seal. NOTE: After the removal, check if the crankshaft is not damaged. If there is, mend it with a sandpaper (#400).
4. Install engine rear oil seal . Apply MP grease to a new oil seal lip. NOTE: Keep the lip off foreign materials. 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) NOTE: Wipe off extra grease on the crankshaft.
5. Install drive plate & ring gear sub-assy . Fix the crankshaft with SST. SST 09213-54015 (91651-60855), 09330-00021 Clean the bolt and the bolt hole. Apply Adhesive to 2 or 3 threads of the bolt end. Adhesive : Part No. 08833-00070, THREE BOND or equivalent Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown. Torque: 98 N.m (1,000 kgf.cm, 72 ft.lbf)
6. Install automatic transaxle assy (See «REPLACEMENT»(ref-159280-S38378971012005062900000) ) .