Motor 1GR-FE PDF

EM-1
ENGINE MECHANICAL (1GR-FE) - CO/HC
CO/HC EM0KQ-10
INSPECTION
HINT:
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 hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST

40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
CO/HC Meter
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow
the measurement orders prescribed by the applicable local reg-
ulations.
A19383
Author: Date: 3209

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 sensors
operation (See page DI-84 and DI-90 ).
(2) See the table below for possible causes, and then
inspect and correct the corresponding causes if
necessary.
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 1. Vacuum leaks:

(fluctuating HC reading) PCV hose
Intake manifold
Throttle body
2. Lean mixture causing misfire
High High Rough idle 1. Restricted air filter
(Black smoke from exhaust) 2. Faulty SFI system:
Faulty pressure regulator
Defective ECT sensor
Faulty ECM
Faulty injectors
Faulty throttle position sensor
Faulty MAF meter
Author: Date: 3210

EM-3
ENGINE MECHANICAL (1GR-FE) - COMPRESSION
COMPRESSION EM06C-06
INSPECTION
HINT:
If there is a lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow 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 speed
of 250 rpm or more.
A22796 (d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in the shortest possible
time.
Compression pressure:
1.3 MPa (13.3 kgf/cm2, 189 psi) or more
Minimum pressure: 1.0 MPa (10.2 kgf/cm2, 145 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm2, 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 are
worn or damaged.
If compression pressure stays low, a valve may be
sticking, seating may be improper, or there may be
a 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.
Author: Date: 3211

EM-1 11
ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK
CYLINDER BLOCK
EM1XY-01
COMPONENTS
Piston Ring (No. 1 Compression Ring)

Piston Ring (No. 2 Compression Ring)
Piston Ring (Expander)
Piston Ring (Side Rail)

Piston
Piston Pin Hole Snap Ring
Piston Pin
Water Outlet Pipe No.1
10 (102, 7)
Piston Pin Hole 10 (102, 7)
Snap Ring Connecting Rod
Knock Sensor
Connecting Rod 20 (204, 15)
Bearing
Connecting Rod
Cap 20 (204, 15)
Knock Sensor
Water Drain Cock
25 (255, 18) Knock Sensor Wire
Engine Rear Oil
Seal Retainer 10 (102, 7)
See page EM-128 Oil Seal
1st 25 (250, 18)
2nd Turn 90
x5
x2
Water Drain Cock

25 (255, 18)
9.0 (92, 80 in.·lbf)

Crankshaft Bearing
x8
Upper Crankshaft Oil Nozzle
Thrust Washer 25 (255, 18)
9.0 (92, 80 in.·lbf)
Crankshaft
Lower Crankshaft Thrust Washer
Crankshaft Bearing Cap
Crankshaft Bearing See page EM-128

N·m (kgf·cm, ft·lbf) : Specified torque 1st 61 (622, 45)
Non-reusable part 2nd Turn 90
A23200
Author: Date: 3319

EM-1 12
EM1XZ-01
DISASSEMBLY
1. REMOVE WATER OUTLET PIPE NO.1
(a) Separate the knock sensor wire.
(b) Remove the 3 bolts and water outlet pipe.
A22979
2. REMOVE KNOCK SENSOR

(a) Disconnect the knock sensor connectors.
(b) Remove the 2 bolts and 2 knock sensors.
3. REMOVE WATER DRAIN COCK
A22980
4. REMOVE ENGINE REAR OIL SEAL RETAINER

Pry (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.
A22981
5. INSPECT CONNECTING ROD THRUST CLEARANCE

Using 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
A23021 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.
Author: Date: 3320

EM-1 13
(e) Lay a strip of Plastigage across the crank pin.

Plastigage
A23022
(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.
Protrusion
A23023
(h) Using SST, tighten the bolts alternately to the specified

torque.
SST 09011-38121
Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
A23024
Painted Mark (i) Mark the front side of each connecting cap bolt with paint.
90 (j) Retighten the cap bolts 90 as shown in the illustration.
NOTICE:
Front 90 Do not turn the crankshaft.
(k) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
A23025
(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.
A23026
Author: Date: 3321

EM-1 14
Number Mark (m) If replacing a bearing, replace it with one that has the
Number Mark
same number marked on the connecting rod. There are
4 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)
A23027 ”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
A23028 correct order.
8. REMOVE CONNECTING ROD BEARING
9. 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.
A23029
10. REMOVE PISTON PIN HOLE SNAP RING

Using a screwdriver, pry out the 2 snap rings.
A23030
Author: Date: 3322

EM-1 15
11. REMOVE PISTON PIN

80C
(a) Gradually heat the piston to approx. 80C (176F).
A23031
(b) Using a plastic-faced hammer and brass bar, lightly tap

out 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.
A23032
12. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
If the thrust clearance is greater than the maximum, replace the
pair of the thrust washers or the crankshaft.
A23033 HINT:
Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780
in.)
13. REMOVE CRANKSHAFT

5
8 (a) Using several steps, uniformly loosen and remove the 8
7 main bearing cap bolts and seal washers in the sequence
2 as shown in the illustration.
3
6
4
1
A23034
Author: Date: 3323

EM-1 16
(b) Using several steps, uniformly loosen and remove the 16

main bearing cap bolts in the sequence as shown in the
4
8 12 illustration.
6 16 11
14 15 3
2 10 13 7
5
9
1
A23035
(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.
A23036
Be careful not to damage the joint surface of the cylin-

der block and the main bearing cap.
Main Bearing Cap 14. REMOVE CRANKSHAFT THRUST WASTER SET
15. REMOVE CRANKSHAFT BEARING
Cylinder
Block
A23037
16. REMOVE OIL NOZZLE

Using a 5 mm socket hexagon wrench, remove the 3 oil
nozzles.
A23038
Author: Date: 3324

EM-1 17
EM1Y0-01
INSPECTION
1. INSPECT CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
flatness of the surface that is in contact with the cylinder head
gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than the maximum, replace the cylinder
block.
A23039
2. INSPECT CYLINDER BORE

Using a cylinder gauge, measure the cylinder bore diameter at
positions A and B in the thrust and axial directions.
Standard diameter:
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 the
maximum, replace the cylinder block.
Thrust Direction
Front
Axial Direction
A 10 mm
A23040
3. INSPECT PISTON
Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 27.7 mm (1.091 in.) from the
piston head.
Piston diameter:
93.910 to 93.940 mm (3.6972 to 3.6984 in.)
27.7 mm
(1.091 in.)
A23041
Author: Date: 3325

EM-1 18
4. INSPECT PISTON OIL CLEARANCE

Subtract the piston diameter measurement from the cylinder
bore diameter measurement.
0.060 to 0.102 mm (0.0024 to 0.0040 in.)
If the oil clearance is greater than the maximum, replace all the
6 pistons. If necessary, replace the cylinder block.
5. INSPECT CONNECTING ROD

Using a rod aligner and feeler gauge, check the connecting rod
alignment.
(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.
Z00064
(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 rod
assembly.
Z00065
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.)
A13490 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)
Author: Date: 3326

EM-1 19
(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)
EM0227 C 22.004 to 22.006 (0.8663 to 0.8664)
(c) Using a caliper gauge, measure the inside diameter of the

connecting 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)
EM6525 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 the

piton pin hole diameter measurement.
0.001 to 0.007 mm (0.00004 to 0.00028 in.)
(e) If the oil clearance is greater than the maximum, replace

the bushing. If necessary, replace the piston and piston
pin together.
(f) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Front Mark 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Piston Pin Hole
Inside Diameter
(g) If the oil clearance is greater than the maximum, replace
Mark the bushing. If necessary, replace the connecting rod and
piston pin together.
Front Mark
Connecting Rod
Bushing Inside
Diameter Mark
A23042
Author: Date: 3327

EM-120
7. INSPECT RING GROOVE CLEARANCE

Using a feeler gauge, measure the clearance between the new
piston 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.)
A23044
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 the
cylinder block.
110 mm
A23045
(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.)
EM7639 Oil (Side rail): 1.0 mm (0.039 in.)
9. INSPECT CONNECTING ROD BOLT

Using a vernier caliper, measure the tension portion diameter
of 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.
A23046
10. INSPECT CRANKSHAFT BEARING CAP SET BOLT

Using a vernier caliper, measure the tension portion diameter
of 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.
A23046
Author: Date: 3328

EM-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.)
A23047
(b) Using a micrometer, measure the diameter of each main

journal.
Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.)
(c) Check each main journal for taper and out-of-round as
shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
A23048
(d) Using a micrometer, measure the diameter of each crank

pin.
Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.)
(e) Check each crank pin for taper and out-of-round as
shownin the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
A23049
12. INSPECT CRANKSHAFT OIL CLEARANCE

No. 1 and No. 4 No. 2 and No. 3 HINT:
Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4
mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the
No. 1 and No. 4 cylinder block journal positions with the main
bearing 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.
22.4 mm 19.0 mm
A23050
(b) Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
A23051
Author: Date: 3329

EM-122
(c) Align the bearing claw with the claw groove of the main
bearing 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 the
Mark
installation position.
1, 2, 3, or 4
(d) Place the crankshaft on the cylinder block.
A23052
(e) Lay a strip of Plastigage across each journal.

Plastigage
A23053
(f) Examine the front marks and numbers and install the
bearing 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.
A23054
(i) Install the main bearing caps. Tighten the 2 bolts for each
bearing cap until the clearance between the bearing cap
and the cylinder block becomes less than 6 mm (0.23 in.).
Less than 6 mm
A23055
(j) Using a plastic-faced hammer, lightly tap the bearing cap

to ensure a proper fit.
(k) Apply a light coat of engine oil to the threads of the main
bearing cap bolts.
A23056
Author: Date: 3330

EM-123
(l) Install the 16 main bearing cap bolts. Using several steps,
uniformly tighten the bolts in the sequence as shown in
13 the illustration.
9 5 6
11 1 2 Torque: 61 N⋅m (622 kgf⋅cm, 45 ft⋅lbf)
3 4 14
10
15 7 8 12
16
A23057
Painted Mark
(m) Mark the front side of the bearing cap bolts with paint.
90 (n) Retighten the bearing cap bolts until 90 in the sequence
Front
90
(o) Check that the painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
A23058
(p) Install the 8 main bearing cap bolts. Using several steps,
4
1 uniformly tighten the bolts in the sequence as shown in
2 the illustration.
7
3 Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
6
5
(q) Remove the main bearing caps.
A23059
(r) Measure the Plastigage at its widest point.

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 the
bearings. If necessary, replace the crankshaft.
NOTICE:
Completely remove the Plastigage.
A23060
Author: Date: 3331

EM-124
(s) If replacing a bearing, replace it with one that has the

same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together
No. 1 the numbers imprinted on the cylinder block and crank-
No. 2 shaft, then refer to the table below for the appropriate
No. 3
No. 4 bearing number. There are 5 sizes of standard bearings,
marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly
Journal bearings
Number Mark
Cylinder
block (A)
0 to 5 6 to 11 12 to 17 18 to 23 24 to 28
+
Crankshaft
Use
”1” ”2” ”3” ”4” ”5”
Bearing
HINT:
No. 1 EXAMPLE
No. 2 Cylinder block ”11” (A) + Crankshaft ”06” (B)
No. 4 = Total number 17 (Use bearing ”3”)
Number No. 3
Mark Number MarkA23061
Item Mark mm (in.)

”00” 77.000 (3.0315)
”01” 77.001 (3.0315)
”02” 77.002 (3.0316)
”03” 77.003 (3.0316)
”04” 77.004 (3.0317)
”05” 77.005 (3.0317)
”06” 77.006 (3.0317)
”07” 77.007 (3.0318)
Cylinder block main journal bore diameter (A) ”08” 77.008 (3.0318)
”09” 77.009 (3.0319)
”10” 77.010 (3.0319)
”11” 77.011 (3.0319)
”12” 77.012 (3.0320)
”13” 77.013 (3.0320)
”14” 77.014 (3.0320)
”15” 77.015 (3.0321)
”16” 77.016 (3.0321)
Author: Date: 3332

EM-125
Crankshaft main journal diameter (B)

”00” 71.999 to 72.000 (2.8346 to 2.8346)
”01” 71.998 to 71.999 (2.8346 to 2.8346)
”02” 71.997 to 71.998 (2.8345 to 2.8346)
”03” 71.996 to 71.997 (2.8345 to 2.8346)
”04” 71.995 to 71.996 (2.8344 to 2.8345)
”05” 71.994 to 71.995 (2.8344 to 2.8344)
”06” 71.993 to 71.994 (2.8343 to 2.8344)
”07” 71.992 to 71.993 (2.8343 to 2.8343)
”08” 71.991 to 71.992 (2.8343 to 2.8343)
”09” 71.990 to 71.991 (2.8343 to 2.8343)
”10” 71.989 to 71.990 (2.8342 to 2.8343)
”11” 71.988 to 71.989 (2.8342 to 2.8342)
Standard bearing center wall thickness ”1” 2.488 to 2.491 (0.0980 to 0.0981)
”2” 2.491 to 2.494 (0.0981 to 0.0982)
”3” 2.494 to 2.497 (0.0982 to 0.0983)
”4” 2.497 to 2.500 (0.0982 to 0.0984)
”5” 2.500 to 2.503 (0.0984 to 0.0985)
Author: Date: 3333

EM-128
EM1Y2-01
REASSEMBLY
1. 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)
Front Side Upper Side
42 mm C
(1.65 in.)
A 23 mm
A (0.91 in.)
M6
Lower Side
56 mm
(2.20 in.)
B B
A23062
Author: Date: 3336

EM-129
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.)
Front Side Front Side
10 mm
(0.39 in.)
A 4 mm
(0.16 in.)
D
36 mm D
(1.42 in.)
Protrusion Height: 5.5 to 6.5 mm 12 mm
Protrusion Height: 22.5 to 23.5 mm
(0.886 to 0.925 in.) Rear Side (0.217 to 0.256 in.) (0.47 in.)
Rear Side
B
10 mm
(0.39 in.) 4 mm
(0.16 in.)
22 mm D
B (0.87 in.)
12 mm
Protrusion Height: 10.5 to 11.5 mm Protrusion Height: 5.5 to 6.5 mm (0.47 in.)
(0.217 to 0.256 in.)
(0.413 to 0.453 in.) Lower Side
D
Upper Side
8 mm 4 mm
(0.31 in.) (0.16 in.)
18 mm
C C (0.71 in.)
C C 12 mm
D (0.47 in.)
Protrusion Height: 5.5 to 6.5 mm
(0.217 to 0.256 in.)
Protrusion Height: 8.5 to 9.5 mm (0.335 to 0.374 in.) A23063
Author: Date: 3337

EM-130
3. INSTALL TIGHT PLUG

(a) Apply adhesive around the tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or 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.)
Right Side Left Side
0.2 to 1.2 mm
(0.008 to 0.047 in.)
A23064
4. INSTALL OIL JET

Using a screwdriver and hammer, tap in an oil jet.
26.55
A23065
5. INSTALL OIL NOZZLE

Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
A23038
Author: Date: 3338

EM-131
6. INSTALL PISTON PIN HOLE SNAP RING

Using a screwdriver, install a new snap ring at one side of the
piston pin hole.
HINT:
Check that the end gap of the snap ring does not overlap the
pin hole cutout portion of the piston.
A23066
7. INSTALL PISTON
(a) Gradually heat the piston to about 80C (176F).
P12417
(b) Coat the piston pin with engine oil.

Front Mark (c) Align the front marks of the piston and connecting rod,
and push in the piston pin with a thumb.
Front
Mark
A23067
8. INSTALL PISTON PIN HOLE SNAP RING

Using a screwdriver, install a new snap ring on the other side
of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring does not overlap the
pin hole cutout portion of the piston.
A23066
9. INSTALL PISTON RING SET

(a) Install the oil ring expander and 2 side rails by hand.
Upward (b) Using a piston ring expander, install the 2 compression
rings.
NOTICE:
Install the compression ring No. 2 with the painted mark
facing upward.
Painted Mark
A23068
Author: Date: 3339

EM-132
No. 2 Lower side rail (c) Position the piston rings so that the ring ends are as
Compression shown in the illustration.
Front Mark
Expander Side Rail
No. 1
Compression
Upper side rail A23069
10. INSTALL CONNECTING ROD BEARING

Align the bearing claw with the groove of the connecting rod or
connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod and prevent oil from adhering to
them.
A23070
11. INSTALL CRANKSHAFT BEARING

No. 1 and No. 4 No. 2 and No. 3 HINT:
Upper Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4
mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the
No. 1 and No. 4 cylinder block journal positions with the main
Lower bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
22.4 mm 19.0 mm (a) Clean each main journal and bearing.
A23050
(b) Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
A23071
(c) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 lower bearings.
NOTICE:
HINT:
The number marked on each main bearing cap indicates the
Mark
1, 2, 3 or 4 installation position.
A23052
Author: Date: 3340

EM-133
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.
A23072
(c) Install the 2 lower thrust washers on the No. 2 bearing cap
with the grooves facing outward.
A23073
(d) Examine the front marks and numbers and install the
bearing 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.
A23054
(g) Install the main bearing caps. Tighten the 2 bolts for each
bearing cap until the clearance between the bearing cap
and the cylinder block becomes less than 6 mm (0.23 in.).
Less than 6 mm
A23055
Author: Date: 3341

EM-134
(h) Using a plastic-faced hammer, lightly tap the bearing cap

to ensure a proper fit.
(i) Apply a light coat of engine oil to the threads of the main
bearing cap bolts.
A23056
(j) Install the 16 main bearing cap bolts. Using several steps,
uniformly tighten the bolts in the sequence shown in the
13 illustration.
9 5 6
1 2 14
11
3 4
10
15 7 8 12
16
A23057
Painted Mark (k) Mark the front side of the bearing cap bolts with paint.
90 (l) Retighten the bearing cap bolts 90 in the sequence as
Front (m) Check that the painted mark is now at a 90 angle to the
90
front.
(n) Check that the crankshaft turns smoothly.
A23058
(o) Using several steps, uniformly tighten the 8 main bearing

4
1 cap bolts in the sequence as shown in the illustration.
2 Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
3 7
6
5
A23059
Author: Date: 3342

EM-135
13. INSTALL PISTON W/CONNECTING ROD

Front Mark (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 each
cylinder with the front mark of the piston facing forward.
NOTICE:
A23074 Clean the backside of the bearing and the bearing
surface of the connecting rod cap and prevent oil
from 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.
Protrusion
A23023
(f) Using SST, tighten the bolts alternately to the specified

torque.
SST 09011-38121
A23024
Painted Mark (g) Mark the front side of each connecting cap bolt with paint.
90 (h) Retighten the cap bolts 90 as shown.
(i) Check that the crankshaft turns smoothly.
Front 90 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 seal
retainer and cylinder block.
A23025
Author: Date: 3343

EM-136
Seal Packing (b) Apply a continuous bead of seal packing (diameter 2 to

3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown
in 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.
Seal Width: 2 to 3 mm (0.08 to 0.12 in.)
A23004 (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

Adhesive (a) Apply adhesive to 2 or 3 threads of the drain cock ends.
or equivalent
A23018
(b) After tightening the drain cocks to the specified torque, ro-
tate them clockwise as shown in the illustration.
NOTICE:
Do not rotate the drain cocks more than 1 complete
45 15
revolution (360) after tightening the drain cocks to
the specified torque.
Do not loosen the drain cocks after setting them cor-
45 45
A23019 rectly.
Author: Date: 3344

EM-137
16. INSTALL KNOCK SENSOR

LH Bank Upper (a) Install the 2 knock sensors with the 2 bolts within a 15°
Engine angle as shown in the illustration.
Rear Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf)
15
(b) Connect the knock sensor connectors.
RH Bank Upper
Engine
Front 15
A23005
17. INSTALL WATER OUTLET PIPE NO.1

Install the water outlet pipe with the 3 bolts.
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft·lbf)
A22979
Author: Date: 3345

EM-126
EM1Y1-01
REPLACEMENT
1. REPLACE CONNECTING ROD SMALL END BUSH
SST
Using SST and a press, press out the bushing.
SST 09222-30010
EM6363
2. INSTALL CONNECTING ROD SMALL END BUSH

(a) Align the oil holes of a new bushing and the connecting
rod.
A23043
(b) Using SST and a press, press in the bushing.

SST 09222-30010
SST
EM6363
(c) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance between the bushing and
piston pin.
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-
EM6535 ing rod with a thumb.
P20668
Author: Date: 3334

EM-127
3. REPLACE ENGINE REAR OIL SEAL

HINT:
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.
A22982
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223-78010
(3) Apply MP grease to the oil seal lip.
SST
A23003
(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.
Cut Position NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
A23080
(3) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-78010
(4) Apply MP grease to a new oil seal lip.
SST
A23081
Author: Date: 3335

EM-53
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
CYLINDER HEAD
EM1XO-01
COMPONENTS
7.5 (76, 66 in.·lbf)
V-Bank Cover
Air Cleaner Hose 8.0 (82, 71 in.·lbf)
Vacuum Hose
Mass Air Flow
Meter Connector
Ventilation Hose No.2 Air Cleaner
Battery Clamp
Battery
Battery Tray
N·m (kgf·cm, ft·lbf) : Specified torque A23192
Author: Date: 3261

EM-54
Radiator
Fan Shroud
Fan w/ Fluid Coupling
Fan Pulley
21 (214, 15)
Drive Belt
Author: Date: 3262

EM-55
VSV Connector
28 (286, 21)
Water By-pass Hose
x4 Intake Air Surge Tank
x2
VSV Connector
Fuel Vaper Feed Hose
Throttle Body Surge Tank Stay No.2

Connector
21 (214, 15)
21 (214, 15)
Throttle Body Bracket
Ventilation Hose No.1
21 (214, 15)
Surge Tank Stay No.1
Gasket
Oil Baffle Plate
Vane Pump
9.0 (92, 80 in.·lbf)
43 (438, 32)
9.8 (100, 7)
Terminal Cap
Generator
43 (438, 32)
Generator Wire
Generator Connector
Cooler Compressor
8.0 (82, 71 in.·lbf)
43 (438, 32)
8.0 (82, 71 in.·lbf)

25 (255, 18)
Wire Harness Clamp Bracket
N·m (kgf·cm, ft·lbf) : Specified torque Cooler Compressor Connector

Non-reusable part A22959
Author: Date: 3263

EM-56
40 (408, 30)
Gasket Manifold Stay

40 (408, 30)
21 (214, 15)
Gasket
x6
9.0 (92, 80 in.·lbf)
RH Exhaust Manifold 43 (440, 32)
RH Front Exhaust Pipe Gasket Water By-pass Joint
x2 Spring
62 (630, 46) Ventilation Hose
Gasket
Upper Radiator Hose O-ring
Gasket
9.0 (92, 80 in.·lbf)
Ventilation Hose
Manifold Stay
40 (408, 30)
40 (408, 30)
40 (408, 30)
Gasket 48 (490, 35)
Lower Radiator Hose

LH Exhaust Manifold x6
Gasket
21 (214, 15)
Gasket
x2
N·m (kgf·cm, ft·lbf) : Specified torque
62 (630, 46) LH Front Exhaust Pipe
Author: Date: 3264

EM-57
26 (265, 19)
Intake Manifold
x10 9.0 (92, 80 in.·lbf)
Oil Level Gauge
Gasket
10 (102, 7)
Ignition Coil Spark Plug 9.0 (92, 80 in.·lbf)

10 (102, 7)
Camshaft Timing
Oil Control Valve Ignition Coil
Water By-pass
Water By-pass Hose No.1 Hose No.2
Water By-pass Hose No.3
Oil Filter Cap

O-ring
Spark Plug
Gasket
9.0 (92, 80 in.·lbf)
x5 Water Inlet Oil Filter Cap

Housing
9.0 (92, 80 in.·lbf)
Idler Pulley No.2

Gasket
Washer Idler Pulley No.1 V-Ribbed Belt Tensioner
39 (398, 29) Washer

54 (551, 40)
36 (367, 27)

36 (367, 27)
Author: Date: 3265

EM-58
9.0 (92, 80 in.·lbf)
9.0 (92, 80 in.·lbf) 10 (102, 7)

Seal Washer x3 Seal Washer
9.0 (92, 80 in.·lbf) Ventilation Valve
x3 x7 x3 27 (275, 20)
10 (102, 7)
x3
Cylinder Head
x7
Cover RH
9.0 (92, 80 in.·lbf)
9.0 (92, 80 in.·lbf)
Cylinder Head
Cover LH
VVT Sensor
Cylinder Head Cover Gasket VVT Sensor
Cylinder Head Cover Gasket
Gasket
Filter
62 (632, 46)
9.0 (92, 80 in.·lbf)

Filter
Gasket
O-ring 62 (632, 46)
O-ring
Oil Level Gauge Guide
x2
21 (214, 15) 10 (102, 7)
x2
Oil Pan
x9 x6 Gasket x4
21 (214, 15)
37 (377, 27)
Oil Strainer
21 (214, 15)
9.0 (92, 80 in.·lbf)
Oil Pan No.2
9.0 (92, 80 in.·lbf) x15

x2 10 (102, 7)
Gasket
Drain Plug
Non-reusable part 40 (408, 30) A23198
Author: Date: 3266

EM-59
23 (235, 17)
Crankshaft Pulley
Oil Seal x15
250 (2,549, 184) Timing Chain Cover
19 (194, 14)
23 (235, 17) 19 (194, 14)

Chain Tensioner No.2
x9 Chain Tensioner No.2
Camshaft Timing
Sprocket
23 (235, 17) Timing Chain No.2
x2
Camshaft Timing
Gear Assembly
Timing Chain No.2
100 (1,020, 74)
Camshaft Timing
Gear Assembly 100 (1,020, 74)
100 (1,020, 74) Camshaft Timing
100 (1,020, 74)
Sprocket
10 (102, 7)
Chain Vibration
Damper No.2
Timing Chain
Chain Tensioner
Slipper
Idle Gear Shaft No.2

60 (612, 44)
Idle Gear No.1

O-ring
Crankshaft Timing
Sprocket
N·m (kgf·cm, ft·lbf) : Specified torque Chain Vibration
19 (194, 14) Damper No.1
Author: Date: 3267

EM-60
9.0 (92, 80 in.·lbf)
24 (245, 18)
Camshaft Bearing Cap No.1

24 (245, 18)
9.0 (92, 80 in.·lbf)
Camshaft Bearing
Camshaft Bearing Cap No.2
9.0 (92, 80 in.·lbf) Cap No.2
24 (245, 18) 24 (245, 18)
9.0 (92, 80 in.·lbf)
Camshaft
Camshaft Camshaft Bearing Cap No.1
Camshaft Bearing No.1
Camshaft Bearing
Camshaft Bearing Cap No.2 Cap No.2
Camshaft
Camshaft
Camshaft Bearing Cap No.1 See page EM-89
See page EM-89 1st 36 (367, 27)

2nd Turn 180 x8
1st 36 (367, 27)
x8 2nd Turn 180 x8
30 (306, 22)
Camshaft Bearing No.2 x2
Plate Washer
x8
Cylinder Head LH
Cylinder Head RH
RH Cylinder Head Gasket

LH Cylinder Head Gasket

Author: Date: 3268

EM-61
Valve Lifter
Valve Spring Retainer Lock
Valve Spring Retainer
Inner Compression Spring
Valve Stem Oil Seal
Exhaust Valve Guide Bush Valve Spring Seat
Intake Valve Guide Bush
Intake Valve
Exhaust Valve
Author: Date: 3269

EM-68
EM1XQ-01
DISASSEMBLY
1. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifter in the correct order.
A22924
2. REMOVE VALVE
SST HINT:
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)
Wooden Block
A22925 (c) Remove the valve, inner compression spring, valve
spring and valve spring retainer.
3. REMOVE VALVE SPRING SEAL
Using compressed air and a magnetic finger, remove the valve
spring seat by blowing air.
A22926
4. REMOVE VALVE STEM OIL SEAL

Using needle-nose pliers, remove the valve stem oil seal.
A22927
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.
A22928
Author: Date: 3276

EM-69
(b) Using a wire brush, remove all the carbon from the com-
bustion chambers.
NOTICE:
Be careful not to scratch the combustion chambers.
A22929
(c) Using a valve guide bushing brush and solvent, clean all
the valve guide bushes.
A22930
(d) Using a soft brush and solvent, thoroughly clean the cylin-
der head.
A22931
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.
EM0580
Author: Date: 3277

EM-70
EM1XR-01
INSPECTION
1. INSPECT CYLINDER HEAD
(a) Inspect flatness.
Using a precision straight edge and feeler gauge, mea-
sure the flatness of the contact surfaces of the cylinder
block and manifolds.
Cylinder Block Side:
If warpage is greater than the maximum, replace the cylinder
head.
Intake Manifold Side:
Exhaust Manifold Side:
A22932
(b) Inspect cranks.

Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
A22933
Author: Date: 3278

EM-71
2. INSPECT INTAKE MANIFOLD FOR FLATNESS

Intake Air Surge Tank Side Using a precision straight edge and feeler gauge, mea-
sure the flatness of the contact surfaces of the cylinder
head 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 intake
manifold.
Cylinder Head Side
A22967
3. INSPECT EXHAUST MANIFOLD FOR FLATNESS

Using a precision straight edge and feeler gauge, measure the
flatness of the contact surface the cylinder head.
If warpage is greater than the maximum, replace the exhaust
manifold.
HINT:
Maximum warpage of each installation surface:
A22968 0.3 mm (0.012 in.)
4. INSPECT VALVE
(a) Inspect valve stem diameter.
Using a micrometer, measure the diameter of the valve
stem.
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.)
Z00052
(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
44.5
Z00054
Author: Date: 3279

EM-72
(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 the
valve.
EM0181
(d) Inspect overall length.

Using vernier calipers, check the overall length.
Standard overall length:
Intake 106.95 mm (4.2106 in.)
Overall
Length Exhaust 105.80 mm (4.1654 in.)
Minimum overall length:
Intake 106.40 mm (4.1890 in.)
Exhaust 105.30 mm (4.1457 in.)
EM2534
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 or
replace the valve.
EM0255
5. CLEAN VALVE SEAT

(a) Using a 45 carbide cutter, resurface the valve seats.
(b) Clean the valve seats.
A22934
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:
Width
Do not rotate the valve.
(c) Check the valve face and seat according to the following
procedure.
P12729 (1) If prussian blue (or white lead) appears around the
entire face, the valve is centered.
Author: Date: 3280

EM-73
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 SEAT

NOTICE:
45 Take off a cutter gradually to make the intake valve seat
30 smooth.
(a) If the seating is too high to the valve face, use 30 and 45
cutters to correct the seat.
1.0 to 1.4 mm
A01476
Intake Side: (b) Intake side:

If the seating is too low to the valve face, use 60 and 45
60
cutters to correct the seat.
45
1.0 to 1.4 mm
A23191
Exhaust Side: (c) Exhaust side:

If the seating is too low to the valve face, use 75 and 45
75 cutters to correct the seat.
45
1.0 to 1.4 mm
A01477
(d) Handrub the valve and valve seat with an abrasive com-
pound.
(e) After handrubbing, clean the valve and valve seat.
A22935
Author: Date: 3281

EM-74
8. INSPECT INNER COMPRESSION SPRING

Deviation
(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 inner
compression spring.
EM0988
(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.
EM0801
(c) Inspect tension.

Using a spring tester, measure the tension of the inner
compression 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) at
33.3 mm (1.311 in.)
If the installed tension is not as specified, replace the inner com-
pression spring.
EM0281
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.
A22936 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..)
valve and valve guide bush.
Author: Date: 3282

EM-75
10. INSPECT VALVE LIFTER

Using a micrometer, measure the valve lifter diameter.
Valve lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
P16860
11. INSPECT VALVE LIFTER OIL CLEARANCE

(a) Using a caliper gauge, measure the lifter bore diameter
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.
A22942 0.033 to 0.059 mm (0.0013 to 0.0023 in.)
valve lifter.
If necessary, replace the cylinder head.
12. INSPECT CAMSHAFT OIL CLEARANCE

Plastigage (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 ).
A22943 NOTICE:
Do not turn the camshafts.
(f) Remove the camshaft bearing caps (See page EM-62 ).
Author: Date: 3283

EM-76
(g) Measure the Plastigage at its widest point.

Standard oil clearance (Cylinder head RH):
No. 1
0.008 to 0.038 mm (0.0003 to 0.0015 in.)
(Intake)
No. 1
0.040 to 0.079 mm (0.0016 to 0.0031 in.)
(Exhaust)
Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Standard oil clearance (Cylinder head LH):
A22944
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
0.07 mm (0.0028 in.)
(Intake)
Others 0.10 mm (0.0039 in.)
Maximum oil clearance (Cylinder head LH):

0.10 mm (0.0039 in.)
camshaft bearings and/or camshaft.
If necessary, replace the camshaft bearing caps and cylinder
head together.
Reference:
Cylinder head journal
40.009 to 40.017 mm (1.5752 to 1.5755 in.)
bore diameter
Camshaft bearing
center wall thickness 2.004 to 2.008 mm (0.0789 to 0.0791 in.)
(Mark ”2”)
Camshaft journal di-
35.971 to 35.985 mm (1.4165 to 1.4167 in.)
ameter
(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.
0.04 to 0.09 mm (0.0016 to 0.0035 in.)
If the thrust clearance is greater than the maximum, replace the
A22945 camshafts.
Author: Date: 3284

EM-77
If necessary, replace the camshaft bearing caps and cylinder

head 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
.
A22983
(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.)
EM2011 If the cam lobe height is less than the minimum, replace the
camshaft.
(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.
A22984
Author: Date: 3285

EM-78
(b) Align the knock pin hole in the camshaft timing gear as-
Knock Pin sembly with the knock pin of the camshaft, and install the
camshaft 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.
A22985
(d) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with mask-
Retard Side ing tape as shown in the illustration.
Paths
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 oil
Advance paths. Plug one of the oil paths for each groove with rubber
Side Paths pieces before wrapping the cam journal with tape.
(2) Prick a hole in the tape placed on the advance side
path. Prick a hole in the retard side path, on the op-
posite side to that of the advance side path, as
Open Close
Close Open
Rubber
Piece Masking Tape
A22986
(3) Apply about 200 kPa (2.0 kgf/cm2) of air pressure

Advance to the two broken paths (the advance side path and
Retard
Side Path Side Path the retard side path).
NOTICE:
Cover the paths with a shop rag to avoid oil splashing.
A22987
(4) Confirm that the camshaft timing gear assembly ro-

Advance Retard tates in the advance direction when reducing the air
Side Path Side Path
pressure applied to the retard path.
HINT:
When the lock pin is released, the camshaft timing gear rotates
in the advance direction.
(5) When the camshaft timing gear comes to the most
advanced position, release the air pressure from
Hold Pressure Decompress
A22988 the retard side path, and then release the air pres-
sure from the advance side path.
Author: Date: 3286

EM-79
NOTICE:
The camshaft timing assembly gear occasionally shifts to
the retard side abruptly if the air pressure of the advanced
side path is released first. This often results in breakage of
the lock pin.
(e) Check for smooth revolution.
Allow the camshaft timing gear assembly to turn back and
forth at any position, except where the lock pin meets at
the most retarded angle. Check the movable range and
that 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 locked
at the most retarded position.
(g) Remove the set bolt and camshaft timing gear assembly.
NOTICE:
Be sure not to remove the other 3 bolts.
Set Bolt
A22989
16. INSPECT CYLINDER HEAD SET BOLT

Using a vernier caliper, measure the outside thread diameter of
the 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.)
A22890
Author: Date: 3287

EM-89
EM1XU-01
INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
not to drop any oil on the contact surfaces of the cylinder
head and cylinder block.
(b) Install the RH cylinder head gasket.
(1) Apply a continuous bead of seal packing (diameter

10 to 15 mm 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder
head gasket as shown in the illustration.
φ 2.5 to 3 mm NOTICE:
Install the cylinder head within 3 minutes after applying
Gasket
seal packing. After installing it, the cylinder head bolts
must be tightened within 15 minutes. Otherwise the seal
1.25 to packing must be removed and reapplied.
1.5 mm
10 to 15 mm
Seal Packing A22891
(2) Place the cylinder head gasket on the cylinder block

Lot No. surface 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.
A22892
Author: Date: 3297

EM-90
(c) Install the LH cylinder head gasket.

10 to 15 mm
2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder
φ 2.5 to 3 mm head gasket as shown in the illustration.
Gasket Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the cylinder head within 3 minutes after applying
1.25 to seal packing. After installing it, the cylinder head bolts
1.5 mm must be tightened within 15 minutes. Otherwise the seal
packing must be removed and reapplied.
10 to 15 mm
Seal Packing A22914
(2) Place the cylinder head gasket on the cylinder block

surface with the Lot No. stamp upper sied facing up-
ward.
NOTICE:
Place the cylinder head carefully in order not to dam-
age the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD
Lot No. A22915 (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 mm

6 4 2 7
bi-hexagon wrench uniformly in the sequence as
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
NOTICE:
8 1 3 5 Do not drop the washers into the cylinder head.
A22888
Author: Date: 3298

EM-91
(4) Mark the front side of each cylinder head bolt with
180 paint.
(5) Retighten the cylinder head bolts by 180 as
shown.
Engine (6) Check that the painted marks are now at 180 op-
Front
posite to the engine front.
(c) Place the LH cylinder head on the cylinder head gasket.
Paint Mark (d) Install the 8 cylinder head bolts.
A22893 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.
cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.
(3) Using several steps, tighten each bolt with a 10 mm

8 1 3 5 bi-hexagon wrench uniformly in the sequence as
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
NOTICE:
Do not drop the washers into the cylinder head.
6 4 2 7
A22912
(4) Mark the front side of each cylinder head bolt with
180 paint.
(5) Retighten the cylinder head bolts by 180 as
shown.
Engine (6) Check that the painted marks are now at 180 op-
Front
posite to the engine front.
Paint Mark
A22893
(e) Install the 2 cylinder head bolts.

1 cylinder head bolts.
(2) Install the 2 cylinder head bolts. Using several
steps, tighten the bolts uniformly in the sequence as
2 shown in the illustration.
A22911
Author: Date: 3299

EM-92
3. INSTALL CAMSHAFT BEARING NO.1

Align the bearing claw with the claw groove of the bearing cap,
and push in the camshaft bearing.
NOTICE:
Claw 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-
A23006 ing to them.
4. INSTALL CAMSHAFT BEARING NO.2

Install the camshaft bearing No. 2 to the cylinder head.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the cylinder head and prevent oil from adhering to them.
5. INSTALL CAMSHAFT
NOTICE:
As the thrust clearance of the camshaft is small, the cam-
A22894 shaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
which receives the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
(a) Set the crankshaft position.

90 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 the
Set Key
piston head and valve head to come into contact with each
Turn other when you install the camshaft, causing damage. So
A22895 always set the crankshaft at the correct angle.
(b) Apply new engine oil to the thrust portion and journal of
the camshafts.
Author: Date: 3300

EM-93
RH 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 each
direction as shown in the illustration.
A22896
RH Bank (2) Install the 8 bearing caps in their proper locations.

bearing cap bolts.
A22897
RH Bank (4) Install the 16 bearing cap bolts. Using several

6
14 10 2 shown in the illustration.
Torque:
13 9 1 5 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head
15 11 3 7 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head
16 12 4 8
A22898
RH Bank (5) Turn the camshafts clockwise with a wrench until

the camshaft knock pin comes 90 position to the
Turn
cylinder head.
Turn
90
90
A22899
LH Bank
(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 shown
A22917
Author: Date: 3301

EM-94
LH Bank (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.
A22918
LH Bank
(4) Install the 16 bearing cap bolts. Using several
6
2 10 14 shown in the illustration.
Torque:
5 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head
1 3 9 11 13 15
7 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head
6. INSTALL TIMING CHAIN (See page EM-44 )
4 12 16 7. INSTALL TIMING CHAIN COVER (See page EM-44 )
8
A22910 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 the
oval shape facing forward.
Oval Shape
NOTICE:
Forward
A22906
(2) Install the exhaust manifold with the 6 nuts. Tighten

the nuts uniformly in several steps.
(3) Connect the A/F sensor connector.
(4) Install the manifold stay with the 3 bolts.
A23251
(b) Install the LH exhaust manifold.

(1) Set a new gasket to the LH cylinder head with the
oval shape facing backward.
Oval shape NOTICE:
Forward
A22922
Author: Date: 3302

EM-95
(2) Install the exhaust manifold with the 6 nuts. Tighten

the nuts uniformly in several steps.
(3) Connect the A/F sensor connector.
(4) Install the manifold stay with the 3 bolts.
10. INSTALL RH AND LH FRONT EXHAUST PIPE
(See page EM-138 )
A23252 11. INSTALL VVT SENSOR (See page IG-12 )
12. INSTALL OIL CONTROL VALVE FILTER

Mesh Part (a) Check that no foreign objects on the mesh part of the 2
filters.
Apply
Adhesive (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.
LOCTITE 242 or equivalent
A23017 (e) Install the plugs to each cylinder head.
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.
A22904
(c) Install 2 new gaskets and water by-pass joint with the 2
bolts and 4 nuts.
(d) Connect the heater hose.
(e) Connect the engine coolant temperature sensor connec-
tor.
A22883
Author: Date: 3303

EM-96
15. INSTALL INTAKE MANIFOLD

(a) Set a new gasket on each cylinder head.
NOTICE:
Align the port holes of the gasket and cylinder head.
(b) Set the intake manifold on the cylinder heads.
A22905
(c) Install and tighten the 10 bolts uniformly in several steps.

(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 be
careful not to drop any oil on the contact surfaces
of the cylinder head, timing chain cover and cylinder
A22882 head cover.

Seal Packing
2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
NOTICE:
Install the cylinder head cover within 3 minutes after apply-
ing seal packing. After installing it, cylinder head cover
bolts and nuts must be tightened within 15 minutes. Other-
Seal Width: 2 to 3 mm A23016 wise the seal packing must be removed and reapplied.
(3) Install the seal washers to the bolts.
B (4) Install the cylinder head cover with the 10 bolts and
B B B 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 2
B A A A
nuts.
B Nut B NutA23092 Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(c) Install the LH cylinder head cover.

Seal Packing
2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
NOTICE:
Install the cylinder head cover within 3 minutes after apply-
ing seal packing. After installing it, cylinder head cover
Seal Width: 2 to 3 mm A23015 bolts and nuts must be tightened within 15 minutes. Other-
wise the seal packing must be removed and reapplied.
Author: Date: 3304

EM-97
(2) Install the seal washers to the bolts.
B (3) Install the cylinder head cover with the 10 bolts and
B B
B 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)
B Bolt B: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
A 17. INSTALL IGNITER
A A B
Nut B Nut A22970
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.
(c) Install the 2 intake air surge tank nuts.
A23091
(d) Install the 2 surge tank stays with the 4 bolts.

(e) Install the oil baffle plate with the bolt.
A23090
(f) Install the throttle body bracket with the 2 bolts.

A23089
Author: Date: 3305

EM-98
(g) Install the 3 wire harness clamps and hose clamp.

(h) Connect the throttle body w/ motor connector.
(i) Connect the 2 VSV connectors.
A23088
(j) Connect the ventilation hose.
A23087
(k) Connect the fuel vapor feed hose.
A23086
(l) Connect the 2 water by-pass hoses.

19. CONNECT HEATER WATER OUTLET AND INLET
HOSE
20. 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
A23085
Author: Date: 3306

EM-99
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 the
holes to fix the belt tensioner.
(b) Install the V-ribbed belt.
(c) While turning the belt tensioner counterclockwise, re-
move the bar.
Turn
Holes
A22798
Water Pump Generator

(d) If it is hard to install the V-ribbed belt, perform the follow-
P/S Pump Idler No. 2 ing procedure.
(1) Put the V-ribbed belt on every parts except the P/S
pump as shown in the illustration.
Tensioner (2) While releasing the belt tension by turning the belt
tensioner counterclockwise, put the V-ribbed belt
Idler No. 2 on the P/S pump.
Crankshaft
Idler No. 1 A/C Compressor
A22799
25. TIGHTEN FAN W/FLUID COUPLING

Tighten the 4 fluid coupling bolts.
26. INSTALL RADIATOR (See page CO-18 )
27. INSTALL FAN SHROUD
28. CONNECT FUEL PIPE (See page SF-1 )
A23114
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.
A23210
Author: Date: 3307

EM-100
(c) Install the 2 wire harness clamps.

(d) Connect the mass air flow meter connector.
(e) Connect the vacuum hose.
A23209
(f) Connect the ventilation hose No.2.

30. ADD ENGINE COOLANT
31. ADD ENGINE OIL
32. CHECK FOR LEAK
A23095
33. INSTALL V-BANK COVER

Install the V-bank cover with the 2 nuts.
Torque: 7.5 N·m (76 kgf·cm, 66 in.·lbf)
A23407
Author: Date: 3308

EM-82
EM1XT-01
REASSEMBLY
1. INSTALL RING PIN
Using a plastic-faced hammer, tap in the new ring pins until
they reach the specified protrusion height.
Specified protrusion height:
2.7 to 3.3 mm (0.106 to 0.130 in.)
Cylinder Head RH Side: Cylinder Head LH Side:
11 mm
Protrusion
8 mm Height
Engine Engine
Front Front
A22946
Author: Date: 3290

EM-83
2. INSTALL STRAIGHT PIN

Using a plastic-faced hammer, tap in the new straight pins until
they 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.)
Cylinder Head RH Side:

Upper Side:
Front Side:
B
Cylinder Head LH Side: C

Upper Side:
Front Side:
B
8 mm
5 mm
Protrusion
34 mm Height 13.8 mm Protrusion
Height
C
B and C
A
A22947
Author: Date: 3291

EM-84
3. INSTALL STUD BOLT

Using 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, C
19.5 N⋅m (199 kgf⋅cm, 14 ft·lbf) for stud bolt B
Cylinder Head RH Side:
Upper Side:
Rear Side:
Exhaust Manifold Side:
Cylinder Head LH Side:

B
Upper Side:
Rear Side:
C
A
Exhaust Manifold Side: 20 mm

12 mm
16 mm
33.3 mm 42 mm 27 mm
9 mm 13 mm 9 mm
B A B C
A22948
Author: Date: 3292

EM-85
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.
Adhesive
A22949
Cylinder Head RH (Front) Side: Cylinder Head LH (Intake Manifold) Side:
A B
67 mm
9 mm 9 mm
30 mm
A B A22950
Author: Date: 3293

EM-86
5. INSTALL TIGHT PLUG

(a) Apply adhesive around the tight plugs.
Adhesive (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.)
A22951
Cylinder Head RH (Rear) Side: Cylinder Head LH (Rear) Side:
SST
Depth
1.5 mm
A22952
Author: Date: 3294

EM-87
6. INSTALL STRAIGHT SCREW PLUG

(a) Using a straight hexagon wrench 14, install a new gasket
and straight screw plug.
Cylinder Head RH Side: Cylinder Head LH Side:

Upper Side: Upper Side:
Front Side: Front Side:
A22953
7. INSTALL VALVE STEM OIL SEAL

Light Brown
HINT:
Gray
The intake valve stem oil seal is light brown and the exhaust
valve stem oil seal is gray.
(a) Apply a light coat of engine oil to the valve guide bush.
Intake Side: Exhaust Side:

A22954
SST
(b) Using SST, push in a new valve stem oil seal.
SST 09201-41020
A22955
Author: Date: 3295

EM-88
8. INSTALL VALVE SPRING SEAT
A22956
9. INSTALL VALVE
(a) Apply engine oil to the valve as shown in the illustration.
35 mm
(1.378 in.)
A22957
(b) Place the cylinder head on a wooden block.

SST (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 valve
stem.
SST 09202-70020 (09202-00010)
Wooden Block
A22925
(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.
A22958
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.
A22924
Author: Date: 3296

EM-62
EM1XP-01
REMOVAL
1. PREVENT GASOLINE FROM SPILLING OUT
2. DRAIN ENGINE COOLANT (See page CO-2 )
3. DRAIN ENGINE OIL (See page LU-3 )
4. REMOVE V-BANK COVER

Remove the 2 nuts and V-bank cover.
A23208
5. REMOVE AIR CLEANER

(a) Disconnect the ventilation hose No.2.
A23095
(b) Disconnect the vacuum hose.

(c) Disconnect the mass air flow meter connector.
(d) Remove the 2 wire harness clamps.
A23209
(e) Loosen the 2 hose clamps.

(f) Remove the 2 bolts and air cleaner
6. DISCONNECT FUEL PIPE (See page SF-1 )
7. REMOVE FAN SHROUD
8. REMOVE RADIATOR (See page CO-17 )
A23210
Author: Date: 3270

EM-63
9. LOOSEN FAN W/FLUID COUPLING

Loosen the 4 nuts of the fan w/ fluid coupling.
A23114
10. REMOVE DRIVE BELT

Release the belt tension by turning the belt tensioner counter-
clockwise. Remove the V-ribbed belt from the belt tensioner.
11. REMOVE FAN W/FLUID COUPLING
12. SEPARATE VANE PUMP (See page SR-47 )
13. REMOVE GENERATOR (See page CH-7 )
14. SEPARATE COOLER COMPRESSOR
(See page AC-54 )
A22797 15. DISCONNECT HEATER WATER OUTLET AND INLET
HOSE
16. REMOVE INTAKE AIR SURGE TANK

(a) Disconnect the 2 water by-pass hoses.
A23085
(b) Disconnect the fuel vapor feed hose.
A23086
Author: Date: 3271

EM-64
(c) Disconnect the ventilation hose.
A23087
(d) Disconnect the 2 VSV connectors.

(e) Disconnect the throttle body w/ motor connector.
(f) Separate the 3 wire harness clamps and hose clamp.
A23088
(g) Remove the 2 bolts and throttle body bracket.
A23089
(h) Remove the bolt and oil baffle plate.

(i) Remove the 4 bolts and 2 surge tank stays.
A23090
Author: Date: 3272

EM-65
(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 )
A23091
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.
A22970
(c) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder

head cover LH and gasket.
19. REMOVE INTAKE MANIFOLD
(a) Disconnect the 6 fuel injector connectors.
A23092
(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.
A22882
(c) Remove the 2 bolts, 4 nuts, water by-pass joint RR and

2 gaskets.
(d) Remove the O-ring from the water outlet pipe.
21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
A22883
Author: Date: 3273

EM-66
22. REMOVE OIL CONTROL VALVE FILTER

RH Bank LH Bank
Remove the plug, filter and gasket from each cylinder head.
23. REMOVE VVT SENSOR
24. REMOVE RH AND LH FRONT EXHAUST PIPE
25. 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.
A22969 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 CAMSHAFT
NOTICE:
shaft must be kept level while it is being removed. If the
RH Bank (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 cylinder
face each direction as shown in the illustration.
A22886
RH Bank (2) Using several steps, uniformly loosen and remove

the 16 bearing cap bolts in the sequence as shown
15 11
3 7 in the illustration.
(3) Remove the 8 bearing caps and 2 camshafts.
4 8 16 12
2 6 14
10
1 5 13 9
A22887
LH Bank (b) Remove the camshafts of the LH bank.

(1) Using several steps, uniformly loosen and remove
11 the 16 bearing cap bolts in the sequence as shown
15 7 3
12 (2) Remove the 8 bearing caps and 2 camshafts.
16 8 4
10 14 6 2 30. REMOVE CAMSHAFT BEARING NO.1 AND NO.2
9 13 5 1
A22910
Author: Date: 3274

EM-67
LH Cylinder Head 31. REMOVE CYLINDER HEAD

(a) Using several steps, remove the 2 cylinder head bolts on
2 the LH cylinder head in the sequence as shown in the il-
lustration.
A22911
RH Cylinder Head (b) Using several steps, loosen the 8 cylinder head bolts on
3 5 7 2 each cylinder head with a 10 mm bi-hexagon wrench in
the sequence as shown in the illustration. Remove the 16
cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the plate washers into the cylin-
der head.
1 8 6 4 Cylinder head warpage or cracking could result from
removing the bolts in the incorrect order.
LH Cylinder Head
1 8 6 4
3 5 7 2
A22977
(c) Lift the cylinder head from the dowels on the cylinder
block, and place the 2 cylinder heads on wooden blocks
on 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 cylinder
A22978 head and cylinder block with a screwdriver.
(d) Remove the RH and LH cylinder head gaskets.
32. REMOVE CYLINDER HEAD GASKET
Author: Date: 3275

EM-80
EM1XS-01
REPLACEMENT
1. REPLACE VALVE GUIDE BUSH
(a) Gradually heat the cylinder head to between 80 and
100C (176 to 212F).
A22937
(b) Place the cylinder head on a wooden block.

SST (c) Using SST, tap out the valve guide bush.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
Wooden Block
A22938
(d) Using a caliper gauge, measure the bush bore diameter

of the cylinder head.
Bush bore diameter:
Diameter 10.295 to 10.315 mm (0.4053 to 0.4061 in.)
If the bush bore diameter of the cylinder head is greater than
10.315 mm (0.4061 in.), machine the bush bore to dimensions
of 10.345 to 10.365 mm (0.4073 to 0.4081 in.).
Valve guide bush diameter
A22939 STD 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 and

100C (176 to 212F).
A22937
Author: Date: 3288

EM-81
(f) Place the cylinder head on a wooden block.

SST
Protrusion (g) Using SST, tap in a new valve guide bush to the specified
Height 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.)
Wooden Block
A22940
(h) Using a sharp 5.5 mm reamer, ream the valve guide bush
to obtain the standard specified clearance between the
valve guide bush and valve stem.
Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
A22941
Author: Date: 3289

EM-101
ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT
ENGINE UNIT
EM1XV-01
COMPONENTS
7.5 (76, 66 in.·lbf) V-Bank Cover
Hood
Air Cleaner Hose No.2
Air Cleaner Assembly

MAF Meter Connector
Heater Hose
Battery Clamp
Battery
Battery Tray
Fuel Pipe Fuel Pipe Clamp

Author: Date: 3309

EM-102
No.1 Fan Shroud 5.0 (50, 44 in.·lbf)
Radiator Assembly
No.2 Fan Shroud
12 (120, 9)
Oil Cooler Pipe for

AutomaticTransmission
V-Belt Fan w/ Fluid Coupling Fan Pulley
Author: Date: 3310

EM-103
12 (122, 9) 34 (346, 25)

Clamp
Transmission
71 (724, 52)
Oil Cooler Pipe

Shift Control Cable
2.0 Kw:
Torque
Converter
Clutch x6 14.5 (148, 11)
19.5 (199, 14)
48 (490, 35) 37 (377, 27)
Starter
37 (377, 27)
9.8 (100, 7)
9.8 (100, 7) Flywheel Housing Side Cover
Engine Rear
48 (490, 35) 1.6 Kw:
40 (408, 30) Mounting Insulator
Front Exhaust Pipe RH 43 (440, 32) Starter
Manifold Stay 65 (660, 48)
40 (408, 30) Gasket

72 (734, 53)
Spring Front Exhaust

Gasket
Gasket Pipe LH
Manifold Stay
18 (185, 13)
Crossmember
62 (630, 46)
Gasket
Exhaust Pipe Support

62 (630, 46)
Propeller Shaft
37 (377, 27)
88 (897, 65)
40 (410, 30)
Bushing
Stabilizer Bar Bracket
Stabilizer Bar

Non-reusable part Engine Under Cover
D14136
Author: Date: 3311

EM-104
Water By-pass Hose

VSV Connector
Throttle Body Motor

VSV Connector
Connector
Vane Pump Connector
Generator
43 (438, 32)
Generator Wire
43 (438, 32) Vane Pump
Generator Connector
A/C Compressor
25 (255, 18) Wire Harness Clamp Bracket
A/C Compressor
Connector
A23386
Author: Date: 3312

EM-108
EM1XX-01
INSTALLATION
1. INSTALL DRIVE PLATE
HINT:
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:
Adhesive
lent
A04869
(b) Install the front spacer, drive plate and rear spacer on the
crankshaft.
1 (c) Install and uniformly tighten the 8 mounting bolts in sever-
5
8 al steps, in the sequence shown in the illustration.
3 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
4
If any of the mounting bolts do not meet the torque specification,
7 replace it.
6 2
A23391
(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
Painted
Mark it was in step (e).
90° 2. INSTALL ENGINE ASSEMBLY IN VEHICLE
90° (a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine assembly into the engine
A23392 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.
(e) Remove the engine chain hoist.
(f) Remove the 4 bolts and 2 engine hangers.
Author: Date: 3316

EM-109
3. INSTALL PS PUMP
Install the PS pump with the 3 bolts.
A23390
4. INSTALL A/C COMPRESSOR

(a) Install the A/C compressor with the 3 bolts.
(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.
A23389 (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 and
connect the engine wire to the bracket.
(c) Connect the 3 connectors to the ECM.
(d) Connect the 2 wire harness connectors (cassette con-
Connect nector).
(e) Install the ECM with the 3 screws.
(f) Install the heater to register duct.
(g) Install the lower No.2 finish panel.
A09152 (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 BATTERY
A23387 9. INSTALL RADIATOR ASSEMBLY (See page CO-18 )
10. INSTALL FRONT EXHAUST PIPES
(See page EM-139 )
Author: Date: 3317

EM-1 10
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 LEAKS
16. INSTALL ENGINE UNDER COVERS
18. INSTALL HOOD
19. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
20. RECHECK ENGINE COOLANT AND OIL LEVELS
Author: Date: 3318

EM-105
EM1XW-01
REMOVAL
(See page SF-1 )
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE V-BANK COVER
4. REMOVE ENGINE UNDER COVER
5. 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.
A23387 (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.
Author: Date: 3313

EM-106
(f) Disconnect the engine wire from the engine wire bracket
and 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
Disconnect
(a) Disconnect the generator connector.
(b) Disconnect the 2 heater hoses.
(c) Disconnect the ground strap from the cowl panel.
B07536 (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.
A23389
15. DISCONNECT PS PUMP FROM ENGINE

Remove the 3 bolts, and disconnect the PS pump from the en-
gine.
HINT:
Suspend the PS pump securely.
A23390
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 12281-31060
Bolt 90119-08177
A22965 (b) Attach the engine sling device and suspend the engine
using a chain block.
Author: Date: 3314

EM-107
(c) Remove the 4 bolts and 4 nuts, and separate the engine
mounting 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.
A22966
17. REMOVE DRIVE PLATE

Remove the 8 bolts, front spacer, drive plate and rear spacer.
A23391
Author: Date: 3315

EM-101
ENGINE UNIT
EM1XV-01
COMPONENTS
7.5 (76, 66 in.·lbf) V-Bank Cover
Hood
Air Cleaner Hose No.2
Air Cleaner Assembly

MAF Meter Connector
Heater Hose
Battery Clamp
Battery
Battery Tray
Fuel Pipe Fuel Pipe Clamp

Author: Date: 3309

EM-102
No.1 Fan Shroud 5.0 (50, 44 in.·lbf)
Radiator Assembly
No.2 Fan Shroud
12 (120, 9)
Oil Cooler Pipe for

AutomaticTransmission
V-Belt Fan w/ Fluid Coupling Fan Pulley
Author: Date: 3310

EM-103
12 (122, 9) 34 (346, 25)

Clamp
Transmission
71 (724, 52)
Oil Cooler Pipe

Shift Control Cable
2.0 Kw:
Torque
Converter
Clutch x6 14.5 (148, 11)
19.5 (199, 14)
48 (490, 35) 37 (377, 27)
Starter
37 (377, 27)
9.8 (100, 7)
9.8 (100, 7) Flywheel Housing Side Cover
Engine Rear
48 (490, 35) 1.6 Kw:
40 (408, 30) Mounting Insulator
Front Exhaust Pipe RH 43 (440, 32) Starter
Manifold Stay 65 (660, 48)
40 (408, 30) Gasket

72 (734, 53)
Spring Front Exhaust

Gasket
Gasket Pipe LH
Manifold Stay
18 (185, 13)
Crossmember
62 (630, 46)
Gasket

62 (630, 46)
Propeller Shaft
37 (377, 27)
88 (897, 65)
40 (410, 30)
Bushing
Stabilizer Bar Bracket
Stabilizer Bar

Non-reusable part Engine Under Cover
D14136
Author: Date: 3311

EM-104
Water By-pass Hose

VSV Connector
Throttle Body Motor

VSV Connector
Connector
Vane Pump Connector
Generator
43 (438, 32)
Generator Wire
43 (438, 32) Vane Pump
Generator Connector
A/C Compressor
25 (255, 18) Wire Harness Clamp Bracket
A/C Compressor
Connector
A23386
Author: Date: 3312

EM-108
EM1XX-01
INSTALLATION
1. INSTALL DRIVE PLATE
HINT:
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:
Adhesive
lent
A04869
(b) Install the front spacer, drive plate and rear spacer on the
crankshaft.
1 (c) Install and uniformly tighten the 8 mounting bolts in sever-
5
8 al steps, in the sequence shown in the illustration.
3 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
4
If any of the mounting bolts do not meet the torque specification,
7 replace it.
6 2
A23391
(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
Painted
Mark it was in step (e).
90° 2. INSTALL ENGINE ASSEMBLY IN VEHICLE
90° (a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine assembly into the engine
A23392 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.
(e) Remove the engine chain hoist.
(f) Remove the 4 bolts and 2 engine hangers.
Author: Date: 3316

EM-109
3. INSTALL PS PUMP
Install the PS pump with the 3 bolts.
A23390
4. INSTALL A/C COMPRESSOR

(a) Install the A/C compressor with the 3 bolts.
(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.
A23389 (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 and
connect the engine wire to the bracket.
(c) Connect the 3 connectors to the ECM.
(d) Connect the 2 wire harness connectors (cassette con-
Connect nector).
(e) Install the ECM with the 3 screws.
(f) Install the heater to register duct.
(g) Install the lower No.2 finish panel.
A09152 (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 BATTERY
A23387 9. INSTALL RADIATOR ASSEMBLY (See page CO-18 )
10. INSTALL FRONT EXHAUST PIPES
(See page EM-139 )
Author: Date: 3317

EM-1 10
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 LEAKS
16. INSTALL ENGINE UNDER COVERS
18. INSTALL HOOD
19. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
20. RECHECK ENGINE COOLANT AND OIL LEVELS
Author: Date: 3318

EM-105
EM1XW-01
REMOVAL
(See page SF-1 )
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE V-BANK COVER
4. REMOVE ENGINE UNDER COVER
5. 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.
A23387 (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.
Author: Date: 3313

EM-106
(f) Disconnect the engine wire from the engine wire bracket
and 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
Disconnect
(a) Disconnect the generator connector.
(b) Disconnect the 2 heater hoses.
(c) Disconnect the ground strap from the cowl panel.
B07536 (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.
A23389
15. DISCONNECT PS PUMP FROM ENGINE

Remove the 3 bolts, and disconnect the PS pump from the en-
gine.
HINT:
Suspend the PS pump securely.
A23390
16. REMOVE ENGINE ASSEMBLY FROM VEHICLE

(a) Install the 2 engine hangers with the 4 bolts as shown in
the illustration.
Part No. :
Bolt 90119-08177
A22965 (b) Attach the engine sling device and suspend the engine
using a chain block.
Author: Date: 3314

EM-107
(c) Remove the 4 bolts and 4 nuts, and separate the engine
mounting 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.
A22966
17. REMOVE DRIVE PLATE

Remove the 8 bolts, front spacer, drive plate and rear spacer.
A23391
Author: Date: 3315

EM-138
ENGINE MECHANICAL (1GR-FE) - EXHAUST SYSTEM
EXHAUST SYSTEM
EM1Y3-01
COMPONENTS
32 (326, 24)
Clamp

Gasket
Exhaust Tail Pipe

Heated Oxygen
Sensor (Bank 1) 48 (490, 35)
44 (450, 33) 43 (440, 32)
Gasket
Exhaust Center Pipe
48 (490, 35)
Gasket
Gasket Spring
Front Exhaust Pipe RH
Heated Oxygen
62 (630, 46) Sensor (Bank 2)
44 (450, 33)
62 (630, 46)
Gasket
62 (630, 46)
Front Exhaust Pipe LH

Author: Date: 3346

EM-139
EM1Y4-01
REPLACEMENT
1. REMOVE EXHAUST TAIL PIPE
(a) Remove the bolt and clamp.
(b) Remove the 3 exhaust pipe supports and exhaust tail
pipe.
A23249
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)
A23248 (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
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the heated oxygen sensor.
A23247
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.
A23246
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.
(c) Install the exhaust pipe support.
8. INSTALL HEATED OXYGEN SENSOR
(a) Install the heated oxygen sensor.
A23247 Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(b) Connect the heated oxygen sensor connector.
Author: Date: 3347

EM-140
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.
10. INSTALL HEATED OXYGEN SENSOR
(BANK2 OXYGEN SENSOR)
(a) Install the heated oxygen sensor.
A23246 (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.)
Front If the free length is less than minimum, replace the spring.
(b) Install the 2 exhaust pipe supports.
A23075
(c) Install the 2 bolts.

(d) Install the 2 bolts and springs.
A23248
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.
30°
A23250
Author: Date: 3348

EM-25
ENGINE MECHANICAL (1GR-FE) - IDLE SPEED
Hand-Held Tester IDLE SPEED EM1XI-01
INSPECTION
1. 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 connect
the CAN VIM to the Date Link Connector 3 (DLC3).
CAN VIM
(b) Please refer to the hand-held tester operator’s manual
DLC3
D13872
for 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.
TAC 2. When not using a hand-held tester or OBD II scan

tool.
(a) Using SST, connect the tachometer probe to terminal
TAC of the DLC3.
SST 09843-18030
DLC3
SST
(b) Switch the air conditioning OFF.
(c) Race the engine at 2,500 rpm for approx. 90 seconds.
(d) Check the idle speed.
A23201 Idle speed: 650 to 750 rpm
If the idle speed is not as specified, check the air intake system.
(e) Disconnect the tachometer from the DLC3.
Author: Date: 3233

EM-23
ENGINE MECHANICAL (1GR-FE) - IGNITION TIMING
IGNITION TIMING EM1XH-01
INSPECTION
1. WARM UP ENGINE
Hand-Held Tester 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 Area
Network Vehicle Interface Module (CAN VIM). Then
connect the CAN VIM to the Date Link Connector 3
(DLC3).
CAN VIM
(2) Please refer to the hand-held tester operator’s
manual for further details.
DLC3
D13872 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.
A22794
(3)Using SST, connect terminals TC and CG of the

DLC3.
TC SST 09843-18040
SST
CG
DLC3 A14755
Author: Date: 3231

EM-24
(4) Using the timing light, check the ignition timing.

Ignition timing: 8 to 12° BTDC at idle
(5) Remove the SST from the DLC3.
(6) Check the ignition timing.
(7) Disconnect the timing light from the engine.
A22795 (8) Install the air cleaner cap.
Author: Date: 3232

EM-23
IGNITION TIMING EM1XH-01
INSPECTION
1. WARM UP ENGINE
Hand-Held Tester 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 Area
Network Vehicle Interface Module (CAN VIM). Then
connect the CAN VIM to the Date Link Connector 3
(DLC3).
CAN VIM
(2) Please refer to the hand-held tester operator’s
manual for further details.
DLC3
D13872 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.
A22794
(3)Using SST, connect terminals TC and CG of the

DLC3.
TC SST 09843-18040
SST
CG
DLC3 A14755
Author: Date: 3231

EM-24
(4) Using the timing light, check the ignition timing.

(5) Remove the SST from the DLC3.
(6) Check the ignition timing.
(7) Disconnect the timing light from the engine.
A22795 (8) Install the air cleaner cap.
Author: Date: 3232

EM-26
ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN
TIMING CHAIN
EM1XJ-01
COMPONENTS
7.5 (76, 66 in.·lbf)
V-Bank Cover
Air Cleaner Hose 8.0 (82, 71 in.·lbf)
Vacuum Hose
Mass Air Flow
Meter Connector
Ventilation Hose No.2 Air Cleaner
Battery Clamp
Battery
Battery Tray
Author: Date: 3234

EM-27
Radiator
Fan Shroud
Fan w/ Fluid Coupling
Fan Pulley
21 (214, 15)
Drive Belt
Author: Date: 3235

EM-28
Oil Level Gauge

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

O-ring
Vane Pump
43 (438, 32)
9.8 (100, 7)
Terminal Cap
Generator
43 (438, 32)
Generator Wire
Generator Connector
Cooler Compressor
8.0 (82, 71 in.·lbf)
43 (438, 32)
8.0 (82, 71 in.·lbf)

25 (255, 18)
Wire Harness Clamp Bracket
Cooler Compressor Connector

Author: Date: 3236

EM-29

O-ring
Gasket
x5
9.0 (92, 80 in.·lbf) Water Inlet
Oil Cooler Hose
Idler Pulley No.2
Washer V-Ribbed Belt Tensioner

Idler Pulley No.1
39 (398, 29)
Washer
54 (551, 40)
O-ring 36 (367, 27)
36 (367, 27)
21 (214, 15) 10 (102, 7)

x2 x2
Oil Pan
Gasket
21 (214, 15) x6
x4 37 (377, 27)
x9
Oil Strainer
21 (214, 15)
9.0 (92, 80 in.·lbf)
Oil Pan No.2
9.0 (92, 80 in.·lbf) x15

x2 10 (102, 7)
Gasket
N·m (kgf·cm, ft·lbf) : Specified torque Drain Plug

40 (408, 30)
Author: Date: 3237

EM-30
28 (286, 21)
VSV Connector
Water By-pass Hose
x4 Intake Air Surge Tank
x2
VSV Connector
Fuel Vapor Feed Hose

Throttle Body
Connector Surge Tank Stay No.2
21 (214, 15) 21 (214, 15)
Throttle Body Bracket

21 (214, 15) 10 (102, 7)
Gasket
Surge Tank Stay No.1
10 (102, 7) 9.0 (92, 80 in.·lbf)
Oil Baffle Plate
9.0 (92, 80 in.·lbf)
Ignition Coil 9.0 (92, 80 in.·lbf)
x3
x3 10 (102, 7) Ignition Coil
9.0 (92, 80 in.·lbf) x3 9.0 (92, 80 in.·lbf)
x7
10 (102, 7) x3
Cylinder Head
x7
Cover RH
Cylinder Head
Cover LH

Author: Date: 3238

EM-31
23 (235, 17)
Crankshaft Pulley
Oil Seal x15
Timing Chain Cover
250 (2,549, 184)
19 (194, 14)
23 (235, 17) 19 (194, 14)

x9 Chain Tensioner No.2
Camshaft Timing
Sprocket
23 (235, 17) Timing Chain No.2
x2
Camshaft Timing
Gear Assembly
Timing Chain No.2
100 (1,020, 74)
Camshaft Timing
Gear Assembly 100 (1,020, 74)
100 (1,020, 74) Camshaft Timing
100 (1,020, 74)
Sprocket
10 (102, 7)
Chain Vibration
Damper No.2
Timing Chain
Chain Tensioner
Slipper

60 (612, 44)
Idle Gear No.1

O-ring
Crankshaft Timing
Sprocket
N·m (kgf·cm, ft·lbf) : Specified torque Chain Vibration
19 (194, 14) Damper No.1
Author: Date: 3239

EM-38
EM1XL-01
INSPECTION
1. INSPECT NO.1 AND NO.2 TIMING CHAINS
Using 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 chain
sub assembly using a vernier caliper.
Measuring Area Maximum chain elongation: 146.8 mm (5.780 in.)
NOTICE:
Perform the same measurements by pulling at random in
0 1 2 3 4 5 15 A23207
3 or more places to obtain an average length.
If the elongation is greater than the maximum, replace the
chain.
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:
A22990 The vernier caliper must contact the chain rollers for the
measuring.
If the diameter is less than the minimum, replace the No. 1 chain
and camshaft timing gear assembly.
Author: Date: 3246

EM-39
(c) Put the No. 2 chain on the smaller gear of the camshaft
timing gear assembly.
(d) Using a vernier caliper, measure the timing gear with the
chain.
73.1 mm (2.878 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
A22991 measuring.
and 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 .
73.1 mm (2.878 in.)
NOTICE:
A22992 measuring.
and the camshaft timing sprocket.
Author: Date: 3247

EM-40
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.
61.0 mm (2.402 in.)
NOTICE:
A22993 measuring.
and 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.
61.0 mm (2.402 in.)
NOTICE:
A22994 measuring.
and 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.)
A22995
Author: Date: 3248

EM-41
(b) Using a caliper gauge, measure the inside diameter of the

idle 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 from
the idle gear inside diameter measurement.
0.020 to 0.043 mm (0.0008 to 0.0017 in.)
A22996 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
Raise pawl is raised with a finger.
Lock
Move
(b) Release the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushing with a finger.
A22997
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.
Move
A22998
9. INSPECT CHAIN TENSIONER SLIPPER

Measure the worn depth of the chain tensioner slipper.
If the depth is greater than the maximum, replace the chain ten-
sioner slipper.
A23000
Author: Date: 3249

EM-42
10. INSPECT CHAIN VIBRATION DAMPER NO.1 AND

No.1
NO.2
Measure the worn depth of the chain vibration damper No. 1
and No. 2.
If the depth is greater than the maximum, replace the chain
vibration damper No. 1 or No.2.
No.2
A23001
Author: Date: 3250

EM-44
EM1XN-01
INSTALLATION
90
1. SET CRANKSHAFT POSITION
Using the crankshaft pulley set bolt, turn the crankshaft, and set
the crankshaft set key into the left horizontal position.
NOTICE:
Set Key Having the crankshaft at the wrong angle can cause the
piston head and valve head to come into contact with each
Turn other when you install the camshaft, causing damage. So
A22895
always 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.
Push
A22900
(b) Install the chain tensioner No. 2 with the bolt.

A22885
Mark Links 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.
Timing Marks
A22901
Timing Marks (b) Align the timing marks on the camshaft timing gear as-
sembly and camshaft timing sprocket with the timing
marks 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.
Timing Marks
A22902
Author: Date: 3252

EM-45
(d) Hold the hexagonal portion of the camshaft with a

wrench, and tighten the 2 bolts.
(e) Remove the pin from the chain tensioner No. 2.
A22903
4. INSTALL CHAIN VIBRATION DAMPER NO.1

(a) Install the chain vibration damper No. 1 with the 2 bolts.
A22921
5. INSTALL CRANKSHAFT TIMING SPROCKET

Inward
(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
A23007
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 the
holes in the stopper plate and tensioner to fix the stopper
Stopper Plate plate.
Stopper Plate Push (c) Install the chain tensioner with the 2 bolts.
A22850
Author: Date: 3253

EM-46
RH Bank 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.
Timing Marks
LH Bank
Timing Marks A22801
(b) Using the crankshaft pulley set bolt, turn the crankshaft
Timing Line to align the crankshaft set key with the timing line of the
cylinder block.
Set Key
A22869
9. INSTALL TIMING CHAIN NO.1

(a) Align the mark link (yellow) with the timing mark of the
crankshaft timing sprocket.
Mark Link
Timing Mark A22870
(b) Align the mark links (orange) with the timing marks of the
Mark Links
camshaft timing gear assembly and camshaft timing
sprocket, and install the chain.
10. INSTALL CHAIN VIBRATION DAMPER NO.2
Install the 2 chain vibration damper No.2.
Timing Marks
A22871
Author: Date: 3254

EM-47
11. INSTALL IDLE GEAR NO.1

Forward
(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 the
knock pin of the idle gear shaft No. 1 with the knock pin
groove 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.
Knock Pin
(d) Remove the bar from the chain tensioner.
A22872 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 timing
chain cover, cylinder head and cylinder block.
(b) Install a new O-ring to the LH cylinder head as shown in

the illustration.
A23009
(c) Apply a continuous bead of seal packing (diameter 3 to

4 mm (0.12 to 0.16 in.)) to 4 locations as shown in the il-
lustration.
Seal
Packing
A23010
Author: Date: 3255

EM-48
Seal Packing (d) Apply a continuous bead of seal packing (diameter 3 to

4 mm (0.12 to 0.16 in.)) to the timing chain cover as shown
Seal packing:
A
Water pump part: Part No. 08826-00100 or equivalent
Other part: Part No. 08826-00080 or equivalent
B NOTICE:
B Install the timing chain cover within 3 minutes after
Water Pump Water applying seal packing. After installing it, the timing
Part Pump chain cover bolts and nuts must be tightened within
Part 15 minutes. Otherwise the seal packing must be re-
3 to 4 mm moved and reapplied.
Seal Packing
Do not apply seal packing to the ”A” as shown in the
Seal Width 3 to 4 mm illustration.
3 to 4 mm
3 to 4 mm
16.7 mm
B - B
A23011
(e) Align the key way of the oil pump drive rotor with the rect-
15 angular portion of the crankshaft timing gear, and slide
the timing chain cover into place.
A23012
A A (f) Install the timing chain cover with the 24 bolts and 2 nuts.
A
Tighten the bolts and nuts uniformly in several steps.
B Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf)
A A A NOTICE:
A B A
B B
B Pay attention not to wrap the chain and slipper over
B
B the timing chain cover seal line.
B
AB Install the water pump within 15 minutes after instal-
BB B B B
B Nut
ling the timing chain cover.
Nut A23186 HINT:
Each bolt length is as follows:
A: 25 mm (0.98 in.)
B: 55 mm (2.17 in.)
Author: Date: 3256

EM-49
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.
A23120
(d) Install the water inlet with the 5 bolts.

(e) Connect the 5 water by-pass hoses.
(f) Connect the 2 radiator hoses.
(g) Connect the 2 oil cooler hoses (w/ oil cooler).
A23121
A 14. INSTALL OIL PAN

(a) Install the 4 stud bolts.
(b) Remove any old packing material (FIPG) and be careful
B not to drop any oil on the contact surfaces of the cylinder
block, rear oil seal retainer and oil pan.
13 16.5
22.5 27.5
8 9
Stud Bolt A Stud Bolt B [mm]
A23013
(c) Install a new O-ring to the oil pump.
A22873
Author: Date: 3257

EM-50
(d) Apply a continuous bead of seal packing (diameter 3 to

Seal Packing
4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the il-
lustration.
NOTICE:
Install the oil pan within 3 minutes after applying seal pack-
ing. After installing it, the oil pan bolts and nuts must be
tightened within 15 minutes. Otherwise the seal packing
Seal Width: 3 to 4 mm must be removed and reapplied.
A22874
A A B B (e) Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
A Torque:
A B Bolt A, B, Nut: 21 N⋅m (214 kgf⋅cm, 15 ft·lbf)
A A C
Bolt C: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
B C
HINT:
B Each bolt length is as follows:
A: 25 mm (0.98 in.)
Nut B B Nut B B A22863 B: 45 mm (1.77 in.)
C: 14 mm (0.55 in.)
(f) Install the 4 housing bolts.
(g) Install the flywheel housing under cover.
Flywheel Housing
Under Cover
A22862
15. INSTALL OIL STRAINER

(a) Install a new gasket and the oil strainer with the 2 nuts.
16. INSTALL OIL PAN NO.2
not to drop any oil on the contact surfaces of the oil pan
and oil pan No. 2.
A22861
(b) Apply a continuous bead of the seal packing (diameter 3

Seal Packing
to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
NOTICE:
Install the oil pan No. 2 within 3 minutes after applying seal
packing. After installing it, the oil pan No. 2 bolts and nuts
must be tightened within 15 minutes. Otherwise the seal
packing must be removed and reapplied.
Seal Width: 3 to 4 mm A22875
Author: Date: 3258

EM-51
(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)
A22859
17. INSTALL CRANKSHAFT PULLEY

Using SST, install the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
SST
A22876
18. INSTALL IDLER PULLEY NO.1

Install the idler pulley with the bolt.
HINT:
”DOUBLE” is marked on the idler pulley No. 1 to distinguish it
from the idler pulley No. 2.
”DOUBLE”
A22877
19. INSTALL IDLER PULLEY NO.2

Install the 2 idler pulleys with the 2 bolts.
A22878
A-1 20. INSTALL V-RIBBED BELT TENSIONER ASSY

Tighten bolts A-1 and B-1 in order first, then tighten the remain-
A ing bolts.
B
HINT:
B-1
Each bolt length is as follows:
B B A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)
B
A22856 21. INSTALL COOLER COMPRESSOR
(See page AC-58 )
Author: Date: 3259

EM-52
22. INSTALL GENERATOR (See page CH-15 )
23. INSTALL VANE PUMP

(a) Install the vane pump with the 2 bolts.
NOTICE:
Do not hit the pulley to other parts when installing the vane
pump.
(b) Connect the P/S oil pressure switch connector.
24. INSTALL WATER INLET (See page EM-89 )
A22855
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.
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.
Push Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(e) Install the oil level gauge.
A22879 26. INSTALL CYLINDER HEAD COVER
(See page EM-89 )
(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 COUPLING
32. INSTALL RADIATOR (See page CO-18 )
34. INSTALL BATTERY
35. ADD ENGINE OIL (See page LU-3 )
36. ADD ENGINE COOLANT (See page CO-2 )
37. CHECK FOR LEAKS
38. CHECK IGNITION TIMING (See page EM-23 )
39. CHECK IDLE SPEED (See page EM-25 )
Author: Date: 3260

EM-32
EM1XK-01
REMOVAL
2. DRAIN ENGINE OIL
3. REMOVE BATTERY
5. 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 COUPLING
9. REMOVE AIR CLEANER (See page EM-62 )
(See page EM-62 )
(See page EM-62 )
12. REMOVE VVT SENSOR
13. 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 the
vane pump.
HINT:
The vane pump is suspended securely.
A22855 15. REMOVE GENERATOR (See page CH-7 )
16. SEPARATE COOLER COMPRESSOR
(See page AC-54 )
17. REMOVE V-RIBBED BELT TENSIONER

Remove the 5 bolts and V-ribbed belt tensioner.
18. REMOVE IDLER PULLEY NO.1 AND NO.2
A22856
Author: Date: 3240

EM-33
19. REMOVE CRANKSHAFT PULLEY

(a) Using SST, hold the crankshaft pulley and loosen the
pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
SST
A22857
(b) Using the pulley set bolt and SST, remove the crankshaft
pulley.
SST
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
A22858
20. REMOVE OIL PAN NO.2

(a) Remove the 15 bolts and 2 nuts.
A22859
(b) Insert the blade of SST between the oil pan and oil pan
No. 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.
SST
A22860
21. REMOVE OIL STRAINER

Remove the 2 nuts, oil strainer and gasket.
A22861
Author: Date: 3241

EM-34
22. REMOVE OIL PAN

(a) Remove the 4 housing bolts.
(b) Remove the flywheel housing under cover.
Flywheel Housing
Under Cover
A22862
(c) Remove 17 bolts and 2 nuts.
A22863
(d) Using a screwdriver, remove the oil pan by prying be-

tween the oil pan and cylinder block in the sequence
shown.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and oil pan.
Pry
(e) Remove the O-ring from the oil pump.
LH Side
RH Side
A22864
23. REMOVE WATER INLET

(a) Disconnect the 2 oil cooler hoses (w/ oil cooler).
A23116
Author: Date: 3242

EM-35
(b) Disconnect the 2 radiator hoses.
A23117
(c) Disconnect the 5 water by-pass hoses.
A23118
(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.
A23119
24. REMOVE TIMING CHAIN COVER

(a) Remove the 24 bolts and 2 nuts.
A23186
Author: Date: 3243

EM-36
(b) Remove the timing chain cover by prying between the tim-
ing chain cover and cylinder head or cylinder block with
a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder block and cylinder head.
(c) Remove the O-ring from the LH cylinder head.
A23187
25. SET NO.1 CYLINDER TO TDC/COMPRESSION

Timing Line
(a) Install the crankshaft pulley set bolt, and turn the crank-
shaft to align the crankshaft set key with the timing line of
the cylinder block.
Set Key
A22865
RH Bank Timing Marks (b) Check that the timing marks of the camshaft timing gear
assembly and camshaft timing sprocket are aligned with
the timing marks of the bearing caps as shown in the il-
lustration.
If not, turn the crankshaft 1 complete revolution (360 ) and
align the timing marks as above.
26. REMOVE CHAIN TENSIONER NO.1
NOTICE:
Never rotate the crankshaft with the chain tensioner
Timing Marks removed.
LH Bank
When rotating the camshaft with the timing chain re-
moved, rotate the crankshaft counterclockwise 40
from the TDC first.
Timing Marks A22866
Author: Date: 3244

EM-37
(a) While turning the stopper plate of the tensioner clockwise,

push in the plunger of the chain tensioner as shown in the
Push
illustration.
(b) While turning the stopper plate of the tensioner counter-
clockwise, insert a bar of φ 3.5 mm (0.138 in.) into the
holes in the stopper plate and tensioner to fix the stopper
plate.
Stopper
Stopper Plate (c) Remove the 2 bolts and chain tensioner.
Plate
A22807 27. REMOVE CHAIN TENSIONER SLIPPER
28. REMOVE IDLE GEAR NO.1

Using 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.2
Remove the 2 chain vibration damper No.2.
30. REMOVE NO.1 TIMING CHAIN
31. REMOVE CRANKSHAFT TIMING SPROCKET
A22867
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.
Raise
A22884
(b) Hold the hexagonal portion of the camshaft with a

wrench, 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.
A22903
33. REMOVE CHAIN TENSIONER NO.2

Remove the bolt and chain tensioner No.2.
A22885
Author: Date: 3245

EM-43
EM1XM-01
REPLACEMENT
HINT:
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:
Pry (1) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the oil pump. Wrap the tip of the
A22976
screwdriver with tape.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09226-10010
(3) Apply MP grease to the oil seal lip.
SST
A23008
(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 the
screwdriver with tape.
A23076
(2) Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing chain cover edge.
SST 09226-10010
(3) Apply MP grease to a new oil seal lip.
SST
A23077
Author: Date: 3251

EM-4
ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE
VALVE CLEARANCE EM1XG-01
INSPECTION
3. REMOVE AIR CLEANER (See page EM-62 )
(See page EM-62 )
5. REMOVE IGNITION COIL
(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.
A22800
RH Bank Timing Marks (b) Check that the timing marks of the camshaft timing gears
are aligned with the timing marks of the bearing caps as
Timing Marks
LH Bank
Timing Marks A22801
Author: Date: 3212

EM-5
8. INSPECT VALVE CLEARANCE

RH Bank: 3 3
(a) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance be-
EX tween the valve lifter and camshaft.
Valve clearance (Cold):
IN Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)
(2) Record the out-of-specification valve clearance
1 1 measurements. They will be used later to determine
LH Bank: Front 6 6 the required replacement valve lifter.
IN
EX
2 2
A22802
(b) Turn the crankshaft 2/3 of a revolution (240), and check

RH Bank: 5 5
the valves indicated in the illustration.
Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)
IN
LH Bank: Front the required replacement valve lifter.
2 2
IN
EX
4 4
A22803
Author: Date: 3213

EM-6
(c) Turn the crankshaft 2/3 of a revolution (240), and check

RH Bank: 1 1
the valves indicated in the illustration.
Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)
IN
LH Bank: Front the required replacement valve lifter.
4 4
IN
EX
6 6
A22804
9. ADJUST VALVE CLEARANCE

(a) Set the No. 1 cylinder to the TDC/compression.
(1) Turn the crankshaft pulley, and align the notch with
the timing mark ”0” of the timing chain cover.
A22800
RH Bank Timing Marks (2) Check that the timing marks of the camshaft timing
gears are aligned with the timing marks of the bear-
ing caps as shown in the illustration.
Timing Marks
LH Bank
Timing Marks A22801
Author: Date: 3214

EM-7
(3)Place paint marks on the No. 1 chain links that cor-

Paint Marks
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.
Timing Marks When rotating the camshaft with the timing chain re-
A22805 moved, turn the crankshaft counterclockwise 40
from the TDC first.
(1) Remove the 4 bolts, timing chain cover plate and
gasket.
A22806
(2) While rotating the stopper plate of the tensioner up-

ward, push in the plunger of the chain tensioner as
Push
(3) While rotating the stopper plate of the tensioner
downward, insert a bar of φ 3.5 mm (0.138 in.) into
the holes in the stopper plate and tensioner to fix the
stopper plate.
Stopper
Stopper Plate (4) Remove the 2 bolts and chain tensioner No.1.
Plate
A22807 (c) Remove the No. 2 camshaft.
NOTICE:
(1) While raising up the chain tensioner No. 2, insert a

pin of φ 1.0 mm (0.039 in.) into the hole to fix it.
Raise
A22808
Author: Date: 3215

EM-8
(2) Hold the hexagonal portion of the No. 2 camshaft

with a wrench, and remove the camshaft timing
sprocket set bolt.
NOTICE:
Be careful not to damage the cylinder head and valve lifter
with the wrench.
(3) Separate the camshaft timing sprocket from the No.
2 camshaft.
A22809
(4) Rotate the camshaft counterclockwise using the

wrench so that the cam lobes of the No. 1 cylinder
face upward as shown in the illustration.
A22810
(5) Using several steps, loosen and remove the 8 bear-

ing cap bolts uniformly in the sequence as shown in
the illustration.
(6) Remove the 4 bearing caps and No. 2 camshaft.
2 4 8 6
1 3 7 5
A22811
(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 timing
sprocket.
(e) Remove the camshaft.
NOTICE:
A22812 camshaft is not kept level, the portion of the cylinder head
Author: Date: 3216

EM-9

with a wrench, and loosen the camshaft timing gear
assembly 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.
A22813
(2) Slide the camshaft timing gear assembly and sepa-

rate the No. 1 chain from the camshaft timing gear
sprocket.
Slide
A22814
(3) Rotate the No. 1 camshaft counterclockwise using

a wrench so that the cam lobes of No. 1 cylinder
face upward as shown in the illustration.
A22815

5 the illustration.
1 3 7
(5) Remove the 4 bearing caps.
2 4 8 6
A22816
(6) Remove the camshaft timing gear assembly set bolt

with the No. 1 camshaft lifted up, and then remove
the No. 1 camshaft and camshaft timing gear as-
sembly w/ No. 2 chain.
A22817
Author: Date: 3217

EM-10
(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:
A22818 shaft must be kept level while it is being removed. If the
(1) While pushing down the chain tensioner No. 2, in-

Push sert a pin of φ 1.0 mm (0.039 in.) into the hole to fix
it.
A22819

with a wrench, and remove the camshaft timing
sprocket set bolt.
NOTICE:
Be careful not to damage the cylinder head and valve lifter
with the wrench.
(3) Separate the camshaft timing sprocket from the No.
4 camshaft.
A22820

the illustration.
(5) Remove the 4 bearing caps and No. 4 camshaft.
6 8 4 2
5 7 3 1
A22821
Author: Date: 3218

EM-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 timing
sprocket.
(h) Remove the No. 3 camshaft.
NOTICE:
A22822 camshaft is not kept level, the portion of the cylinder head

5 the illustration.
7 3 1
(2) Remove the 4 bearing caps.
8 4 2
6
A22823
(3) Hold the No. 1 chain, and remove the No. 3 cam-
shaft, camshaft timing gear assembly and No. 2
chain.
A22824
(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.
A22825
Author: Date: 3219

EM-12
(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 lifter
A: Measured valve clearance
A01082 N: Thickness of new lifter
Intake:
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 (0.2260
in.).
Author: Date: 3220

Valve Lifter Selection Chart (Intake)
Removed lifter
thickness
mm (in.)
Measured
clearance mm (in.)
ENGINE MECHANICAL (1GR-FE)

-
VALVE CLEARANCE
New Lifter Thickness mm (in.)
No. Thickness No. Thickness No. Thickness
Author:
Intake valve clearance (Cold):

Date:
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter is installed, and the
measured clearance is 0.400 mm (0.0158 in.).
Replace the 5.250 mm (0.2067 in.) shim with a new
No. 46 lifter.
EM-13
3221
A22826
EM-14
Valve Lifter Selection Chart (Exhaust)
Removed lifter
thickness
mm (in.)
Measured
clearance mm (in.)
ENGINE MECHANICAL (1GR-FE)

-
VALVE CLEARANCE
New Lifter Thickness mm (in.)
No. Thickness No. Thickness No. Thickness
Author:
Exhaust valve clearance (Cold):

Date:
0.29 to 0.39 mm (0.0114 to 0.0154 in.)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter is installed, and the
measured clearance is 0.480 mm (0.0189 in.).
Replace the 5.340 mm (0.2102 in.) shim with a new
No. 48 lifter.
A22827
3222
EM-15
(k) Install the No. 3 camshaft.

NOTICE:
shaft must be kept level while it is being installed. If the
Mark Links (1) Align the mark link (yellow) with the timing mark
(2-dot mark) of the camshaft timing gear assembly
(2) Apply new engine oil to the thrust portions and jour-
nals of the camshafts.
Timing Marks
A22828
(3) Temporarily put the No. 1 chain on the No. 2 chain

of the camshaft timing gear assembly.
A22829
(4) Set the No. 3 camshaft onto the LH cylinder head

with the cam lobes of the No. 2 cylinder facing
downward as shown in the illustration.
A22830
(5) Install the 4 bearing caps in their proper locations.

bearing cap bolts.
A22831
Author: Date: 3223

EM-16
(7) Install the 8 bearing cap bolts. Using several steps,

tighten the bolts uniformly in the sequence as
2 6 8
Torque:
9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head
1 5 7 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head
3
A22832
(8) Set the paint mark of the No. 1 chain between the
Paint Mark timing marks of the camshaft timing gear assembly.
Timing Marks
A22833
(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.
Push
A22834
(2) Temporarily install the camshaft timing assembly

Mark Links
and chain tensioner No. 2 and align the mark links
(yellow) with the timing marks (1-dot mark and
2-dot mark) of the camshaft timing sprocket and
camshaft timing gear assembly.
(3) Tighten the chain tensioner No. 3 bolt.
(m) Install the No. 4 camshaft.
Timing Marks A22835 NOTICE:
Author: Date: 3224

EM-17
(1) Align the knock pin hole on the camshaft timing

sprocket 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 set
bolt.
A22836

A22837

Torque:
4 2 6 8
A22821

with a wrench, and tighten the camshaft timing
sprocket set bolt.
(7) Remove the pin from the chain tensioner No. 2.
(n) Install the camshaft.
NOTICE:
A22820 shaft must be kept level while it is being installed. If the
Author: Date: 3225

EM-18
Mark Links (1) Align the mark link (yellow) with the timing mark
(1-dot mark) of the camshaft timing gear assembly
(2) Apply new engine oil to the thrust portions and jour-
nals of the camshafts.
Timing Mark
A22838
(3) Temporarily put the No. 1 chain on the No. 2 chain

of the camshaft timing gear assembly.
A22839
(4) Align the knock pin hole on the camshaft timing gear
Knock Pin
assembly 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.
A22840
(6) Set the No. 1 camshaft onto the RH cylinder head

with the cam lobes of the No. 1 cylinder facing
downward as shown in the illustration.
A22841

A22842
Author: Date: 3226

EM-19

8 6 2
Torque:
A22816
(10) Rotate the No. 1 camshaft clockwise using the hex-

Timing Marks
agonal portion of the No. 1 camshaft so that the tim-
ing mark of the camshaft timing gear assembly is
aligned with the timing mark of the camshaft bear-
ing cap.
A22843
(11) Align the paint mark of the No. 1 chain with the tim-
Paint Mark
ing mark of the camshaft timing gear assembly.
Timing Mark
A22844

with a wrench, and tighten the camshaft timing gear
assembly set bolt.
A22813
(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.
Push
A22900
Author: Date: 3227

EM-20
Mark Links (2) Temporarily install the camshaft timing gear and
chain 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 timing
sprocket.
(3) Tighten the chain tensioner No. 2 bolt.
(p) Install the No. 2 camshaft.
Timing Marks A22846 NOTICE:
(1) Set the No. 2 camshaft onto the RH cylinder head

with the cam lobes of No. 1 cylinder facing upward
A22847

A22848

Torque:
7 5 1 3
24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head
8 6 2 4
A22811
Author: Date: 3228

EM-21
(5) Rotate the No. 2 camshaft clockwise using a

wrench so that the knock pin of the No. 2 camshaft
is aligned with the knock pin hole of the camshaft
timing sprocket.
Knock Pin
A22849

with a wrench, and install the camshaft timing
sprocket set bolt.
(7) Remove the pin from the chain tensioner No. 2.
A22809
(q) Install the chain tensioner No. 1.

(1) While turning the stopper plate of the tensioner
clockwise, push in the plunger of the tensioner as
(2) While turning the stopper plate of the tensioner
counterclockwise, insert a bar of φ 3.5 mm (0.138
in.) into the holes on the stopper plate and tensioner
Stopper Plate to fix the stopper plate.
Stopper Plate Push (3) Install the chain tensioner with the 2 bolts.
A22850

(4) Remove the bar from the chain tensioner.
(5) Install a new gasket and the timing chain cover plate
with the 4 bolts.
(6) Turn the crankshaft pulley 2 complete revolutions

slowly, and align the notch with the timing mark ”0”
of the timing chain cover.
A22800
Author: Date: 3229

EM-22
RH Bank Timing Marks (7) Check that the timing marks of the camshaft timing
gear assembly and camshaft timing sprocket are
aligned with the timing marks of the bearing caps as
10. INSTALL CYLINDER HEAD COVER (See page
EM-89 )
11. INSTALL IGNITION COIL
(See page EM-89 )
Timing Marks 13. INSTALL AIR CLEANER (See page EM-89 )
LH Bank
14. ADD ENGINE COOLANT (See page CO-2 )
16. INSPECT IGNITION TIMING (See page EM-23 )
Timing Marks A22801
Author: Date: 3230

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EM-1

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

4. INSERT CO/HC METER TESTING PROBE AT LEAST

Author: Date: 3209

If the CO/HC concentration does not comply with regulations,

Low High Rough idle 1. Vacuum leaks:

Author: Date: 3210

Author: Date: 3211

Piston Ring (No. 1 Compression Ring)

Piston Ring (Side Rail)

Water Drain Cock

9.0 (92, 80 in.·lbf)

Lower Crankshaft Thrust Washer

Crankshaft Bearing Cap

Crankshaft Bearing See page EM-128

Author: Date: 3319

2. REMOVE KNOCK SENSOR

4. REMOVE ENGINE REAR OIL SEAL RETAINER

5. INSPECT CONNECTING ROD THRUST CLEARANCE

Author: Date: 3320

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

(h) Using SST, tighten the bolts alternately to the specified

(l) Measure the Plastigage at its widest point.

Author: Date: 3321

7. REMOVE PISTON W/CONNECTING ROD

10. REMOVE PISTON PIN HOLE SNAP RING

Author: Date: 3322

11. REMOVE PISTON PIN

(b) Using a plastic-faced hammer and brass bar, lightly tap

12. INSPECT CRANKSHAFT THRUST CLEARANCE

13. REMOVE CRANKSHAFT

Author: Date: 3323

(b) Using several steps, uniformly loosen and remove the 16

Be careful not to damage the joint surface of the cylin-

16. REMOVE OIL NOZZLE

Author: Date: 3324

2. INSPECT CYLINDER BORE

Author: Date: 3325

4. INSPECT PISTON OIL CLEARANCE

5. INSPECT CONNECTING ROD

(2) Check twist.

6. INSPECT PISTON PIN OIL CLEARANCE

Author: Date: 3326

(b) Using a micrometer, measure the piston pin diameter.

(c) Using a caliper gauge, measure the inside diameter of the

(d) Subtract the piston pin diameter measurement from the

(e) If the oil clearance is greater than the maximum, replace

Author: Date: 3327

7. INSPECT RING GROOVE CLEARANCE

8. INSPECT PISTON RING END GAP

(b) Using a feeler gauge, measure the end gap.

9. INSPECT CONNECTING ROD BOLT

10. INSPECT CRANKSHAFT BEARING CAP SET BOLT

Author: Date: 3328

11. INSPECT CRANKSHAFT

(b) Using a micrometer, measure the diameter of each main

(d) Using a micrometer, measure the diameter of each crank

12. INSPECT CRANKSHAFT OIL CLEARANCE

Author: Date: 3329

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

(j) Using a plastic-faced hammer, lightly tap the bearing cap

Author: Date: 3330

(r) Measure the Plastigage at its widest point.