co/hc - maxim.int.rumaxim.int.ru/prado/1gr-fe/1gr-fe engine mechanical.pdf · em-2 engine...

EM0KQ-10

A19383

CO/HC Meter

-ENGINE MECHANICAL (1GR-FE) CO/HCEM-1

3209Author�: Date�:

CO/HCINSPECTIONHINT:This check is used only to determine whether or not the idle CO/HC complies with regulations.1. INITIAL CONDITIONS(a) Engine at normal operating temperature(b) Air cleaner installed(c) All pipes and hoses of air induction system connected(d) All accessories switched OFF(e) All vacuum lines properly connected(f) SFI system wiring connectors fully plugged(g) Correct ignition timing(h) Transmission in neutral position(i) Tachometer and CO/HC meter calibrated by hand2. START ENGINE3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-

CONDS

4. INSERT CO/HC METER TESTING PROBE AT LEAST40 cm (1.3 ft) INTO TAILPIPE DURING IDLING

5. IMMEDIATELY CHECK CO/HC CONCENTRATION ATIDLE AND/OR 2,500 RPM

HINT:When performing the 2 mode (2,500 rpm and idle) test, followthe measurement orders prescribed by the applicable local reg-ulations.

EM-2-ENGINE MECHANICAL (1GR-FE) CO/HC


If the CO/HC concentration does not comply with regulations,perform troubleshooting in the order given below.

(1) Check the A/F sensors and heated oxygen sensorsoperation (See page DI-84 and DI-90 ).

(2) See the table below for possible causes, and theninspect and correct the corresponding causes ifnecessary.

CO HC Problems Causes

Normal High Rough idle 1. Faulty ignitions:

� Incorrect timing

�Fouled, shorted or improperly gapped plugs

2. Incorrect valve clearance

3. Leaky intake and exhaust valves

4. Leaky cylinders

Low High Rough idle

(fluctuating HC reading)

1. Vacuum leaks:

�PCV hose

� Intake manifold

�Throttle body

2. Lean mixture causing misfire

High High Rough idle

(Black smoke from exhaust)

1. Restricted air filter

2. Faulty SFI system:

�Faulty pressure regulator

�Defective ECT sensor

�Faulty ECM

�Faulty injectors

�Faulty throttle position sensor

�Faulty MAF meter

EM06C-06

A22796

-ENGINE MECHANICAL (1GR-FE) COMPRESSIONEM-3


COMPRESSIONINSPECTIONHINT:If there is a lack of power, excessive oil consumption or poor fueleconomy, measure the compression pressure.1. WARM UP AND STOP ENGINEAllow the engine to warm up to normal operating temperature.

2. REMOVE SPARK PLUGS(a) Remove the V-bank cover.(b) Remove the air cleaner.(c) Remove the intake air surge tank (See page EM-62 ).(d) Remove the 6 ignition coils.(e) Remove the 6 spark plugs.(f) Disconnect the 6 injector connectors.3. CHECK CYLINDER COMPRESSION PRESSURE(a) Insert a compression gauge into the spark plug hole.(b) Fully open the throttle.(c) While cranking the engine, measure the compression

pressure.HINT:Always use a fully charged battery to obtain an engine speedof 250 rpm or more.(d) Repeat steps (a) through (c) for each cylinder.NOTICE:This measurement must be done in the shortest possibletime.

Compression pressure:1.3 MPa (13.3 kgf/cm 2, 189 psi) or moreMinimum pressure: 1.0 MPa (10.2 kgf/cm 2, 145 psi)Difference between each cylinder:0.1 MPa (1.0 kgf/cm 2, 15 psi) or less

(e) If the cylinder compression pressure in 1 or more cylin-ders is low, pour a small amount of engine oil into the cylin-der through the spark plug hole and repeat steps (a)through (c) for cylinders with low compression pressure.� If adding oil improves the compression pressure, it

is likely that the piston rings and/or cylinder bore areworn or damaged.

� If compression pressure stays low, a valve may besticking, seating may be improper, or there may bea leak past the gasket.

4. REINSTALL SPARK PLUGS(a) Connect the 6 injector connectors.(b) Install the 6 spark plugs.

Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)(c) Install the 6 ignition coils.(d) Install the intake air surge tank (See page EM-89 ).(e) Install the air cleaner.(f) Install the V-bank cover.

EM1XY-01

A23200

Piston Ring (No. 1 Compression Ring)

Piston Ring (No. 2 Compression Ring)

Piston Ring (Side Rail)

Piston Ring (Expander)

Piston

Piston Pin

Connecting Rod Bearing

Connecting Rod Cap

Connecting Rod

Crankshaft Bearing

Upper Crankshaft Thrust Washer

Crankshaft

Lower Crankshaft Thrust Washer

Crankshaft Bearing Cap

Crankshaft Bearing

� Piston Pin Hole Snap Ring

1st 61 (622, 45)2nd Turn 90 �

See page EM-128

1st 25 (250, 18)2nd Turn 90 �

x8

� Non-reusable part

N·m (kgf·cm, ft·lbf) : Specified torque

� Piston Pin Hole Snap Ring

Oil Nozzle

9.0 (92, 80 in.·lbf)

Knock Sensor Wire

Water Outlet Pipe No.1

Water Drain Cock

Water Drain Cock

Knock Sensor

Knock Sensor

10 (102, 7)

10 (102, 7)

25 (255, 18)

25 (255, 18)

20 (204, 15)

20 (204, 15)

Engine Rear OilSeal Retainer

� Oil Seal

9.0 (92, 80 in.·lbf)

x2

x5

25 (255, 18)

10 (102, 7)

See page EM-128

-ENGINE MECHANICAL (1GR-FE) CYLINDER BLOCKEM-1 11


CYLINDER BLOCKCOMPONENTS

EM1XZ-01

A22979

A22980

A22981

Pry

A23021

EM-1 12-ENGINE MECHANICAL (1GR-FE) CYLINDER BLOCK


DISASSEMBLY1. REMOVE WATER OUTLET PIPE NO.1(a) Separate the knock sensor wire.(b) Remove the 3 bolts and water outlet pipe.

2. REMOVE KNOCK SENSOR(a) Disconnect the knock sensor connectors.(b) Remove the 2 bolts and 2 knock sensors.3. REMOVE WATER DRAIN COCK

4. REMOVE ENGINE REAR OIL SEAL RETAINER(a) Remove the 5 bolts and 2 nuts.(b) Using a screwdriver, remove the oil seal retainer by prying

between the oil seal retainer and crankshaft bearing cap.

5. INSPECT CONNECTING ROD THRUST CLEARANCEUsing a dial indicator, measure the thrust clearance while mov-ing the connecting rod back and forth.

Standard thrust clearance:0.15 to 0.30 mm (0.0059 to 0.0118 in.)Maximum thrust clearance: 0.35 mm (0.0138 in.)

6. INSPECT CONNECTING ROD OIL CLEARANCE(a) Check that the matchmarks on the connecting rod and

cap are aligned to ensure correct reassembling.(b) Using SST, remove the 2 connecting rod cap bolts.

SST 09011-38121(c) Clean the crank pin, bearing and connecting rod.(d) Check the crank pin and bearing for pits and scratches.

A23022

Plastigage

A23023

Protrusion

A23024

A23025

90�

Front

Painted Mark

90�

A23026



(e) Lay a strip of Plastigage across the crank pin.

(f) Check that the protrusion of the connecting rod cap is fac-ing the correct direction.

(g) Apply a light coat of engine oil to the threads of the con-necting rod cap bolts.

(h) Using SST, tighten the bolts alternately to the specifiedtorque.SST 09011-38121Torque: 25 N ⋅m (250 kgf ⋅cm, 18 ft ⋅lbf)

(i) Mark the front side of each connecting cap bolt with paint.(j) Retighten the cap bolts 90� as shown in the illustration.NOTICE:Do not turn the crankshaft.(k) Remove the 2 bolts, connecting rod cap and lower bear-

ing.

(l) Measure the Plastigage at its widest point.Standard oil clearance:0.026 to 0.046 mm (0.0010 to 0.0018 in.)Maximum oil clearance: 0.066 mm (0.0025 in.)

NOTICE:Completely remove the Plastigage.

A23027

Number Mark Number Mark

A23028

A23029

A23030



(m) If replacing a bearing, replace it with one that has thesame number marked on the connecting rod. There are4 sizes of standard bearings, marked ”1 ”, ”2”, ”3” and ”4”accordingly.

HINT:Standard bearing center wall thickness

Mark mm (in.)

”1” 1.484 to 1.487 (0.0584 to 0.0585)

”2” 1.487 to 1.490 (0.0585 to 0.0587)

”3” 1.490 to 1.493 (0.0587 to 0.0588)

”4” 1.493 to 1.496 (0.0588 to 0.0589)

7. REMOVE PISTON W/CONNECTING ROD(a) Using a ridge reamer, remove all the carbon from the top

of the cylinder.(b) Push in the piston w/ connecting rod and upper bearing

through the top of the cylinder block.HINT:� Keep the bearings, connecting rod and cap together.� Arrange the piston and connecting rod assemblies in the

correct order.8. REMOVE CONNECTING ROD BEARING9. REMOVE PISTON RING SET(a) Using a piston ring expander, remove the 2 compression

rings.(b) Remove the 2 side rails and oil ring by hand.

10. REMOVE PISTON PIN HOLE SNAP RINGUsing a screwdriver, pry out the 2 snap rings.

A23031

80�C

A23032

A23033

A23034

1

43

2

58

7

6



11. REMOVE PISTON PIN(a) Gradually heat the piston to approx. 80�C (176�F).

(b) Using a plastic-faced hammer and brass bar, lightly tapout the piston pin and remove the connecting rod.

HINT:� The piston and pin are a matched set.� Arrange the pistons, pins, rings, connecting rods and

bearings in the correct order.

12. INSPECT CRANKSHAFT THRUST CLEARANCE(a) Using a dial indicator, measure the thrust clearance while

prying the crankshaft back and forth with a screwdriver.Standard thrust clearance:0.04 to 0.24 mm (0.0016 to 0.0094 in.)Maximum thrust clearance: 0.30 mm (0.0118 in.)

If the thrust clearance is greater than the maximum, replace thepair of the thrust washers or the crankshaft.HINT:Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780in.)

13. REMOVE CRANKSHAFT(a) Using several steps, uniformly loosen and remove the 8

main bearing cap bolts and seal washers in the sequenceas shown in the illustration.

A23035

2

68

4 12

109

1315

113

75

1

1416

A23036

A23037

Main Bearing Cap

Cylinder Block

A23038



(b) Using several steps, uniformly loosen and remove the 16main bearing cap bolts in the sequence as shown in theillustration.

(c) Using a screwdriver, pry out the main bearing caps. Re-move the 4 main bearing caps and lower bearings.

NOTICE:� Pull up the main bearing cap while turning it little by

little to the right and the left.

� Be careful not to damage the joint surface of the cylin-der block and the main bearing cap.

14. REMOVE CRANKSHAFT THRUST WASTER SET15. REMOVE CRANKSHAFT BEARING

16. REMOVE OIL NOZZLEUsing a 5 mm socket hexagon wrench, remove the 3 oilnozzles.

EM1Y0-01

A23039

A23040

FrontThrust Direction

Axial Direction

A

B

10 mm

A23041

27.7 mm(1.091 in.)



INSPECTION1. INSPECT CYLINDER BLOCK FOR FLATNESSUsing a precision straight edge and feeler gauge, measure theflatness of the surface that is in contact with the cylinder headgasket.

Maximum warpage: 0.05 mm (0.0020 in.)If warpage is greater than the maximum, replace the cylinderblock.

2. INSPECT CYLINDER BOREUsing a cylinder gauge, measure the cylinder bore diameter atpositions A and B in the thrust and axial directions.

Standard diameter:94.000 to 94.012 mm (3.7008 to 3.7013 in.)Maximum diameter: 94.132mm (3.7060 in.)

If the average diameter of the 4 positions is greater than themaximum, replace the cylinder block.

3. INSPECT PISTONUsing a micrometer, measure the piston diameter at rightangles to the piston pin center line, 27.7 mm (1.091 in.) from thepiston head.

Piston diameter:93.910 to 93.940 mm (3.6972 to 3.6984 in.)

Z00064

Z00065

A13490



4. INSPECT PISTON OIL CLEARANCESubtract the piston diameter measurement from the cylinderbore diameter measurement.

Standard oil clearance: 0.060 to 0.102 mm (0.0024 to 0.0040 in.)Maximum oil clearance: 0.13 mm (0.0051 in.)

If the oil clearance is greater than the maximum, replace all the6 pistons. If necessary, replace the cylinder block.

5. INSPECT CONNECTING RODUsing a rod aligner and feeler gauge, check the connecting rodalignment.

(1) Check for misalignment.Maximum misalignment:0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

If misalignment is greater than the maximum, replace the con-necting rod assembly.

(2) Check twist.Maximum twist:0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

If twist is greater than the maximum, replace the connecting rodassembly.

6. INSPECT PISTON PIN OIL CLEARANCE(a) Using a caliper gauge, measure the inside diameter of the

piston pin hole.Piston pin hole inside diameter:22.001 to 22.010 mm (0.8662 to 0.8665 in.)

HINT:Piston pin hole inside diameter

Mark mm (in.)

A 22.001 to 22.004 (0.8662 to 0.8663)

B 22.005 to 22.007 (0.8663 to 0.8664)

C 22.008 to 22.010 (0.8665 to 0.8665)

EM0227

EM6525

A23042

Piston Pin Hole Inside Diameter Mark

Front Mark

Front MarkConnecting Rod Bushing Inside Diameter Mark



(b) Using a micrometer, measure the piston pin diameter.Piston pin diameter:21.997 to 22.006 mm (0.8660 to 0.8664 in.)

HINT:Piston pin diameter

Mark mm (in.)

A 21.997 to 22.000 (0.8660 to 0.8661)

B 22.001 to 22.003 (0.8661 to 0.8663)

C 22.004 to 22.006 (0.8663 to 0.8664)

(c) Using a caliper gauge, measure the inside diameter of theconnecting rod bushing.Bushing inside diameter:22.005 to 22.014 mm (0.8663 to 0.8667 in.)

HINT:Bushing inside diameter

Mark mm (in.)

A 22.005 to 22.008 (0.8663 to 0.8665)

B 22.009 to 22.011 (0.8665 to 0.8666)

C 22.012 to 22.014 (0.8666 to 0.8667)

(d) Subtract the piston pin diameter measurement from thepiton pin hole diameter measurement.Standard oil clearance:0.001 to 0.007 mm (0.00004 to 0.00028 in.)Maximum oil clearance: 0.040 mm (0.0016 in.)

(e) If the oil clearance is greater than the maximum, replacethe bushing. If necessary, replace the piston and pistonpin together.

(f) Subtract the piston pin diameter measurement from thebushing inside diameter measurement.Standard oil clearance:0.005 to 0.011 mm (0.0002 to 0.0004 in.)Maximum oil clearance: 0.050 mm (0.0020 in.)

(g) If the oil clearance is greater than the maximum, replacethe bushing. If necessary, replace the connecting rod andpiston pin together.

A23044

A23045

110 mm

EM7639

A23046

A23046

EM-120-ENGINE MECHANICAL (1GR-FE) CYLINDER BLOCK


7. INSPECT RING GROOVE CLEARANCEUsing a feeler gauge, measure the clearance between the newpiston ring and the wall of the ring groove.

Ring groove clearance:No.1: 0.02 to 0.07 mm (0.0008 to 0.0028 in.)No.2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.)Oil: 0.07 to 0.15 mm (0.0028 to 0.0060 in.)

8. INSPECT PISTON RING END GAP(a) Using a piston, push the piston ring a little beyond the bot-

tom of the ring travel, 110 mm (4.33 in.) from the top of thecylinder block.

(b) Using a feeler gauge, measure the end gap.Standard end gap:No. 1: 0.30 to 0.40 mm (0.0118 to 0.0157 in.)No. 2: 0.40 to 0.50 mm (0.0157 to 0.0197 in.)Oil (Side rail): 0.10 to 0.40 mm (0.0039 to 0.0157 in.)Maximum end gap:No. 1: 1.0 mm (0.039 in.)No. 2: 1.1 mm (0.043 in.)Oil (Side rail): 1.0 mm (0.039 in.)

9. INSPECT CONNECTING ROD BOLTUsing a vernier caliper, measure the tension portion diameterof the bolt.

Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)Minimum diameter: 7.0 mm (0.276 in.)

If the diameter is less than the minimum, replace the bolt.

10. INSPECT CRANKSHAFT BEARING CAP SET BOLTUsing a vernier caliper, measure the tension portion diameterof the bolt.

Standard diameter:10.0 to 10.2 mm (0.393 to 0.402 in.)

If the diameter is less than the minimum, replace the bolt.

A23047

A23048

A23049

A23050

No. 1 and No. 4 No. 2 and No. 3

22.4 mm 19.0 mm

A23051

-ENGINE MECHANICAL (1GR-FE) CYLINDER BLOCKEM-121


11. INSPECT CRANKSHAFT(a) Using a dial indicator and V-blocks, measure the runout

as shown in the illustration.Maximum circle runout: 0.06 mm (0.0024 in.)

(b) Using a micrometer, measure the diameter of each mainjournal.Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.)

(c) Check each main journal for taper and out-of-round asshown in the illustration.Maximum taper and out-of-round:0.02 mm (0.0008 in.)

(d) Using a micrometer, measure the diameter of each crankpin.Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.)

(e) Check each crank pin for taper and out-of-round asshownin the illustration.Maximum taper and out-of-round:0.02 mm (0.0008 in.)

12. INSPECT CRANKSHAFT OIL CLEARANCEHINT:Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in theNo. 1 and No. 4 cylinder block journal positions with the mainbearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.2 and No. 3 positions.(a) Clean each main journal and bearing.

(b) Align the bearing claw with the claw groove of the cylinderblock, and push in the 4 upper bearings.

NOTICE:Do not apply engine oil to the bearing and its contact sur-face.

A23052

Mark 1, 2, 3, or 4

A23053

Plastigage

A23054

A23055

Less than 6 mm

A23056



(c) Align the bearing claw with the claw groove of the mainbearing cap, and push in the 4 bottom bearings.

NOTICE:Do not apply engine oil to the bearing or its contact surface.HINT:A number marked on each main bearing cap indicates theinstallation position.(d) Place the crankshaft on the cylinder block.

(e) Lay a strip of Plastigage across each journal.

(f) Examine the front marks and numbers and install thebearing caps on the cylinder block.

(g) Apply a light coat of engine oil to the threads of the bear-ing cap bolts.

(h) Temporarily install the 8 main bearing cap bolts to the in-side positions.

(i) Install the main bearing caps. Tighten the 2 bolts for eachbearing cap until the clearance between the bearing capand the cylinder block becomes less than 6 mm (0.23 in.).

(j) Using a plastic-faced hammer, lightly tap the bearing capto ensure a proper fit.

(k) Apply a light coat of engine oil to the threads of the mainbearing cap bolts.

A23057

26

8

4

1210

913

15

113

7

51 14

16

A23058

90�

Front

Painted Mark

90�

A23059

14

3

2

5

8

76

A23060



(l) Install the 16 main bearing cap bolts. Using several steps,uniformly tighten the bolts in the sequence as shown inthe illustration.Torque: 61 N ⋅m (622 kgf ⋅cm, 45 ft ⋅lbf)

(m) Mark the front side of the bearing cap bolts with paint.(n) Retighten the bearing cap bolts until 90� in the sequence

as shown in the illustration.(o) Check that the painted mark is now at a 90� angle to the

front.NOTICE:Do not turn the crankshaft.

(p) Install the 8 main bearing cap bolts. Using several steps,uniformly tighten the bolts in the sequence as shown inthe illustration.Torque: 25 N ⋅m (255 kgf ⋅cm, 18 ft ⋅lbf)

(q) Remove the main bearing caps.

(r) Measure the Plastigage at its widest point.Standard oil clearance: 0.018 to 0.030 mm (0.0007 to 0.0012 in.)Maximum clearance: 0.046 mm (0.0018 in.)

If the oil clearance is greater than the maximum, replace thebearings. If necessary, replace the crankshaft.NOTICE:Completely remove the Plastigage.

A23061

No. 1No. 2No. 3No. 4

Number Mark

No. 1No. 2

No. 3No. 4

Number MarkNumber Mark



(s) If replacing a bearing, replace it with one that has thesame number. If the number of the bearing cannot be de-termined, select the correct bearing by adding togetherthe numbers imprinted on the cylinder block and crank-shaft, then refer to the table below for the appropriatebearing number. There are 5 sizes of standard bearings,marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly

Journal bearingsCylinderblock (A)

+Crankshaft

0 to 5 6 to 11 12 to 17 18 to 23 24 to 28

UseBearing

”1” ”2” ”3” ”4” ”5”

HINT:EXAMPLECylinder block ”11” (A) + Crankshaft ”06” (B)= Total number 17 (Use bearing ”3”)

Item Mark mm (in.)

Cylinder block main journal bore diameter (A)

”00”

”01”

”02”

”03”

”04”

”05”

”06”

”07”

”08”

”09”

”10”

”11”

”12”

”13”

”14”

”15”

”16”

77.000 (3.0315)

77.001 (3.0315)

77.002 (3.0316)

77.003 (3.0316)

77.004 (3.0317)

77.005 (3.0317)

77.006 (3.0317)

77.007 (3.0318)

77.008 (3.0318)

77.009 (3.0319)

77.010 (3.0319)

77.011 (3.0319)

77.012 (3.0320)

77.013 (3.0320)

77.014 (3.0320)

77.015 (3.0321)

77.016 (3.0321)



Crankshaft main journal diameter (B)”00””01””02””03””04””05””06””07””08””09””10””11”

71.999 to 72.000 (2.8346 to 2.8346)71.998 to 71.999 (2.8346 to 2.8346)71.997 to 71.998 (2.8345 to 2.8346)71.996 to 71.997 (2.8345 to 2.8346)71.995 to 71.996 (2.8344 to 2.8345)71.994 to 71.995 (2.8344 to 2.8344)71.993 to 71.994 (2.8343 to 2.8344)71.992 to 71.993 (2.8343 to 2.8343)71.991 to 71.992 (2.8343 to 2.8343)71.990 to 71.991 (2.8343 to 2.8343)71.989 to 71.990 (2.8342 to 2.8343)71.988 to 71.989 (2.8342 to 2.8342)

Standard bearing center wall thickness ”1””2””3””4””5”

2.488 to 2.491 (0.0980 to 0.0981)2.491 to 2.494 (0.0981 to 0.0982)2.494 to 2.497 (0.0982 to 0.0983)2.497 to 2.500 (0.0982 to 0.0984)2.500 to 2.503 (0.0984 to 0.0985)

EM1Y2-01

A23062

Front Side

Lower Side

Upper Side

42 mm(1.65 in.)

56 mm(2.20 in.)

23 mm(0.91 in.)

M6A

A

C

C

B B



REASSEMBLY1. INSTALL STUD BOLT(a) Install the stud bolts as shown in the illustration.

Torque:Stud bolt A: 11 N ⋅m (112 kgf ⋅cm, 8.1 ft ⋅lbf)Stud bolt B: 4.5 N ⋅m (46 kgf ⋅cm, 40 in. ⋅lbf)Stud bolt C: 4.0 N ⋅m (41 kgf ⋅cm, 35 in. ⋅lbf)

B

A23063

Front Side

Rear Side

Upper Side

Front Side

Rear Side

Lower Side

Protrusion Height: 22.5 to 23.5 mm





10 mm(0.39 in.)

8 mm(0.31 in.)

36 mm(1.42 in.)

22 mm(0.87 in.)

18 mm(0.71 in.)

4 mm(0.16 in.)

12 mm(0.47 in.)

A

B

C

C

C

C

D

D

D


D

D

10 mm(0.39 in.) 4 mm

(0.16 in.)

12 mm(0.47 in.)

4 mm(0.16 in.)

12 mm(0.47 in.)

(0.886 to 0.925 in.) (0.217 to 0.256 in.)

(0.413 to 0.453 in.) (0.217 to 0.256 in.)

(0.217 to 0.256 in.)

(0.335 to 0.374 in.)



2. INSTALL STRAIGHT PIN(a) Using a plastic-faced hammer, tap in the straight pin.

Standard protrusion: Pin A: 22.5 to 23.5 mm (0.886 to 0.925 in.)Pin B: 10.5 to 11.5 mm (0.413 to 0.453 in.)Pin C: 8.5 to 9.5 mm (0.335 to 0.374 in.)Pin D: 5.5 to 6.5 mm (0.217 to 0.256 in.)

A23064

Right Side Left Side

0.2 to 1.2 mm(0.008 to 0.047 in.)

A23065

26.5��5�

A23038



3. INSTALL TIGHT PLUG(a) Apply adhesive around the tight plugs.

Adhesive: Part No. 08833-00070, THREE BOND 1324or equivalent.

(b) Using SST, install the tight plugs as shown in the illustra-tion.SST 09950- 60010 (09951- 00350), 09950- 70010

(09951-07150)Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 in.)

4. INSTALL OIL JETUsing a screwdriver and hammer, tap in an oil jet.

5. INSTALL OIL NOZZLEUsing a 5 mm socket hexagon wrench, install the 3 oil nozzles.

Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)

A23066

P12417

A23067

Front Mark

Front Mark

A23066

A23068

Upward

Painted Mark



6. INSTALL PISTON PIN HOLE SNAP RINGUsing a screwdriver, install a new snap ring at one side of thepiston pin hole.HINT:Check that the end gap of the snap ring does not overlap thepin hole cutout portion of the piston.

7. INSTALL PISTON(a) Gradually heat the piston to about 80�C (176�F).

(b) Coat the piston pin with engine oil.(c) Align the front marks of the piston and connecting rod,

and push in the piston pin with a thumb.

8. INSTALL PISTON PIN HOLE SNAP RINGUsing a screwdriver, install a new snap ring on the other sideof the piston pin hole.HINT:Be sure that the end gap of the snap ring does not overlap thepin hole cutout portion of the piston.

9. INSTALL PISTON RING SET(a) Install the oil ring expander and 2 side rails by hand.(b) Using a piston ring expander, install the 2 compression

rings.NOTICE:Install the compression ring No. 2 with the painted markfacing upward.

A23069

Side Rail

Upper side rail

Lower side rail

No. 1 Compression

Expander

Front Mark

No. 2 Compression

A23070

A23050

22.4 mm

No. 1 and No. 4 No. 2 and No. 3

19.0 mm

Upper

Lower

A23071

A23052

Mark 1, 2, 3 or 4



(c) Position the piston rings so that the ring ends are asshown in the illustration.

10. INSTALL CONNECTING ROD BEARINGAlign the bearing claw with the groove of the connecting rod orconnecting cap.NOTICE:Clean the backside of the bearing and the bearing surfaceof the connecting rod and prevent oil from adhering tothem.

11. INSTALL CRANKSHAFT BEARINGHINT:Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in theNo. 1 and No. 4 cylinder block journal positions with the mainbearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.2 and No. 3 positions.(a) Clean each main journal and bearing.

(b) Align the bearing claw with the claw groove of the cylinderblock, and push in the 4 upper bearings.

NOTICE:Do not apply engine oil to the bearing or its contact surface.

(c) Align the bearing claw with the claw groove of the mainbearing cap, and push in the 4 lower bearings.

NOTICE:Do not apply engine oil to the bearing or its contact surface.HINT:The number marked on each main bearing cap indicates theinstallation position.

A23072

A23073

A23054

A23055

Less than 6 mm



12. INSTALL CRANKSHAFT(a) Apply engine oil to the upper bearing and install the crank-

shaft on the cylinder block.

(b) Install the 2 upper thrust washers to the No. 2 journal posi-tion of the cylinder block.(1) Push the crankshaft toward the front (rear) side.(2) Install the 2 upper thrust washers with the oil

grooves facing outward.

(c) Install the 2 lower thrust washers on the No. 2 bearing capwith the grooves facing outward.

(d) Examine the front marks and numbers and install thebearing caps on the cylinder block.

(e) Apply a light coat of engine oil to the threads of the bear-ing cap bolts.

(f) Temporarily install the 8 main bearing cap bolts to the in-side positions.

(g) Install the main bearing caps. Tighten the 2 bolts for eachbearing cap until the clearance between the bearing capand the cylinder block becomes less than 6 mm (0.23 in.).

A23056

A23057

16

315

13

14

12

11 241

10

5 6

7 8

9

A23058

90�

Front

Painted Mark

90�

A23059

14

23

56

7

8



(h) Using a plastic-faced hammer, lightly tap the bearing capto ensure a proper fit.

(i) Apply a light coat of engine oil to the threads of the mainbearing cap bolts.

(j) Install the 16 main bearing cap bolts. Using several steps,uniformly tighten the bolts in the sequence shown in theillustration.Torque: 61 N ⋅m (622 kgf ⋅cm, 45 ft ⋅lbf)

(k) Mark the front side of the bearing cap bolts with paint.(l) Retighten the bearing cap bolts 90� in the sequence as

shown in the illustration.(m) Check that the painted mark is now at a 90� angle to the

front.(n) Check that the crankshaft turns smoothly.

(o) Using several steps, uniformly tighten the 8 main bearingcap bolts in the sequence as shown in the illustration.Torque: 25 N ⋅m (255 kgf ⋅cm, 18 ft ⋅lbf)

A23074

Front Mark

A23023

Protrusion

A23024

A23025

90�

Front

Painted Mark

90�



13. INSTALL PISTON W/CONNECTING ROD(a) Apply engine oil to the cylinder walls, the pistons, and the

surfaces of the connecting rod bearings.(b) Check the position of the piston ring ends.(c) Using a piston ring compressor, push the correctly num-

bered piston and connecting rod assemblies into eachcylinder with the front mark of the piston facing forward.

NOTICE:� Clean the backside of the bearing and the bearing

surface of the connecting rod cap and prevent oilfrom adhering to them.

� Match the numbered connecting rod cap with the con-necting rod.

(d) Check that the protrusion of the connecting rod cap is fac-ing the correct direction.

(e) Apply a light coat of engine oil to the threads of the con-necting rod cap bolts.

(f) Using SST, tighten the bolts alternately to the specifiedtorque.SST 09011-38121Torque: 25 N ⋅m (250 kgf ⋅cm, 18 ft ⋅lbf)

(g) Mark the front side of each connecting cap bolt with paint.(h) Retighten the cap bolts 90� as shown.(i) Check that the crankshaft turns smoothly.14. INSTALL ENGINE REAR OIL SEAL RETAINER(a) Remove any old packing material (FIPG) and be careful

not to drop any oil on the contact surfaces of the oil sealretainer and cylinder block.

A23004

Seal Packing

Seal Width: 2 to 3 mm (0.08 to 0.12 in.)

A23018

Adhesive

A23019

15�

45� 45�

45�



(b) Apply a continuous bead of seal packing (diameter 2 to3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shownin the illustration.Seal packing: Part No. 08826-00080 or equivalent

NOTICE:Parts must be assembled within 3 minutes of application.Otherwise the seal packing must be removed and reap-plied.(c) Install the oil seal retainer with the 5 bolts and 2 nuts.

Torque: Bolt: 10 N ⋅m (102 kgf ⋅cm, 7 ft ⋅lbf)Nut: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)

15. INSTALL WATER DRAIN COCK(a) Apply adhesive to 2 or 3 threads of the drain cock ends.

Adhesive: Part No. 08833-00070, THREE BOND 1324or equivalent

(b) After tightening the drain cocks to the specified torque, ro-tate them clockwise as shown in the illustration.Torque: 25 N ⋅m (255 kgf ⋅cm, 18 ft ⋅lbf)

NOTICE:� Do not rotate the drain cocks more than 1 complete

revolution (360 �) after tightening the drain cocks tothe specified torque.

� Do not loosen the drain cocks after setting them cor-rectly.

A23005

LH Bank Upper

Engine Rear

15�

15�

Engine Front

UpperRH Bank

A22979



16. INSTALL KNOCK SENSOR(a) Install the 2 knock sensors with the 2 bolts within a 15°

angle as shown in the illustration.Torque: 20 N ⋅m (204 kgf ⋅cm, 15 ft ⋅lbf)

(b) Connect the knock sensor connectors.

17. INSTALL WATER OUTLET PIPE NO.1Install the water outlet pipe with the 3 bolts.

Torque: 10 N ⋅m (102 kgf ⋅cm, 7 ft·lbf)

EM1Y1-01

EM6363

SST

A23043

EM6363

SST

EM6535

P20668



REPLACEMENT1. REPLACE CONNECTING ROD SMALL END BUSHUsing SST and a press, press out the bushing.

SST 09222-30010

2. INSTALL CONNECTING ROD SMALL END BUSH(a) Align the oil holes of a new bushing and the connecting

rod.

(b) Using SST and a press, press in the bushing.SST 09222-30010

(c) Using a pin hole grinder, hone the bushing to obtain thestandard specified clearance between the bushing andpiston pin.Standard oil clearance:0.005 to 0.011 mm (0.0002 to 0.0004 in.)

HINT:Check that the piston pin fits at a normal room temperature.Coat the piston pin with engine oil, and push it into the connect-ing rod with a thumb.

A22982

A23003

SST

A23080

Cut Position

A23081

SST



3. REPLACE ENGINE REAR OIL SEALHINT:There are 2 methods ((a) and (b)) to replace the oil seal.(a) If the rear oil seal retainer is removed from the cylinder

block:(1) Using a screwdriver and hammer, tap out the oil

seal.

(2) Using SST and a hammer, tap in a new oil seal untilits surface is flush with the rear oil seal retaineredge.

SST 09223-78010(3) Apply MP grease to the oil seal lip.

(b) If the rear oil seal retainer is installed to the cylinder block:(1) Using a knife, cut off the oil seal lip.(2) Using a screwdriver, pry out the oil seal.

NOTICE:Be careful not to damage the crankshaft. Tape the screw-driver tip.

(3) Using SST and a hammer, tap in the oil seal until itssurface is flush with the rear oil seal retainer edge.

SST 09223-78010(4) Apply MP grease to a new oil seal lip.

EM1XO-01

A23192

V-Bank Cover

Vacuum Hose

Air Cleaner Hose

Mass Air Flow Meter Connector

Ventilation Hose No.2

Battery Clamp

Battery

Battery Tray


8.0 (82, 71 in.·lbf)

7.5 (76, 66 in.·lbf)

Air Cleaner

-ENGINE MECHANICAL (1GR-FE) CYLINDER HEADEM-53


CYLINDER HEADCOMPONENTS

A23193

Radiator

Fan Shroud

Fan Pulley

Fan w/ Fluid Coupling

Drive Belt

21 (214, 15)


EM-54-ENGINE MECHANICAL (1GR-FE) CYLINDER HEAD


A22959

Vane Pump

GeneratorTerminal Cap

Generator Wire

Generator Connector

Wire Harness Clamp Bracket

Cooler Compressor Connector

Cooler Compressor

43 (438, 32)

8.0 (82, 71 in.·lbf)

8.0 (82, 71 in.·lbf)

9.8 (100, 7)

43 (438, 32)

43 (438, 32)

25 (255, 18)



VSV Connector

Intake Air Surge Tank

VSV Connector

Fuel Vaper Feed Hose

Surge Tank Stay No.2



Water By-pass Hose

Throttle Body Connector

Throttle Body Bracket

� Gasket

21 (214, 15)

Oil Baffle Plate

28 (286, 21)

9.0 (92, 80 in.·lbf)

21 (214, 15)

21 (214, 15)

x2

x4



A23196

RH Exhaust Manifold

� Gasket

Manifold Stay

RH Front Exhaust Pipe

Upper Radiator Hose

Ventilation Hose

Water By-pass Joint

� O-ring

Lower Radiator Hose

LH Exhaust Manifold

LH Front Exhaust PipeN·m (kgf·cm, ft·lbf) : Specified torque


Manifold Stay

Ventilation Hose

� Gasket

9.0 (92, 80 in.·lbf)

� Gasket

9.0 (92, 80 in.·lbf)

� Gasket

� Gasket

� Gasket

� Gasket

� Gasket

40 (408, 30)

40 (408, 30)

40 (408, 30)40 (408, 30)

21 (214, 15)

21 (214, 15)

62 (630, 46)�

x6

x2

x6

x262 (630, 46)�

48 (490, 35)

43 (440, 32)

40 (408, 30)

Spring



A23197

Water By-pass Hose No.1



� O-ring

� Gasket

Water Inlet9.0 (92, 80 in.·lbf)

Washer

Idler Pulley No.2

Idler Pulley No.1

Washer

V-Ribbed Belt Tensioner

� Gasket

Intake Manifold

Camshaft Timing Oil Control Valve

� Gasket

Oil Filter Cap Housing

Oil Filter Cap

Ignition Coil Spark Plug

26 (265, 19)

Ignition Coil

9.0 (92, 80 in.·lbf)

36 (367, 27)

36 (367, 27)

Spark Plug

9.0 (92, 80 in.·lbf)

54 (551, 40)

39 (398, 29)



x10 9.0 (92, 80 in.·lbf)Oil Level Gauge

x5

10 (102, 7)

10 (102, 7)



A23198

Oil Pan

Oil Strainer

Oil Pan No.2

Drain Plug

� O-ring

� Gasket

� Gasket

40 (408, 30)

10 (102, 7)9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)

10 (102, 7)21 (214, 15)

21 (214, 15)

21 (214, 15)



Cylinder Head Cover LH

� Cylinder Head Cover Gasket


10 (102, 7)

9.0 (92, 80 in.·lbf)

Cylinder Head Cover RH

10 (102, 7)

9.0 (92, 80 in.·lbf)Seal Washer Seal Washer

Oil Level Gauge Guide

� O-ring

9.0 (92, 80 in.·lbf)

Filter

62 (632, 46)

62 (632, 46)

� Gasket

� Gasket

Filter

9.0 (92, 80 in.·lbf)

VVT Sensor

VVT Sensor

37 (377, 27)

x15x2

x2

x4x6x9

x2

x7

x7

x3

x3

x3

x3 Ventilation Valve27 (275, 20)

9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)



A23195

Crankshaft Pulley

� Oil Seal

Timing Chain Cover

Camshaft Timing Sprocket

Timing Chain No.2

Camshaft Timing Gear Assembly


Timing Chain No.2


Chain Vibration Damper No.2

Chain Tensioner No.1

Timing Chain

Idle Gear Shaft No.2

Idle Gear No.1


� O-ring

Crankshaft Timing Sprocket

Chain VibrationDamper No.1

23 (235, 17)

x15250 (2,549, 184)

100 (1,020, 74)

100 (1,020, 74)

23 (235, 17)

23 (235, 17)

100 (1,020, 74)

100 (1,020, 74)


19 (194, 14)Chain Tensioner No.2

19 (194, 14)

10 (102, 7)

Chain Tensioner Slipper

60 (612, 44)

19 (194, 14)N·m (kgf·cm, ft·lbf) : Specified torque


x9

x2



A23199

Camshaft Bearing Cap No.1

Camshaft Bearing No.1


Camshaft Bearing No.2Plate Washer

Cylinder Head RH

� RH Cylinder Head Gasket

Cylinder Head LH

� LH Cylinder Head Gasket

See page EM-89

1st 36 (367, 27)2nd Turn 180 �x8

x8

x8x8

x2

See page EM-89

1st 36 (367, 27)2nd Turn 180 �

Camshaft

CamshaftCamshaft

Camshaft

24 (245, 18)

9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)


Camshaft BearingCap No.2


Camshaft BearingCap No.2

24 (245, 18)

24 (245, 18)

24 (245, 18)

30 (306, 22)






A22923

Valve Lifter

Valve Spring Retainer Lock

Valve Spring Retainer

Inner Compression Spring

� Valve Stem Oil Seal

Valve Spring Seat

� Intake Valve Guide Bush

Exhaust ValveIntake Valve

� Exhaust Valve Guide Bush




EM1XQ-01

A22924

A22925

SST

Wooden Block

A22926

A22927

A22928



DISASSEMBLY1. REMOVE VALVE LIFTERHINT:Arrange the valve lifter in the correct order.

2. REMOVE VALVEHINT:Arrange the valves, inner compression springs, valve spring re-tainers and valve spring retainer locks in the correct order.(a) Place the cylinder head on a wooden block.(b) Using SST, compress the inner compression spring and

remove the 2 valve spring retainer locks.SST 09202-70020 (09202-00010)

(c) Remove the valve, inner compression spring, valvespring and valve spring retainer.

3. REMOVE VALVE SPRING SEALUsing compressed air and a magnetic finger, remove the valvespring seat by blowing air.

4. REMOVE VALVE STEM OIL SEALUsing needle-nose pliers, remove the valve stem oil seal.

5. CLEAN CYLENDER HEAD(a) Using a gasket scraper, remove all the gasket material

from the cylinder block contact surface.NOTICE:Be careful not to scratch the cylinder block contact sur-face.

A22929

A22930

A22931

EM0580



(b) Using a wire brush, remove all the carbon from the com-bustion chambers.

NOTICE:Be careful not to scratch the combustion chambers.

(c) Using a valve guide bushing brush and solvent, clean allthe valve guide bushes.

(d) Using a soft brush and solvent, thoroughly clean the cylin-der head.

6. CLEAN VALVE(a) Using a gasket scraper, chip off any carbon from the valve

head.(b) Using a wire brush, thoroughly clean the valve.

EM1XR-01

A22932

Cylinder Block Side:

Intake Manifold Side:

Exhaust Manifold Side:

A22933



INSPECTION1. INSPECT CYLINDER HEAD(a) Inspect flatness.

Using a precision straight edge and feeler gauge, mea-sure the flatness of the contact surfaces of the cylinderblock and manifolds.Maximum warpage: 0.10 mm (0.0039 in.)

If warpage is greater than the maximum, replace the cylinderhead.

(b) Inspect cranks.Using a dye penetrant, check the combustion chamber,intake ports, exhaust ports and cylinder block surface forcracks.

If cracked, replace the cylinder head.

A22967

Cylinder Head Side

Intake Air Surge Tank Side

A22968

Z00052

Z00054

44.5�



2. INSPECT INTAKE MANIFOLD FOR FLATNESSUsing a precision straight edge and feeler gauge, mea-sure the flatness of the contact surfaces of the cylinderhead and intake air surge tank.Maximum warpage: Intake air surge tank side: 0.8 mm (0.031 in.)Cylinder head side: 0.2 mm (0.008 in.)

If warpage is greater than the maximum, replace the intakemanifold.

3. INSPECT EXHAUST MANIFOLD FOR FLATNESSUsing a precision straight edge and feeler gauge, measure theflatness of the contact surface the cylinder head.

Maximum warpage: 0.7 mm (0.028 in.)If warpage is greater than the maximum, replace the exhaustmanifold.HINT:Maximum warpage of each installation surface: 0.3 mm (0.012 in.)

4. INSPECT VALVE(a) Inspect valve stem diameter.

Using a micrometer, measure the diameter of the valvestem.Valve stem diameter:Intake 5.470 to 5.485 mm (0.2154 to 0.2159 in.)

Exhaust 5.465 to 5.480 mm (0.2152 to 0.2158 in.)

(b) Inspect valve face angle.(1) Grind the valve enough to remove pits and carbon.(2) Check that the valve is ground to the correct valve

face angle.Valve face angle: 44.5 �

EM0181

EM2534

Overall Length

EM0255

A22934

P12729

Width



(c) Inspect valve head margin thickness.Using vernier calipers, check the valve head margin thick-ness.Standard margin thickness: 1.0 mm (0.039 in.)Minimum margin thickness: 0.5 mm (0.020 in.)

If the margin thickness is less than the minimum, replace thevalve.

(d) Inspect overall length.Using vernier calipers, check the overall length.Standard overall length:Intake 106.95 mm (4.2106 in.)

Exhaust 105.80 mm (4.1654 in.)

Minimum overall length:Intake 106.40 mm (4.1890 in.)

Exhaust 105.30 mm (4.1457 in.)

If the overall length is less than the minimum, replace the valve.

(e) Inspect valve stem tip.Check the surface of the valve stem tip for wear.

NOTICE:Do not grind off more than the minimum length.If the valve stem tip is worn, resurface the tip with a grinder orreplace the valve.

5. CLEAN VALVE SEAT(a) Using a 45� carbide cutter, resurface the valve seats.(b) Clean the valve seats.

6. INSPECT VALVE SEAT(a) Apply a light coat of prussian blue (or white lead) to the

valve face.(b) Lightly press the valve against the valve seat.NOTICE:Do not rotate the valve.(c) Check the valve face and seat according to the following

procedure.(1) If prussian blue (or white lead) appears around the

entire face, the valve is centered.

A01476

45�

1.0 to 1.4 mm

30�

A23191

Intake Side:

60�

1.0 to 1.4 mm

45�

A01477

Exhaust Side:

75�

1.0 to 1.4 mm

45�

A22935



If not, replace the valve.(2) If the prussian blue (or white lead) appears around

the entire valve seat, the guide and face are cen-tered.

If not, resurface the valve seat.(3) Check that the seat contacts the middle of the valve

face with the width below.Standard width: 1.0 to 1.4 mm (0.039 to 0.055 in.)

7. REPAIR VALVE SEATNOTICE:Take off a cutter gradually to make the intake valve seatsmooth.(a) If the seating is too high to the valve face, use 30� and 45�

cutters to correct the seat.

(b) Intake side: If the seating is too low to the valve face, use 60� and 45�cutters to correct the seat.

(c) Exhaust side: If the seating is too low to the valve face, use 75� and 45�cutters to correct the seat.

(d) Handrub the valve and valve seat with an abrasive com-pound.

(e) After handrubbing, clean the valve and valve seat.

EM0988

Deviation

EM0801

EM0281

A22936



8. INSPECT INNER COMPRESSION SPRING(a) Inspect squareness.

Using a steel square, measure the squareness of the in-ner compression spring.Maximum deviation: 2.0 mm (0.079 in.)

If the deviation is greater than the maximum, replace the innercompression spring.

(b) Inspect free length.Using vernier calipers, measure the free length of the in-ner compression spring.Free length: 47.80 mm (1.8819 in.)

If the free length is not as specified, replace the inner compres-sion spring.

(c) Inspect tension.Using a spring tester, measure the tension of the innercompression spring at the specified installed length.Installed tension: 186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at33.3 mm (1.311 in.)

If the installed tension is not as specified, replace the inner com-pression spring.

9. INSPECT VALVE GUIDE BUSH OIL CLEARANCE(a) Using a caliper gauge, measure the inside diameter of the

valve guide bush.Inside diameter: 5.51 to 5.53 mm (0.2169 to 0.2177 in.)

(b) Subtract the valve stem diameter measurement (Step 8)from the valve guide bush inside diameter measurement.Standard oil clearance:Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)


Maximum oil clearance:Intake 0.08 mm (0.0031 in.)

Exhaust 0.10 mm (0.0039 in..)

If the oil clearance is greater than the maximum, replace thevalve and valve guide bush.

P16860

A22942

Diameter

A22943

Plastigage



10. INSPECT VALVE LIFTERUsing a micrometer, measure the valve lifter diameter.

Valve lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.)

11. INSPECT VALVE LIFTER OIL CLEARANCE(a) Using a caliper gauge, measure the lifter bore diameter

of the cylinder head.Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.)

(b) Subtract the valve lifter diameter measurement (Step 10)from the lifter bore diameter measurement.Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.)Maximum oil clearance: 0.08 mm (0.0031 in.)

If the oil clearance is greater than the maximum, replace thevalve lifter.If necessary, replace the cylinder head.

12. INSPECT CAMSHAFT OIL CLEARANCE(a) Clean the camshaft bearing caps, camshaft bearings and

camshaft journals.(b) Install the camshaft bearing (See page EM-89 ).(c) Place the camshaft on the cylinder head.(d) Lay a strip of Plastigage across each of the camshaft jour-

nals.(e) Install the camshaft bearing caps (See page EM-89 ).NOTICE:Do not turn the camshafts.(f) Remove the camshaft bearing caps (See page EM-62 ).

A22944

A22945



(g) Measure the Plastigage at its widest point.Standard oil clearance (Cylinder head RH):No. 1

(Intake)0.008 to 0.038 mm (0.0003 to 0.0015 in.)

No. 1 (Exhaust)

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Standard oil clearance (Cylinder head LH):No. 1 0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum oil clearance (Cylinder head RH):No. 1

(Intake)0.07 mm (0.0028 in.)

Others 0.10 mm (0.0039 in.)

Maximum oil clearance (Cylinder head LH): 0.10 mm (0.0039 in.)

If the oil clearance is greater than the maximum, replace thecamshaft bearings and/or camshaft.If necessary, replace the camshaft bearing caps and cylinderhead together.

Reference:Cylinder head journal

bore diameter40.009 to 40.017 mm (1.5752 to 1.5755 in.)

Camshaft bearing

center wall thickness

(Mark ”2”)

2.004 to 2.008 mm (0.0789 to 0.0791 in.)

Camshaft journal di-

ameter35.971 to 35.985 mm (1.4165 to 1.4167 in.)

(h) Remove the Plastigage completely.(i) Remove the camshafts.(j) Remove the camshaft bearing.

13. INSPECT CAMSHAFT THRUST CLEARANCE(a) Install the camshafts (See page EM-89 ).(b) Using a dial indicator, measure the thrust clearance while

moving the camshaft back and forth.Standard thrust clearance: 0.04 to 0.09 mm (0.0016 to 0.0035 in.)Maximum thrust clearance: 0.11 mm (0.0043 in.)

If the thrust clearance is greater than the maximum, replace thecamshafts.

A22983

EM2011

A22984



If necessary, replace the camshaft bearing caps and cylinderhead as a set.

14. INSPECT CAMSHAFT(a) Inspect the camshaft for runout.

(1) Place the camshaft on V-blocks.(2) Using a dial indicator, measure the runout at the

center journal.Maximum runout: 0.06 mm (0.0024 in.)

If the runout is greater than the maximum, replace the camshaft.

(b) Inspect the cam lobes.Using a micrometer, measure the cam lobe height.Standard cam lobe height: Intake: 44.168 to 44.268 mm (1.7389 to 1.7428 in.)Exhaust: 44.580 to 44.680 mm (1.7551 to 1.7591 in.)Minimum cam lobe height: Intake: 44.018 mm (1.7330 in.)Exhaust: 44.430 mm (1.7492 in.)

If the cam lobe height is less than the minimum, replace thecamshaft.(c) Inspect the camshaft journals.

Using a micrometer, measure the journal diameter.No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.)Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.)

If the journal diameter is not as specified, check the oil clear-ance.15. INSPECT CAMSHAFT TIMING GEAR(a) Fix the intake camshaft with a vise.NOTICE:Be careful not to damage the camshaft.

A22985

Knock Pin

A22986

Retard Side Paths

Advance Side Paths

Close

Open

Masking Tape

Open

Close

Rubber Piece

A22987

Advance Side Path

Retard Side Path

A22988

Advance Side Path

Retard Side Path

DecompressHold Pressure



(b) Align the knock pin hole in the camshaft timing gear as-sembly with the knock pin of the camshaft, and install thecamshaft timing gear assembly with the bolt.Torque: 100 N ⋅m (1,020 kgf ⋅cm, 74 ft ⋅lbf)

(c) Confirm that the camshaft timing gear assembly is locked.

(d) Release the lock pin.(1) Cover the 4 oil paths of the cam journal with mask-

ing tape as shown in the illustration.HINT:One of the 2 grooves on the cam journal is for retards (upper)and the other is for advances (lower). Each groove has 2 oilpaths. Plug one of the oil paths for each groove with rubberpieces before wrapping the cam journal with tape.

(2) Prick a hole in the tape placed on the advance sidepath. Prick a hole in the retard side path, on the op-posite side to that of the advance side path, asshown in the illustration.

(3) Apply about 200 kPa (2.0 kgf/cm2) of air pressureto the two broken paths (the advance side path andthe retard side path).

NOTICE:Cover the paths with a shop rag to avoid oil splashing.

(4) Confirm that the camshaft timing gear assembly ro-tates in the advance direction when reducing the airpressure applied to the retard path.

HINT:When the lock pin is released, the camshaft timing gear rotatesin the advance direction.

(5) When the camshaft timing gear comes to the mostadvanced position, release the air pressure fromthe retard side path, and then release the air pres-sure from the advance side path.

A22989

Set Bolt

A22890



NOTICE:The camshaft timing assembly gear occasionally shifts tothe retard side abruptly if the air pressure of the advancedside path is released first. This often results in breakage ofthe lock pin.(e) Check for smooth revolution.

Allow the camshaft timing gear assembly to turn back andforth at any position, except where the lock pin meets atthe most retarded angle. Check the movable range andthat there is no disturbance.Standard: Moves smoothly in a range of about 31 �

NOTICE:Be sure to perform this check by hand, instead of air pres-sure.(f) Check the lock in the most retarded position.

Confirm that the camshaft timing gear assembly is lockedat the most retarded position.

(g) Remove the set bolt and camshaft timing gear assembly.NOTICE:Be sure not to remove the other 3 bolts.

16. INSPECT CYLINDER HEAD SET BOLTUsing a vernier caliper, measure the outside thread diameter ofthe bolt.

Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 in.)Minimum outside diameter: 10.7 mm (0.421 in.)

EM1XU-01

A22891

10 to 15 mm

φ 2.5 to 3 mm

Gasket

1.25 to 1.5 mm

10 to 15 mmSeal Packing

A22892

Lot No.



INSTALLATION1. INSTALL CYLINDER HEAD GASKET(a) Remove any old packing material (FIPG) and be careful

not to drop any oil on the contact surfaces of the cylinderhead and cylinder block.

(b) Install the RH cylinder head gasket.

(1) Apply a continuous bead of seal packing (diameter2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinderhead gasket as shown in the illustration.

Seal packing: Part No. 08826-00080 or equivalentNOTICE:Install the cylinder head within 3 minutes after applyingseal packing. After installing it, the cylinder head boltsmust be tightened within 15 minutes. Otherwise the sealpacking must be removed and reapplied.

(2) Place the cylinder head gasket on the cylinder blocksurface with the Lot No. stamp upper side facing up-ward.

NOTICE:� Be careful of the installation direction.� Place the cylinder head carefully in order not to dam-

age the gasket with the bottom part of the head.

A22914

10 to 15 mm

φ 2.5 to 3 mmGasket

1.25 to 1.5 mm

10 to 15 mm

Seal Packing

A22915Lot No.

A22888

3

7

1

246

8 5



(c) Install the LH cylinder head gasket.(1) Apply a continuous bead of seal packing (diameter

2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinderhead gasket as shown in the illustration.

Seal packing: Part No. 08826-00080 or equivalentNOTICE:Install the cylinder head within 3 minutes after applyingseal packing. After installing it, the cylinder head boltsmust be tightened within 15 minutes. Otherwise the sealpacking must be removed and reapplied.

(2) Place the cylinder head gasket on the cylinder blocksurface with the Lot No. stamp upper sied facing up-ward.

NOTICE:� Be careful of the installation direction.� Place the cylinder head carefully in order not to dam-

age the gasket with the bottom part of the head.2. INSTALL CYLINDER HEAD(a) Place the RH cylinder head on the cylinder head gasket.(b) Install the 8 cylinder head bolts.HINT:� The cylinder head bolts are tightened in 2 successive

steps (steps (3) and (5)).� If any cylinder head bolt is broken or deformed, replace

it.(1) Apply a light coat of engine oil to the threads of the

cylinder head bolts.(2) Install the plate washer to the cylinder head bolt.

(3) Using several steps, tighten each bolt with a 10 mmbi-hexagon wrench uniformly in the sequence asshown in the illustration.

Torque: 36 N ⋅m (367 kgf ⋅cm, 27 ft ⋅lbf)If any one of the cylinder head bolts does not meet the torquespecification, replace the cylinder head bolt.NOTICE:Do not drop the washers into the cylinder head.

A22893

Engine Front

180 �

Paint Mark

A22912

3

7

1

246

8 5

A22893

Engine Front

180 �

Paint Mark

A22911

1

2



(4) Mark the front side of each cylinder head bolt withpaint.

(5) Retighten the cylinder head bolts by 180 � asshown.

(6) Check that the painted marks are now at 180� op-posite to the engine front.

(c) Place the LH cylinder head on the cylinder head gasket.(d) Install the 8 cylinder head bolts.HINT:� The cylinder head bolts are tightened in 2 successive

steps (steps (3) and (5)).� If any cylinder head bolt is broken or deformed, replace

it.(1) Apply a light coat of engine oil to the threads of the

cylinder head bolts.(2) Install the plate washer to the cylinder head bolt.

(3) Using several steps, tighten each bolt with a 10 mmbi-hexagon wrench uniformly in the sequence asshown in the illustration.

Torque: 36 N ⋅m (367 kgf ⋅cm, 27 ft ⋅lbf)If any one of the cylinder head bolts does not meet the torquespecification, replace the cylinder head bolt.NOTICE:Do not drop the washers into the cylinder head.

(4) Mark the front side of each cylinder head bolt withpaint.

(5) Retighten the cylinder head bolts by 180 � asshown.

(6) Check that the painted marks are now at 180� op-posite to the engine front.

(e) Install the 2 cylinder head bolts.(1) Apply a light coat of engine oil to the threads of the

cylinder head bolts.(2) Install the 2 cylinder head bolts. Using several

steps, tighten the bolts uniformly in the sequence asshown in the illustration.

Torque: 30 N ⋅m (306 kgf ⋅cm, 22 ft ⋅lbf)

A23006

Claw

A22894

A22895

90 �

Set Key

Turn



3. INSTALL CAMSHAFT BEARING NO.1Align the bearing claw with the claw groove of the bearing cap,and push in the camshaft bearing.NOTICE:� Install the bearing while aligning it with the oil hole in

the bearing cap.� Clean the backside of the bearing and the bearing

surface of the bearing cap and prevent oil from adher-ing to them.

4. INSTALL CAMSHAFT BEARING NO.2Install the camshaft bearing No. 2 to the cylinder head.NOTICE:Clean the backside of the bearing and the bearing surfaceof the cylinder head and prevent oil from adhering to them.5. INSTALL CAMSHAFTNOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

(a) Set the crankshaft position.Using the crankshaft pulley set bolt, turn the crankshaft,and set the crankshaft set key into the left horizontal posi-tion.

NOTICE:Having the crankshaft at the wrong angle can cause thepiston head and valve head to come into contact with eachother when you install the camshaft, causing damage. Soalways set the crankshaft at the correct angle.(b) Apply new engine oil to the thrust portion and journal of

the camshafts.

A22896

RH Bank

A22897

RH Bank

A22898

3 715 11 1

2

4

6

8

14

16 12

10

913 5

RH Bank

A22899

Turn

90 �

Turn

90 �

RH Bank

A22917

LH Bank



(c) Install the camshaft of the RH bank.(1) Place the 2 camshafts onto the RH cylinder head

with the cam lobes of No. 1 cylinder facing eachdirection as shown in the illustration.

(2) Install the 8 bearing caps in their proper locations.(3) Apply a light coat of engine oil to the threads of the

bearing cap bolts.

(4) Install the 16 bearing cap bolts. Using severalsteps, tighten the bolts uniformly in the sequence asshown in the illustration.

Torque:9.0 N⋅m (92 kgf ⋅cm, 80 in. ⋅lbf) for 10 mm (0.39 in.) head24 N⋅m (245 kgf ⋅cm, 18 ft ⋅lbf) for 12 mm (0.47 in.) head

(5) Turn the camshafts clockwise with a wrench untilthe camshaft knock pin comes 90� position to thecylinder head.

(d) Install the camshafts of the LH bank.(1) Place the 2 camshafts onto the LH cylinder head

with the cam lobes of No. 2 cylinder facing as shownin the illustration.

A22918

LH Bank

A22910

37 15111

2

4

6

8

14

1612

10

9 135

LH Bank

A22906

Oval Shape

Forward

A23251

A22922

Oval shape

Forward



(2) Install the 8 bearing caps in their proper locations.(3) Apply a light coat of engine oil to the threads and un-

der the heads of the bearing cap bolts.

(4) Install the 16 bearing cap bolts. Using severalsteps, tighten the bolts uniformly in the sequence asshown in the illustration.


6. INSTALL TIMING CHAIN (See page EM-44 )7. INSTALL TIMING CHAIN COVER (See page EM-44 )8. INSTALL OIL PAN (See page EM-44 )

9. INSTALL EXHAUST MANIFOLD(a) Install the RH exhaust manifold.

(1) Set a new gasket to the RH cylinder head with theoval shape facing forward.

NOTICE:Be careful of the installation direction.

(2) Install the exhaust manifold with the 6 nuts. Tightenthe nuts uniformly in several steps.

Torque: 21 N ⋅m (214 kgf ⋅cm, 15 ft ⋅lbf)(3) Connect the A/F sensor connector.(4) Install the manifold stay with the 3 bolts.Torque: 40 N ⋅m (408 kgf ⋅cm, 30 ft ⋅lbf)

(b) Install the LH exhaust manifold.(1) Set a new gasket to the LH cylinder head with the

oval shape facing backward.NOTICE:Be careful of the installation direction.

A23252

A23017

Mesh Part

Apply Adhesive

A22904

A22883



(2) Install the exhaust manifold with the 6 nuts. Tightenthe nuts uniformly in several steps.

Torque: 21 N ⋅m (214 kgf ⋅cm, 15 ft ⋅lbf)(3) Connect the A/F sensor connector.(4) Install the manifold stay with the 3 bolts.Torque: 40 N ⋅m (408 kgf ⋅cm, 30 ft ⋅lbf)

10. INSTALL RH AND LH FRONT EXHAUST PIPE(See page EM-138 )

11. INSTALL VVT SENSOR (See page IG-12 )

12. INSTALL OIL CONTROL VALVE FILTER(a) Check that no foreign objects on the mesh part of the 2

filters.(b) Install 2 new gaskets to each new plug.(c) Insert the filters to the plugs.(d) Apply adhesive to 2 or 3 threads of the plugs.

Adhesive: Part No. 08833-00080, THREE BOND 1344LOCTITE 242 or equivalent

(e) Install the plugs to each cylinder head.Torque: 62 N ⋅m (632 kgf ⋅cm, 46 ft ⋅lbf)

13. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE

14. INSTALL WATER BY-PASS JOINT(a) Install a new O-ring to the water outlet pipe.(b) Apply soapy water to the O-ring.

(c) Install 2 new gaskets and water by-pass joint with the 2bolts and 4 nuts.Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)

(d) Connect the heater hose.(e) Connect the engine coolant temperature sensor connec-

tor.

A22905

A22882

A23016

Seal Packing

Seal Width: 2 to 3 mm

A23092

A A A

B

B Nut

B

B

BBB

Nut

A23015

Seal Packing




15. INSTALL INTAKE MANIFOLD(a) Set a new gasket on each cylinder head.NOTICE:� Align the port holes of the gasket and cylinder head.� Be careful of the installation direction.

(b) Set the intake manifold on the cylinder heads.

(c) Install and tighten the 10 bolts uniformly in several steps.Torque: 26 N ⋅m (265 kgf ⋅cm, 19 ft ⋅lbf)

(d) Connect the 6 fuel injector connectors.16. INSTALL CYLINDER HEAD COVER(a) Install the RH cylinder head cover.

(1) Remove any old packing material (FIPG) and becareful not to drop any oil on the contact surfacesof the cylinder head, timing chain cover and cylinderhead cover.

(2) Apply a continuous bead of seal packing (diameter2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head andtiming chain cover as shown in the illustration.

Seal packing: Part No. 08826-00080 or equivalentNOTICE:Install the cylinder head cover within 3 minutes after apply-ing seal packing. After installing it, cylinder head coverbolts and nuts must be tightened within 15 minutes. Other-wise the seal packing must be removed and reapplied.

(3) Install the seal washers to the bolts.(4) Install the cylinder head cover with the 10 bolts and

2 nuts. Tighten the bolts and nuts uniformly in sever-al steps.

Torque: Bolt A, Nut: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)Bolt B: 10 N ⋅m (102 kgf ⋅cm, 7 ft ⋅lbf)

(b) Install a new gasket and oil filler cap housing with the 2nuts.Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)

(c) Install the LH cylinder head cover.(1) Apply a continuous bead of seal packing (diameter

2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head andtiming chain cover as shown in the illustration.

Seal packing: Part No. 08826-00080 or equivalentNOTICE:Install the cylinder head cover within 3 minutes after apply-ing seal packing. After installing it, cylinder head coverbolts and nuts must be tightened within 15 minutes. Other-wise the seal packing must be removed and reapplied.

A22970

ANut

B

AA

Nut

B B B

B

BB

A23091

A23090

A23089



(2) Install the seal washers to the bolts.

(3) Install the cylinder head cover with the 10 bolts and2 nuts. Tighten the bolts and nuts uniformly in sever-al steps.

Torque: Bolt A, Nut: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)Bolt B: 10 N ⋅m (102 kgf ⋅cm, 7 ft ⋅lbf)

17. INSTALL IGNITER

18. INSTALL INTAKE AIR SURGE TANK(a) Install a new gasket to the intake air surge tank.(b) Using the socket hexagon wrench 8, install the intake air

surge tank with the 4 bolts.Torque: 28 N ⋅m (286 kgf ⋅cm, 21 ft ⋅lbf)

(c) Install the 2 intake air surge tank nuts.Torque: 28 N ⋅m (286 kgf ⋅cm, 21 ft ⋅lbf)

(d) Install the 2 surge tank stays with the 4 bolts.Torque: 21 N ⋅m (214 kgf ⋅cm, 15 ft ⋅lbf)

(e) Install the oil baffle plate with the bolt.Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)

(f) Install the throttle body bracket with the 2 bolts.Torque: 21 N ⋅m (214 kgf ⋅cm, 15 ft ⋅lbf)

A23088

A23087

A23086

A23085



(g) Install the 3 wire harness clamps and hose clamp.(h) Connect the throttle body w/ motor connector.(i) Connect the 2 VSV connectors.

(j) Connect the ventilation hose.

(k) Connect the fuel vapor feed hose.

(l) Connect the 2 water by-pass hoses.19. CONNECT HEATER WATER OUTLET AND INLET

HOSE20. INSTALL COOLER COMPRESSOR

(See page AC-58 )21. INSTALL GENERATOR (See page CH-15 )22. INSTALL VANE PUMP (See page SR-57 )23. INSTALL FAN W/FLUID COUPLING

A22798

Holes

Turn

A22799

P/S PumpWater Pump

Idler No. 2Generator

Idler No. 2

Idler No. 1 A/C CompressorCrankshaft

Tensioner

A23114

A23210



24. INSTALL DRIVE BELT(a) While turning the belt tensioner counterclockwise, align

with the holes. Insert a bar of 6 mm (0.24 in.) into theholes to fix the belt tensioner.

(b) Install the V-ribbed belt.(c) While turning the belt tensioner counterclockwise, re-

move the bar.

(d) If it is hard to install the V-ribbed belt, perform the follow-ing procedure.(1) Put the V-ribbed belt on every parts except the P/S

pump as shown in the illustration.(2) While releasing the belt tension by turning the belt

tensioner counterclockwise, put the V-ribbed belton the P/S pump.

25. TIGHTEN FAN W/FLUID COUPLINGTighten the 4 fluid coupling bolts.

Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)26. INSTALL RADIATOR (See page CO-18 )27. INSTALL FAN SHROUD28. CONNECT FUEL PIPE (See page SF-1 )

29. INSTALL AIR CLEANER(a) Install the air cleaner with the 2 bolts.

Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)(b) Tighten the 2 hose clamps.

A23209

A23095

A23407



(c) Install the 2 wire harness clamps.(d) Connect the mass air flow meter connector.(e) Connect the vacuum hose.

(f) Connect the ventilation hose No.2.30. ADD ENGINE COOLANT31. ADD ENGINE OIL32. CHECK FOR LEAK

33. INSTALL V-BANK COVERInstall the V-bank cover with the 2 nuts.

Torque: 7.5 N·m (76 kgf·cm, 66 in.·lbf)

EM1XT-01

A22946

Cylinder Head RH Side: Cylinder Head LH Side:

11 mm

8 mmProtrusion Height

Engine Front

Engine Front



REASSEMBLY1. INSTALL RING PINUsing a plastic-faced hammer, tap in the new ring pins untilthey reach the specified protrusion height.

Specified protrusion height: 2.7 to 3.3 mm (0.106 to 0.130 in.)

A22947

Cylinder Head RH Side:

Front Side:

Upper Side:


Cylinder Head LH Side:

Upper Side:Front Side:


A

B and C

13.8 mm

5 mm8 mm

34 mm

A

A

B

C

C

B

Protrusion Height Protrusion

Height



2. INSTALL STRAIGHT PINUsing a plastic-faced hammer, tap in the new straight pins untilthey reach the specified protrusion height.

Specified protrusion height:A 17.5 to 19.5 mm (0.689 to 0.768 in.)

B 7.5 to 8.5 mm (0.295 to 0.335 in.)

C 7.0 to 9.0 mm (0.276 to 0.354 in.)

A22948

Cylinder Head RH Side:

Cylinder Head LH Side:

Rear Side:Upper Side:


A

C

B

A

Upper Side:Rear Side:


B

12 mm

9 mm

33.3 mm

A

20 mm

42 mm

13 mmB

C

16 mm

27 mm

9 mmC



3. INSTALL STUD BOLTUsing the Torx® socket wrench E5 and E7, install the stud bolts.

Torque:4.0 N⋅m (41 kgf ⋅cm, 35 in. ⋅lbf) for stud bolt A, C19.5 N⋅m (199 kgf ⋅cm, 14 ft·lbf) for stud bolt B

A22949

Adhesive

A22950

Cylinder Head RH (Front) Side: Cylinder Head LH (Intake Manifold) Side:

67 mm

9 mm30 mm

9 mm

A B

A B



4. INSTALL UNION(a) Apply adhesive to 2 or 3 threads of the bolt end.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equiva-lent

(b) Using a deep socket wrench 12, install the unions.Torque: 15 N ⋅m (153 kgf ⋅cm, 11 ft ⋅lbf)

A22951

Adhesive

A22952

Cylinder Head RH (Rear) Side: Cylinder Head LH (Rear) Side:

SST

Depth

1.5 mm



5. INSTALL TIGHT PLUG(a) Apply adhesive around the tight plugs.(b) Using SST, tap in the tight plugs to the specified depth.

SST 09950-60010 (09951-00250), 09950-70010 (09951-07150)

Specified depth: 1.5 mm (0.059 in.)

A22953

Cylinder Head RH Side:Upper Side:

Cylinder Head LH Side:Upper Side:

Front Side:Front Side:

A22954

Light Brown Gray

Intake Side: Exhaust Side:

A22955

SST



6. INSTALL STRAIGHT SCREW PLUG(a) Using a straight hexagon wrench 14, install a new gasket

and straight screw plug.Torque: 80 N ⋅m (816 kgf ⋅cm, 59 ft ⋅lbf)

7. INSTALL VALVE STEM OIL SEALHINT:The intake valve stem oil seal is light brown and the exhaustvalve stem oil seal is gray.(a) Apply a light coat of engine oil to the valve guide bush.

(b) Using SST, push in a new valve stem oil seal.SST 09201-41020

A22956

A22957

35 mm (1.378 in.)

A22925

SST

Wooden Block

A22958

A22924



8. INSTALL VALVE SPRING SEAT

9. INSTALL VALVE(a) Apply engine oil to the valve as shown in the illustration.

(b) Place the cylinder head on a wooden block.(c) Install the valve, inner compression spring and valve

spring retainer.(d) Using SST, compress the inner compression spring and

place the 2 valve spring retainer locks around the valvestem.SST 09202-70020 (09202-00010)

(e) Using a pin punch 5, lightly tap the valve stem tip to en-sure a proper fit.

NOTICE:Be careful not to damage the valve stem tip.

10. INSTALL VALVE LIFTER(a) Apply engine oil to the valve stem end and valve lifter, and

install the valve lifter to the valve stem.(b) Check that the valve lifter rotates smoothly by hand.

EM1XP-01

A23208

A23095

A23209

A23210



REMOVAL1. PREVENT GASOLINE FROM SPILLING OUT2. DRAIN ENGINE COOLANT (See page CO-2 )3. DRAIN ENGINE OIL (See page LU-3 )

4. REMOVE V-BANK COVERRemove the 2 nuts and V-bank cover.

5. REMOVE AIR CLEANER(a) Disconnect the ventilation hose No.2.

(b) Disconnect the vacuum hose.(c) Disconnect the mass air flow meter connector.(d) Remove the 2 wire harness clamps.

(e) Loosen the 2 hose clamps.(f) Remove the 2 bolts and air cleaner6. DISCONNECT FUEL PIPE (See page SF-1 )7. REMOVE FAN SHROUD8. REMOVE RADIATOR (See page CO-17 )

A23114

A22797

A23085

A23086



9. LOOSEN FAN W/FLUID COUPLINGLoosen the 4 nuts of the fan w/ fluid coupling.

10. REMOVE DRIVE BELTRelease the belt tension by turning the belt tensioner counter-clockwise. Remove the V-ribbed belt from the belt tensioner.11. REMOVE FAN W/FLUID COUPLING12. SEPARATE VANE PUMP (See page SR-47 )13. REMOVE GENERATOR (See page CH-7 )14. SEPARATE COOLER COMPRESSOR

(See page AC-54 )15. DISCONNECT HEATER WATER OUTLET AND INLET

HOSE

16. REMOVE INTAKE AIR SURGE TANK(a) Disconnect the 2 water by-pass hoses.

(b) Disconnect the fuel vapor feed hose.

A23087

A23088

A23089

A23090



(c) Disconnect the ventilation hose.

(d) Disconnect the 2 VSV connectors.(e) Disconnect the throttle body w/ motor connector.(f) Separate the 3 wire harness clamps and hose clamp.

(g) Remove the 2 bolts and throttle body bracket.

(h) Remove the bolt and oil baffle plate.(i) Remove the 4 bolts and 2 surge tank stays.

A23091

A22970

A23092

A22882

A22883



(j) Remove the 2 nuts.(k) Using a socket hexagon wrench 8, remove the 4 bolts, in-

take air surge tank and gasket.17. REMOVE IGNITER (See page IG-6 )

18. REMOVE CYLINDER HEAD COVER(a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder

head cover RH and gasket.(b) Remove the 2 nuts, oil filter cap housing and gasket.

(c) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinderhead cover LH and gasket.

19. REMOVE INTAKE MANIFOLD(a) Disconnect the 6 fuel injector connectors.

(b) Remove the 10 bolts, intake manifold and 2 gaskets.20. REMOVE WATER BY-PASS JOINT(a) Disconnect the engine coolant temperature sensor con-

nector.(b) Disconnect the heater hose.

(c) Remove the 2 bolts, 4 nuts, water by-pass joint RR and2 gaskets.

(d) Remove the O-ring from the water outlet pipe.21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE

A22969

RH Bank LH Bank

A22886

RH Bank

A22887

3 7 15 11

1

2 46

814

16 12

10

9135

RH Bank

A22910

371511

1

246814 161210

9 13 5

LH Bank



22. REMOVE OIL CONTROL VALVE FILTERRemove the plug, filter and gasket from each cylinder head.23. REMOVE VVT SENSOR24. REMOVE RH AND LH FRONT EXHAUST PIPE25. REMOVE RH AND LH EXHAUST MANIFOLD(a) Remove the 6 bolts and 2 exhaust manifold stays.(b) Remove the 12 nuts, RH and LH exhaust manifold and 2

gaskets.26. REMOVE OIL PAN (See page EM-32 )27. REMOVE TIMING CHAIN COVER (See page EM-32 )28. REMOVE TIMING CHAIN (See page EM-32 )29. REMOVE CAMSHAFTNOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

(a) Remove the camshafts of the RH bank.(1) Rotate the camshafts counterclockwise using the

wrench so that the cam lobes of the No. 1 cylinderface each direction as shown in the illustration.

(2) Using several steps, uniformly loosen and removethe 16 bearing cap bolts in the sequence as shownin the illustration.

(3) Remove the 8 bearing caps and 2 camshafts.

(b) Remove the camshafts of the LH bank.(1) Using several steps, uniformly loosen and remove

the 16 bearing cap bolts in the sequence as shownin the illustration.

(2) Remove the 8 bearing caps and 2 camshafts.30. REMOVE CAMSHAFT BEARING NO.1 AND NO.2

A22911

1

2

LH Cylinder Head

A22977

3 7

1

2

468

5

3 7

1

2

468

5

LH Cylinder Head

RH Cylinder Head

A22978



31. REMOVE CYLINDER HEAD(a) Using several steps, remove the 2 cylinder head bolts on

the LH cylinder head in the sequence as shown in the il-lustration.

(b) Using several steps, loosen the 8 cylinder head bolts oneach cylinder head with a 10 mm bi-hexagon wrench inthe sequence as shown in the illustration. Remove the 16cylinder head bolts and plate washers.

NOTICE:� Be careful not to drop the plate washers into the cylin-

der head.� Cylinder head warpage or cracking could result from

removing the bolts in the incorrect order.

(c) Lift the cylinder head from the dowels on the cylinderblock, and place the 2 cylinder heads on wooden blockson a bench.

NOTICE:Be careful not to damage the contact surfaces of the cylin-der head and cylinder block.HINT:If the cylinder head is difficult to lift off, pry between the cylinderhead and cylinder block with a screwdriver.(d) Remove the RH and LH cylinder head gaskets.32. REMOVE CYLINDER HEAD GASKET

EM1XS-01

A22937

A22938

SST

Wooden Block

A22939

Diameter

A22937



REPLACEMENT1. REPLACE VALVE GUIDE BUSH(a) Gradually heat the cylinder head to between 80 and

100�C (176 to 212�F).

(b) Place the cylinder head on a wooden block.(c) Using SST, tap out the valve guide bush.

SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)

(d) Using a caliper gauge, measure the bush bore diameterof the cylinder head.Bush bore diameter: 10.295 to 10.315 mm (0.4053 to 0.4061 in.)

If the bush bore diameter of the cylinder head is greater than10.315 mm (0.4061 in.), machine the bush bore to dimensionsof 10.345 to 10.365 mm (0.4073 to 0.4081 in.).

Valve guide bush diameterSTD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)

O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)

(e) Gradually heat the cylinder head to between 80 and100�C (176 to 212�F).

A22940

SST

Wooden Block

Protrusion Height

A22941



(f) Place the cylinder head on a wooden block.(g) Using SST, tap in a new valve guide bush to the specified

protrusion height.SST 09201-10000, 09201-01055, 09950-70010

(09951-07100)Protrusion height: 9.3 to 9.7 mm (0.366 to 0.382 in.)

(h) Using a sharp 5.5 mm reamer, ream the valve guide bushto obtain the standard specified clearance between thevalve guide bush and valve stem.Standard oil clearance:Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)


EM1XV-01

A23384

MAF Meter Connector

Air Cleaner Hose No.2

Hood

Fuel Pipe Clamp

V-Bank Cover

Air Cleaner Assembly

Battery Tray

Heater Hose

Fuel Pipe


Battery

Battery Clamp


7.5 (76, 66 in.·lbf)

-ENGINE MECHANICAL (1GR-FE) ENGINE UNITEM-101


ENGINE UNITCOMPONENTS

A23385

Radiator Assembly

No.1 Fan Shroud

Oil Cooler Pipe forAutomaticTransmission

V-Belt Fan PulleyFan w/ Fluid Coupling

12 (120, 9)


No.2 Fan Shroud

5.0 (50, 44 in.·lbf)

EM-102-ENGINE MECHANICAL (1GR-FE) ENGINE UNIT


D14136

N·m (kgf·cm, ft·lbf) : Specified torque� Non-reusable part

2.0 Kw:

Clamp

Oil Cooler Pipe

Transmission

Shift Control Cable

12 (122, 9) 34 (346, 25)

71 (724, 52)

14.5 (148, 11)

19.5 (199, 14)

37 (377, 27)

1.6 Kw:Starter

Starter

9.8 (100, 7) Flywheel Housing Side Cover

72 (734, 53)

65 (660, 48)

18 (185, 13)

Engine Rear Mounting Insulator

Gasket�

Crossmember

Front Exhaust Pipe LH

Torque Converter Clutch x6

48 (490, 35)

43 (440, 32)

48 (490, 35)

Gasket�

40 (408, 30)

40 (408, 30)

Manifold Stay

Front Exhaust Pipe RH

Gasket�

Spring

Manifold Stay

Exhaust Pipe Support

Gasket�

62 (630, 46)�

62 (630, 46)�

40 (410, 30)

37 (377, 27)88 (897, 65)

Stabilizer Bar

Bushing

Stabilizer Bar Bracket

Engine Under Cover

Propeller Shaft

9.8 (100, 7)

37 (377, 27)



A23386

Water By-pass Hose

A/C Compressor

VSV Connector


A/C CompressorConnector

43 (438, 32)

25 (255, 18)

Generator

Vane Pump43 (438, 32)

Vane Pump Connector

Throttle Body MotorConnector VSV Connector

Generator Connector


Generator Wire



EM1XX-01

A04869

Adhesive

A23391

1

2

3

47

6

85

A23392

PaintedMark

90°90°



INSTALLATION1. INSTALL DRIVE PLATEHINT:� The mounting bolts are tightened in 2 progressive steps

(steps (c) and (e)).� If any of the mounting bolts is broken or deformed, re-

place it.

(a) Apply adhesive to 2 or 3 threads of the mounting bolt end.Adhesive:Part No. 08833-00070, THREE BOND 1324 or equiva-lent

(b) Install the front spacer, drive plate and rear spacer on thecrankshaft.

(c) Install and uniformly tighten the 8 mounting bolts in sever-al steps, in the sequence shown in the illustration.Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

If any of the mounting bolts do not meet the torque specification,replace it.

(d) Mark the mounting bolt with paint.(e) Retighten the mounting bolts 90° in the order shown in

the illustration.(f) Check that the painted mark is now at a 90° angle to what

it was in step (e).2. INSTALL ENGINE ASSEMBLY IN VEHICLE(a) Attach the engine chain hoist to the engine hangers.(b) Slowly lower the engine assembly into the engine

compartment.(c) Attach the engine mounting brackets to the frame brack-

ets.(d) Install the engine mounting brackets to the frame brack-

ets with the 2 nuts and 4 bolts.Torque: 38 N·m (388 kgf·cm, 28 ft·lbf)

(e) Remove the engine chain hoist.(f) Remove the 4 bolts and 2 engine hangers.

A23390

A23389

A09152

Connect

A23387



3. INSTALL PS PUMPInstall the PS pump with the 3 bolts.

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

4. INSTALL A/C COMPRESSOR(a) Install the A/C compressor with the 3 bolts.

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)(b) Connect the A/C compressor connector.5. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS,

GROMMET AND CABLES(a) Connect the generator wire and connector.(b) Connect the 2 heater hoses.(c) Connect the ground strap to the cowl panel.(d) Connect the fuel inlet hose and clamps.(e) Connect the fuel return hose and clamp.(f) Connect the air inlet hose to the charcoal canister.(g) Connect the EVAP hose to the charcoal canister.(h) Connect the brake booster tube.6. CONNECT ENGINE WIRE TO CABIN(a) Push the engine wire through the cowl panel.

(b) Install the engine wire bracket with the 2 nuts and bolt andconnect the engine wire to the bracket.

(c) Connect the 3 connectors to the ECM.(d) Connect the 2 wire harness connectors (cassette con-

nector).(e) Install the ECM with the 3 screws.(f) Install the heater to register duct.(g) Install the lower No.2 finish panel.(h) Install the glove compartment door.

7. INSTALL AIR CLEANER ASSEMBLY(a) Install the air cleaner assembly with the 2 bolts.(b) Connect the air cleaner case to the air cleaner hose No.1.(c) Connect the air cleaner case with the 2 wire clamps.(d) Connect the PCV hose to the air cleaner case.(e) Connect the MAF meter connector.(f) Connect the air cleaner hose No.2 to the air cleaner case.8. INSTALL BATTERY9. INSTALL RADIATOR ASSEMBLY (See page CO-18 )10. INSTALL FRONT EXHAUST PIPES

(See page EM-139 )

EM-1 10-ENGINE MECHANICAL (1GR-FE) ENGINE UNIT


11. INSTALL AUTOMATIC TRANSMISSION (See page AT-29 )

12. INSTALL MANUAL TRANSMISSION (See page MT-7 )

13. FILL WITH ENGINE COOLANT (See page CO-2 )14. FILL WITH ENGINE OIL (See page LU-3 )15. START ENGINE AND CHECK FOR LEAKS16. INSTALL ENGINE UNDER COVERS17. INSTALL V-BANK COVER18. INSTALL HOOD19. PERFORM ROAD TESTCheck for abnormal noise, shock, slippage, correct shift pointsand smooth operation.20. RECHECK ENGINE COOLANT AND OIL LEVELS

EM1XW-01

A23387



REMOVAL1. PREVENT GASOLINE FROM SPILLING OUT

(See page SF-1 )2. REMOVE ENGINE HOOD3. REMOVE ENGINE V-BANK COVER4. REMOVE ENGINE UNDER COVER5. REMOVE AUTOMATIC TRANSMISSION

(See page AT-25 )6. REMOVE MANUAL TRANSMISSION

(See page MT-4 )7. REMOVE FRONT EXHAUST PIPES

(See page EM-139 )8. REMOVE RADIATOR ASSEMBLY (See page CO-17 )9. REMOVE BATTERY

10. REMOVE AIR CLEANER ASSEMBLY(a) Disconnect the air cleaner hose No.2 from the air cleaner

case.(b) Disconnect the MAF meter connector.(c) Disconnect the PCV hose from the air cleaner case.(d) Disconnect the 2 wire clamps from the air cleaner case.(e) Disconnect the air cleaner case from the air cleaner hose

No.1.(f) Remove the 2 bolts and air cleaner assembly.11. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND

FAN PULLEY(a) Loosen the 4 nuts holding the fluid coupling to the fan

bracket.(b) Remove the drive belt. (See page CH-7 )(c) Remove the 4 nuts, fan, fluid coupling assembly and fan

pulley.12. DISCONNECT ENGINE WIRE FROM CABIN(a) Remove the glove compartment door.(b) Remove the lower No.2 finish panel.(c) Remove the heater to register duct.(d) Remove the 3 screws, and disconnect the ECM from the

body bracket.(e) Disconnect the 3 wire harness connectors from the ECM.

B07536

Disconnect

A23389

A23390

A22965



(f) Disconnect the engine wire from the engine wire bracketand remove the 2 nuts, bolt and bracket.

(g) Pull out the engine wire from the cowl panel.13. DISCONNECT HOSES, WIRES, CONNECTORS,

CLAMPS, GROMMET AND CABLES(a) Disconnect the generator connector.(b) Disconnect the 2 heater hoses.(c) Disconnect the ground strap from the cowl panel.(d) Disconnect the fuel inlet hose and clamps.(e) Disconnect the fuel return hose and clamp.(f) Disconnect the air inlet hose from the charcoal canister.(g) Disconnect the EVAP hose from the charcoal canister.

14. DISCONNECT A/C COMPRESSOR FROM ENGINE(a) Disconnect the A/C compressor connector.(b) Remove the 3 bolts, and disconnect the A/C compressor

from the engine.HINT:Suspend the A/C compressor securely.

15. DISCONNECT PS PUMP FROM ENGINERemove the 3 bolts, and disconnect the PS pump from the en-gine.HINT:Suspend the PS pump securely.

16. REMOVE ENGINE ASSEMBLY FROM VEHICLE(a) Install the 2 engine hangers with the 4 bolts as shown in

the illustration.Part No. : Engine hanger No. 1 12281-31060Engine hanger No. 2 12282-31040Bolt 90119-08177Torque: 33 N·m (336 kgf·cm, 24 ft·lbf)

(b) Attach the engine sling device and suspend the engineusing a chain block.

A22966

A23391



(c) Remove the 4 bolts and 4 nuts, and separate the enginemounting brackets from the frame brackets.

(d) Lift the engine out of the vehicle carefully.NOTICE:Make sure the engine is clear of all wiring and hoses.(e) Place the engine onto a working bench.

17. REMOVE DRIVE PLATERemove the 8 bolts, front spacer, drive plate and rear spacer.

EM1XV-01

A23384

MAF Meter Connector

Air Cleaner Hose No.2

Hood

Fuel Pipe Clamp

V-Bank Cover

Air Cleaner Assembly

Battery Tray

Heater Hose

Fuel Pipe


Battery

Battery Clamp


7.5 (76, 66 in.·lbf)



ENGINE UNITCOMPONENTS

A23385

Radiator Assembly

No.1 Fan Shroud

Oil Cooler Pipe forAutomaticTransmission

V-Belt Fan PulleyFan w/ Fluid Coupling

12 (120, 9)


No.2 Fan Shroud

5.0 (50, 44 in.·lbf)



D14136

N·m (kgf·cm, ft·lbf) : Specified torque� Non-reusable part

2.0 Kw:

Clamp

Oil Cooler Pipe

Transmission

Shift Control Cable

12 (122, 9) 34 (346, 25)

71 (724, 52)

14.5 (148, 11)

19.5 (199, 14)

37 (377, 27)

1.6 Kw:Starter

Starter

9.8 (100, 7) Flywheel Housing Side Cover

72 (734, 53)

65 (660, 48)

18 (185, 13)

Engine Rear Mounting Insulator

Gasket�

Crossmember


Torque Converter Clutch x6

48 (490, 35)

43 (440, 32)

48 (490, 35)

Gasket�

40 (408, 30)

40 (408, 30)

Manifold Stay


Gasket�

Spring

Manifold Stay


Gasket�

62 (630, 46)�

62 (630, 46)�

40 (410, 30)

37 (377, 27)88 (897, 65)

Stabilizer Bar

Bushing

Stabilizer Bar Bracket

Engine Under Cover

Propeller Shaft

9.8 (100, 7)

37 (377, 27)



A23386

Water By-pass Hose

A/C Compressor

VSV Connector


A/C CompressorConnector

43 (438, 32)

25 (255, 18)

Generator

Vane Pump43 (438, 32)

Vane Pump Connector

Throttle Body MotorConnector VSV Connector

Generator Connector


Generator Wire



EM1XX-01

A04869

Adhesive

A23391

1

2

3

47

6

85

A23392

PaintedMark

90°90°



INSTALLATION1. INSTALL DRIVE PLATEHINT:� The mounting bolts are tightened in 2 progressive steps

(steps (c) and (e)).� If any of the mounting bolts is broken or deformed, re-

place it.

(a) Apply adhesive to 2 or 3 threads of the mounting bolt end.Adhesive:Part No. 08833-00070, THREE BOND 1324 or equiva-lent

(b) Install the front spacer, drive plate and rear spacer on thecrankshaft.

(c) Install and uniformly tighten the 8 mounting bolts in sever-al steps, in the sequence shown in the illustration.Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

If any of the mounting bolts do not meet the torque specification,replace it.

(d) Mark the mounting bolt with paint.(e) Retighten the mounting bolts 90° in the order shown in

the illustration.(f) Check that the painted mark is now at a 90° angle to what

it was in step (e).2. INSTALL ENGINE ASSEMBLY IN VEHICLE(a) Attach the engine chain hoist to the engine hangers.(b) Slowly lower the engine assembly into the engine

compartment.(c) Attach the engine mounting brackets to the frame brack-

ets.(d) Install the engine mounting brackets to the frame brack-

ets with the 2 nuts and 4 bolts.Torque: 38 N·m (388 kgf·cm, 28 ft·lbf)

(e) Remove the engine chain hoist.(f) Remove the 4 bolts and 2 engine hangers.

A23390

A23389

A09152

Connect

A23387



3. INSTALL PS PUMPInstall the PS pump with the 3 bolts.


4. INSTALL A/C COMPRESSOR(a) Install the A/C compressor with the 3 bolts.

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)(b) Connect the A/C compressor connector.5. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS,

GROMMET AND CABLES(a) Connect the generator wire and connector.(b) Connect the 2 heater hoses.(c) Connect the ground strap to the cowl panel.(d) Connect the fuel inlet hose and clamps.(e) Connect the fuel return hose and clamp.(f) Connect the air inlet hose to the charcoal canister.(g) Connect the EVAP hose to the charcoal canister.(h) Connect the brake booster tube.6. CONNECT ENGINE WIRE TO CABIN(a) Push the engine wire through the cowl panel.

(b) Install the engine wire bracket with the 2 nuts and bolt andconnect the engine wire to the bracket.

(c) Connect the 3 connectors to the ECM.(d) Connect the 2 wire harness connectors (cassette con-

nector).(e) Install the ECM with the 3 screws.(f) Install the heater to register duct.(g) Install the lower No.2 finish panel.(h) Install the glove compartment door.

7. INSTALL AIR CLEANER ASSEMBLY(a) Install the air cleaner assembly with the 2 bolts.(b) Connect the air cleaner case to the air cleaner hose No.1.(c) Connect the air cleaner case with the 2 wire clamps.(d) Connect the PCV hose to the air cleaner case.(e) Connect the MAF meter connector.(f) Connect the air cleaner hose No.2 to the air cleaner case.8. INSTALL BATTERY9. INSTALL RADIATOR ASSEMBLY (See page CO-18 )10. INSTALL FRONT EXHAUST PIPES

(See page EM-139 )

EM-1 10-ENGINE MECHANICAL (1GR-FE) ENGINE UNIT


11. INSTALL AUTOMATIC TRANSMISSION (See page AT-29 )

12. INSTALL MANUAL TRANSMISSION (See page MT-7 )

13. FILL WITH ENGINE COOLANT (See page CO-2 )14. FILL WITH ENGINE OIL (See page LU-3 )15. START ENGINE AND CHECK FOR LEAKS16. INSTALL ENGINE UNDER COVERS17. INSTALL V-BANK COVER18. INSTALL HOOD19. PERFORM ROAD TESTCheck for abnormal noise, shock, slippage, correct shift pointsand smooth operation.20. RECHECK ENGINE COOLANT AND OIL LEVELS

EM1XW-01

A23387



REMOVAL1. PREVENT GASOLINE FROM SPILLING OUT

(See page SF-1 )2. REMOVE ENGINE HOOD3. REMOVE ENGINE V-BANK COVER4. REMOVE ENGINE UNDER COVER5. REMOVE AUTOMATIC TRANSMISSION

(See page AT-25 )6. REMOVE MANUAL TRANSMISSION

(See page MT-4 )7. REMOVE FRONT EXHAUST PIPES

(See page EM-139 )8. REMOVE RADIATOR ASSEMBLY (See page CO-17 )9. REMOVE BATTERY

10. REMOVE AIR CLEANER ASSEMBLY(a) Disconnect the air cleaner hose No.2 from the air cleaner

case.(b) Disconnect the MAF meter connector.(c) Disconnect the PCV hose from the air cleaner case.(d) Disconnect the 2 wire clamps from the air cleaner case.(e) Disconnect the air cleaner case from the air cleaner hose

No.1.(f) Remove the 2 bolts and air cleaner assembly.11. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND

FAN PULLEY(a) Loosen the 4 nuts holding the fluid coupling to the fan

bracket.(b) Remove the drive belt. (See page CH-7 )(c) Remove the 4 nuts, fan, fluid coupling assembly and fan

pulley.12. DISCONNECT ENGINE WIRE FROM CABIN(a) Remove the glove compartment door.(b) Remove the lower No.2 finish panel.(c) Remove the heater to register duct.(d) Remove the 3 screws, and disconnect the ECM from the

body bracket.(e) Disconnect the 3 wire harness connectors from the ECM.

B07536

Disconnect

A23389

A23390

A22965



(f) Disconnect the engine wire from the engine wire bracketand remove the 2 nuts, bolt and bracket.

(g) Pull out the engine wire from the cowl panel.13. DISCONNECT HOSES, WIRES, CONNECTORS,

CLAMPS, GROMMET AND CABLES(a) Disconnect the generator connector.(b) Disconnect the 2 heater hoses.(c) Disconnect the ground strap from the cowl panel.(d) Disconnect the fuel inlet hose and clamps.(e) Disconnect the fuel return hose and clamp.(f) Disconnect the air inlet hose from the charcoal canister.(g) Disconnect the EVAP hose from the charcoal canister.

14. DISCONNECT A/C COMPRESSOR FROM ENGINE(a) Disconnect the A/C compressor connector.(b) Remove the 3 bolts, and disconnect the A/C compressor

from the engine.HINT:Suspend the A/C compressor securely.

15. DISCONNECT PS PUMP FROM ENGINERemove the 3 bolts, and disconnect the PS pump from the en-gine.HINT:Suspend the PS pump securely.

16. REMOVE ENGINE ASSEMBLY FROM VEHICLE(a) Install the 2 engine hangers with the 4 bolts as shown in

the illustration.Part No. : Engine hanger No. 1 12281-31060Engine hanger No. 2 12282-31040Bolt 90119-08177Torque: 33 N·m (336 kgf·cm, 24 ft·lbf)

(b) Attach the engine sling device and suspend the engineusing a chain block.

A22966

A23391



(c) Remove the 4 bolts and 4 nuts, and separate the enginemounting brackets from the frame brackets.

(d) Lift the engine out of the vehicle carefully.NOTICE:Make sure the engine is clear of all wiring and hoses.(e) Place the engine onto a working bench.

17. REMOVE DRIVE PLATERemove the 8 bolts, front spacer, drive plate and rear spacer.

EM1Y3-01

A23202

Exhaust Center Pipe

Exhaust Tail Pipe



� Clamp

� Gasket

� Gasket

� Gasket

� Gasket

� Gasket




Heated Oxygen Sensor (Bank 2)

Heated Oxygen Sensor (Bank 1)



Spring



32 (326, 24)

48 (490, 35)

43 (440, 32)

48 (490, 35)

44 (450, 33)

62 (630, 46)�

62 (630, 46)�

44 (450, 33)

62 (630, 46)�

EM-138-ENGINE MECHANICAL (1GR-FE) EXHAUST SYSTEM


EXHAUST SYSTEMCOMPONENTS

EM1Y4-01

A23249

A23248

A23247

A23246

A23247

-ENGINE MECHANICAL (1GR-FE) EXHAUST SYSTEMEM-139


REPLACEMENT1. REMOVE EXHAUST TAIL PIPE(a) Remove the bolt and clamp.(b) Remove the 3 exhaust pipe supports and exhaust tail

pipe.

2. REMOVE EXHAUST CENTER PIPE(a) Remove the 2 bolts and springs.(b) Remove the 2 bolts.(c) Remove the 2 exhaust pipe support and exhaust center

pipe.(d) Remove the gasket from the exhaust tail pipe.3. REMOVE HEATED OXYGEN SENSOR

(BANK 1 OXYGEN SENSOR)(a) Disconnect the heated oxygen sensor.(b) Remove the heated oxygen sensor.4. REMOVE RH FRONT EXHAUST PIPE(a) Remove the 2 nuts and RH front exhaust pipe.(b) Remove the 2 gaskets from the RH front exhaust pipe.5. REMOVE HEATED OXYGEN SENSOR

(BANK 2 OXYGEN SENSOR)(a) Disconnect the heated oxygen sensor connector.(b) Remove the heated oxygen sensor.

6. REMOVE LH FRONT EXHAUST PIPE(a) Remove the 2 nuts, exhaust pipe support and LH front ex-

haust pipe.(b) Remove the 2 gaskets from the LH front exhaust pipe.

7. INSTALL RH FRONT EXHAUST PIPE(a) Install 2 new gaskets to the LH front exhaust pipe.(b) Install the LH front exhaust pipe with the 2 new nuts.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)(c) Install the exhaust pipe support.8. INSTALL HEATED OXYGEN SENSOR

(BANK 1 OXYGEN SENSOR)(a) Install the heated oxygen sensor.

Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)(b) Connect the heated oxygen sensor connector.

A23246

A23075

Front

A23248

A23250

30°

EM-140-ENGINE MECHANICAL (1GR-FE) EXHAUST SYSTEM


9. INSTALL RH FRONT EXHAUST PIPE(a) Install 2 new gaskets to the RH front exhaust pipe.(b) Install the RH front exhaust pipe with the 2 new nuts.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)10. INSTALL HEATED OXYGEN SENSOR

(BANK2 OXYGEN SENSOR)(a) Install the heated oxygen sensor.

Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)(b) Connect the heated oxygen sensor connector.

11. INSTALL EXHAUST CENTER PIPE(a) Using a vernier caliper, measure the free length of the

spring.Minimum length: 40.5 mm (1.5945 in.)

If the free length is less than minimum, replace the spring.(b) Install the 2 exhaust pipe supports.

(c) Install the 2 bolts.Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)

(d) Install the 2 bolts and springs.Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)

12. INSTALL EXHAUST TAIL PIPE(a) Install a new gasket to the exhaust center pipe.(b) Install the 3 exhaust pipe supports.(c) Install a new clamp and bolt.


D13872

Hand-Held Tester

DLC3

CAN VIM

EM1XI-01

A23201

DLC3SST

TAC

-ENGINE MECHANICAL (1GR-FE) IDLE SPEEDEM-25


IDLE SPEEDINSPECTION1. When using a hand-held tester or OBD II scan tool.(a) Connect a hand-held tester to the Controller Area Net-

work Vehicle Interface Module (CAN VIM). Then connectthe CAN VIM to the Date Link Connector 3 (DLC3).

(b) Please refer to the hand-held tester operator’s manualfor further details.

(c) Switch the air conditioning OFF.(d) Race the engine at 2,500 rpm for approx. 90 seconds.(e) Check the idle speed.

Idle speed: 650 to 750 rpm (Transmission in neutral position)

If the idle speed is not as specified, check the air intake system.(f) Disconnect the hand-held tester or OBD II scan tool from

the DLC3.

2. When not using a hand-held tester or OBD II scantool.

(a) Using SST, connect the tachometer probe to terminalTAC of the DLC3.SST 09843-18030

(b) Switch the air conditioning OFF.(c) Race the engine at 2,500 rpm for approx. 90 seconds.(d) Check the idle speed.

Idle speed: 650 to 750 rpm (Transmission in neutral position)

If the idle speed is not as specified, check the air intake system.(e) Disconnect the tachometer from the DLC3.

EM1XH-01

D13872

Hand-Held Tester

DLC3

CAN VIM

A22794

A14755DLC3

SST

TC

CG

-ENGINE MECHANICAL (1GR-FE) IGNITION TIMINGEM-23


IGNITION TIMINGINSPECTION1. WARM UP ENGINEAllow the engine to warm up to normal operating temperature.

2. INSPECT IGNITION TIMING(a) When using a hand-held tester or OBD II scan tool.

(1) Connect a hand-held tester to the Controller AreaNetwork Vehicle Interface Module (CAN VIM). Thenconnect the CAN VIM to the Date Link Connector 3(DLC3).

(2) Please refer to the hand-held tester operator’smanual for further details.

Ignition timing: 7 to 24 ° BTDC at idle(Transmission in neutral)(3) Disconnect the hand-held tester or OBD II scan tool

from the DLC3.

(b) When not using a hand-held tester or OBD II scan tool.(1) Remove the air cleaner cap.(2) Connect the tester probe of a timing light to the wire

of the ignition coil connector for the No. 1 cylinder.

(3) Using SST, connect terminals TC and CG of theDLC3.

SST 09843-18040

A22795

EM-24-ENGINE MECHANICAL (1GR-FE) IGNITION TIMING


(4) Using the timing light, check the ignition timing.Ignition timing: 8 to 12 ° BTDC at idle(Transmission in neutral position)(5) Remove the SST from the DLC3.(6) Check the ignition timing.Ignition timing: 7 to 24 ° BTDC at idle(Transmission in neutral position)(7) Disconnect the timing light from the engine.(8) Install the air cleaner cap.

EM1XH-01

D13872

Hand-Held Tester

DLC3

CAN VIM

A22794

A14755DLC3

SST

TC

CG

-ENGINE MECHANICAL (1GR-FE) IGNITION TIMINGEM-23


IGNITION TIMINGINSPECTION1. WARM UP ENGINEAllow the engine to warm up to normal operating temperature.

2. INSPECT IGNITION TIMING(a) When using a hand-held tester or OBD II scan tool.

(1) Connect a hand-held tester to the Controller AreaNetwork Vehicle Interface Module (CAN VIM). Thenconnect the CAN VIM to the Date Link Connector 3(DLC3).

(2) Please refer to the hand-held tester operator’smanual for further details.

Ignition timing: 7 to 24 ° BTDC at idle(Transmission in neutral)(3) Disconnect the hand-held tester or OBD II scan tool

from the DLC3.

(b) When not using a hand-held tester or OBD II scan tool.(1) Remove the air cleaner cap.(2) Connect the tester probe of a timing light to the wire

of the ignition coil connector for the No. 1 cylinder.

(3) Using SST, connect terminals TC and CG of theDLC3.

SST 09843-18040

A22795

EM-24-ENGINE MECHANICAL (1GR-FE) IGNITION TIMING


(4) Using the timing light, check the ignition timing.Ignition timing: 8 to 12 ° BTDC at idle(Transmission in neutral position)(5) Remove the SST from the DLC3.(6) Check the ignition timing.Ignition timing: 7 to 24 ° BTDC at idle(Transmission in neutral position)(7) Disconnect the timing light from the engine.(8) Install the air cleaner cap.

EM1XJ-01

A23192

V-Bank Cover

Vacuum Hose

Air Cleaner Hose

Mass Air Flow Meter Connector


Battery Clamp

Battery

Battery Tray


8.0 (82, 71 in.·lbf)

7.5 (76, 66 in.·lbf)

Air Cleaner

EM-26-ENGINE MECHANICAL (1GR-FE) TIMING CHAIN


TIMING CHAINCOMPONENTS

A23193

Radiator

Fan Shroud

Fan Pulley

Fan w/ Fluid Coupling

Drive Belt

21 (214, 15)


-ENGINE MECHANICAL (1GR-FE) TIMING CHAINEM-27


A22851

Oil Level GaugeOil Level Gauge Guide

� O-ring

Vane Pump

GeneratorTerminal Cap

Generator Wire

Generator Connector


Cooler Compressor Connector

Cooler Compressor

9.0 (92, 80 in.·lbf)

43 (438, 32)

8.0 (82, 71 in.·lbf)

8.0 (82, 71 in.·lbf)

9.8 (100, 7)

43 (438, 32)

43 (438, 32)

25 (255, 18)





A22852




� O-ring

� Gasket

Water Inlet

Oil Cooler Hose

Washer

Idler Pulley No.2

Idler Pulley No.1

Washer

V-Ribbed Belt Tensioner

Oil Pan

Oil Strainer

Oil Pan No.2

Drain Plug

� O-ring

� Gasket

� Gasket

40 (408, 30)

10 (102, 7)9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)

10 (102, 7)21 (214, 15)

21 (214, 15)

21 (214, 15)

36 (367, 27)

36 (367, 27)

54 (551, 40)

39 (398, 29)

9.0 (92, 80 in.·lbf)



37 (377, 27)

x2

x9

x6

x2

x4

x2x15

x5



A23194

VSV Connector

Intake Air Surge Tank

VSV Connector

Fuel Vapor Feed Hose




Water By-pass Hose

Throttle Body Connector

Throttle Body Bracket

� Gasket

Cylinder HeadCover RH

Ignition Coil



Cylinder Head Cover LH

21 (214, 15)

21 (214, 15)

9.0 (92, 80 in.·lbf)

10 (102, 7)

10 (102, 7)

10 (102, 7)

9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)

9.0 (92, 80 in.·lbf)

Oil Baffle Plate

21 (214, 15)

28 (286, 21)



x2

x4

x7

x3

x3x7

x3

x3

Ignition Coil

9.0 (92, 80 in.·lbf)

10 (102, 7)



A23195

Crankshaft Pulley

� Oil Seal Timing Chain Cover


Timing Chain No.2



Timing Chain No.2


Chain Vibration Damper No.2


Timing Chain


Idle Gear No.1


� O-ring

Crankshaft Timing Sprocket

Chain VibrationDamper No.1

23 (235, 17)

x15250 (2,549, 184)

100 (1,020, 74)

100 (1,020, 74)

23 (235, 17)

23 (235, 17)

100 (1,020, 74)

100 (1,020, 74)


19 (194, 14)Chain Tensioner No.2

19 (194, 14)

10 (102, 7)

Chain Tensioner Slipper

60 (612, 44)

19 (194, 14)N·m (kgf·cm, ft·lbf) : Specified torque


x9

x2



EM1XL-01

A23207

Measuring Area

0 1 2 3 4 5 15

A22990



INSPECTION1. INSPECT NO.1 AND NO.2 TIMING CHAINSUsing a spring scale, pull the chain sub assembly with 147 N(15.0 kgf, 33.1 lbf) of force and measure the length of the chainsub assembly using a vernier caliper.

Maximum chain elongation: 146.8 mm (5.780 in.)NOTICE:Perform the same measurements by pulling at random in3 or more places to obtain an average length.If the elongation is greater than the maximum, replace thechain.

2. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY(a) Put the No. 1 chain on the larger gear of the camshaft tim-

ing gear assembly.(b) Using a vernier caliper, measure the timing gear with the

chain.Minimum gear diameter (w/ chain): 115.5 mm (4.547 in.)

NOTICE:The vernier caliper must contact the chain rollers for themeasuring.If the diameter is less than the minimum, replace the No. 1 chainand camshaft timing gear assembly.

A22991

A22992



(c) Put the No. 2 chain on the smaller gear of the camshafttiming gear assembly.

(d) Using a vernier caliper, measure the timing gear with thechain.Minimum gear diameter (w/ chain): 73.1 mm (2.878 in.)

NOTICE:The vernier caliper must contact the chain rollers for themeasuring.If the diameter is less than the minimum, replace the No. 2 chainand camshaft timing gear assembly.

3. INSPECT CAMSHAFT TIMING SPROCKET(a) Put the No. 2 chain on the camshaft timing sprocket.(b) Using a vernier caliper, measure the camshaft timing

sprocket diameter with the chain .Minimum gear diameter (w/ chain): 73.1 mm (2.878 in.)

NOTICE:The vernier caliper must contact the chain rollers for themeasuring.If the diameter is less than the minimum, replace the No. 2 chainand the camshaft timing sprocket.

A22993

A22994

A22995



4. INSPECT CRANKSHAFT TIMING SPROCKET(a) Put the No. 1 chain on the crankshaft timing sprocket.(b) Using a vernier caliper, measure the crankshaft timing

gear diameter with the chain.Minimum gear diameter (w/ chain): 61.0 mm (2.402 in.)

NOTICE:The vernier caliper must contact the chain rollers for themeasuring.If the diameter is less than the minimum, replace the No. 1 chainand crankshaft timing sprocket.

5. INSPECT IDLE GEAR NO.1(a) Put the No. 1 chain on the idle gear.(b) Using a vernier caliper, measure the idle gear with the

chain.Minimum gear diameter (w/ chain): 61.0 mm (2.402 in.)

NOTICE:The vernier caliper must contact the chain rollers for themeasuring.If the diameter is less than the minimum, replace the No. 1 chainand idle gear.

6. INSPECT IDLE GEAR SHAFT OIL CLEARANCE(a) Using a micrometer, measure the idle gear shaft diameter.

Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 in.)

A22996

A22997

Raise

MoveLock

A22998

Move

A23000



(b) Using a caliper gauge, measure the inside diameter of theidle gear.Idle gear inside diameter: 23.02 to 23.03 mm (0.9063 to 0.9067 in.)

(c) Subtract the idle gear shaft diameter measurement fromthe idle gear inside diameter measurement.Standard oil clearance: 0.020 to 0.043 mm (0.0008 to 0.0017 in.)Maximum oil clearance: 0.093 mm (0.0037 in.)

7. INSPECT CHAIN TENSIONER NO.1(a) Check that the plunger moves smoothly when the ratchet

pawl is raised with a finger.(b) Release the ratchet pawl and check that the plunger is

locked in place by the ratchet pawl and does not movewhen pushing with a finger.

8. INSPECT CHAIN TENSIONER NO.2(a) Check that the plunger moves smoothly.(b) Measure the worn depth of the chain tensioner slipper.

Maximum depth: 1.0 mm (0.039 in.)If the depth is greater than the maximum, replace the chain ten-sioner No. 2.

9. INSPECT CHAIN TENSIONER SLIPPERMeasure the worn depth of the chain tensioner slipper.

Maximum depth: 1.0 mm (0.039 in.)If the depth is greater than the maximum, replace the chain ten-sioner slipper.

A23001

No.1

No.2



10. INSPECT CHAIN VIBRATION DAMPER NO.1 ANDNO.2

Measure the worn depth of the chain vibration damper No. 1and No. 2.

Maximum depth: 1.0 mm (0.039 in.)If the depth is greater than the maximum, replace the chainvibration damper No. 1 or No.2.

EM1XN-01

A22895

90 �

Set Key

Turn

A22900

Push

A22885

A22901

Mark Links

Timing Marks

A22902

Timing Marks

Timing Marks



INSTALLATION1. SET CRANKSHAFT POSITIONUsing the crankshaft pulley set bolt, turn the crankshaft, and setthe crankshaft set key into the left horizontal position.NOTICE:Having the crankshaft at the wrong angle can cause thepiston head and valve head to come into contact with eachother when you install the camshaft, causing damage. Soalways set the crankshaft at the correct angle.

2. INSTALL CHAIN TENSIONER NO.2(a) While pushing in the tensioner, insert a pin of φ 1.0 mm

(0.039 in.) into the hole to fix it.

(b) Install the chain tensioner No. 2 with the bolt.Torque: 19 N ⋅m (194 kgf ⋅cm, 14 ft ⋅lbf)

3. INSTALL NO.2 TIMING CHAIN(a) Align the mark links (yellow) with the timing marks (1-dot

mark) of the camshaft timing gear assembly and cam-shaft timing sprocket as shown in the illustration.

(b) Align the timing marks on the camshaft timing gear as-sembly and camshaft timing sprocket with the timingmarks on the bearing caps, and install the camshaft tim-ing gears with the chain to the RH camshafts.

(c) Temporarily install the 2 camshaft timing gear bolts.NOTICE:Do not push camshaft timing gear assembly to the cam-shaft forcibly when installing it.

A22903

A22921

A23007

Inward

A22850PushStopper Plate

Stopper Plate



(d) Hold the hexagonal portion of the camshaft with awrench, and tighten the 2 bolts.Torque: 100 N ⋅m (1,020 kgf ⋅cm, 74 ft ⋅lbf)

(e) Remove the pin from the chain tensioner No. 2.

4. INSTALL CHAIN VIBRATION DAMPER NO.1(a) Install the chain vibration damper No. 1 with the 2 bolts.


5. INSTALL CRANKSHAFT TIMING SPROCKET(a) Align the timing gear set key with the key groove of the

timing sprocket.(b) Install the timing gear onto the crankshaft with the sprock-

et side facing inward.6. INSTALL CHAIN TENSIONER SLIPPER

7. INSTALL CHAIN TENSIONER NO.1(a) While turning the stopper plate of the tensioner clockwise,

push in the plunger of the tensioner as shown in the il-lustration.

(b) While turning the stopper plate of the tensioner counter-clockwise, insert a bar of φ 3.5 mm (0.138 in.) into theholes in the stopper plate and tensioner to fix the stopperplate.

(c) Install the chain tensioner with the 2 bolts.Torque: 10 N ⋅m (102 kgf ⋅cm, 7 ft·lbf)

A22801

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks

A22869

Timing Line

Set Key

A22870Timing Mark

Mark Link

A22871

Mark Links

Timing Marks



8. SET NO.1 CYLINDER TO TDC/COMPRESSION(a) Align the timing marks of the camshaft timing gear assem-

bly, camshaft timing sprocket and bearing caps.

(b) Using the crankshaft pulley set bolt, turn the crankshaftto align the crankshaft set key with the timing line of thecylinder block.

9. INSTALL TIMING CHAIN NO.1(a) Align the mark link (yellow) with the timing mark of the

crankshaft timing sprocket.

(b) Align the mark links (orange) with the timing marks of thecamshaft timing gear assembly and camshaft timingsprocket, and install the chain.

10. INSTALL CHAIN VIBRATION DAMPER NO.2Install the 2 chain vibration damper No.2.

A22872

Forward

Knock Pin

A23009

A23010

Seal Packing



11. INSTALL IDLE GEAR NO.1(a) Apply a light coat of engine oil to the rotating surface of

the idle gear shaft No. 1.(b) Temporarily install the idle gear shaft No. 1 and idle gear

No. 1 with the idle gear shaft No. 2 while aligning theknock pin of the idle gear shaft No. 1 with the knock pingroove of the cylinder block.

NOTICE:Be careful of the idle gear direction.(c) Using a 10 mm hexagon wrench, tighten the idle gear

shaft No. 2.Torque: 60 N ⋅m (612 kgf ⋅cm, 44 ft ⋅lbf)

(d) Remove the bar from the chain tensioner.12. INSTALL TIMING CHAIN COVER(a) Remove any old packing (FIPG) material and be careful

not to drop any oil on the contact surfaces of the timingchain cover, cylinder head and cylinder block.

(b) Install a new O-ring to the LH cylinder head as shown inthe illustration.

(c) Apply a continuous bead of seal packing (diameter 3 to4 mm (0.12 to 0.16 in.)) to 4 locations as shown in the il-lustration.Seal packing: Part No. 08826-00080 or equivalent

A23011

Seal Packing

Water Pump Part

Water Pump Part

B

Seal Width 3 to 4 mm

B - B16.7 mm

A

3 to 4 mm

3 to 4 mm

Seal Packing

B

3 to 4 mm

A23012

15�

A23186

AA

A

A

AA

A

B

B

B

BB

AB

NutNut

A

B

B

BB

B BB

B

B



(d) Apply a continuous bead of seal packing (diameter 3 to4 mm (0.12 to 0.16 in.)) to the timing chain cover as shownin the illustration.Seal packing: Water pump part: Part No. 08826-00100 or equivalentOther part: Part No. 08826-00080 or equivalent

NOTICE:� Install the timing chain cover within 3 minutes after

applying seal packing. After installing it, the timingchain cover bolts and nuts must be tightened within15 minutes. Otherwise the seal packing must be re-moved and reapplied.

� Do not apply seal packing to the ”A” as shown in theillustration.

(e) Align the key way of the oil pump drive rotor with the rect-angular portion of the crankshaft timing gear, and slidethe timing chain cover into place.

(f) Install the timing chain cover with the 24 bolts and 2 nuts.Tighten the bolts and nuts uniformly in several steps.Torque: 23 N ⋅m (235 kgf ⋅cm, 17 ft ⋅lbf)

NOTICE:� Pay attention not to wrap the chain and slipper over

the timing chain cover seal line.� Install the water pump within 15 minutes after instal-

ling the timing chain cover.HINT:Each bolt length is as follows: A: 25 mm (0.98 in.)B: 55 mm (2.17 in.)

A23120

A23121

A23013

A

B

13

8 9

16.522.5 27.5

Stud Bolt A Stud Bolt B [mm]

A

A22873



13. INSTALL WATER INLET(a) Install a new O-ring to the water outlet pipe.(b) Install a new gasket to the water pump.(c) Apply soapy water to the O-ring.

(d) Install the water inlet with the 5 bolts.Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)

(e) Connect the 5 water by-pass hoses.(f) Connect the 2 radiator hoses.(g) Connect the 2 oil cooler hoses (w/ oil cooler).

14. INSTALL OIL PAN(a) Install the 4 stud bolts.

Torque: 4.0 N ⋅m (41 kgf ⋅cm, 35 in. ⋅lbf)(b) Remove any old packing material (FIPG) and be careful

not to drop any oil on the contact surfaces of the cylinderblock, rear oil seal retainer and oil pan.

(c) Install a new O-ring to the oil pump.

A22874

Seal Packing


A22863

B

A A B B

C

C

BBNutBBNut

B

A

A

B

A A

A22862

Flywheel Housing Under Cover

A22861

A22875

Seal Packing




(d) Apply a continuous bead of seal packing (diameter 3 to4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the il-lustration.Seal packing: Part No. 08826-00080 or equivalent

NOTICE:Install the oil pan within 3 minutes after applying seal pack-ing. After installing it, the oil pan bolts and nuts must betightened within 15 minutes. Otherwise the seal packingmust be removed and reapplied.

(e) Install the oil pan with the 17 bolts and 2 nuts. Tighten thebolts and nuts uniformly in several steps.Torque:Bolt A, B, Nut: 21 N ⋅m (214 kgf ⋅cm, 15 ft·lbf)Bolt C: 10 N ⋅m (102 kgf ⋅cm, 7 ft ⋅lbf)

HINT:Each bolt length is as follows: A: 25 mm (0.98 in.)B: 45 mm (1.77 in.)C: 14 mm (0.55 in.)(f) Install the 4 housing bolts.

Torque: 37 N ⋅m (377 kgf ⋅cm, 27 ft ⋅lbf)(g) Install the flywheel housing under cover.

15. INSTALL OIL STRAINER(a) Install a new gasket and the oil strainer with the 2 nuts.

Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)16. INSTALL OIL PAN NO.2(a) Remove any old packing material (FIPG) and be careful

not to drop any oil on the contact surfaces of the oil panand oil pan No. 2.

(b) Apply a continuous bead of the seal packing (diameter 3to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.Seal packing: Part No. 08826-00080 or equivalent

NOTICE:Install the oil pan No. 2 within 3 minutes after applying sealpacking. After installing it, the oil pan No. 2 bolts and nutsmust be tightened within 15 minutes. Otherwise the sealpacking must be removed and reapplied.

A22859

A22876

SST

A22877

”DOUBLE”

A22878

A22856

A

B

B

B

B

A-1

B-1



(c) Install the oil pan No. 2 with the 15 bolts and 2 nuts. Tight-en the bolts and nuts uniformly in several steps.Torque: Bolt: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)Nut: 10 N ⋅m (102 kgf ⋅cm, 7 ft ⋅lbf)

17. INSTALL CRANKSHAFT PULLEYUsing SST, install the pulley set bolt.

SST 09213-54015 (91651-60855), 09330-00021Torque: 250 N ⋅m (2,549 kgf ⋅cm, 184 ft ⋅lbf)

18. INSTALL IDLER PULLEY NO.1Install the idler pulley with the bolt.

Torque: 54 N ⋅m (551 kgf ⋅cm, 40 ft ⋅lbf)HINT:”DOUBLE” is marked on the idler pulley No. 1 to distinguish itfrom the idler pulley No. 2.

19. INSTALL IDLER PULLEY NO.2Install the 2 idler pulleys with the 2 bolts.


20. INSTALL V-RIBBED BELT TENSIONER ASSYTighten bolts A-1 and B-1 in order first, then tighten the remain-ing bolts.

Torque: 36 N ⋅m (367 kgf ⋅cm, 27 ft ⋅lbf)HINT:Each bolt length is as follows: A: 70 mm (2.76 in.)B: 33 mm (1.30 in.)21. INSTALL COOLER COMPRESSOR

(See page AC-58 )

A22855

A22879

O-Ring

Push



22. INSTALL GENERATOR (See page CH-15 )

23. INSTALL VANE PUMP(a) Install the vane pump with the 2 bolts.

Torque: 43 N ⋅m (438 kgf ⋅cm, 32 ft ⋅lbf)NOTICE:Do not hit the pulley to other parts when installing the vanepump.(b) Connect the P/S oil pressure switch connector.24. INSTALL WATER INLET (See page EM-89 )

25. INSTALL OIL LEVEL GAUGE GUIDE(a) Install a new O-ring to the oil level gauge guide.(b) Apply a light coat of engine oil to the O-ring.(c) Push in the oil level gauge guide end into the guide hole

of the oil pan.(d) Install the oil level gauge guide with the bolt.

Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)(e) Install the oil level gauge.26. INSTALL CYLINDER HEAD COVER

(See page EM-89 )27. INSTALL INTAKE AIR SURGE TANK

(See page EM-89 )28. INSTALL AIR CLEANER (See page EM-89 )29. INSTALL FAN W/FLUID COUPLING

(See page EM-89 )30. INSTALL DRIVE BELT (See page EM-89 )31. FULLY TIGHTEN FAN W/FLUID COUPLING32. INSTALL RADIATOR (See page CO-18 )33. INSTALL V-BANK COVER34. INSTALL BATTERY35. ADD ENGINE OIL (See page LU-3 )36. ADD ENGINE COOLANT (See page CO-2 )37. CHECK FOR LEAKS38. CHECK IGNITION TIMING (See page EM-23 )39. CHECK IDLE SPEED (See page EM-25 )

EM1XK-01

A22855

A22856



REMOVAL1. DRAIN ENGINE COOLANT (See page CO-2 )2. DRAIN ENGINE OIL3. REMOVE BATTERY4. REMOVE V-BANK COVER5. REMOVE RADIATOR (See page CO-17 )6. LOOSEN FAN W/FLUID COUPLING

(See page EM-62 )7. REMOVE DRIVE BELT (See page EM-62 )8. REMOVE FAN W/FLUID COUPLING9. REMOVE AIR CLEANER (See page EM-62 )10. REMOVE INTAKE AIR SURGE TANK

(See page EM-62 )11. REMOVE CYLINDER HEAD COVER

(See page EM-62 )12. REMOVE VVT SENSOR13. REMOVE OIL LEVEL GAUGE GUIDE(a) Remove the oil level gauge.(b) Remove the bolt and pull out the oil level gauge guide.(c) Remove the O-ring from the oil level gauge guide.

14. SEPARATE VANE PUMP(a) Disconnect the P/S oil pressure switch connector.(b) Remove the 2 bolts, and separate the vane pump.NOTICE:Do not hit the pulley to other parts when separating thevane pump.HINT:The vane pump is suspended securely.15. REMOVE GENERATOR (See page CH-7 )16. SEPARATE COOLER COMPRESSOR

(See page AC-54 )

17. REMOVE V-RIBBED BELT TENSIONERRemove the 5 bolts and V-ribbed belt tensioner.18. REMOVE IDLER PULLEY NO.1 AND NO.2

A22857

SST

A22858

SST

A22859

A22860SST

A22861



19. REMOVE CRANKSHAFT PULLEY(a) Using SST, hold the crankshaft pulley and loosen the

pulley set bolt.SST 09213-54015 (91651-60855), 09330-00021

(b) Using the pulley set bolt and SST, remove the crankshaftpulley.SST 09950-50013 (09951-05010, 09952-05010,

09953-05020, 09954-05031)

20. REMOVE OIL PAN NO.2(a) Remove the 15 bolts and 2 nuts.

(b) Insert the blade of SST between the oil pan and oil panNo. 2, cut off applied sealer and remove the oil pan No.2.SST 09032-00100

NOTICE:� Be careful not to damage the contact surface of the oil

pan and oil pan No. 2.� Be careful not to damage the oil pan No. 2 flange.

21. REMOVE OIL STRAINERRemove the 2 nuts, oil strainer and gasket.

A22862

Flywheel Housing Under Cover

A22863

A22864

Pry

LH Side

RH Side

A23116



22. REMOVE OIL PAN(a) Remove the 4 housing bolts.(b) Remove the flywheel housing under cover.

(c) Remove 17 bolts and 2 nuts.

(d) Using a screwdriver, remove the oil pan by prying be-tween the oil pan and cylinder block in the sequenceshown.

NOTICE:Be careful not to damage the contact surfaces of the cylin-der block and oil pan.(e) Remove the O-ring from the oil pump.

23. REMOVE WATER INLET(a) Disconnect the 2 oil cooler hoses (w/ oil cooler).

A23117

A23118

A23119

A23186



(b) Disconnect the 2 radiator hoses.

(c) Disconnect the 5 water by-pass hoses.

(d) Remove the 5 bolts and water inlet.(e) Remove the O-ring from the water outlet pipe.(f) Remove the gasket from the water pump.

24. REMOVE TIMING CHAIN COVER(a) Remove the 24 bolts and 2 nuts.

A23187

A22865

Timing Line

Set Key

A22866

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks



(b) Remove the timing chain cover by prying between the tim-ing chain cover and cylinder head or cylinder block witha screwdriver.

NOTICE:Be careful not to damage the contact surfaces of the timingchain cover, cylinder block and cylinder head.(c) Remove the O-ring from the LH cylinder head.

25. SET NO.1 CYLINDER TO TDC/COMPRESSION(a) Install the crankshaft pulley set bolt, and turn the crank-

shaft to align the crankshaft set key with the timing line ofthe cylinder block.

(b) Check that the timing marks of the camshaft timing gearassembly and camshaft timing sprocket are aligned withthe timing marks of the bearing caps as shown in the il-lustration.

If not, turn the crankshaft 1 complete revolution (360 �) andalign the timing marks as above.26. REMOVE CHAIN TENSIONER NO.1NOTICE:� Never rotate the crankshaft with the chain tensioner

removed.� When rotating the camshaft with the timing chain re-

moved, rotate the crankshaft counterclockwise 40 �

from the TDC first.

A22807

Push

Stopper PlateStopper Plate

A22867

A22884

Raise

A22903

A22885



(a) While turning the stopper plate of the tensioner clockwise,push in the plunger of the chain tensioner as shown in theillustration.

(b) While turning the stopper plate of the tensioner counter-clockwise, insert a bar of φ 3.5 mm (0.138 in.) into theholes in the stopper plate and tensioner to fix the stopperplate.

(c) Remove the 2 bolts and chain tensioner.27. REMOVE CHAIN TENSIONER SLIPPER

28. REMOVE IDLE GEAR NO.1Using a 10 mm hexagon wrench, remove the idle gear shaft No.2, idle gear No. 1 and idle gear shaft No. 1.29. REMOVE CHAIN VIBRATION DAMPER NO.2Remove the 2 chain vibration damper No.2.30. REMOVE NO.1 TIMING CHAIN31. REMOVE CRANKSHAFT TIMING SPROCKET

32. REMOVE NO.2 TIMING CHAIN(a) While raising the chain tensioner No. 2, insert a pin of φ

1.0 mm (0.039 in.) into the hole to fix it.

(b) Hold the hexagonal portion of the camshaft with awrench, and remove the 2 bolts, camshaft timing sprock-et, camshaft timing gear assembly and timing chain No.2.

NOTICE:� Be careful not to damage the cylinder head and valve

lifter with the wrench.� Do not disassemble the camshaft timing gear assem-

bly.

33. REMOVE CHAIN TENSIONER NO.2Remove the bolt and chain tensioner No.2.

EM1XM-01

A22976

Pry

A23008

SST

A23076

A23077

SST



REPLACEMENTHINT:There are 2 methods ((a) and (b)) to replace the oil seal.REPLACE TIMING CHAIN COVER OIL SEAL(a) If the rear timing chain cover is removed:

(1) Using a screwdriver, pry out the oil seal.NOTICE:Be careful not to damage the oil pump. Wrap the tip of thescrewdriver with tape.

(2) Using SST and a hammer, tap in a new oil seal untilits surface is flush with the timing chain cover edge.

SST 09226-10010(3) Apply MP grease to the oil seal lip.

(b) If the rear timing chain cover is installed:(1) Using a screwdriver, pry out the oil seal.

NOTICE:Be careful not to damage the crankshaft. Wrap the tip of thescrewdriver with tape.

(2) Using SST and a hammer, tap in the oil seal until itssurface is flush with the timing chain cover edge.

SST 09226-10010(3) Apply MP grease to a new oil seal lip.

EM1XG-01

A22800

A22801

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks

EM-4-ENGINE MECHANICAL (1GR-FE) VALVE CLEARANCE


VALVE CLEARANCEINSPECTION1. DRAIN ENGINE COOLANT (See page CO-2 )2. REMOVE V-BANK COVER3. REMOVE AIR CLEANER (See page EM-62 )4. REMOVE INTAKE AIR SURGE TANK

(See page EM-62 )5. REMOVE IGNITION COIL6. REMOVE CYLINDER HEAD COVER

(See page EM-62 )

7. SET NO. 1 CYLINDER TO TDC/COMPRESSION(a) Turn the crankshaft pulley, and align its groove with the

timing mark ”0” of the timing chain cover.

(b) Check that the timing marks of the camshaft timing gearsare aligned with the timing marks of the bearing caps asshown in the illustration.

If not, turn the crankshaft 1 complete revolution (360 �) andalign the timing marks as above.

A22802

6 6

2 2

Front1 1

3 3RH Bank:

LH Bank:

EX

IN

EX

IN

A22803

2 2

4 4

Front3 3

5 5RH Bank:

LH Bank:

EX

IN

EX

IN

-ENGINE MECHANICAL (1GR-FE) VALVE CLEARANCEEM-5


8. INSPECT VALVE CLEARANCE(a) Check the valves indicated in the illustration.

(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.

Valve clearance (Cold):Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)Exhaust: 0.29 to 0.39 mm (0.011 to 0.015 in.)(2) Record the out-of-specification valve clearance

measurements. They will be used later to determinethe required replacement valve lifter.

(b) Turn the crankshaft 2/3 of a revolution (240�), and checkthe valves indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-

tween the valve lifter and camshaft.Valve clearance (Cold):Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)Exhaust: 0.29 to 0.39 mm (0.011 to 0.015 in.)(2) Record the out-of-specification valve clearance


A22804

4 4

6 6

Front5 5

1 1RH Bank:

LH Bank:

EX

IN

EX

IN

A22800

A22801

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks



(c) Turn the crankshaft 2/3 of a revolution (240�), and checkthe valves indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-

tween the valve lifter and camshaft.Valve clearance (Cold):Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)Exhaust: 0.29 to 0.39 mm (0.011 to 0.015 in.)(2) Record the out-of-specification valve clearance


9. ADJUST VALVE CLEARANCE(a) Set the No. 1 cylinder to the TDC/compression.

(1) Turn the crankshaft pulley, and align the notch withthe timing mark ”0” of the timing chain cover.

(2) Check that the timing marks of the camshaft timinggears are aligned with the timing marks of the bear-ing caps as shown in the illustration.

If not, turn the crankshaft 1 complete revolution (360 �) andalign the timing marks as above.

A22805

Paint Marks

Timing Marks

A22806

A22807

Push

Stopper PlateStopper Plate

A22808

Raise



(3) Place paint marks on the No. 1 chain links that cor-respond with the timing marks of the camshaft tim-ing gears.

(b) Remove the chain tensioner No. 1.NOTICE:� Never rotate the crankshaft with the chain tensioner

removed.� When rotating the camshaft with the timing chain re-

moved, turn the crankshaft counterclockwise 40 �

from the TDC first.(1) Remove the 4 bolts, timing chain cover plate and

gasket.

(2) While rotating the stopper plate of the tensioner up-ward, push in the plunger of the chain tensioner asshown in the illustration.

(3) While rotating the stopper plate of the tensionerdownward, insert a bar of φ 3.5 mm (0.138 in.) intothe holes in the stopper plate and tensioner to fix thestopper plate.

(4) Remove the 2 bolts and chain tensioner No.1.(c) Remove the No. 2 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

(1) While raising up the chain tensioner No. 2, insert apin of φ 1.0 mm (0.039 in.) into the hole to fix it.

A22809

A22810

A22811

1

2 4 8 6

573

A22812



(2) Hold the hexagonal portion of the No. 2 camshaftwith a wrench, and remove the camshaft timingsprocket set bolt.

NOTICE:Be careful not to damage the cylinder head and valve lifterwith the wrench.

(3) Separate the camshaft timing sprocket from the No.2 camshaft.

(4) Rotate the camshaft counterclockwise using thewrench so that the cam lobes of the No. 1 cylinderface upward as shown in the illustration.

(5) Using several steps, loosen and remove the 8 bear-ing cap bolts uniformly in the sequence as shown inthe illustration.

(6) Remove the 4 bearing caps and No. 2 camshaft.

(d) Remove the chain tensioner No. 2.(1) Remove the chain tensioner No. 2 bolt, and then re-

move the chain tensioner No. 2 and camshaft timingsprocket.

(e) Remove the camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

A22813

A22814

Slide

A22815

A22816

1

2 4 8 6

573

A22817



(1) Hold the hexagonal portion of the No. 1 camshaftwith a wrench, and loosen the camshaft timing gearassembly set bolt.

NOTICE:� Be careful not to damage the cylinder head and valve

lifter with the wrench.� Do not disassemble the camshaft timing gear assem-

bly.

(2) Slide the camshaft timing gear assembly and sepa-rate the No. 1 chain from the camshaft timing gearsprocket.

(3) Rotate the No. 1 camshaft counterclockwise usinga wrench so that the cam lobes of No. 1 cylinderface upward as shown in the illustration.


(5) Remove the 4 bearing caps.

(6) Remove the camshaft timing gear assembly set boltwith the No. 1 camshaft lifted up, and then removethe No. 1 camshaft and camshaft timing gear as-sembly w/ No. 2 chain.

A22818

A22819

Push

A22820

A22821

1

2486

5 7 3



(7) Tie the No. 1 chain with a string as shown in the il-lustration.

NOTICE:Be careful not to drop anything inside the timing chain cov-er.(f) Remove the No. 4 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

(1) While pushing down the chain tensioner No. 2, in-sert a pin of φ 1.0 mm (0.039 in.) into the hole to fixit.

(2) Hold the hexagonal portion of the No. 4 camshaftwith a wrench, and remove the camshaft timingsprocket set bolt.

NOTICE:Be careful not to damage the cylinder head and valve lifterwith the wrench.

(3) Separate the camshaft timing sprocket from the No.4 camshaft.


(5) Remove the 4 bearing caps and No. 4 camshaft.

A22822

A22823

1

2486

5 7 3

A22824

A22825

-ENGINE MECHANICAL (1GR-FE) VALVE CLEARANCEEM-1 1


(g) Remove the chain tensioner No. 2.(1) Remove the chain tensioner No. 3 bolt, and then re-

move the chain tensioner No. 3 and camshaft timingsprocket.

(h) Remove the No. 3 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being removed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.


(2) Remove the 4 bearing caps.

(3) Hold the No. 1 chain, and remove the No. 3 cam-shaft, camshaft timing gear assembly and No. 2chain.

(4) Tie the No. 1 chain with a string as shown in the il-lustration.

NOTICE:Be careful not to drop anything inside the timing chain cov-er.(i) Remove the valve lifters.

A01082



(j) Determine the size of the valve lifter to be installed ac-cording to the following formulas or charts:(1) Using a micrometer, measure the thickness of the

removed lifter.(2) Calculate the thickness of a new lifter so that the

valve clearance comes within the specified value.T: Thickness of removed lifterA: Measured valve clearanceN: Thickness of new lifterIntake: N = T + (A - 0.20 mm (0.008 in.))Exhaust: N = T + (A - 0.30 mm (0.012 in.))(3) Select a new lifter with a thickness as close as pos-

sible to the calculated value.HINT:Lifters are available in 35 sizes in increments of 0.020 mm(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260in.).

A22826

Valve Lifter Selection Chart (Intake)

Removed lifter

New Lifter Thickness mm (in.)

thicknessmm (in.)

Measuredclearance mm (in.)

No. Thickness No. Thickness No. Thickness

Intake valve clearance (Cold): 0.15 to 0.25 mm (0.0059 to 0.0098 in.)

EXAMPLE:The 5.250 mm (0.2067 in.) lifter is installed, and themeasured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) shim with a newNo. 46 lifter.

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M-13

3221Author�:

Date�:

A22827

Valve Lifter Selection Chart (Exhaust)

Removed lifter

New Lifter Thickness mm (in.)

thicknessmm (in.)

Measuredclearance mm (in.)

No. Thickness No. Thickness No. Thickness

Exhaust valve clearance (Cold): 0.29 to 0.39 mm (0.0114 to 0.0154 in.)

EXAMPLE:The 5.340 mm (0.2102 in.) lifter is installed, and themeasured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) shim with a newNo. 48 lifter.

EM

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CLE

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3222Author�:

Date�:

A22828

Mark Links

Timing Marks

A22829

A22830

A22831



(k) Install the No. 3 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

(1) Align the mark link (yellow) with the timing mark(2-dot mark) of the camshaft timing gear assemblyas shown in the illustration.

(2) Apply new engine oil to the thrust portions and jour-nals of the camshafts.

(3) Temporarily put the No. 1 chain on the No. 2 chainof the camshaft timing gear assembly.

(4) Set the No. 3 camshaft onto the LH cylinder headwith the cam lobes of the No. 2 cylinder facingdownward as shown in the illustration.

(5) Install the 4 bearing caps in their proper locations.(6) Apply a light coat of engine oil to the threads of the

bearing cap bolts.

A22832

8

7513

4 2 6

A22833

Timing Marks

Paint Mark

A22834

Push

A22835Timing Marks

Mark Links



(7) Install the 8 bearing cap bolts. Using several steps,tighten the bolts uniformly in the sequence asshown in the illustration.


(8) Set the paint mark of the No. 1 chain between thetiming marks of the camshaft timing gear assembly.

(l) Install the chain tensioner No. 2.(1) While pushing in the tensioner, insert a pin of φ 1.0

mm (0.039 in.) into the hole to fix it.

(2) Temporarily install the camshaft timing assemblyand chain tensioner No. 2 and align the mark links(yellow) with the timing marks (1-dot mark and2-dot mark) of the camshaft timing sprocket andcamshaft timing gear assembly.

(3) Tighten the chain tensioner No. 3 bolt.Torque: 19 N ⋅m (194 kgf ⋅cm, 14 ft ⋅lbf)

(m) Install the No. 4 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

A22836

A22837

A22821

8

7513

4 2 6

A22820



(1) Align the knock pin hole on the camshaft timingsprocket with the knock pin of the No. 4 camshaft,and insert the No. 4 camshaft into the camshaft tim-ing sprocket.

(2) Temporarily install the camshaft timing sprocket setbolt.





(6) Hold the hexagonal portion of the No. 4 camshaftwith a wrench, and tighten the camshaft timingsprocket set bolt.

Torque: 100 N ⋅m (1,020 kgf ⋅cm, 74 ft ⋅lbf)(7) Remove the pin from the chain tensioner No. 2.

(n) Install the camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

A22838

Mark Links

Timing Mark

A22839

A22840

Knock Pin

A22841

A22842



(1) Align the mark link (yellow) with the timing mark(1-dot mark) of the camshaft timing gear assemblyas shown in the illustration.

(2) Apply new engine oil to the thrust portions and jour-nals of the camshafts.

(3) Temporarily put the No. 1 chain on the No. 2 chainof the camshaft timing gear assembly.

(4) Align the knock pin hole on the camshaft timing gearassembly with the knock pin of the No. 1 camshaft,and insert the No. 1 camshaft into the camshaft tim-ing gear assembly.

(5) Temporarily install the camshaft timing gear assem-bly set bolt.

(6) Set the No. 1 camshaft onto the RH cylinder headwith the cam lobes of the No. 1 cylinder facingdownward as shown in the illustration.



A22816

8

7 5 1 3

426

A22843

Timing Marks

A22844

Paint Mark

Timing Mark

A22813

A22900

Push





(10) Rotate the No. 1 camshaft clockwise using the hex-agonal portion of the No. 1 camshaft so that the tim-ing mark of the camshaft timing gear assembly isaligned with the timing mark of the camshaft bear-ing cap.

(11) Align the paint mark of the No. 1 chain with the tim-ing mark of the camshaft timing gear assembly.

(12) Hold the hexagonal portion of the No. 1 camshaftwith a wrench, and tighten the camshaft timing gearassembly set bolt.

Torque: 100 N ⋅m (1,020 kgf ⋅cm, 74 ft ⋅lbf)

(o) Install the chain tensioner No. 2.(1) While pushing in the tensioner, insert a pin of φ 1.0

mm (0.039 in.) into the hole to fix it.

A22846

Mark Links

Timing Marks

A22847

A22848

A22811

8

7 5 1 3

426



(2) Temporarily install the camshaft timing gear andchain tensioner No. 2 and align the mark links (yel-low) with the timing marks (1-dot mark) of the cam-shaft timing gear assembly and camshaft timingsprocket.

(3) Tighten the chain tensioner No. 2 bolt.Torque: 19 N ⋅m (194 kgf ⋅cm, 14 ft ⋅lbf)

(p) Install the No. 2 camshaft.NOTICE:As the thrust clearance of the camshaft is small, the cam-shaft must be kept level while it is being installed. If thecamshaft is not kept level, the portion of the cylinder headwhich receives the shaft thrust may crack or be damaged,causing the camshaft to seize or break. To avoid this, thefollowing steps should be carried out.

(1) Set the No. 2 camshaft onto the RH cylinder headwith the cam lobes of No. 1 cylinder facing upwardas shown in the illustration.





A22849

Knock Pin

A22809

A22850PushStopper Plate

Stopper Plate

A22800



(5) Rotate the No. 2 camshaft clockwise using awrench so that the knock pin of the No. 2 camshaftis aligned with the knock pin hole of the camshafttiming sprocket.

(6) Hold the hexagonal portion of the No. 2 camshaftwith a wrench, and install the camshaft timingsprocket set bolt.

Torque: 100 N ⋅m (1,020 kgf ⋅cm, 74 ft ⋅lbf)(7) Remove the pin from the chain tensioner No. 2.

(q) Install the chain tensioner No. 1.(1) While turning the stopper plate of the tensioner

clockwise, push in the plunger of the tensioner asshown in the illustration.

(2) While turning the stopper plate of the tensionercounterclockwise, insert a bar of φ 3.5 mm (0.138in.) into the holes on the stopper plate and tensionerto fix the stopper plate.

(3) Install the chain tensioner with the 2 bolts.Torque: 10 N ⋅m (102 kgf ⋅cm, 7 ft·lbf)(4) Remove the bar from the chain tensioner.(5) Install a new gasket and the timing chain cover plate

with the 4 bolts.Torque: 9.0 N ⋅m (92 kgf ⋅cm, 80 in. ⋅lbf)

(6) Turn the crankshaft pulley 2 complete revolutionsslowly, and align the notch with the timing mark ”0”of the timing chain cover.

A22801

RH Bank

LH Bank

Timing Marks

Timing Marks

Timing Marks



(7) Check that the timing marks of the camshaft timinggear assembly and camshaft timing sprocket arealigned with the timing marks of the bearing caps asshown in the illustration.

10. INSTALL CYLINDER HEAD COVER (See page EM-89 )

11. INSTALL IGNITION COIL12. INSTALL INTAKE AIR SURGE TANK

(See page EM-89 )13. INSTALL AIR CLEANER (See page EM-89 )14. ADD ENGINE COOLANT (See page CO-2 )15. INSTALL V-BANK COVER16. INSPECT IGNITION TIMING (See page EM-23 )

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