Engine Mechanical: Other Toyota Sequoia I

COMPONENTS

For Timing Belt Component locations, see illustrations. (Scheme 72)- (Scheme 75).

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Scheme 86

1. Remove engine under cover.
2. Drain engine coolant.
3. REMOVE RADIATOR ASSEMBLY
4. Remove throttle body cover.
5. Remove intake air connector assembly.
6. Remove drive belt, fan, fluid coupling and fan pulley: Loosen the 4 nuts holding the fluid coupling to the fan bracket. Remove the drive belt. Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley. (Scheme 76)
7. Remove the 3 bolts, and disconnect the PS pump from the engine.
8. Remove drive belt idler pulley bolt, cover plate and idler pulley.
9. Remove the 3 bolts, nut and RH No. 3 timing belt cover. (Scheme 77)
10. Remove LH No. 3 timing belt cover: Disconnect the engine wire from the 2 wire clamps. (Scheme 78) Remove the 4 bolts and nut. Disconnect the camshaft position sensor wire from the wire clamp on the LH No. 3 timing belt cover. Disconnect the camshaft position sensor connector from the connector bracket. Disconnect the camshaft position sensor connector. Remove the wire grommet from the LH No. 3 timing belt cover. Remove the LH No. 3 timing belt cover. Remove the bolt, nut and oil cooler pipe.
11. Remove the 2 bolts and No. 2 timing belt cover. (Scheme 79)
12. w/ A/C: Disconnect A/C compressor from engine. See Step 16- «REMOVAL»(ref-170140-S21639208912005010400000).
13. Remove the 2 bolts, 2 nuts and fan bracket. (Scheme 80)
14. If re-using timing belt, check installation marks on timing belt: Check that there are 3 installation marks on the timing belt by turning the crankshaft pulley as shown in the illustration. (Scheme 81)
15. Using SST, loosen crankshaft pulley bolt. (Scheme 82) SST 09213-70011 (90105-08076), 09330-00021.
16. Set No. 1 cylinder to TDC/compression: Turn the crankshaft pulley and align its groove with timing mark "0" of the No. 1 timing belt cover. (Scheme 83) Check that the timing marks of the camshaft timing pulleys and timing belt rear plates aligned. (Scheme 84) If not, turn the crankshaft 1 revolution (360 degrees). NOTE: Do not turn the crankshaft pulley. Remove the crankshaft pulley bolt.
17. Remove timing belt tensioner: Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. (Scheme 87)
18. Disconnect timing belt from camshaft timing pulleys: Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise. (Scheme 88) SST 09960-10010 (09962-01000, 09963-01000) Disconnect the timing belt from the camshaft timing pulleys.
19. Using SST, remove the bolt and timing pulley. Remove the 2 timing pulleys. (Scheme 89) SST 09960-10010 (09962-01000, 09963-01000)
20. REMOVE GENERATOR.
21. Remove the bolt, 2 nuts and belt tensioner.
22. Using SST, remove the crankshaft pulley. (Scheme 90) SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)
23. Remove the 4 bolts and No. 1 timing belt cover.
24. Remove timing belt guide.
25. Remove timing belt cover spacer.
26. Remove timing belt.
27. Remove No. 1 idler pulley and No. 2 idler pulley: Using a 10 mm hexagon wrench, remove the bolt, No. 1 idler pulley and plate washer. (Scheme 92) Remove the bolt and No. 2 idler pulley.
28. Using SST, remove the crankshaft timing pulley. (Scheme 93) SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05011)

Scheme 87

Scheme 88

Scheme 89

Scheme 90

1. Inspect timing belt, If there is any defect, as shown in the illustration (Scheme 94), check these points: Premature parting: Check for proper installation. Check the timing cover gasket for damage and proper installation. If the belt teeth are cracked or damaged, check to see if either camshaft is locked. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. If there is wear or damage on even one side of the belt, check the belt guide and the alignment of each pulley. If there is noticeable wear on the belt teeth, check timing cover for damage and for foreign material on the pulley teeth. If necessary, replace the timing belt.
2. Inspect idler pulleys: Visually check the seal portion of the idler pulley for oil leakage. (Scheme 95) If leakage is found, replace the idler pulley. Check that the idler pulley turns smoothly. If necessary, replace the idler pulley.
3. Inspect timing belt tensioner: NOTE: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. Visually check the seal portion of the tensioner for oil leakage. If leakage is found, replace the tensioner. NOTE: Never hold the tensioner push rod facing downward. Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. (Scheme 97) Measure the protrusion of the push rod from the housing end. (Scheme 98) Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 in.). If the protrusion is not as specified, replace the tensioner.
4. INSPECT WATER PUMP.

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Scheme 105

1. Install crankshaft timing pulley: Align the timing pulley set key with the key groove of the pulley. (Scheme 99) Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-46011.
2. Install No. 1 idler pulley and No. 2 idler pulley: Apply adhesive 2 or 3 threads of the pivot bolt. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. Using a 10 mm hexagon wrench, install the plate washer and No. 1 idler pulley with the pivot bolt. (Scheme 100) Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) Install the No. 2 idler pulley with the bolt. Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) Check that the No. 1 and No. 2 idler pulleys moves smoothly.
3. Temporarily install timing belt: NOTE: Only wipe the pulleys; do not use any cleansing agent. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No. 1 idler pulley and No. 2 idler pulley, and keep them clean. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (Scheme 101) Install the timing belt on the crankshaft timing pulley, No. 1 idler pulley and No. 2 idler pulley.
4. Install timing belt cover spacer: Install the gasket to the cover spacer. Install the cover spacer.
5. Install timing belt guide, facing the cup side outward. (Scheme 102)
6. Install No. 1 timing belt cover with the 4 bolts.
7. Install crankshaft pulley: Align the pulley set key with the key groove of the crankshaft pulley. (Scheme 103) Using SST and a hammer, tap in the crankshaft pulley. SST 09223-46011
8. Install drive belt tensioner with the bolt and 2 nuts. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf)
9. INSTALL GENERATOR.
10. Check crankshaft pulley position. Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No. 1 timing belt cover. (Scheme 104)
11. Install RH, LH camshaft timing pulleys: Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the timing pulley. Using SST, install the pulley bolt. (Scheme 89) SST 09960-10010 (09962-01000, 09963-01000). Torque: 108 N.m (1,100 kgf.cm, 80 ft.lbf).
12. Connect timing belt to LH camshaft timing pulley: NOTE: Only wipe the pulleys; do not use any cleansing agent. Remove any oil or water on the LH camshaft timing pulley, and keep it clean. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley. (Scheme 105) Turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and LH camshaft timing pulley. (Scheme 106)
13. Connect timing belt to rh camshaft timing pulley: NOTE: Only wipe the pulleys; do not use any cleansing agent. Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and keep them clean. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley. (Scheme 107)
14. Set timing belt tensioner: Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. (Scheme 108) Release the press. Install the dust boot to the belt tensioner.
15. Install timing belt tensioner: Temporarily install the belt tensioner with the 2 bolts. (Scheme 109) Alternately tighten the 2 bolts. Torque: 26 N.m (270 kgf.cm, 19 ft.lbf) Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
16. Check valve timing: Temporarily install the crankshaft pulley bolt. NOTE: Always turn the crankshaft pulley clockwise. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. (Scheme 110) Check that each pulley aligns with the timing marks as shown in the illustration. (Scheme 111) If the timing marks do not align, remove the timing belt and reinstall it.
17. Tighten crankshaft pulley bolt. Using SST, install the pulley bolt. (Scheme 112) SST 09213-70011 (90119-08216), 09330-00021. Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf).
18. Install the fan bracket with the 2 bolts and 2 nuts. (Scheme 113) Torque: 12 mm head: 16 N.m (160 kgf.cm, 12 ft.lbf) for (A). 14 mm head: 32 N.m (330 kgf.cm, 24 ft.lbf) for (B). Each bolt length is indicated in the illustration. (Scheme 113) Bolt Length: 106 mm (4.17 in.) for 12 mm head (A). 114 mm (4.49 in.) for 14 mm head (B).
19. w A/C: INSTALL A/C COMPRESSOR
20. Install the No. 2 timing belt cover with the 2 bolts. (Scheme 79) Torque: 16 N.m (160 kgf.cm, 12 ft.lbf).
21. Install RH No. 3 timing belt cover: Fit the RH No. 3 timing belt cover, matching it with the fan bracket. Install the RH No. 3 timing belt cover with the 3 bolts and nut. (Scheme 77) Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf).
22. INSTALL LH No. 3 TIMING BELT COVER Install the oil cooler pipe with the bolt and nut. (Scheme 78)Run the camshaft position sensor wire through the LH No. 3 timing belt cover hole. Fit the LH No. 3 timing belt cover, matching it with the fan bracket. Install the LH No. 3 timing belt cover with the 4 bolts and nut. Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf). Install the wire grommet to the LH No. 3 timing belt cover. Install the camshaft position sensor connector to the connector bracket. Connect the camshaft position sensor connector. Install the sensor wire to the wire clamp on the LH No. 3 timing belt cover. Install the engine wire to the 2 wire clamps on the LH No. 3 timing belt cover.
23. Install the drive belt idler pulley and cover plate with the bolt. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf).
24. Install the PS pump with the 3 bolts. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf).
25. Install fan pulley, fan, fluid coupling and drive belt: Temporarily install the fan pulley, the fan, fluid coupling assembly with the 4 nuts. Install the drive belt. Tighten the 4 nuts holding the fluid coupling to the fan bracket. (Scheme 76) Torque: 29 N.m (296kgf.cm, 21 ft.lbf).
26. Intake air connector assembly.
27. Install throttle body cover.
28. INSTALL RADIATOR ASSEMBLY.
29. Fill with engine coolant.
30. Start engine and check for leaks.
31. Recheck engine coolant level.
32. Install engine under cover.

For locations of cylinder head components, see illustrations. (Scheme 72)- (Scheme 74) and (Scheme 114) - (Scheme 118).

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Scheme 139

1. Drain engine coolant.
2. Remove throttle body cover.
3. Disconnect timing belt from camshaft timing pulleys. See «REMOVAL»(ref-170140-S30536911172005010400000).
4. Remove camshaft timing pulleys. See «REMOVAL»(ref-170140-S30536911172005010400000).
5. REMOVE CAMSHAFT POSITION SENSOR.
6. Disconnect PS pump from engine. (Scheme 210)and Step 17) under «REMOVAL»(ref-170140-S21639208912005010400000).
7. Remove front exhaust pipe. see scheme 307
8. Remove oil dipstick and guide for A/T.
9. Remove ignition coils.
10. Remove timing belt rear plates: Remove the 3 bolts, stud bolt and RH No. 1 timing belt rear plates. Disconnect the wire clamp from the LH timing belt rear plate. Remove the 3 bolts, stud bolt and LH No. 1 timing belt rear plates.
11. Disconnect fuel inlet hose and fuel return hose.
12. Disconnect connectors from intake manifold: Disconnect the throttle position sensor connector. Disconnect the accelerator pedal position sensor connector. Disconnect the throttle control motor connector. Disconnect the VSV connector for EVAP. Disconnect the 8 injector connectors. Disconnect the ECT sensor connector. Disconnect the water sender gauge connector. Disconnect the 8 ignition coil connectors. Disconnect the 2 heated oxygen sensor connectors.
13. Disconnect hoses from intake manifold: NOTE: Letters in illustration correspond to following steps. Disconnect the vacuum hose from the fuel pressure regulator. (Scheme 119) Disconnect the PCV hose from the PCV valve on the LH cylinder head. Disconnect the EVAP hose (from charcoal canister) from the VSV for the EVAP. Disconnect the EVAP hose (from charcoal canister) from EVAP pipe on the intake manifold. Disconnect the EVAP hose (from intake air connector) from EVAP pipe on the intake manifold. Disconnect the PS air hose from the intake manifold. Disconnect the brake booster tube.
14. Remove intake manifold assembly: Disconnect the accelerator cable from the throttle body. Disconnect the 2 wire clamps from the throttle body. (Scheme 120) Disconnect the No. 1 water bypass hose (from the front water bypass joint). Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe. (Scheme 121) Remove the 3 bolts holding the engine wire protector from the rear water bypass joint, RH and LH cylinder heads. (Scheme 122) Remove the guide for the A/T bracket from the LH and LH cylinder heads. Remove the 2 ground cables from the RH and LH cylinder heads. Remove the bolt and throttle body cover bracket from the intake manifold. (Scheme 123) Disconnect the engine wire from the engine hanger and wire bracket. Remove the wire bracket from the intake manifold. Remove the 2 nuts and accelerator cable bracket from the intake manifold. Remove the 6 bolts, 4 nuts, the intake manifold assembly and 2 gaskets. (Scheme 124)
15. Disassemble upper and lower intake manifolds: Remove the throttle body. Remove the 13 bolts, 3 nuts, upper intake manifold and gasket. (Scheme 125) Disconnect the EVAP hose from the upper intake manifold, and remove the accelerator cable clamp and VSV for EVAP. Remove the bolt, union, 2 gaskets and brake booster tube from the upper intake manifold. Remove the 2 bolts and EVAP pipe from the intake manifold. (Scheme 126) Disconnect the fuel return hose from the fuel pressure regulator. (Scheme 127) Remove the 3 bolts holding the fuel return hose from the lower intake manifold. Remove the fuel pressure regulator, fuel pressure pulsation damper and 2 gaskets. Remove the bolt and rear fuel pipe. Remove the 2 delivery pipes and 8 injectors.
16. Remove water inlet and inlet housing assembly.
17. Remove the 4 nuts, front water bypass joint and 2 gaskets. (Scheme 128)
18. Remove the 4 nuts, rear water bypass joint and 2 gaskets. (Scheme 129)
19. Remove engine hangers.
20. Remove the 18 bolts, seal washers, RH and LH cylinder head covers and 2 gaskets. (Scheme 130)
21. If necessary, remove semi-circular plugs and camshaft housing plugs.
22. Remove camshafts. CAUTION: Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft, causing damage. So always set the crankshaft pulley at the correct angle. Check the crankshaft pulley position. Check that the timing mark of the crankshaft pulley is in aligned with the centers of the crankshaft pulley bolt and idler pulley bolt. (Scheme 131) Remove the RH camshafts. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. (Scheme 132) NOTE: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by this operation. Secure the sub-gear to the main gear with a service bolt. (Scheme 132)and (Scheme 133). Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10 degree angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. (Scheme 134) Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown. (Scheme 135) Remove the oil feed pipe, 9 bearing caps and camshafts. CAUTION: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. Remove the LH camshafts. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. (Scheme 136) Secure the sub-gear to the main gear with a service bolt. (Scheme 138) For Recommended service bolt specifications (Scheme 137) Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. NOTE: Arrange the bearing caps in correct order. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown. (Scheme 139) Remove the oil feed pipe, 9 bearing caps and camshafts.
23. Disassemble exhaust camshafts: CAUTION: Be careful not to damage the camshaft. Be careful not to damage the camshaft timing tube. Mount the hexagon wrench head portion of the camshaft in a vise. (Scheme 140) Using SST, turn the sub-gear clockwise, and remove the service bolt. (Scheme 141) SST 09960-10010 (09962-01000, 09963-00500) NOTE: Arrange the camshaft sub-gears and gear spring (RH and LH sides). Using snap ring pliers, remove the snap ring. (Scheme 142) Remove the wave washer. Remove the camshaft sub-gear. Remove the camshaft gear spring.
24. Remove oil seal from intake camshaft. (Scheme 143)
25. Remove spark plugs.
26. Remove cylinder head and exhaust manifold assemblies: CAUTION: Cylinder head warpage or cracking could result from removing bolts in incorrect order. (Scheme 144) Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. (Scheme 145) Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown, then do the other side as shown. (Scheme 144) Remove the 20 cylinder head bolts and plate washers. CAUTION: Be careful not to damage the surfaces contacting the cylinder head and cylinder block. The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly. NOTE: If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver. (Scheme 146) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.
27. Remove RH exhaust manifold from cylinder head: Remove the 4 bolts and heat insulator. Remove the 8 nuts, exhaust manifold and gasket. (Scheme 147)
28. Remove LH exhaust manifold from cylinder head: Remove the 4 bolts and heat insulator. Remove the 8 nuts, exhaust manifold and gasket. (Scheme 148)

Scheme 140

Scheme 141

1. Remove valve lifters and shims.
2. Remove valves: Using SST, compress the valve spring and remove the 2 keepers. (Scheme 149) SST 09202-70020 (09202-00010) NOTE: Arrange the valves, valve springs, spring seats and spring retainers incorrect order. Remove the spring retainer, the valve spring, the valve and the spring seat. Using needle-nose pliers, remove the oil seal. (Scheme 150)

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Scheme 185

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 top surface. (Scheme 151) Using a surface contacting gasket scraper, remove all the gasket materials from the cylinder block. (Scheme 152) WARNING: Protect your eyes when using high pressure compressed air. Using compressed air, blow carbon and oil from the bolt holes.
2. Remove gasket material: Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. (Scheme 153)
3. Using a wire brush, remove all the carbon from the combustion chambers. (Scheme 154)
4. Using a valve guide bushing brush and solvent, clean all the guide bushings. (Scheme 155)
5. Using a soft brush and solvent, thoroughly clean the cylinder head. (Scheme 156)
6. Inspect for flatness: Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. (Scheme 157) Maximum warpage: 0.10 mm (0.0039 in.). If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. (Scheme 158) If cracked, replace the cylinder head.
8. Clean valves: Using a gasket scraper, chip off any carbon from the valve head. (Scheme 159) Using a wire brush, thoroughly clean the valve.
9. Inspect valve stems and guide bushings: Using a caliper gauge, measure the inside diameter of the guide bushing. (Scheme 160) Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 in.) Using a micrometer, measure the diameter of the valve stem. (Scheme 161) For valve stem specifications (Scheme 162) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. For oil clearance specifications (Scheme 163)and (Scheme 164). If the clearance is greater than maximum, replace the valve and guide bushing. See «REPLACEMENT»(ref-170140-S18263091782005010400000).
10. Inspect and grind valves: Grind the valve enough to remove pits and carbon. (Scheme 165) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5 degrees Check the valve head margin thickness. (Scheme 166) Standard margin thickness: 1.00 mm (0.039 in.). Minimum margin thickness: 0.5 mm (0.020 in.). If the margin thickness is less than minimum, replace the valve. Check the valve overall length. (Scheme 167) For Valve Length Specifications (Scheme 168)and (Scheme 169). If the overall length is less than minimum, replace the valve. NOTE: Do not grind off more than minimum. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. (Scheme 170)
11. Inspect and clean valve seats: Using a 45 degree carbide cutter, resurface the valve seats. Remove only metal enough to clean the seats. (Scheme 171) Check the valve seating position. (Scheme 172) Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate the valve. Check the valve face and seat for the following: If blue appears 360 degree around the face, the valve is concentric. If not, replace the valve. If blue appears 360 degree 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 degree and 45 degree cutters to correct the seat. (Scheme 173) If the seating is too low on the valve face, use 60 degree and 45 degree cutters to correct the seat. (Scheme 174) Hand-lap the valve and valve seat with an abrasive compound. (Scheme 175) After hand-lapping, clean the valve and valve seat.
12. Inspect valve springs: Using a steel square, measure the deviation of the valve spring. (Scheme 176) Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. Using vernier calipers, measure the free length of the valve spring. (Scheme 177) Free length: 54.1 mm (2.130 in.) If the free length is not as specified, replace the valve spring. Using a spring tester, measure the tension of the valve spring at the specified installed length. (Scheme 178) Installed tension: 204 - 226 N (20.8 - 23.0 kgf, 45.9 - 50.7 lbf) at 35.0 mm (1.378 in.) If the installed tension is not as specified, replace the valve spring.
13. Inspect camshaft for runout: Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. (Scheme 179) Maximum circle runout: 0.08 mm (0.0031 in.). If the circle runout is greater than maximum, replace the camshaft.
14. Inspect cam lobes. Using a micrometer, measure the cam lobe height. (Scheme 180) For cam lobe height specifications (Scheme 181)and (Scheme 182). If the cam lobe height is less than minimum, replace the camshaft.
15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. (Scheme 183) Journal diameter: 26.954 - 26.970 mm (1.0612 - 1.0618 in.). If the journal diameter is not as specified, check the oil clearance.
16. Inspect camshaft gear spring: Using vernier calipers, measure the free distance between the spring ends. (Scheme 184) Free distance: 18.2 - 18.8 mm (0.712 - 0.740 in.). If the free distance is not as specified, replace the gear spring.
17. Inspect camshaft bearings: Check bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
18. Inspect camshaft journal 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 journals. (Scheme 185) NOTE: Do not turn the camshaft. Install the bearing caps. (Scheme 186)and «INSTALLATION»(ref-170140-S13010331002005010400000). Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) Remove the bearing caps. Measure the Plastigage at its widest point. (Scheme 187) Standard oil clearance: 0.030 - 0.067 mm (0.0012 - 0.0026 in.). Maximum oil clearance: 0.10 mm (0.0039 in.). If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Completely remove the plastigage. Remove the camshafts.
19. Inspect camshaft thrust clearance: Install the camshaft. See «INSTALLATION»(ref-170140-S13010331002005010400000). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. (Scheme 189) For standard thrust clearance specifications (Scheme 188) Maximum thrust clearance: 0.12 mm (0.0047 in.). If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Remove the camshafts.
20. Inspect camshaft gear backlash: Install the camshafts without installing the exhaust cam sub-gear and front bearing cap. See «INSTALLATION»(ref-170140-S13010331002005010400000). Using a dial indicator, measure the backlash. (Scheme 190) Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 in.). Maximum backlash: 0.30 mm (0.0188 in.). If the backlash is greater then maximum, replace the camshafts. Remove the camshafts.
21. Inspect valve lifters and lifter bores: Using a caliper gauge, measure the lifter bore diameter of the cylinder head. (Scheme 191) Lifter bore diameter: 31.000 - 31.016 mm (1.2205 - 1.2211 in.). Using a micrometer, measure the lifter diameter at the valve lifter center line, 12.3 - 12.7 mm (0.484 - 0.500 in.) from the valve lifter head. (Scheme 192) Lifter diameter: 30.968 - 30.976 mm (1.2192 - 1.2195 in.). Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 - 0.048 mm (0.0009 - 0.0019 in.). Maximum oil clearance: 0.07 mm (0.0028 in.). If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.
22. Inspect intake manifold: Upper intake manifold: Using a precision straight edge and feeler gauge, measure the surface contacting the lower intake manifold for warpage. (Scheme 193) Maximum warpage: 0.15 mm (0.0059 in.). If warpage is greater than maximum, replace the upper intake manifold. Lower intake manifold: Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and upper intake manifold for warpage. Maximum warpage: 0.15 mm (0.0059 in.). If warpage is greater than maximum, replace the lower intake manifold.
23. Inspect exhaust manifolds: Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. (Scheme 195) Maximum warpage: 0.50 mm (0.0197 in.). If warpage is greater than maximum, replace the manifold.
24. Inspect cylinder head bolts: Using vernier calipers, measure the thread outside diameter of the bolt. see scheme 125 Standard outside diameter: 9.810 - 9.960 mm (0.3862 - 0.3921 in.). Minimum outside diameter: 9.700 mm (0.3819 in.). If the diameter is less than minimum, replace the bolt.

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

1. REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 80 - 100°C (176 - 212°F). see scheme 126 Using SST and a hammer, tap out the guide bushing. see scheme 127 SST 09201 - 10055, 09950-70010 (09951 - 07100). Using a caliper gauge, measure the bushing bore diameter of the cylinder head. see scheme 128 NOTE: Different the bushings are used for the Intake and Exhaust. see scheme 129 Select a new guide bushing (STD or O/S 0.05). see scheme 130 If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bushing bore to the following dimension. 10.335 - 10.356 mm (0.4069 - 0.4077 in.). If the bushing bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. Gradually heat the cylinder head to 80 - 100°C (176 - 212°F). Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. see scheme 131and see scheme 132. SST 09201 - 10055, 09950 - 70010 (09951 - 07100). Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See Step 9 a - BUSHING INSIDE DIAMETER under INSPECTION) between the guide bushing and valve stem. see scheme 133
2. Replace spark plug tube gaskets: Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90 degrees or more. CAUTION: Be careful not to damage the cylinder head cover. Tape the screwdriver tip. Using a screwdriver, pry out the gasket. see scheme 134 NOTE: Be careful of the installation direction. see scheme 135 Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. see scheme 135 SST 09950-60010 (09551-00240, 09951-00440, 09952-06010), 09950-70010 (09951- 07100). Apply a light coat of MP grease to the gasket lip. Return the 4 ventilation case claws to its original position.

For 2 Wheel Drive (2WD) engine component locations, see illustrations. (Scheme 207)- (Scheme 211).

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

1. Remove engine hood.
2. Remove engine under cover.
3. Drain engine coolant.
4. REMOVE RADIATOR ASSEMBLY.
5. Remove throttle body cover.
6. Remove air cleaner and intake air connector assembly: Disconnect the MAF meter connector. Loosen the 3 bolts, and remove the air cleaner case. With A/C: Remove the suction hose from the intake air connector. Disconnect the PS air hose, air inlet hose for EVAP, PCV hose and MAF meter wire from the air intake connector. Disconnect the intake air connector from the throttle body.
7. Disconnect battery cables: Disconnect the clamp on battery negative (-) cable from the No. 2 relay box. Disconnect the battery positive (+) terminal cable. Disconnect battery negative (-) cable from the left fender apron.
8. Remove drive belt, fan, fluid coupling and fan pulley: Loosen the 4 nuts holding the fluid coupling to the fan bracket. (Scheme 76) Remove the drive belt. Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley.
9. Disconnect engine wire from cabin: Remove the glove compartment door. Remove the lower No. 2 panel. Remove the 3 screws, and disconnect the ECM from the body bracket. Disconnect the 3 wire harness connectors from the ECM. Disconnect the 2 wire harness connectors (cassette connector). Disconnect the engine wire from the engine wire bracket and remove the bolt, 2 nuts and bracket. (Scheme 212) Pull out the engine wire from the cowl panel.
10. Disconnect hoses, wires, connectors, clamps, grommet and cables: Disconnect the accelerator cable from the engine. Disconnect the 2 PS air hoses from hose clamp on the No. 3 RH timing belt cover. Disconnect the generator wire. Disconnect the generator connector. Disconnect the hose clamp for the PS air hose. Disconnect the PS air hose from the upper intake manifold. Disconnect the 2 heater hoses. Disconnect the ground strap from the cowl panel. Disconnect the fuel inlet hose and clamps. Disconnect the fuel return hose and clamp. Disconnect the air inlet hose from the charcoal canister. Disconnect the EVAP hose from the charcoal canister. W/O Hydraulic brake booster: disconnect the brake booster tube.
11. Remove front exhaust pipes. see scheme 307
12. Remove propeller shaft.
13. Remove front stabilizer bar.
14. Disconnect power steering gear pipes. Disconnect the pressure feed tube, turn tube and pressure tubes from the PS gear assembly.
15. Remove transmission control cable: Remove the 2 bolts and control cable bracket from the transmission. (Scheme 213) Remove the control cable from the control shift lever.
16. With A/C Remove the 3 bolts, and disconnect the A/C compressor from the engine. (Scheme 214)
17. Remove the 3 bolts, and disconnect the PS pump from the engine. (Scheme 215)
18. Remove engine mounting brackets: Attach the engine chain hoist to the engine hangers. Remove the 4 nuts and 4 bolts holding the engine mounting brackets to the frame brackets. (Scheme 216)
19. Place jack under transmission.
20. Remove engine rear mounting bracket. Remove the 8 bolts, 2 nuts and frame crossmember. (Scheme 217) Remove the 4 bolts and engine rear mounting bracket from the transmission. (Scheme 218)
21. Remove engine and transmission assembly from vehicle: CAUTION: Make sure the engine is clear of all wiring, hoses and cables. Lift the engine out of the vehicle slowly and carefully. (Scheme 219) Place the engine and transmission assembly onto the stand.
22. Disconnect engine wire from transmission: Disconnect the 5 connectors. Disconnect the 2 wire clamps.
23. Remove oil dipstick guide and dipstick for transmission: Disconnect the 2 breather hoses from the dipstick guide. Remove the 2 bolts. Pull out the dipstick guide and dipstick from the dipstick tube of transmission. Remove the O-ring from the dipstick guide.
24. Remove oil cooler pipes for transmission: Remove the 3 bolts and 3 stays. Loosen the 2 union nuts, and remove the 2 oil cooler pipes.
25. Remove torque converter clutch bolts: Remove the bolt and flywheel housing under cover. (Scheme 220) Turn the crankshaft pulley bolt to gain access to each bolt. (Scheme 221) Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
26. Remove transmission: Remove the 10 bolts. (Scheme 222) Remove the transmission together with the torque converter clutch from the engine.
27. Remove the 8 bolts, front spacer, drive plate and rear spacer. (Scheme 223)

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

1. Install drive plate: Apply adhesive to 2 or 3 threads of the mounting bolt end. (Scheme 224) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. Install the front spacer, drive plate and rear spacer on the crankshaft. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown. (Scheme 223) Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt. Mark the mounting bolt with paint. (Scheme 225) Retighten the mounting bolts by 90 degrees in the numerical order shown. Check that the painted mark is now at a 90 degree angle to (e).
2. Install transmission to engine: Check the torque converter clutch installation. Attach the transmission to the engine. Install the 10 bolts. (Scheme 222) Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) for 14 mm head 72 N.m (730 kgf.cm, 53 ft.lbf) for 17 mm head
3. Install torque converter clutch bolts: Apply adhesive to 2 or 3 threads of the bolt end. (Scheme 224) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. NOTE: First install the black colored bolt, install the other bolts. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly. (Scheme 221) Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) Install the flywheel housing under cover with the bolt. (Scheme 220) Torque: 18 N.m (185 kgf.cm, 13 ft.lbf).
4. Install oil cooler pipe for transmission
5. Install oil dipstick guide and dipstick for transmission: Install a new O-ring to the dipstick guide. Apply soapy water to the O-ring. Connect the dipstick guide end to the dipstick tube of the oil pan. Install the dipstick guide with the bolt. Install the dipstick. Connect the 2 breather hoses to the dipstick guide.
6. Connect engine wire to transmission: Connect the 5 connectors. Connect the 2 wire clamps.
7. Install engine and transmission assembly in vehicle: Attach the engine chain hoist to the engine hangers. See. Slowly lower the engine and transmission assembly into the engine compartment. Attach the engine mounting brackets to the frame brackets. Keep the engine level with a jack. (Scheme 227)
8. Install engine rear mounting bracket: Install the engine rear mounting bracket to the transmission with the 4 bolts. (Scheme 218) Torque: 65 N.m (663 kgf.cm,48 ft.lbf). Install the frame crossmember with the 8 bolts and 4 nuts. (Scheme 217) Torque: A: 18 N.m (183 kgf.cm, 13 ft.lbf) for bolts. B: 72 N.m (730 kgf.cm, 53 ft.lbf) for nuts.
9. Install engine mounting brackets: Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts. (Scheme 216) Torque: 38 N.m (388 kgf.cm, 28 ft.lbf). Remove the engine chain hoist.
10. Install PS pump with the 3 bolts. (Scheme 215) Torque: 17 N.m (175 kgf.cm, 13 ft.lbf).
11. With A/C install A/C compressor: Install the A/C compressor with the 3 bolts. (Scheme 214) Torque: 49 N.m (500 kgf.cm, 36 ft.lbf). Connect the A/C compressor connector.
12. Install transmission control cable: Install the control cable to the control shift lever. (Scheme 228) Torque: 13 N.m (130 kgf.cm, 9 ft.lbf). Install the control cable bracket to the transmission with the 2 bolts.
13. Connect power steering gear pipes: Connect the pressure feed tube, turn tube and turn pressure tubes to the ps gear assembly.
14. Install front stabilizer bar
15. Install propeller shaft.
16. INSTALL FRONT EXHAUST PIPES. see scheme 307
17. Connect hoses, wires, connectors, clamps, grommet and cables: Connect the accelerator cable to the engine. Connect the 2 PS air hoses to hose clamp on the No. 3 RH timing belt cover. Connect the generator wire. Connect the generator connector. Connect the hose clamp for the PS air hose. Connect the PS air hose to the upper intake manifold. Connect the 2 heater hoses. Connect the ground strap connector. Connect the fuel inlet hose and clamps. Connect the fuel return hose and clamp. Connect the air inlet hose to the charcoal canister. Connect the EVAP hose to the charcoal canister. Connect the brake booster tube.
18. Connect engine wire to cabin: Push into the engine wire through the cowl panel. Install the engine wire bracket with the 2 nuts and bolt and connect the engine wire to the bracket. Connect the 2 wire harness connectors (cassette connector). Connect the 3 connectors to the ECM. Install the ECM with the 3 screws. Install the lower No. 2 panel. Install the glove compartment door.
19. Install fan pulley, fan, fluid coupling and drive belt: Temporarily install the fan pulley, the fan and fluid coupling assembly with the 4 nuts. (Scheme 229) Install the drive belt. Tighten the 4 nuts holding the fluid coupling to the fan bracket. (Scheme 76)
20. Install battery cables: Connect the clamp on battery negative (-) cable to No. 2 relay box. Connect the battery positive (+) terminal cable. Connect the battery negative cable to the left fender apron.
21. Install air cleaner and intake air connector assembly: Install the air cleaner with the 3 bolt. Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf). Connect the intake air connector to the throttle body. Connect the MAF meter connector. W/A/C: install the suction hose to the intake air connector. Connect the PS air hose, air inlet hose for EVAP, PCV hose and MAF meter wire to the air intake connector.
22. Install throttle body cover.
23. Install radiator assembly.
24. Fill with engine coolant.
25. Fill with engine oil.
26. Start engine and check for leaks.
27. Install engine under cover.
28. Install hood.
29. Perform road test: Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
30. Recheck engine coolant and oil levels.

For 4 Wheel Drive (4WD) engine component locations, see illustrations. (Scheme 230)- (Scheme 234).

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

1. Remove front exhaust pipes. see scheme 307
2. Remove front and rear propeller shafts.
3. Remove front stabilizer bar.
4. Remove transmission.
5. Remove engine hood.
6. Remove engine under cover.
7. Drain engine coolant.
8. Remove radiator assembly.
9. Remove throttle body cover.
10. Remove air cleaner and intake air connector assembly: Disconnect the MAF meter connector. Loosen the 3 bolts, and remove the air cleaner case. With A/C: remove the suction hose from the intake air connector. Disconnect the PS air hose, air inlet hose for EVAP, PCV hose and MAF meter wire from the air intake connector. Disconnect the intake air connector from the throttle body.
11. Disconnect battery cables: Disconnect the clamp on battery negative (-) cable from the No. 2 relay box. Disconnect the battery positive (+) terminal cable. Disconnect the battery negative (-) cable from the left fender apron.
12. Remove drive belt, fan, fluid coupling and fan pulley: Loosen the 4 nuts holding the fluid coupling to the fan bracket. Remove the drive belt. Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley.
13. Disconnect engine wire from cabin: Remove the glove compartment door. Remove the lower No. 2 panel. Remove the 3 screws, and disconnect the ECM from the body bracket. Disconnect the 3 wire harness connectors from the ECM. Disconnect the 2 wire harness connectors (cassette connector). Disconnect the engine wire from the engine wire bracket and remove the 2 nuts, bolt and bracket. (Scheme 235) Pull out the engine wire from the cowl panel.
14. Disconnect hoses, wires, connectors, clamps, grommet and cables: Disconnect the accelerator cable from the engine. Disconnect the 2 PS air hoses from hose clamp on the No. 3 RH timing belt cover. Disconnect the generator wire. Disconnect the generator connector. Disconnect the hose clamp for the PS air hose. Disconnect the PS air hose from the upper intake manifold. Disconnect the 2 heater hoses. Disconnect the ground strap from the cowl panel. Disconnect the fuel inlet hose and clamps. Disconnect the fuel return hose and clamp. Disconnect the air inlet hose from the charcoal canister. Disconnect the EVAP hose from the charcoal canister. Disconnect the brake booster tube.
15. With A/C disconnect A/C compressor from engine: Disconnect the A/C compressor connector. NOTE: Suspend the A/C compressor securely. Remove the 3 bolts, and disconnect the A/C compressor from the engine. (Scheme 214)
16. Remove the 3 bolts, and disconnect the PS pump from the engine. (Scheme 215)
17. Remove oil cooler pipes for transmission: Remove the 3 bolts and 3 stays. Loosen the 2 union nuts, and remove the 2 oil cooler pipes.
18. Remove engine assembly from vehicle: Attach the engine chain hoist to the engine hangers. Remove the 4 bolts holding the engine mounting brackets to the frame brackets. (Scheme 236) NOTE: Make sure the engine is clear of all wiring, hoses and cables. Lift the engine out of the vehicle slowly and carefully. (Scheme 237) Place the engine and transmission assembly onto the stand.
19. Remove drive plate: Remove the 8 bolts, front spacer, drive plate and rear spacer. (Scheme 223)

Scheme 225

Scheme 226

1. Install drive plate: Apply adhesive to 2 or 3 threads of the mounting bolt end. (Scheme 224) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. Install the front spacer, drive plate and rear spacer on the crankshaft. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown. (Scheme 223) Torque: 49 N.m (500 kgf.cm, 36 ft.lbf). If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt. Mark the mounting bolt with paint. (Scheme 225) Retighten the mounting bolts by 90 degrees in the numerical order shown. Check that the painted mark is now at a 90 degree angle to (e).
2. Install engine assembly in vehicle: Attach the engine chain hoist to the engine hangers. Slowly lower the engine assembly into the engine compartment. (Scheme 238) Attach the engine mounting brackets to the frame brackets. Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts. (Scheme 236) Torque: 38 N.m (388 kgf.cm, 28 ft.lbf). Remove the engine chain hoist.
3. Install PS pump with the 3 bolts. (Scheme 215) Torque: 17 N.m (175 kgf.cm, 13 ft.lbf).
4. w/ A/C: install A/C compressor: Install the A/C compressor with the 3 bolts. (Scheme 214) Torque: 49 N.m (500 kgf.cm, 36 ft.lbf). Connect the A/C compressor connector.
5. Connect hoses, wires, connectors, clamps, grommet and cables: Connect the accelerator cable to the engine. Connect the 2 PS air hoses to hose clamp on the No. 3 RH timing belt cover. Connect the generator wire. Connect the generator connector. Connect the hose clamp for the PS air hose. Connect the PS air hose to the upper intake manifold. Connect the 2 heater hoses. Connect the ground strap to the cowl panel. Connect the fuel inlet hose and clamps. Connect the fuel return hose and clamp. Connect the air inlet hose to the charcoal canister. Connect the EVAP hose to the charcoal canister. Connect the brake booster tube.
6. Connect engine wire to cabin: Push into the engine wire through the cowl panel. Install the engine wire bracket with the 2 nuts and bolt and connect the engine wire to the bracket. (Scheme 239) Connect the 3 connectors to the ECM. Connect the 2 wire harness connectors (cassette connector). Install the ECM with the 3 screws. Install the lower No. 2 panel. Install the glove compartment door.
7. Install fan pulley, fan, fluid coupling and drive belt: Temporarily install the fan pulley, the fan and fluid coupling assembly with the 4 nuts. Install the drive belt. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
8. Install battery cables: Connect the battery positive (+) terminal cable. Connect the battery negative (-) cable to the battery and left fender apron. Connect the clamp on battery negative (-) cable to No. 2 relay box.
9. Install air cleaner and intake air connector pipe assembly: Install the air cleaner case with the 3 bolts. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf). Connect the intake air connector to the throttle body. Connect the MAF meter connector. w/ A/C: install the suction hose to the intake air connector. Connect the PS air hose, air inlet hose for EVAP, PCV hose and MAF meter connector to the intake air connector.
10. Install throttle body cover.
11. Install transmission.
12. Install radiator assembly.
13. Install front stabilizer bar.
14. Install front and rear propeller shafts.
15. INSTALL FRONT EXHAUST PIPES. see scheme 307
16. Fill with engine coolant.
17. Fill with engine oil.
18. Start engine and check for leaks.
19. Install engine under covers.
20. Install hood.
21. Perform road test: Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
22. Recheck engine coolant and oil levels.

For cylinder block component locations, see illustrations. (Scheme 240)and (Scheme 241).

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

1. Install engine to engine stand.
2. Remove timing belt and pulleys. See «REMOVAL»(ref-170140-S30536911172005010400000).
3. Remove cylinder head. See «REMOVAL»(ref-170140-S05579202982005010400000).
4. Remove water bypass pipe: Disconnect the wire clamp (for knock sensor 1, 2) from bracket of the water bypass pipe. (Scheme 242) Remove the bolt. Pull out the water bypass pipe from the water pump. Remove the O-ring from the water bypass pipe.
5. Remove Starter.
6. Remove Knock Sensors.
7. Disconnect engine wire from LH side of cylinder block: Remove the 2 bolts and engine wire cover from the LH side of the cylinder block. Remove the 2 bolts, disconnect the brackets on the engine wire from the cylinder block and engine mounting bracket.
8. Remove oil cooler pipe bracket for A/T: Remove the bolt and bracket.
9. REMOVE ENGINE MOUNTING BRACKETS Remove the 4 bolts and mounting bracket. Remove the 2 mounting brackets. (Scheme 243)
10. Remove water pump.
11. Remove No. 2 oil pan.
12. Remove oil pan baffle plate.
13. Remove No. 1 oil pan.
14. Remove oil strainer.
15. Remove oil pump.
16. Remove engine coolant drain unions: Remove the 2 drain unions.
17. Remove rear oil seal retainer: Remove the 7 bolts. (Scheme 244) Using a screwdriver, remove the oil seal retainer by prying the portion between the oil seal retainer and main bearing cap. Remove the "O" ring.
18. Check connecting rod thrust clearance: Using a dial indicator, measure the thrust clearance while moving the connecting rod back an forth. (Scheme 245) Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0138 in.). Maximum thrust clearance: 0.35 mm (0.0138 in.). If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 in.).
19. Remove connecting rod caps and check oil clearance: Check the matchmarks on the connecting rod and see it cap to ensure correct reassembly. (Scheme 246) Remove the 2 connecting rod cap bolts. NOTE: Keep the lower bearing inserted with the connecting rod cap. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. (Scheme 247) Clean the crank pin and bearing. Check the crank pin and bearing for peeling and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of Plastigage across the crank pin. (Scheme 248) NOTE: Do not turn the crankshaft. Install the connecting rod cap with the 2 bolts. (Scheme 249)and «REASSEMBLY»(ref-170140-S10326567672005010400000). Remove the 2 bolts, connecting rod cap and lower bearing. See procedure b and c. Measure the Plastigage at its widest point. (Scheme 250) Standard oil clearance: 0.027 - 0.053 mm (0.0011 - 0.0021 in.). Maximum oil clearance: 0.065 mm (0.0026 in.). If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: If using a standard bearing, replace it with one having the same number. (Scheme 251) If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7". (Scheme 252) Example: connecting rod cap "3" + crankshaft "1" = total number 4 (use bearing "4") Reference: For connecting rod big end inside diameter (Scheme 253) For crankshaft crank pin diameter (Scheme 254) For standard sized bearing center wall thickness (Scheme 255) 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. (Scheme 256) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
21. Check crankshaft thrust clearance. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. (Scheme 257) Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.). Maximum thrust clearance: 0.30 mm (0.0118 in.). If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 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. (Scheme 258) CAUTION: Be careful not to damage the cylinder block. NOTE: Keep the lower bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct order. Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 main bearing cap only). (Scheme 259) NOTE: Keep the upper bearings and upper thrust washers together with the cylinder block. Lift out the crankshaft. Clean each main journal and bearing. Check each main journal and bearing for peelings and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. (Scheme 260) NOTE: Do not turn the crankshaft. Install the main bearing caps. (Scheme 261)and «REASSEMBLY»(ref-170140-S10326567672005010400000). Remove the main bearing caps. See a and b. Measure the Plastigage at its widest point. (Scheme 262) Standard clearance: No. 1, No. 5: 0.028 - 0.046 mm (0.0011 - 0.0018 in.). Others: 0.040 - 0.058 mm (0.0016 - 0.0023 in.). Maximum clearance: 0.065 mm (0.0026 in.). If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: If using a standard bearing, replace it with one having the same number. (Scheme 263) If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No.5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For others position bearings, use bearings marked "1", "2", "3", "4" and "5". For No. 1, No. 5 crankshaft bearings (Scheme 264) EXAMPLE: cylinder block "08" + Crankshaft "06" = total number 14 (use bearing "5"). For Other crankshaft bearings (Scheme 265) EXAMPLE: cylinder block "08" + crankshaft "06" = total number 14 (use bearing "3") Reference: For Cylinder block main journal bore diameter (A): (Scheme 266) For Crankshaft main journal diameter (B): (Scheme 267) Standard bearing center wall thickness: For No. 1 and No. 5 (Scheme 268) For Others (Scheme 269) Completely remove the Plastigage.
23. Remove crankshaft: Lift up the crankshaft. NOTE: Arrange the main bearing caps, bearings and thrust washers in correct order. Remove the 5 upper main bearings and 2 upper thrust washers from the cylinder block.
24. Check fit between piston and piston pin: Try to move the piston back and forth on the piston pin. (Scheme 270) If any movement is felt, replace the piston and pin as a set.
25. Remove piston rings: NOTE: Arrange the piston rings in correct order only. Using a piston ring expander, remove the 2 compression rings. (Scheme 271) Remove the 2 side rails and oil ring by hand.
26. Disconnect connecting rod from piston: Using a small screwdriver, pry out the 2 snap rings. (Scheme 272) Gradually heat the piston to approx. 60°C (140°F). (Scheme 273) NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and pin and remove the connecting rod. (Scheme 274)

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

1. Clean cylinder block: Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. (Scheme 275) Using a soft brush and solvent, thoroughly clean the cylinder block.
2. Inspect cylinder block: Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage. (Scheme 276) Maximum warpage: 0.07 mm (0.0028 in.). If warpage is greater than maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. (Scheme 277) If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. See «REPLACEMENT»(ref-170140-S35197254202005010400000). If necessary, replace the cylinder block. NOTE: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block. (Scheme 279) Inspect the cylinder bore diameter. (Scheme 278) Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. For Standard diameter (Scheme 280) For Maximum diameter (Scheme 281) If the diameter is greater than maximum, rebore all the 8 cylinders and replace all the 8 pistons. See «REPLACEMENT»(ref-170140-S35197254202005010400000). If necessary, replace the cylinder block. Remove The Cylinder Ridge. (Scheme 282) If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. Using vernier calipers, measure the thread outside diameter of the main bearing cap bolt. (Scheme 283) Standard diameter: 10.760 - 10.970 mm (0.4236 - 0.4319 in.). Minimum diameter: 10.40 mm (0.4094 in.). If the diameter is less than minimum, replace the cap bolt.
3. CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. (Scheme 284) Using a groove cleaning tool or broken ring, clean the piston ring grooves. (Scheme 285) NOTE: Do not use a wire brush. Using solvent and a brush, thoroughly clean the piston. (Scheme 286)
4. Inspect piston and connecting rod: Inspect the piston oil clearance. NOTE: There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. For Piston diameter (Scheme 287) Measure the cylinder bore diameter in the thrust directions. See Step 2. NOTE: Use a piston with the same number mark as the cylinder diameter marked on the cylinder block. The shape of the piston varies for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R". (Scheme 288) When replacing block, use new cylinder block. Subtract the piston diameter measurement from the cylinder bore diameter measurement. (Scheme 289) Standard oil clearance: 0.090 - 0.111 mm (0.0035 - 0.0044 in.). Maximum oil clearance: 0.13 mm (0.0051 in.). If the oil clearance is greater than maximum, replace all the 8 pistons and rebore all the 8 cylinders. See «REPLACEMENT»(ref-170140-S35197254202005010400000) If necessary, replace the cylinder block. Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. (Scheme 290) For Ring groove clearance (Scheme 291) If the clearance is not as specified, replace the piston. Inspect the piston ring end gap: Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little to the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. (Scheme 292) Using a feeler gauge, measure the end gap. (Scheme 293) For standard end gap (Scheme 294) For maximum end gap (Scheme 295) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 8 cylinders. See «REPLACEMENT»(ref-170140-S35197254202005010400000), or replace the cylinder block. Inspect the piston pin fit. At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb. (Scheme 296) Using a rod aligner and feeler gauge, check the connecting rod alignment. see scheme 260 Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly. Check for twist. see scheme 261 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. see scheme 262 Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 in.). Using a micrometer, measure the piston pin diameter. see scheme 263 Piston pin diameter: 21.997 - 22.009 mm (0.8660 - 0.8664 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.). Maximum oil clearance: 0.05 mm (0.0020 in.). If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set. Using vernier calipers, measure the tension portion of the connecting rod bolt. see scheme 264 Standard diameter: 7.200 - 7.300 mm (0.2835 - 0.2874 in.). Minimum diameter: 7.00 mm (0.2756 in.). If the diameter is less than minimum, replace the bolt.
5. Inspect crankshaft: Inspect for circle runout: Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. see scheme 265 Maximum circle runout: 0.08 mm (0.0031 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. Main journal diameter: 66.988 - 67.000 mm (2.6373 - 2.6378 in.). Crank pin diameter: 51.982 - 52.000 mm (2.0465 - 2.0472 in.) If the diameter is not as specified, check the oil clearance. See «DISASSEMBLY»(ref-170140-S37421934552005010400000). If necessary, replace the crankshaft. Check each main journal and crank pin for taper and out-of-round as shown. see scheme 266 Maximum taper and out-of-round: 0.02 mm (0.0008 in.). If the taper and out-of-round is greater than maximum, replace the crankshaft.

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

1. Replace oversized (O/S) pistons for cylinder boring: NOTE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R". (Scheme 288) Keep 8 new O/S pistons. O/S 0.50 piston diameter: 94.402 - 94.430 mm (3.7166 - 3.7177 in.). Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. Calculate the amount each cylinder is to be rebored as follows: Size to be rebored = P + C - H P = Piston diameter. C = Piston clearance: 0.090 - 0.111 mm (0.0035 - 0.0044 in.). H = Allowance for honing: 0.02 mm (0.0008 in.) or less. CAUTION: Excess honing will destroy the finished roundness. Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.)
2. Replace connecting rod bushings: Using SST and a press, press out the bushing. see scheme 267 SST 09222-30010 Align the of a new bushing and the connecting rod. see scheme 268 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 Step 4 f under Inspection, between the bushing and piston pin. see scheme 269 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. (Scheme 296)
3. Replace crankshaft front oil seal.
4. Replace crankshaft rear oil seal: There are 2 methods a b to replace the oil seal. If the rear oil seal retainer is removed from the cylinder block: Using a screwdriver and hammer, tap out the oil seal. see scheme 270 Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. see scheme 271 SST 09223-56010 Apply MP grease to the oil seal lip. If the rear oil seal retainer is installed to the cylinder block: Using a knife, cut off the oil seal lip. see scheme 272 CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver tip. Using a screwdriver, pry out the oil seal. Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. see scheme 271 SST 09223-56010

Oil Pressure

With engine at normal operating temperature, oil pressure should be at least 4.30 psi (0.3 kg/cm 2 ) at idle and approximately 43.00-85.00 psi (3.0-5.9 kg/cm 2 ) at 3000 RPM.

Scheme 297

For exhaust system component locations see illustration. see scheme 307

Scheme 298

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS

CONNECTING RODS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

CYLINDER BLOCK

CYLINDER BLOCK

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

CYLINDER HEAD

CYLINDER HEAD

CAMSHAFT

CAMSHAFT

VALVE LIFTERS

VALVE LIFTERS

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304