Engine Mechanical: Removal & Installation Toyota RAV4 II

REMOVAL

Note. Under the condition with the timing chain cover removed, in case of rotating the camshafts, make the position of the crankshaft rotated clockwise by about 45° from TDC/compression of No. 1 cylinder.

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1. Drain engine oil .
2. Remove RH engine under cover .
3. Remove PS vane pump (See «POWER STEERING VANE PUMP»(ref-178339-S03063819242005061400000) ) .
4. Remove ABS actuator (See «ACTUATOR/ABS ECU»(ref-153887-S10315722832003042800000) ) .
5. Remove RH engine mounting insulator (See «REMOVAL»(ref-159218-S05684818652005060800000) ) .
6. Remove drive belt (See «CHARGING SYSTEM»(ref-173302-S31295051822005050300000) ) .
7. Remove generator (See «REMOVAL»(ref-173302-S06423806502005050300000) ) .
8. Remove air cleaner assembly (See «REMOVAL»(ref-159218-S10694829132005060800000) ) .
9. Remove ignition coils (See «REMOVAL & INSTALLATION (RAV4)»(ref-133226-S09443296692002021900000) ) .
10. Remove cylinder head cover . Disconnect the 2 PCV hoses from the cylinder head cover. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.
11. Set No. 1 cylinder to TDC/compression . Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
12. Remove crankshaft pulley . Using SST, loosen the pulley bolt. SST 09213-54015, 09330-00021 Remove the pulley bolt and crankshaft pulley. NOTE: If necessary, remove the pulley with SST. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021), 09950- 40011 (09957-04010)
13. Remove chain tensioner . Remove the 2 nuts, chain tensioner and gasket.
14. Remove drive belt tensioner . Remove the bolt, nut and drive belt tensioner.
15. Remove crankshaft position sensor (See «CAMSHAFT POSITION SENSOR»(ref-133226-S02390994892002021900000) ) .
16. Remove oil pan (See «REMOVAL»(ref-177929-S12320336652005060800000) ) .
17. Remove timing chain cover . Using a Torx socket wrench (E10), remove the stud bolt for the drive belt tensioner. Remove the 14 bolts and 2 nuts. Using a screwdriver, pry between the timing chain cover and cylinder head or cylinder block. Remove the timing chain cover. NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
18. Remove crank angle sensor plate .
19. Remove chain tensioner slipper . Remove the bolt and slipper.
20. Remove chain vibration damper . Remove the 2 bolts and damper.
21. Remove timing chain guide . Remove the bolt and chain guide.
22. Remove timing chain .
23. Remove crankshaft timing sprocket .
24. Remove camshaft timing sprocket and VVT timing sprocket . Hold the hexagonal head wrench portion of the camshaft with a wrench, and loosen the sprocket bolts. NOTE: Be careful not to damage the cylinder head and valve lifter by a wrench. Remove the bolt and exhaust camshaft timing sprocket. Remove the bolt and VVT timing sprocket. NOTE: Do not disassemble the VVT timing sprocket.

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1. Inspect timing chain and timing sprockets . Using vernier calipers, measure the length of the 16 links with the chain fully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) If the elongation is greater than maximum, replace the chain. NOTE: Make the same pulling measurements at 3 or more places selected at random. Wrap the chain around the timing sprocket. Using vernier calipers, measure the timing sprocket diameter with the chain. NOTE: Vernier calipers must contact the chain rollers for measuring. Minimum sprocket diameter (w/ Chain): If the diameter is less than minimum, replace the chain and sprockets.
2. Inspect chain tensioner slipper and vibration damper . Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the slipper and/or damper.
3. Inspect chain tensioner . Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
4. Inspect drive belt tensioner . Check the oil leakage and crack. If necessary, replace the drive belt tensioner.

Replace Crankshaft Front Oil Seal

Note. There are 2 methods ((a) and (b)) to replace the oil seal.

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1. If the timing chain cover is removed from the cylinder head and block. Using a screwdriver and a hammer, tap out the oil seal. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010 Apply MP grease to the oil seal lip.
2. If the timing chain cover is installed to the cylinder head and block. Using SST, remove the oil seal. SST 09308-10010, 09950-60010 (09951-00200) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010

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1. Install camshaft timing sprocket and VVT timing sprocket . Install the camshaft timing sprocket. Face the timing mark of the sprocket outward Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark, and slide on the camshaft timing sprocket and VVT timing sprocket. Temporarily install the camshaft timing sprocket set bolt. Hold the hexagon wrench head portion of the exhaust camshaft with a wrench, and tighten the bolt. Torque: 54 N.m (550 kgf. cm, 40 ft. lbf) Install the VVT timing sprocket. Holding the VVT timing sprocket in the position where the VVT timing sprocket pin groove is slightly to right of the camshaft pin looking from the front side, install the VVT timing sprocket to the camshaft, lightly pressing and turning it counter clockwise. Check that there is virtually no clearance between the VVT timing sprocket and camshaft flange. NOTE: Be careful not to turn the VVT timing sprocket clockwise when installing it. Temporarily install the VVT timing sprocket bolt. Hold the hexagon wrench head portion of the intake camshaft with a wrench. Take care to install the VVT timing sprocket with the bolt Torque: 54 N.m (550 kgf. cm, 40 ft. lbf) Check that the valve timing controller turns clockwise and that it is locked securely when the lock pin in hole is at the locking point.
2. Set No. 1 cylinder to TDC/compression . Turn the hexagonal wrench head portion of the camshafts, and align the timing marks of the camshaft timing sprocket and VVT timing sprocket with the timing marks of No 1 and No. 2 bearing caps as shown in the illustration. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
3. Install chain vibration damper . Install the damper with the 2 bolts. Torque: 9 N.m (90 kgf. cm, 80 in. .lbf)
4. Install crankshaft timing sprocket . Align the sprocket set key with the key groove of the sprocket, slide on the sprocket.
5. Install timing chain . Install the timing chain on the crankshaft timing sprocket with the blue or orange mark link aligned with the timing mark on the crankshaft timing sprocket. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the gold or yellow mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket.
6. Install timing chain guide . Install the timing chain guide with the bolt. Torque: 9 N.m (90 kgf. cm, 80 in. .lbf)
7. Install chain tensioner slipper . Install the slipper with the bolt. Torque: 19 N.m (195 kgf. cm, 14 ft. lbf) Check that the slipper is hold on the cylinder block stopper.
8. Install crank angle sensor plate . Install the plate with the F mark facing forward.
9. Install timing chain cover . Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover and cylinder head/block/crank case. Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the timing chain cover as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 in.) opening. NOTE: Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 2 mm (0.08 in.) opening. NOTE: Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the timing chain cover with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 9 N.m (90 kgf. cm, 80 in. .lbf) for bolt A 21 N.m (220 kgf. cm, 15 ft. .lbf) for bolt B 43 N.m (440 kgf. cm, 32 ft. .lbf) for bolt C 43 N.m (440 kgf. cm, 32 ft. .lbf) for bolt D 9 N.m (90 kgf. cm, 80 ft. lbf) for nuts NOTE: Each bolt length in indicated in the illustration. Using a Torx socket wrench (E10), install the stud bolt for the drive belt tensioner. Torque: 9.5 N.m (90 kgf. cm, 84 in. .lbf)
10. Install drive belt tensioner . Install the drive belt tensioner with the bolt and nut. Torque: 59.5 N.m (610 kgf. cm, 44 ft. lbf) NOTE: As the drive belt tensioner should be torqued together with the timing chain cover, so be sure install it with in 15 minutes after the timing chain cover is installed.
11. Install crankshaft position sensor (See «CAMSHAFT POSITION SENSOR»(ref-133226-S02390994892002021900000) ) .
12. Install oil pan (See «INSTALLATION»(ref-177929-S10627409592005060800000) ) .
13. Install crankshaft pulley . Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST 09213-54015, 09330-00021 Torque: 170 N.m (1,735 kgf. cm, 125 ft. lbf)
14. 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. Place a new gasket on the timing chain cover with portion A facing as shown in the illustration. Push the chain tensioner into the timing chain cover, and install the 2 nuts. Torque: 9 N.m (90 kgf. cm, 80 in. .lbf)
15. Set chain tension . 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.
16. Check valve timing . Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. NOTE: Always turn the crankshaft clockwise. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
17. Install cylinder head cover . Remove any old packing (FIPG) material. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. If the gasket has damage, replace a new one. NOTE: Part must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N.m (115 kgf. cm, 8 ft. lbf) Install the noise filter. Disconnect the oxygen sensor (bank 1 sensor 1) connector. Connect the 2 PCV hoses to the cylinder head cover.
18. Install ignition coils (See «REMOVAL & INSTALLATION (RAV4)»(ref-133226-S09443296692002021900000) ) .
19. Install vane pump (See «REASSEMBLY»(ref-178339-S17225445762005061400000) ) .
20. Install generator (See «INSTALLATION»(ref-173302-S11495224042005050300000) ) .
21. Install RH engine mounting insulator (See «REMOVAL»(ref-159218-S05684818652005060800000) ) .
22. Install drive belt (See «CHARGING SYSTEM»(ref-173302-S31295051822005050300000) ) .
23. Install ABS actuator (See «ACTUATOR/ABS ECU»(ref-153887-S10315722832003042800000) ) .
24. Install air cleaner assembly (See «INSTALLATION»(ref-159218-S31817310542005060800000) ) .
25. Install engine under cover .
26. Fill with engine oil (See «REPLACEMENT»(ref-177929-S27903999012005060800000) ) .
27. Start engine and check for leak .
28. Recheck engine oil level .

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1. Remove RH engine under cover .
2. Drain engine coolant
3. Drain engine oil .
4. Remove air cleaner assembly . Disconnect the MAF meter connector. Disconnect the 2 EVAP hoses from the VSV. Disconnect VSV connector for EVAP. Disconnect the CCV hose from the air cleaner. Disconnect the PCV hose from the cylinder head cover.
5. Remove drive belt (See «CHARGING SYSTEM»(ref-173302-S31295051822005050300000) ) .
6. Remove generator (See «REMOVAL»(ref-159218-S13219462912005060800000) ) .
7. Remove PS vane pump (See «REMOVAL»(ref-178339-S33193616172005061400000) ) .
8. Remove ignition coils (See «REMOVAL & INSTALLATION (RAV4)»(ref-133226-S09443296692002021900000) ) .
9. Remove spark plugs (See «RAV4»(ref-133196-S04928171832002021900000) ) .
10. Remove injectors (See «FUEL INJECTORS (CELICA, COROLLA, ECHO, HIGHLANDER, RAV4)»(ref-133221-S27199948642002021900000) ) .
11. Remove exhaust manifold assembly . Disconnect the 2 A/F sensor connectors. Disconnect the 2 heated oxygen sensor connectors. Remove the 3 bolts, nut and upper heat insulator. Remove the 2 bolts holding the exhaust manifold stays and crank case. Remove the 5 nuts, 2 bolts, 2 compression springs, the exhaust manifold assembly and 2 gaskets.
12. Remove heat insulators from exhaust manifold . Remove the 3 bolts and No. 1 lower heat insulator. Remove the 4 bolts and No. 2 lower heat insulator. Remove the 2 nuts, No. 1 and No. 2 exhaust manifold stays.
13. Remove oil filler cap .
14. Remove PCV hoses and valve . Remove the 2 PCV hoses. Remove the PCV valve and grommet.
15. Remove intake manifold and throttle body assembly . Disconnect the throttle position sensor connector. Disconnect the IAC valve connector. Disconnect the 2 water hoses from the throttle body. Disconnect the 2 vacuum hoses from the intake manifold. Disconnect the engine wire harness from the clamp. Remove the 5 bolts, 2 nuts, the intake manifold and throttle body assembly, and gasket. Remove the intake manifold insulator.
16. Disconnect engine wire . Disconnect the OCV connector. Disconnect the crankshaft position sensor connector. Disconnect the oil pressure switch connector and wire. Disconnect the camshaft position sensor connector. Disconnect the ECT sensor connector. Disconnect the noise filter.
17. Remove camshaft timing chain (See «REMOVAL»(ref-159218-S13219462912005060800000) ) .
18. Remove timing sprocket and VVT sprocket (See «REMOVAL»(ref-159218-S13219462912005060800000) ) .
19. Remove camshaft timing oil control valve (OCV) (See «VARIABLE VALVE TIMING CAMSHAFT TIMING OIL CONTROL VALVE»(ref-133226-S07399530522002021900000) ) .
20. Remove camshafts . Uniformly loosen and remove the 20 bearing cap bolts in several passes, in the sequence shown. Remove the 10 bearing caps, intake camshaft and exhaust camshaft. Remove the camshaft bearings from the No. 1 camshaft bearing cap and intake camshaft No. 1 journal part of the cylinder head.
21. Remove cylinder head . Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts in several passes, in the sequence shown. NOTE: Head warpage or cracking could result from removing bolts in an incorrect order. Remove the 10 plate washers. Using a screwdriver, pry between the cylinder head and cylinder block, and remove the cylinder head. NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

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1. Remove oil pressure switch .
2. Remove ECT sensor .
3. Remove camshaft position sensor . Remove the bolt, camshaft position sensor and O-ring.
4. Remove valve lifters . NOTE: Arrange the valve lifters in the correct order.
5. Remove valves . Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00010) Remove the spring retainer, valve spring and valve. Using needle-nose pliers, remove the oil seal. Using compressed air and a magnetic finger, remove the spring seat by blowing air. NOTE: Arrange the valves, valve springs, spring seats and spring retainers in the correct order.

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1. Clean top surfaces of pistons and cylinder block . Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston surface. Using a gasket scraper, remove all the gasket material from the cylinder block surface. Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. NOTE: Be careful not to scratch the cylinder head contact surface.
2. Inspect cylinder block for flatness (See «INSPECTION»(ref-159218-S17089288602005060800000) ) .
3. Clean cylinder head . Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTE: Be careful not to scratch the cylinder block contact surface. Using a wire brush, remove all the carbon from the combustion chambers. NOTE: Be careful not to scratch the cylinder block contact surface. Using a soft brush and solvent, thoroughly clean the cylinder head. Using a valve guide bushing brush and solvent, clean all the guide bushings.
4. Inspect cylinder head . Inspect 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: 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the cylinder head. Inspect for cracks. Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
5. Clean valves . Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve.
6. Inspect valve stems and guide bushings . 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.) Using a micrometer, measure the diameter of valve stem. Valve stem diameter: Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Maximum oil clearance: If the clearance is greater than maximum, replace the valve and guide bushing (See «REPLACEMENT»(ref-159218-S37116284652005060800000) ).
7. Inspect valves . Check the valve is ground to the correct valve face angle. Valve face angle: 44.5° Check that the surface of the valve for wear. If the valve face is worn, replace the valve. Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.028 in.) If the margin thickness is less than minimum, replace the valve. Check the valve overall length. Standard overall length: Minimum overall length: If the overall length is less than minimum, replace the valve. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
8. Inspect and clean valve seats . Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. Check the valve face and seat for the following: If blue appears 360° around the face, the valve is concentric. If not, replace the valve. If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with the following width: 1.0 -1.4 mm (0.039 - 0.055 in.) If not, correct the valve seats as follows: If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat.
9. Inspect valve springs . Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (Reference): 2° If the deviation is greater than maximum, replace the valve spring. Using vernier calipers, measure the free length of the valve spring. Free length: 45.7 mm (1.799 in.) If the free length is not as specified, replace the valve spring. Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 184.3 - 203.7 N (18.8 - 20.8 kgf, 41.4 - 45.9 lbf) at 34.0 mm (1.339 in.) Maximum working tension: 344.8 - 381.2 N (35.2 - 38.9 kgf, 77.4 - 85.8 lbf) at 24.0 mm (0.969 in.) If the tension is not as specified, replace the valve spring.
10. Inspect camshafts . Inspect for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: Minimum cam lobe height: If the lobe height is less than minimum, replace the camshaft. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. Journal diameter: If the journal diameter is not as specified, check the oil clearance. Inspect the journal clearance. Clean the bearings, bearing caps and camshaft journals. Install the bearings (See step 7 ). Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the cam shaft journal. Install the bearing caps (See «INSTALLATION»(ref-159218-S31817310542005060800000) ). Remove the bearing caps. Measure the Plastigage at its widest point. Standard oil clearance: Maximum oil clearance: If the oil clearance is greater than maximum, replace the bearing and/or camshaft. If necessary, replace the bearing caps and cylinder head as a set. NOTE: If using a standard bearing, replace it with one have the same number. Reference Cylinder head journal bore diameter: Standard bearing center wall thickness: Camshaft journal diameter: 35.971 - 35.985 mm (1.4165 -1.4167 in.) Remove the Plastigage completely. Remove the camshafts. Remove the bearings. Inspect the thrust clearance. Install the bearings. Install the camshafts (See «INSTALLATION»(ref-159218-S31817310542005060800000) ). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: Maximum thrust clearance: If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Remove the bearings. Remove the camshafts.
11. Inspect VVT timing sprocket (valve timing controller assembly) . Apply vinyl tape to all the ports except the one. Install the VVT timing sprocket. Torque: 54 N.m (550 kgfcm, 40 ft. lbf) NOTE: Do not push VVT timing sprocket to the camshaft forcibly when installing it. Check that the VVT timing sprocket will not turn. Wind tape around the tip of the air gun and apply air of approx. 100 kPa (1 kgf/cm 2 ,14 psi) to the port of the camshaft. NOTE: When the oil splashes, wipe it off with a shop rag and the likes. NOTE: Perform this in order to release the lock pin for the maximum delay angle locking. Under the condition of (d), turn the VVT timing sprocket to the advance angel side (the arrow marked direction in the illustration) with your hand. Standard: Must turn 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. Except the position where the lock pin meets at the maximum delay angle, let the VVT timing sprocket turn back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 30° Turn the VVT timing sprocket with your hand and lock it at the maximum delay angel position.
12. Inspect valve lifters and lifter bores . 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.) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 - 30.976 mm (1.2191 -1.2195 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 - 0.059 mm (0.0013 - 0.0023 in.) Maximum oil clearance: 0.079 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.
13. Inspect exhaust manifold . Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 1.5 mm (0.0590 in.) If warpage is greater than maximum, replace the exhaust manifold.
14. Inspect cylinder head bolts . Standard nominal length: 161.3 -162.7 mm (6.350 - 6.405 in.) Maximum nominal length: 164.2 mm (6.4646 in.) If the length is greater than maximum, replace the bolt.

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1. Gradually heat the cylinder head to 80 - 100°C (176 212°F).
2. Using SST and a hammer, tap out the guide bushing. SST 09201-01055, 09950-70010(09951-07100)
3. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
4. Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bushing bore to the following dimension: 10.285 -10.306 mm (0.4049 - 0.4057 in.) If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), replace the cylinder head.
5. Gradually heat the cylinder head to 80 - 100°C (176 -212°F).
6. Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201-01055, 09950-70010 (09951-07100) Protrusion height (H): 9.6 -10.0 mm (0.380 - 0.394 in.)
7. Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See «INSPECTION»(ref-159218-S36943987682005060800000) ) between the guide bushing and valve stem.

INSTALLATION

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

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1. Install cylinder head . Place the cylinder head on the cylinder block. Apply seal packing to the cylinder head gasket as shown in the illustration Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 2.5 - 3.0 mm (0.10-0.12 in.) opening. NOTE: Avoid applying an excessive amount to the surface. Part must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Place a new cylinder head gasket on the cylinder block surface with the lot No. upward. NOTE: 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. Install the cylinder head bolts. NOTE: The cylinder head bolts are tightened in 2 steps (steps (2) and (4)). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. 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 (800 kg. fcm, 58 ft. lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. Mark the front of the cylinder head bolt with paint. Retighten the cylinder head bolts 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front.
2. Install camshafts . Install the lower camshaft bearing to the cylinder head. Align the bearing claw with the claw groove of No. 1 bearing cap, and push in the upper camshaft bearing. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration. Install the bearing caps in their proper locations. NOTE: Each of No. 3 camshaft bearing cap has a number and front mark. The No. 1 and No. 2 bearing caps has a front marks. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the 20 bearing cap bolts in several passes, in the sequence shown. Torque: 29.5 N.m (300 kgf. cm, 22 ft. lbf) for No. 1 and No. 2 9 N.m (90 kgf. cm, 80 in. .lbf) for others
3. Check and adjust valve clearance (See «ADJUSTMENT»(ref-159218-S19973640572005060800000) ) . NOTE: Under the condition with the timing chain cover removed, in case of rotating the camshafts, make the position of the crankshaft rotated clockwise by about 45° from TDC/compression of No. 1 cylinder. Turn the camshafts and position the cam lobe upward, and check and adjust the valve clearance.
4. Install camshaft timing sprocket and VVT timing sprocket (See «INSTALLATION»(ref-159218-S28145665832005060800000) ) .
5. Install timing chain (See «INSTALLATION»(ref-159218-S28145665832005060800000) ) .
6. Install camshaft position sensor (See «CAMSHAFT POSITION SENSOR»(ref-133226-S02390994892002021900000) ) .
7. Install camshaft timing oil control valve (OCV) (See «VARIABLE VALVE TIMING CAMSHAFT TIMING OIL CONTROL VALVE»(ref-133226-S07399530522002021900000) ) .
8. Install oil filler cap .
9. Install intake manifold and throttle body assembly Install a new gasket to the intake manifold. Install intake manifold insulator. Install the intake manifold and throttle body assembly with the 5 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 30 N.m (305 kgf. cm, 22 ft. lbf) Connect the engine wire harness to the clamp. Connect the 2 vacuum hoses to the intake manifold. Connect the 2 water hoses to the throttle body. Connect the IAC valve connector. Connect the throttle position sensor connector.
10. Install PCV valve and hoses . Install the PCV valve with the grommet. Install the PCV hoses.
11. Connect engine wire . Connect the noise filter. Connect the ETC sensor connector. Connect the camshaft position sensor connector. Connect the oil pressure switch connector and wire. Connect the crankshaft position sensor. Connect the OCV connector. Install the engine wire with the 2 bolts.
12. Install heat insulators to exhaust manifold . Temporary install the No. 1 and No. 2 exhaust manifold stays to the exhaust manifold with the 2 nuts. Install the No. 2 lower heat insulator to the exhaust manifold with the 4 bolts. Torque: 12 N.m (120 kgf. cm, 9 ft. lbf) Install the No. 1 lower heat insulator to the exhaust manifold with the 3 bolts. Torque: 12 N.m (120 kgf. cm, 9 ft. lbf)
13. Install exhaust manifold assembly . Install a new gasket and the exhaust manifold with the 5 nuts. Torque: 37 N.m (375 kgf. cm, 27 ft. lbf) Install the 2 exhaust manifold stays with the 2 bolts. Torque: 44 N.m (450 kgf. cm, 33 ft. lbf) Tighten the 2 nuts holding the exhaust manifold stays to crank case. Torque: 44 N.m (450 kgf. cm, 33 ft. lbf) Install the 2 compression springs and 2 bolts holding the exhaust manifold and front exhaust pipe. Torque: 43 N.m (439 kgf. cm, 32 ft. lbf) Install the upper heat insulator with the 3 bolts and nut. Torque: 12 N.m (120 kgf. cm, 9 ft. lbf) Connect the 2 A/F sensor connectors. Connect the 2 heated oxygen sensor wires to the wire bracket.
14. Install injectors (See «INSTALLATION»(ref-133226-S33462878592002021900000) ) .
15. Install spark plugs (See «SPARK TEST»(ref-133196-S06466806432002021900000) ) .
16. Install ignition coils (See «REMOVAL & INSTALLATION (RAV4)»(ref-133226-S09443296692002021900000) ) .
17. Install PS vane pump (See «INSTALLATION»(ref-178339-S13581376402005061400000) ) .
18. Install generator (See «INSTALLATION»(ref-173302-S11495224042005050300000) )
19. Install drive belt (See «INSTALLATION»(ref-173302-S11495224042005050300000) ) .
20. Install air cleaner assembly . Connect the PCV hose to the cylinder head cover. Connect the CCV hose to the air cleaner. Connect the VSV connect for EVAP. Connect the 2 EVAP hoses to the VSV. Connect the MAF meter connector.
21. Fill with engine oil (See «REPLACEMENT»(ref-177929-S27903999012005060800000) ) .
22. Fill with engine coolant .
23. Start engine and check for leak .
24. Recheck engine oil and coolant level .
25. Install RH engine under cover .

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1. Remove engine under covers .
2. Drain transaxle oil .
3. Drain transfer oil .
4. Drain engine oil .
5. Drain engine coolant .
6. Remove hood .
7. Remove radiator reservoir .
8. Remove battery and tray . Remove the cowl top ventilation louver (See «REMOVAL»(ref-178537-S13167644722005061600000) ). Remove the hold-down clamp, battery and tray. Remove the 5 bolts and battery bracket.
9. Remove air cleaner assembly . Disconnect the MAF meter connector. Disconnect the 2 EVAP hoses from the VSV. Disconnect VSV connector for EVAP. Disconnect the CCV hose from the air cleaner. Disconnect the PCV hose from the cylinder head cover. Disconnect the air cleaner hose from the throttle body, and remove the 3 bolts and the air cleaner assembly.
10. Remove engine room J/B . Remove the engine room J/B cover. Loosen the bolt. Remove the engine room J/B. Pull out the engine wire connector. Disconnect the connector. Disconnect the engine wire clamp.
11. Disconnect engine wire from cabin . Remove the 2 screws and glove compartment door. Disconnect the 6 engine wire connectors from the ECM and instrument panel wire. Pull out the engine wire from the cabin.
12. Disconnect tubes, hoses, connector, cable and wire . Disconnect the accelerator cable. Disconnect the ground wire from the cylinder head. Disconnect the discharge and liquid tubes from the compressor, and remove the 2 O-rings (See «REMOVAL»(ref-138692-S21631020482005062000000) ). Disconnect the suction hose, pressure feed tube and gasket from the PS vane pump. Disconnect the upper radiator hose. Disconnect the lower radiator hose. Disconnect the fuel tube connector. Disconnect the 2 heater hoses. Disconnect the connector from the fusible link block.
13. M/T: Disconnect shift control cables from transaxle. Remove the 2 clips and 2 washers. Remove the 2 clips, and disconnect the 2 control cables.
14. Remove starter . A/T: Disconnect the hose from the dipstick guide. Disconnect the connector. Remove the 2 bolts, and disconnect the starter. Remove the nut, and disconnect the starter cable. Remove the starter.
15. M/T: Disconnect clutch release cylinder and line from transaxle Remove the 2 bolts and heat insulator. Remove the 5 bolts and disconnect the release cylinder.
16. A/T: Disconnect shift control cable from transaxle Remove the nut holding the control shift lever to the control cable. Remove the clip, and disconnect the control cable. Disconnect the control cable from the cable clamp.
17. A/T: Disconnect oil cooler hoses .
18. Disconnect ground cable from transaxle .
19. 4WD: Remove propeller shaft (See «REMOVAL»(ref-178536-S06235668282005061600000) ) .
20. Remove front drive shafts (See «REMOVAL»(ref-164016-S05961786792004072000000) ) .
21. Remove front exhaust pipe . Remove the 4 bolts, 2 compression rings, 2 gaskets and exhaust pipe.
22. Disconnect stabilizer bar links . Remove the 2 nuts, and disconnect the LH and RH stabilizer links.
23. Disconnect PS gear assembly . Remove the 2 bolts of the PS gear assembly.
24. Attach engine sling device to engine hangers . Install No. 1 and No. 2 engine hangers in the correct direction. Torque: 38 N.m (390 kgf. cm, 28 ft. lbf) Attach the sling device to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
25. Remove engine, transaxle, front suspension crossmember and center engine mounting member assembly Remove the 2 nuts and bolt holding the RH engine mounting insulator to the tinning chain cover. Remove the bolt holding the LH engine mounting insulator to the mounting bracket. Support the suspension crossmember with a jack. Remove the 6 bolts holding the suspension crossmember engine mounting member to the body. Lower the engine out of the vehicle slowly and carefully. NOTE: Make sure the engine is clear of all wiring, hoses and cables.
26. Remove engine and transaxle assembly from front suspension crossmember and center engine mounting member Remove the bolt holding the front engine mounting bracket to the mounting insulator. Remove the bolt holding the rear engine mounting bracket to the mounting insulator. Separate the engine and transaxle assembly from the suspension crossmember and engine mounting member.
27. 4WD: Remove stiffener plate . Remove the 5 bolts and stiffener plate.
28. 2WD: Remove center bearing bracket . Remove the 3 bolts and bearing bracket.
29. A/T: Remove torque converter clutch bolts . Remove the hole plug. Turn the crankshaft to gain access to each bolt. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
30. Remove transaxle from engine . Remove the 4 lower bolts holding the engine to the transaxle. M/T: Disconnect the connectors. Disconnect the vehicle speed sensor connector. Disconnect the back-up light switch connector. A/T: Disconnect the connectors and clamps. Disconnect the park/neutral position switch connector. Disconnect the solenoid wire connector. Disconnect the input turbine speed sensor connector. Disconnect the counter gear speed sensor connector. Disconnect the vehicle speed sensor. Disconnect the wire clamp from the bracket. Disconnect the wire clamp from the engine mounting bracket. Remove the 6 upper bolts holding the transaxle to the engine. Remove the transaxle together with the torque converter clutch (A/T) from the engine.
31. Remove drive belt (See «CHARGING SYSTEM»(ref-173302-S31295051822005050300000) ) .
32. M/T: Remove clutch cover and disc .
33. A/T: Remove drive plate .
34. M/T: Remove flywheel .
35. Remove A/C compressor . Disconnect the magnetic clutch and lock sensor connector from the compressor. Remove the 3 bolts, nut and compressor.
36. Remove PS vane pump . Disconnect the oil pressure switch connector. Remove the 2 bolts and vane pump.
37. Remove generator . Remove the terminal cover and nut, and disconnect the generator wire. Disconnect the generator connector. Disconnect the A/C wire. Remove the 2 bolts and generator.

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1. Install generator . Install the generator with the 2 bolts. Torque: 52 N.m (530 kgf. cm, 38 ft. lbf) for bolt A 21 N.m (214 kgf. cm, 16 ft. lbf) for bolt B Connect the A/C wire. Connect the generator connector. Connect the generator wire with the nut, and install the cover. Torque: 9.7 N.m (100 kgf. cm, 85 in. .lbf)
2. Install PS vane pump . Install the vane pump with the 2 bolts. Torque: 43 N.m (440 kgf. cm, 32 ft. lbf) Connect the oil pressure switch connector.
3. Install A/C compressor . Install the compressor with the 3 bolts and nut. Torque: 24.5 N.m (250 kgf. cm, 18 ft. lbf) Connect the magnetic clutch and lock sensor connector.
4. Install drive belt (See «CHARGING SYSTEM»(ref-173302-S31295051822005050300000) ) .
5. A/T: Install drive plate Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Align the pin of the front spacer with the pin hole of the crankshaft, and install the front spacer. Install the drive plate and rear spacer as shown in the illustration. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown. Torque: 98 N.m (100 kgf. cm, 72 ft. lbf)
6. M/T: Install flywheel (See procedure in step 5 ) . Torque: 130 N.m (1,326 kgf. cm, 96 ft. lbf)
7. MT: Install clutch disc and cover (See «CLUTCH ASSEMBLY»(ref-155645-S15687781302003061900000) ) .
8. Install engine to transaxle . Install the 6 upper bolts holding the transaxle to the engine. Torque: 46 N.m (470 kgf. cm, 34 ft. lbf) for bolt A 64 N.m (650 kgf. cm, 47 ft. lbf) for bolt B A/T: Connect the connectors and clamps. Connect the park/neutral position switch connector. Connect the solenoid wire connector. Connect the input turbine speed sensor connector. Connect the counter gear speed sensor connector. Connect the vehicle speed sensor. Connect the wire clamp from the bracket. Connect the wire clamp to the engine mounting bracket. M/T: Connect the connectors. Connect the vehicle speed sensor connector. Connect the back-up light switch connector. Install the 4 lower bolts holding the engine to the transaxle. Torque: 44 N.m (450 kgf. cm, 32 ft. lbf)
9. A/T: Install torque converter clutch bolts . Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly. Torque: 41 N.m (418 kgf. cm, 30 ft. lbf) NOTE: First tighten the green colored bolt, install the other bolts.
10. 2WD: Install center bearing bracket . Install the bearing bracket with the 3 bolts. Torque: 34 N.m (347 kgf. cm, 25 ft. lbf)
11. 4WD: Install stiffener plate Install the stiffener plate with the 5 bolts. Torque: 34 N.m (347 kgf. cm, 25 ft. lbf)
12. Install engine and transaxle assembly to front suspension crossmember and center engine mounting member Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member. Install the bolt holding the rear engine mounting bracket to the mounting insulator. Torque: 88 N.m (898 kgf. cm, 65 ft. lbf) Install the bolt holding the front engine mounting bracket to the mounting insulator. Torque: 56 N.m (571 kgf. cm, 41 ft. lbf)
13. Install engine, transaxle, front suspension crossmember and center engine mounting member assembly in vehicle . Attach the engine sling device to the engine hangers. Lift the engine into the engine compartment. Install the bolt and 2 nuts holding the RH engine mounting insulator to the timing chain cover. Torque: 52 N.m (530 kgf. cm, 38 ft. lbf) Install the bolt holding the LH engine mounting bracket to the mounting insulator. Torque: 56 N.m (571 kgf. cm, 41 ft. lbf) Support the suspension crossmember with a jack. Install the 6 bolts holding the suspension crossmember engine mounting member to the body. Torque: 39 N.m (400 kgf. cm, 28 ft. lbf) for bolt A, 113 N.m (1,150 kgf. cm, 82 ft. lbf) for bolt B, 157 N.m (1,600 kgf. cm, 115 ft. lbf) for bolt C
14. Install PS gear assembly . Install the PS gear assembly with the 2 bolts. Torque: 137 N.m (1,400 kgf. cm, 101 ft. lbf)
15. Remove No. 1 and No. 2 engine hangers .
16. Connect stabilizer bar links . Connect the LH and RH stabilizer links with the 2 nuts. Torque: 44 N.m (450 kgf. cm, 32 ft. lbf)
17. Install front exhaust pipe . Install 2 new gaskets and the exhaust pipe, with the 2 compression rings and 4 bolts. Torque: 43 N.m (439 kgf. cm, 32 ft. lbf) for bolt A, 49 N.m (500 kgf. cm, 36 ft. lbf) for bolt B
18. Install LH and RH front drive shafts (See «REASSEMBLY»(ref-164016-S29341284332004072000000) ) .
19. 4WD: Install propeller shaft (See «INSTALLATION»(ref-178536-S05025393792005061600000) ) .
20. Connect ground cable to transaxle . Torque: 19 N.m (195 kgf. cm, 14 ft. lbf)
21. A/T: Connect oil cooler hoses .
22. A/T: Connect shift control cable to transaxle . Connect the control cable with the nut. Torque: 15 N.m (150 kgf. cm, 11 ft. lbf) Connect the control cable with the clip. Connect the control cable to the cable clamp.
23. M/T: Install clutch release cylinder and tube . Install the release cylinder with the 5 bolts. Torque: 25 N.m (255 kgf. cm, 18 ft. lbf) for bolt A, 12 N.m (120 kgf. cm, 9 ft. lbf) for bolt B, 5 N.m (51 kgf. cm, 44 in. .lbf) for bolt C Install the heat insulator with the 2 bolts. Torque: 12 N.m (120 kgf. cm, 44 ft. lbf)
24. Install starter . Install the starter. Connect the starter cable with the nut. Torque: 8.8 N.m (86 kgf. cm, 78 in. .lbf) Install the starter with the 2 bolts. Torque: 37 N.m (378 kgf. cm, 28 ft. lbf) Connect the connector. Connect the hose to the dipstick guide.
25. M/T: Connect shift control cables to transaxle . Connect the 2 control cables with the 2 clips. Install the 2 washers and 2 clips.
26. Disconnect tubes, hoses, connector, cable and wire . Install 2 new O-rings, and connect the discharge and liquid tubes to the compressor (See «REMOVAL»(ref-138692-S21631020482005062000000) ). Connect the accelerator cable. Connect the ground wire to the cylinder head. Install a new gasket, and connect the suction hose and pressure feed tube to the PS vane pump. Connect the upper radiator hose. Connect the lower radiator hose. Connect the fuel tube connector. Connect the 2 heater hoses. Connect the connector to the fusible link block.
27. Connect engine wire to cabin . Push in engine wire through the cabin. Connect the 6 engine wire connectors to the ECM and instrument panel wire. Install the glove compartment door with the 2 screws.
28. Install engine room J/B . Connect the engine wire clamp. Connect the connector. Push into the engine wire connector. Install the engine room J/B, and tighten the bolt until it fails to catch. Install the engine room J/B cover.
29. Install air cleaner assembly . Connect the air cleaner hose to the throttle body, and install the air cleaner assembly with the 3 bolts. Connect the MAF meter connector. Connect the 2 EVAP hoses to the VSV. Connect the VSV connector for EVAP. Connect the CCV hose to the air cleaner. Connect the PCV hose to the cylinder head cover.
30. Install battery and tray . Install the battery bracket with the 5 bolts. Install the battery tray and battery with the hold-down clamp. Install the cowl top ventilation louver (See «INSTALLATION»(ref-178537-S11499914692005061600000) ).
31. Install radiator reservoir tank .
32. Install hood .
33. Fill with engine coolant .
34. Fill with engine oil .
35. Fill with transfer oil .
36. Fill with transaxle oil .
37. Start engine and check for leaks .
38. Bleed power steering system (See «POWER STEERING FLUID»(ref-178339-S17834909922005061400000) ) .
39. Perform road test . Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
40. Recheck engine coolant and oil levels .
41. Install engine under covers .

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1. Install engine to engine stand for disassembly .
2. Remove timing chain (See «REMOVAL»(ref-159218-S13219462912005060800000) ) .
3. Remove cylinder head (See «REMOVAL»(ref-159218-S10694829132005060800000) ) .
4. Remove knock sensor (See «REMOVAL (RAV4)»(ref-133226-S00800417142002021900000) ) .
5. Remove engine wire clamps .
6. Remove plug .
7. Remove OCV filter . Using a 12 mm hexagon wrench, remove the plug, gasket and OCV filter.
8. Remove water pump (See «REMOVAL»(ref-177866-S03638101522005060700000) ) .
9. Remove thermostat (See «REMOVAL»(ref-177866-S20398079092005060700000) ) .
10. Remove engine coolant drain union .
11. Remove oil dipstick and guide . Remove the bolt, oil dipstick and guide. Remove the O-ring from the oil dipstick.
12. Remove water bypass pipe . Remove the 2 nuts, bolt, water bypass pipe and gasket.
13. Remove oil pump (See «REMOVAL»(ref-177929-S12320336652005060800000) ) .
14. Remove oil filter (See «REPLACEMENT»(ref-177929-S27903999012005060800000) ) .
15. Remove oil filter union . Using a 12 mm hexagon wrench, remove the oil filter union.
16. Remove crank case . Uniformly loosen and remove the 11 bolts in several passes, in the sequence shown. Using a screwdriver, remove the crank case by prying the portions between the crank case and cylinder block. NOTE: Be careful not to damage the contact surfaces of the crank case and cylinder block. Remove the O-ring.
17. Remove crankshaft rear oil seal .
18. Check connecting rod thrust clearance . Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 - 0.362 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. If necessary, replace the crankshaft. Connecting rod thickness: 19.788 - 19.840 mm (0.7791 - 0.7811 in.)
19. Remove connecting rod caps and check oil clearance . Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. NOTE: Keep the lower bearing inserted with the connecting rod cap. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of Plastigage on the crank pin. Install the connecting rod cap (See «REASSEMBLY»(ref-159218-S22006843382005060800000) ). NOTE: Do not turn the crankshaft. Remove the connecting rod cap (See procedure b and c above). 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.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. Reference Standard bearing center wall thickness: Completely remove the Plastigage.
20. Remove piston and connecting rod assemblies . 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 bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
21. Check crankshaft thrust clearance . Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.040 - 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.)
22. Remove main bearing caps and check oil clearance . Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown. Using the 2 removed main bearing cap bolts, remove the 5 main bearing caps and 5 lower bearings. NOTE: Be careful not to damage the cylinder block. NOTE: Keep the lower bearing and main bearing cap together. Arrange the main bearing caps in the correct order. Lift out the crankshaft. NOTE: Keep the main bearings and thrust washers together with the cylinder block. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Install the main bearing caps (See «REASSEMBLY»(ref-159218-S22006843382005060800000) ). NOTE: Do not turn the crankshaft. Remove the main bearing cap (See procedure a and b above). Measure the Plastigage at its widest point. Standard oil clearance: 0.017 - 0.040 mm (0.0007 - 0.0016 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. EXAMPLE: Cylinder block "4" + Crankshaft "3" = Total number 7 (Use bearing "3") Reference Completely remove the Plastigage.
23. Remove crankshaft . Lift out the crankshaft. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. NOTE: Arrange the main bearings and thrust washers in the correct order.
24. Check fit between piston and piston pin . Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
25. Remove piston rings . Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. NOTE: Arrange the piston rings in the correct order only.
26. Disconnect connecting rod from piston . Using a small screwdriver, pry out the 2 snap rings. Gradually heat the piston to 80 - 90°C (176 - 194°). Using a plastic-faced hammer and a 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.

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1. Clean cylinder block . Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block. NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (133°F) or less.
2. Inspect cylinder block . Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. Inspect the cylinder bore diameter. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 86.000 - 86.013 mm (3.3858 - 3.3863 in.) Maximum diameter: 86.013 mm (3.3863 in.) If the diameter is greater than maximum, replace the cylinder block.
3. Remove cylinder ridge . If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
4. Inspect crankshaft bearing cap bolts . Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.5 - 7.6 mm (0.2953 - 0.2992 in.) Minimum diameter: 7.2 mm (0.284 in.) If the diameter is less than minimum, replace the bolt.
5. Clean piston . Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or a broken ring, clean the piston ring grooves. Using a brush and solvent, thoroughly clean the piston. NOTE: Do not use a wire brush.
6. Inspect piston . Inspect the piston oil clearance. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.4 mm (1.1968 in.) from the piston head. Piston diameter: 85.927 - 85.937 mm (3.3829 - 3.3833 in.) Measure the cylinder bore diameter in the thrust directions (See step 2 ). Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.063 - 0.086 mm (0.0025 - 0.0034 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block. Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance: If the clearance is not as specified, replace the piston. Inspect the piston ring end gap. Insert the piston ring into the cylinder bore. Using the 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: Maximum end gap: If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. Inspect the piston pin fit. At 80 - 90°C (176 - 194°F), you should be able to push the piston pin into the piston pin hole with your thumb.
7. Inspect connecting rod . Using a rod aligner and a 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. Inspect the piston pin oil clearance. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing (See «REPLACEMENT»(ref-159218-S27181638222005060800000) ). If necessary, replace the piston and piston pin as a set.
8. Inspect connecting rod bolts . Using 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.
9. Inspect crankshaft . Inspect for circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the crankshaft. Inspect the main journals and crank pins. Using a micrometer, measure the diameter of each main journal and crank pin. Diameter: If the diameter is not as specified, check the oil clearance (See «DISASSEMBLY»(ref-159218-S08874033862005060800000) ). If necessary, replace the crankshaft. Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.003 mm (0.0001 in.) If the taper and out-of-round is greater than maximum, replace the crankshaft.

Scheme 296

Scheme 297

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Scheme 300

Scheme 301

1. Replace connecting rod bushings . Using SST and a press, press out the bushing. SST 09222-30010 Align the oil hoses of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See «INSPECTION»(ref-159218-S17089288602005060800000) ) between the bushing and piston pin. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
2. Replace crankshaft rear oil seal . If the rear oil seal is installed to the cylinder block. Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100)