Toyota Tuntra Repair Manual

EM−1
ENGINE MECHANICAL (2UZ−FE) − CO/HC
CO/HC EM0KQ−09
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) Ignition timing checked correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
cardiagn.com
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 are prescribed by the applicable local
regulations.
A19383
EM−2
ENGINE MECHANICAL (2UZ−FE) − CO/HC
If the CO/HC concentration does not comply with regulations,

perform troubleshooting in the order given below.
(1) Check the air−fuel ratio sensors and heated oxygen
sensors operation (see page DI−507 and DI−512).
(2) See the table below for possible causes, and then
inspect and correct the applicable causes if neces-
sary.
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
cardiagn.com
Brake booster line
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
EM−3
ENGINE MECHANICAL (2UZ−FE) − COMPRESSION
COMPRESSION EM0KR−11
INSPECTION
HINT:
If there is 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 (See page IG−1)
3. CHECK CYLINDER COMPRESSION PRESSURE

Compression (a) Insert a compression gauge into the spark plug hole.
Gauge
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
cardiagn.com
250 rpm or more.
A04458 (d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,373 kPa (14.0 kgf/cm2, 199 psi) or more
Minimum pressure:
1,030 kPa (10.5 kgf/cm2, 149 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damaged.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS (See page IG−1)
EM−4
ENGINE MECHANICAL (2UZ−FE) − VALVE CLEARANCE
VALVE CLEARANCE EM0KS−10
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE BATTERY CLAMP COVER
2. REMOVE THROTTLE BODY COVER
3. REMOVE AIR CLEANER AND INTAKE AIR CONNEC-
TOR ASSEMBLY
4. REMOVE NO.3 TIMING BELT COVERS
(See page EM−16)
5. REMOVE IGNITION COILS (See page IG−5)
6. REMOVE RH CYLINDER HEAD COVER
Remove the 9 bolts, seal washers and cylinder head cover.
7. REMOVE LH CYLINDER HEAD COVER
(a) Remove the oil dipstick for the transmission.
(b) Disconnect the PCV hose.
cardiagn.com
(c) Disconnect the engine wire clamp from the wire bracket
on the cylinder head cover.
(d) Remove the 9 bolts, 9 seal washers and cylinder head
cover.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley, and align its groove with timing
mark ”0” of the No.1 timing belt cover.
A23300
(b) Check that the timing marks of the camshaft timing pul-
leys and timing belt rear plates are aligned.
If not, turn the crankshaft 1 revolution (360°) and align the mark
as above.
A23301
EM−5
9. INSPECT VALVE CLEARANCE

RH Cylinder Head
(a) Check only the valves indicated.
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.15 − 0.25 mm (0.006 − 0.010 in.)
LH Cylinder Head Front Exhaust 0.25 − 0.35 mm (0.010 − 0.014 in.)
cardiagn.com
A05717
(b) Turn the crankshaft 1 revolution (360°) and align the mark
RH Cylinder Head as above. (See procedure in step 8)
(c) Check only the valves indicated as shown. Measure the
valve clearance. (See procedure in step (a))
Front
LH Cylinder Head
A04457
EM−6
10. ADJUST VALVE CLEARANCE

(a) Remove the timing belt. (See page EM−16)
(b) Remove the camshafts. (See page EM−36)
(c) Remove the valve lifter and adjusting shim.
(d) Determine the replacement adjusting shim size according

to these Formula or Charts:
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within the specified value.
T ........... Thickness of removed shim
cardiagn.com
A ........... Measured valve clearance
A02213 N ........... Thickness of new shim
Intake: N = T + (A − 0.20 mm (0.008 in.))
Exhaust: N = T + (A − 0.30 mm (0.012 in.))
(3) Select a new shim with thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 41 increments of 0.020 mm (0.0008 in.),
from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102 in.).
(e) Place a new adjusting shim on the valve.
(f) Place the valve lifter.
(g) Reinstall the camshafts. (See page EM−60)
(h) Reinstall the timing belt. (See page EM−23)
(i) Recheck the valve clearance.
11. REINSTALL CYLINDER HEAD COVERS
12. REINSTALL IGNITION COILS
13. REINSTALL NO.3 TIMING BELT COVERS
(See page EM−23)
14. REINSTALL AIR CLEANER AND INTAKE AIR
CONNECTOR ASSEMBLY
15. REINSTALL THROTTLE BODY COVER
16. REINSTALL BATTERY CLAMP COVER
Adjusting Shim Selection Chart (Intake)
Installed shim thickness
mm (in.)
Measured clearance
mm (in.)
ENGINE MECHANICAL (2UZ−FE)
cardiagn.com
−
VALVE CLEARANCE
New shim thickness mm (in.)
Shim No. Thickness Shim No. Thickness Shim No. Thickness
Intake valve clearance (Cold):

0.15 − 0.25 mm (0.006 − 0.010 in.)
EXAMPLE:
The 2.300 mm (0.0906 in.) shim is installed,
and the measured clearance is 0.440 mm
(0.0173 in.). Replace the 2.300 mm (0.0906
in.) shim with a No. 54 shim.
EM−7
A03111
EM−8
Adjusting Shim Selection Chart (Exhaust)
Installed shim thickness
mm (in.)
Measured clearance
mm (in.)
ENGINE MECHANICAL (2UZ−FE)
cardiagn.com
−
VALVE CLEARANCE
New shim thickness mm (in.)
Shim No. Thickness Shim No. Thickness Shim No. Thickness
Exhaust valve clearance (Cold):

0.25 − 0.35 mm (0.010 − 0.014 in.)
EXAMPLE:
The 2.300 mm (0.0906 in.) shim is installed,
and the measured clearance is 0.440 mm
(0.0173 in.). Replace the 2.300 mm (0.0906
in.) shim with a No. 44 shim.
A03112
EM−9
ENGINE MECHANICAL (2UZ−FE) − IGNITION TIMING
IGNITION TIMING EM0KT−12
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
Hand−Held Tester 2. INSPECT IGNITION TIMING

(a) When using a hand−held tester.
(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
cardiagn.com
manual for further details.
DLC3
D13872 Ignition timing: 5 to 15° BTDC at idle
(Transmission in neutral)
(3) Disconnect the hand−held tester and CAN VIM
from the DLC3.
(b) When not using a hand−held tester.

(1) Connect the tester probe of a timing light to the wire
(black − red) of the ignition coil connector for the
No.1 cylinder.
A08769
(2)Using SST, connect terminals TC and CG of the

DLC3
DLC3.
SST 09843−18040
TC CG
SST
A23394
EM−10
ENGINE MECHANICAL (2UZ−FE) − IGNITION TIMING
(3) Using a timing light, check the ignition timing.

Ignition timing: 5 to 15° BTDC at idle
(4) Remove the SST from the DLC3.
SST 09843−18040
(5) Disconnect the timing light from the engine.
A04459
cardiagn.com
EM−11
ENGINE MECHANICAL (2UZ−FE) − IDLE SPEED
IDLE SPEED EM1X3−02
INSPECTION
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) iCorrect gnition timing
(h) Transmission in neutral
(i) Air conditioning switched OFF
cardiagn.com
Hand−Held Tester 2. INSPECT ENGINE IDLE SPEED
(a) When using a hand−held tester.
(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 (3) Race the engine speed at 2,500 rpm for approx. 90
seconds.
(4) Check the idle speed.
Idle speed: 700 ± 50 rpm
If the idle speed is not as specified, check the air intake system.
(5) Disconnect the hand−held tester and CAN VIM
from the DLC3.
(b) When not using a hand−held tester.

DLC3
(1) Using SST, connect the tachometer probe to termi-
nal TAC of the DLC3.
SST 09843−18030
TAC (2) Race the engine at 2,500 rpm for approx. 90 se-
conds.
(3) Check the idle speed.
Idle speed: 700 ± 50 rpm
SST (Transmission in neutral )
A23395
If the idle speed is not as specified, check the air intake system.
EM−12
ENGINE MECHANICAL (2UZ−FE) − IDLE SPEED
(4) Disconnect the tachometer from the DLC3.
cardiagn.com
EM−13
ENGINE MECHANICAL (2UZ−FE) − TIMING BELT
TIMING BELT
EM0KV−12
COMPONENTS
A/C Suction Hose
MAF Meter Wire
Vacuum Hose
PS Air Hose Radiator Assembly
PCV Hose
Throttle Body Cover
Clip
No. 2 Fan Shroud

Intake Air Connector
cardiagn.com
17 (175, 13) PS Pump
A/T Oil Cooler Hose

17 (175, 13)
Fan and Fluid Coupling

Assembly
12 (122, 9)
Fan Pulley
29 (296, 21)
A/C Compressor
A/C Compressor
Connector 49 (500, 36)
Drive Belt
x4
29 (296, 21) 2WD Engine Under Cover
Engine Under Cover (4WD)
x5
29 (296, 21)
N·m (kgf·cm, ft·lbf) : Specified torque
A19404
EM−14
RH No.3 Timing Belt Cover
7.5 (76, 66 in.·lbf)
No.2 Timing
Belt Cover
16 (160, 12)
Drive Belt Idler Pulley

39 (400, 29)
Cover Plate
Camshaft Position
Sensor Connector
cardiagn.com
Wire Grommet LH No.3 Timing Belt Cover
Engine Wire 7.5 (76, 66 in.·lbf)

Oil Cooler Pipe
N·m (kgf·cm, ft·lbf) : Specified torque A23302
LH Camshaft Timing Pulley
RH Camshaft Timing Pulley
Timing Belt
8.1 (83, 72 in.·lbf)
245 (2,500, 181)
16 (160, 12)
Timing Belt Tensioner

Dust Boot
32 (330, 24)
Fan Bracket
26 (270, 19)
EM−15
Drive Belt Tensioner

Generator Wire
Generator
No.1 Timing Belt Cover
26 (265, 19)
cardiagn.com
15.5 (158, 11)
39 (400, 29) 39 (400, 29)

Crankshaft Pulley
Timing Belt No.1 Idler Pulley
34.5 (350, 25)
Plate Washer
Crankshaft Timing Pulley
34.5 (350, 25)
Timing Belt Guide No.2 Idler Pulley

Gasket
(Crankshaft Angle Sensor Plate)
N·m (kgf·cm, ft·lbf) : Specified torque Timing Belt Cover Spacer

Precoated part A23304
EM−16
EM1WX−02
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE RADIATOR ASSEMBLY (See page CO−17)
5. REMOVE INTAKE AIR CONNECTOR ASSEMBLY
6. 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 and CH−19)
(c) Remove the 4 nuts, the fan, fluid coupling assembly and
fan pulley.
cardiagn.com
7. DISCONNECT PS PUMP
A08934 Remove the 3 bolts, and disconnect the PS pump from the en-
gine.
HINT:
Suspend the PS pump securely.
8. REMOVE DRIVE BELT IDLER PULLEY
Remove the pulley bolt, cover plate and idler pulley.
9. REMOVE RH NO.3 TIMING BELT COVER

Remove the 3 bolts, nut and RH No.3 timing belt cover.
A04329
10. REMOVE LH NO.3 TIMING BELT COVER

(a) Disconnect the engine wire from the 2 wire clamps.
(b) Remove the 4 bolts and nut.
(c) Disconnect the camshaft position sensor wire from the
wire clamp on the LH No.3 timing belt cover.
(d) Disconnect the camshaft position sensor connector from
the connector bracket.
(e) Disconnect the camshaft position sensor connector.
A04331 (f) Remove the wire grommet from the LH No.3 timing belt
cover.
EM−17
(g) Remove the LH No.3 timing belt cover.

(h) Remove the bolt, nut and oil cooler pipe.
11. REMOVE NO.2 TIMING BELT COVER

Remove the 2 bolts and No.2 timing belt cover.
12. DISCONNECT A/C COMPRESSOR FROM ENGINE
(See page EM−79)
cardiagn.com
A04330
13. REMOVE FAN BRACKET

Remove the 2 bolts, 2 nuts and fan bracket.
A04455
14. IF RE−USING TIMING BELT, CHECK INSTALLATION

MARKS ON TIMING BELT
Check that there are 3 installation marks on the timing belt by
turning the crankshaft pulley as shown in the illustration.
HINT:
If the installation marks have disappeared, place a new installa-
tion mark on the timing belt before removing each part.
A23305
15. LOOSEN CRANKSHAFT PULLEY BOLT

Using SST, loosen the pulley bolt.
SST 09213−70011 (90105−08076), 09330−00021
SST
A23306
EM−18
16. SET NO.1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley and align its groove with timing
mark ”0” of the No.1 timing belt cover.
Turn A23307
(b) Check that the timing marks of the camshaft timing pul-
leys and timing belt rear plates are aligned.
If not, turn the crankshaft 1 revolution (360°).
cardiagn.com
A23308
Approx. 50° Idler (c) Turn the crankshaft pulley approx. 50° clockwise, and
Pulley align the timing mark of the crankshaft pulley with the cen-
Bolt ters of the crankshaft pulley bolt and the No.2 timing belt
idler pulley bolt.
Timing NOTICE:
Mark If the timing belt is disengaged, having the crankshaft
pulley at the wrong angle can cause the piston head and
Crankshaft valve head to come into contact with each other when you
Pulley Bolt Turn A14391 remove the camshaft timing pulley (step 15), causing dam-
age. So always set the crankshaft pulley at the correct
angle.
(d) Remove the crankshaft pulley bolt.
NOTICE:
Do not turn the crankshaft pulley.
17. REMOVE TIMING BELT TENSIONER

HINT:
When re−using the timing belt:
If the installation marks have disappeared, before remove
the timing belt, place 2 new installation marks on the tim-
ing belt to match the timing marks of the camshaft timing
pulleys.
A23309
EM−19
When replacing the timing belt tensioner only:

To avoid meshing of the timing pulley and timing belt, se-
cure one of them with string. And place matchmarks on
the timing belt and RH camshaft timing pulley.
String
A23310
Alternately loosen the 2 bolts, and remove them, the belt ten-
sioner and dust boot.
cardiagn.com
A04339
18. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-

Slightly Turn ING PULLEYS
(a) Hold the camshaft timing pulley with SST, and loosen the
tension spring between the LH and RH camshaft timing
pulleys by slightly turning the LH camshaft timing pulley
clockwise.
SST 09960−10010 (09962−01000, 09963−01000)
HINT:
A23311 Set the SST so that the claw comes in contact with the camshaft
timing pulley bolt, and tighten the lock nut of the SST.
(b) Disconnect the timing belt from the camshaft timing pul-
leys.
SST 19. REMOVE CAMSHAFT TIMING PULLEYS

(a) Hold the camshaft timing pulley with SST, loosen the 4
bolts of the timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the 2 timing pulleys.
20. REMOVE GENERATOR
(See page CH−7 and CH−19)
21. REMOVE DRIVE BELT TENSIONER
A23312 Remove the bolt, 2 nuts and belt tensioner.
EM−20
22. REMOVE CRANKSHAFT PULLEY

Using SST, remove the crankshaft pulley.
SST 09950−50013 (09951−05010, 09952−05010,
09953−05010, 09953−05020, 09954−05021)
NOTICE:
Do not turn the crankshaft pulley.
23. REMOVE NO.1 TIMING BELT COVER
SST
Remove the 4 bolts and timing belt cover.
A23313
24. REMOVE TIMING BELT GUIDE

25. REMOVE TIMING BELT COVER SPACER
cardiagn.com
A04448
26. REMOVE TIMING BELT

HINT:
If re−using the belt and the installation mark has disappeared
from it, place a new installation mark on the timing belt to the
match the dot mark of the crankshaft timing pulley.
A04342
27. REMOVE NO.1 IDLER PULLEY AND NO.2 IDLER

PULLEY
(a) Using a 10 mm hexagon wrench, remove the bolt, No.1
idler pulley and plate washer.
(b) Remove the bolt and No.2 idler pulley.
A04444
28. REMOVE CRANKSHAFT TIMING PULLEY

Using SST, remove the timing pulley.
SST 09950−50013 (09951−05010, 09952−05010,
09953−05010, 09953−05020, 09954−05011)
NOTICE:
Do not turn the timing pulley.
SST A04445
EM−21
EM0KX−08
INSPECTION
NO ! 1. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with
oil, water or steam.
Do not utilize timing belt tension when installing or re-
moving the mount bolt of the camshaft timing pulley.
EM3336
If there is any defect, as shown in the illustration, check these
points:
(a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
cardiagn.com
check to see if there are nicks on the side of the idler
pulley lock and water pump.
(d) If there is wear or damage on even one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check timing
cover for damage and for foreign material on the pulley
teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS

(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
P20079
3. INSPECT TIMING BELT TENSIONER

(a) Visually check the seal portion of the tensioner for oil leak-
age.
HINT:
If there is only the faintest trace of oil on the seal on the push
rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
P20633
EM−22
(b) Hold the tensioner with both hands and push the push rod
strongly as shown to check that it doesn’t move.
If the push rod moves, replace the tensioner.
NOTICE:
Never hold the tensioner push rod facing downward.
P20634
(c) Measure the protrusion of the push rod from the housing
end.
Protrusion
Protrusion: 10.5 to 11.5 mm (0.413 to 0.453 in.)
If the protrusion is not as specified, replace the tensioner.
4. INSPECT WATER PUMP (See page CO−7)
cardiagn.com
P20635
EM−23
EM1WY−02
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
Inward
(a) Align the timing pulley set key with the key groove of the
SST pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the flange side inward.
SST 09223−46011
A04446
2. INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER

PULLEY
(a) Apply adhesive 2 or 3 threads of the pivot bolt.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer
cardiagn.com
and No.1 idler pulley with the pivot bolt.
A04447 Torque: 34.5 N·m (350 kgf·cm, 25 ft·lbf)
(c) Install the No.2 idler pulley with the bolt.
Torque: 34.5 N·m (350 kgf·cm, 25 ft·lbf)
(d) Check that the No.1 and No.2 idler pulleys moves
smoothly.
3. TEMPORARILY INSTALL TIMING BELT

NOTICE:
The engine should be cold.
(a) Remove any oil or water on the crankshaft pulley, oil
pump pulley, water pump pulley, No.1 idler pulley and
No.2 idler pulley, and keep them clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
A04342 (b) Align the installation mark on the timing belt with the tim-
ing mark of the crankshaft timing pulley.
(c) Install the timing belt on the crankshaft timing pulley, No.1
idler pulley and No.2 idler pulley.
4. INSTALL TIMING BELT COVER SPACER
(a) Install the gasket to the cover spacer.
(b) Install the cover spacer.
EM−24
5. INSTALL TIMING BELT GUIDE

Install the belt guide with the cup side facing outward.
6. INSTALL NO.1 TIMING BELT COVER
Install the timing belt cover with the 4 bolts.
A04448
7. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the crank-
shaft pulley.
(b) Using SST and a hammer, tap in the crankshaft pulley.
SST SST 09223−46011
8. INSTALL DRIVE BELT TENSIONER
Install the belt tensioner with the bolt and 2 nuts.
cardiagn.com
Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)
A23314 HINT:
Use a bolt of 106 mm (4.18 in.) in length.
9. INSTALL GENERATOR
(See page CH−16 and CH−28)
10. CHECK CRANKSHAFT PULLEY POSITION

Check that the timing mark of the crankshaft pulley is aligned
with timing mark ”0” of the No.1 timing belt cover.
A08660
SST 11. INSTALL, LH CAMSHAFT TIMING PULLEY

(a) Align the camshaft knock pin with the knock pin groove of
the timing pulley, and slide the timing pulley.
(b) Temporarily install the 4 bolts of the camshaft timing
pulley.
(c) Hold the camshaft timing pulley with SST, and tighten the
pulley bolt.
SST 09960−10010 (09962−01000, 09963−01000)
A23315 Torque: 8.1 N·m (83 kgf·cm, 72 in.·lbf)
EM−25
HINT:
Set the SST so that the claw comes in contact with the camshaft
timing pulley bolt, and tighten the lock nut of the SST.
12. INSTALL RH CAMSHAFT TIMING PULLEY

Hold (a) Align the camshaft timing tube knock pin with the knock
pin groove of the timing pulley.
(b) Temporarily install the 4 bolts of the camshaft timing
SST
pulley.
(c) Hold the camshaft timing pulley with SST, and tighten the
pulley bolt.
cardiagn.com
SST 09960−10010 (09962−01000, 09963−01000)
13. CONNECT TIMING BELT TO LH CAMSHAFT TIMING

PULLEY
Turn
(a) Remove any oil or water on the timing pulley, and keep it
clean.
NOTICE:
SST (b) Using SST, turn the timing pulley. Align the installation
mark on the timing belt with the timing mark of the timing
A23317 pulley, and hang the timing belt on the timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(c) Using SST, turn the LH camshaft timing pulley counter-
Turn clockwise until there is tension between the crankshaft
timing pulley and LH camshaft timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
SST
Tension
A23318
14. CONNECT TIMING BELT TO RH CAMSHAFT TIMING

PULLEY
(a) Remove any oil or water on the camshaft timing pulley
Turn and water pump pulley, and keep them clean.
NOTICE:
SST
(b) Using SST, turn the timing pulley. Align the installation
mark on the timing belt with the timing mark of the timing
A23319 pulley, and hang the timing belt on the timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
EM−26
15. SET TIMING BELT TENSIONER

(a) Using a press, slowly press in the push rod using 981 −
9,807 N (100 − 1,000 kgf, 220 − 2,205 lbf) of pressure.
(b) Align the holes of the push rod and housing, and pass a
1.27 mm hexagon wrench through the holes to keep the
setting position of the push rod.
1.27 mm
(c) Remove the belt tensioner from the press.
Hexagon Wrench
(d) Install the dust boot to the belt tensioner.
P20636
1.27 mm 16. INSTALL TIMING BELT TENSIONER

Hexagon Wrench (a) Temporarily install the belt tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.
(c) Using pliers, remove the 1.27 mm hexagon wrench from
the belt tensioner.
cardiagn.com
A04454
17. CHECK VALVE TIMING

(a) Temporarily install the crankshaft pulley bolt.
(b) Slowly turn the crankshaft pulley 2 revolutions from the
TDC to TDC.
NOTICE:
Always turn the crankshaft pulley clockwise.
Turn A23307
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
A23308
18. TIGHTEN CRANKSHAFT PULLEY BOLT

Using SST, install the pulley bolt.
SST 09213−70011 (90119−08216), 09330−00021
Torque: 245 N·m (2,500 kgf·cm, 181 ft·lbf)
SST
A23306
EM−27
19. INSTALL FAN BRACKET

Install the fan bracket with the 2 bolts and 2 nuts.
Torque:
12 mm head
(A)
16 N·m (160 kgf·cm, 12 ft·lbf) for (A)
14 mm head
32 N·m (330 kgf·cm, 24 ft·lbf) for (B)
(B) HINT:
A04455 Each bolt length is indicated in the illustration.
Bolt Length:
106 mm (4.17 in.) for 12 mm head (A)
114 mm (4.49 in.) for 14 mm head (B)
20. INSTALL A/C COMPRESSOR (See page EM−83)
cardiagn.com
21. INSTALL NO.2 TIMING BELT COVER
Install the No.2 timing belt cover with the 2 bolts.
A04330
22. INSTALL RH NO.3 TIMING BELT COVER

(a) Fit the RH No.3 timing belt cover, matching it with the fan
bracket.
(b) Install the RH No.3 timing belt cover with the 3 bolts and
nut.
Torque: 7.5 N·m (76 kgf·cm, 66 in.·lbf)
A04329
EM−28
23. INSTALL LH NO.3 TIMING BELT COVER

(a) Install the oil cooler pipe with the bolt and nut.
(b) Run the camshaft position sensor wire through the LH
No.3 timing belt cover hole.
(c) Fit the LH No.3 timing belt cover, matching it with the fan
bracket.
(d) Install the LH No.3 timing belt cover with the 4 bolts and
nut.
(e) Install the wire grommet to the LH No.3 timing belt cover.
(f) Install the camshaft position sensor connector to the con-
nector bracket.
(g) Connect the camshaft position sensor connector.
(h) Install the sensor wire to the wire clamp on the LH No.3
timing belt cover.
(i) Install the engine wire to the 2 wire clamps on the LH No.3
timing belt cover.
cardiagn.com
24. INSTALL DRIVE BELT IDLER PULLEY
Install the idler pulley and cover plate with the bolt.
25. INSTALL PS PUMP
Install the PS pump with the 3 bolts.
26. INSTALL FAN PULLEY, FAN, FLUID COUPLING

AND DRIVE BELT
(a) Temporarily install the fan pulley, the fan, fluid coupling
assembly with the 4 nuts.
(b) Install the drive belt. (See page CH−16 and CH−28)
(c) Tighten the 4 nuts holding the fluid coupling to the fan
bracket.
Torque: 29 N·m (296kgf·cm, 21 ft·lbf)
A08934 27. INTAKE AIR CONNECTOR ASSEMBLY
28. INSTALL THROTTLE BODY COVER
29. INSTALL RADIATOR ASSEMBLY (See page CO−18)
30. FILL WITH ENGINE COOLANT
31. START ENGINE AND CHECK FOR LEAKS
32. RECHECK ENGINE COOLANT LEVEL
33. INSTALL ENGINE UNDER COVER
EM−29
ENGINE MECHANICAL (2UZ−FE) − CYLINDER HEAD
CYLINDER HEAD
EM1WZ−02
COMPONENTS
MAF Meter Wire
Vacuum Hose
Suction Hose
PCV Hose Throttle Body Cover
Clip
P/S Air
Hose
No.2 Fan Shroud

Radiator
Assembly
cardiagn.com
Fan And Fluid Coupling
Assembly
A/T Oil Cooler Hose
Fan Pulley 12 (122, 9)
29 (296, 21)
A/C Compressor
A/C Compressor
Drive Belt
29 (296, 21) x4
4WD: Engine Under Cover

Engine Under Cover (2WD)
x5
N·m (kgf·cm, ft·lbf) : Specified torque 29 (296, 21)

A21015
EM−30
Oil Dipstick and

Guide for A/T
PS Pump
17(175, 13)
O−Ring
cardiagn.com
RH Front Exhaust Pipe 48 (489, 35)
Heated Oxygen
Sensor
48 (489, 35)
Gasket
Gasket Ring
Heated Oxygen
Sensor
Gasket
62 (632, 46)
Gasket

62 (632, 46)
Non−reusable part
A21013
EM−31
RH No.3 Timing Belt Cover
7.5 (76, 66 in.·lbf)
No.2 Timing
Belt Cover
16 (160, 12)
Drive Belt Idler Pulley

39 (400, 29)
Cover Plate
Camshaft Position
Sensor Connector
cardiagn.com
Wire Grommet LH No.3 Timing Belt Cover
7.5 (76, 66 in.·lbf)

Engine Wire
Oil Cooler Pipe
RH Camshaft Timing Pulley
LH Camshaft Timing Pulley
Timing Belt
8.1 (83, 72 in.·lbf)
16 (160, 12)
Timing Belt Tensioner
Dust Boot
32 (330, 24)
Fan Bracket 26 (270, 19)

EM−32
Heater Hose Engine Wire Protector
18 (185, 13)
Engine Wire
Rear Water
18 (185, 13) Bypass Joint
Throttle Body
Cover Bracket
7.5 (76, 66 in.·lbf)
Gasket
Throttle Control
Connector
Injection Connector
Fuel Return Hose

VSV Connector
cardiagn.com
ECT for EVAP
Gasket
Sensor Connector
18 (185, 13) EVAP Hose
7.5 (76, 66 in.·lbf)
Fuel Inlet Hose Wire Bracket
O−Ring
Front Water
Engine Wire
Bypass Joint
Gasket
Air Switching Valve No.2
Air Tube No.3
Gasket
Water Inlet and Inlet 10 (102, 7)
Housing Assembly Gasket
Gasket 16 (163, 12)
Water Bypass Hose 16 (163, 12)
Gasket
Air Pump Assembly Air Tube No.3
Ignition Coil Connector
RH No.1 Timing Belt Rear Plate

Heater Hose
7.5 (76, 66 in.·lbf) Gasket
10 (102, 7)
Ignition Coil
Engine Wire
LH No.1 Timing Belt Rear Plate

N·m (kgf·cm, ft·lbf) : Specified torque Non−reusable part
A23320
EM−33
Fuel Pressure Regulator

Vacuum Hose
7.5 (76, 66 in.·lbf)
21 (214, 15) 7.5 (76, 66 in.·lbf)

O−Ring
VSV for Secondary Air Injection System
18 (184, 13)
RH Delivery Pipe
VSV for EVAP
7.5 (76, 66 in.·lbf)
cardiagn.com
VSV Wire Connector
for ACIS
7.5 (76, 66 in.·lbf)

Throttle Body Assembly
Fuel Return Pipe
18 (185, 13)
VSV for ACIS
Ventilation Fuel Pressure

PCV
Hose
Pulsation Damper
* 33 (340, 24)
Union 7.5 (76, 66 in.·lbf) 39 (400, 29)
39 (400, 29)
7.5 (76, 66 in.·lbf) Upper Gasket
Gasket
Union Lower Gasket
39 (400, 29)
21 (214, 15)
Front Fuel Pipe
Gasket
O−Ring LH Delivery Pipe
Grommet
Injector
Insulator

Non−reusable part
* For use with SST A23321
EM−34
6.0 (600, 53 in.·lbf)

Spark Plug Tube Engine Wire
Gasket Clamp
Camshaft Timing LH Cylinder
Oil Control Valve Head Cover
(Bank 2) Connector
x9
6.0 (600, 53 in.·lbf) Camshaft Timing
Oil Control Valve Seal
RH Cylinder (Bank 1) Connector Washer
Head Cover Seal x9
Washer Gasket
Camshaft
Timing Oil
Control Valve 7.5 (76, 66 in.·lbf)
(Bank 1)
Engine
16 (160, 12)
Wire O−Ring
Clamp O−Ring
Bracket 7.5 (76, 66 in.·lbf)
Gasket
Camshaft Timing Oil
Seal
cardiagn.com
Oil Control Valve Feed
Front Washer
(Bank 2) Pipe
Bearing Cap
Front
Camshaft Bearing Cap
Bearing Cap
RH Intake LH Exhaust
Camshaft LH Intake Camshaft Camshaft
(with Timing (with Timing Tube)
RH Exhaust Tube)
Camshaft Semi−circular Plug
Camshaft See page EM−60
Housing 1st 40 (408, 30)
Ground Strap 2nd Turn 90°
Plug Camshaft x 10
Spark Plug 3rd Turn 90°
Housing Plug
Strainer Ground Wire
Engine Ground Wire
Wire
Semi−circular
Plug
Strainer
RH Cylinder
Head Gasket
Engine Wire
Bracket
LH Cylinder Head and

Exhaust Manifold Assembly
Air−fuel Ratio Sensor
(Bank 2 Sensor 1) LH Cylinder Head Gasket
Connector
Air−fuel Ratio Sensor
(Bank 1 Sensor 1) Connector
Non−reusable part A23322
EM−35
Intake Camshaft
Camshaft Drive Gear
Camshaft Timing Tube
Screw Plug
Seal Washer 7.5 (80, 66 in.·lbf)
Exhaust Camshaft
Camshaft Oil Seal

Camshaft Driven Main Gear
78 (790, 58)
15 (150, 11)
Wave Washer
Camshaft Gear Spring
Camshaft Driven Sub−gear
cardiagn.com
N·m (kgf·cm, ft·lbf) : Specified torque Snap Ring
Valve Lifter
Keeper Adjust Shim
RH Cylinder Head Spring Retainer
Valve Spring
Spring Seat
Oil Seal
Valve Guide Bushing
Gasket Valve
RH Exhaust Manifold
LH Cylinder Head
44 (450, 32)
Gasket
LH Exhaust Manifold
44 (450, 32)
Heat Insulator
Heat Insulator
7.5 (76, 66 in.·lbf)

Non−reusable part 7.5 (76, 66 in.·lbf)
A23323
EM−36
EM1X0−02
REMOVAL
3. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEYS (See page EM−16)
NOTICE:
Be careful not to drop anything inside the timing belt
cover.
Do not allow the belt to come into correct with oil, wa-
ter or dust.
4. REMOVE CAMSHAFT TIMING PULLEYS
(See page EM−16)
cardiagn.com
5. REMOVE CAMSHAFT POSITION SENSOR
A02844 (See page IG−8)
6. DISCONNECT PS PUMP FROM ENGINE
(See page EM−79)
7. REMOVE FRONT EXHAUST PIPE (See page EM−126)
8. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
9. REMOVE IGNITION COILS (See page IG−5)
10. REMOVE TIMING BELT REAR PLATES
(a) Remove the 3 bolts, stud bolt and RH No.1 timing belt rear
plates.
(b) Disconnect the wire clamp from the LH timing belt rear
plate.
(c) Remove the 3 bolts, stud bolt and LH No.1 timing belt rear
plates.
11. DISCONNECT FUEL INLET HOSE (See page SF−27)
AND FUEL RETURN HOSE
12. DISCONNECT CONNECTORS FROM INTAKE MAN-
IFOLD
(a) Disconnect the throttle control connector.
(b) Disconnect the VSV connector for EVAP.
(c) Disconnect the 8 injector connectors.
(d) Disconnect the ECT sensor connector.
(e) Disconnect the 2 VSV connectors for the air injection sys-
tem.
(f) Disconnect the 8 ignition coil connectors.
(g) Disconnect the 2 air fuel ratio sensor connectors.
EM−37
13. DISCONNECT HOSES FROM INTAKE MANIFOLD

(d) (a) Disconnect the vacuum hose from the fuel pressure regu-
lator.
(b) Disconnect the PCV hose from the PCV valve on the LH
cylinder head.
(c) Disconnect the EVAP hose (from charcoal canister) from
the VSV for the EVAP.
(d) Disconnect the 2 vacuum hoses from the VSV for the air
injection system.
(a)
(c)
cardiagn.com
(b)
A23324
14. REMOVE INTAKE MANIFOLD ASSEMBLY

(a) Disconnect the 2 water bypass hoses from the throttle
body.
Water Bypass Hose A23325
(b) Disconnect the 2 wire clamps from the wire clamp bracket
on the RH delivery pipe.
A23326
(c) Remove the 2 bolts holding the engine wire protector from
the intake manifold and cylinder head.
(d) Remove the 2 bolts and ground cables from the RH and
LH cylinder heads.
(e) Remove the bolt and throttle body cover bracket from the
intake manifold.
A23327
EM−38
(f) Disconnect the engine wire from the engine hanger and
wire bracket.
(g) Remove the wire bracket from the intake manifold.
A23328
(h) Remove the 6 bolts, 4 nuts, intake manifold assembly and

2 gaskets.
cardiagn.com
A23329
15. DISASSEMBLE INTAKE MANIFOLD

(a)
(a) (a) Remove the 2 bolts and VSVs for the air injection system.
(b) Disconnect the EVAP hose from the upper intake man-
(c) (b) ifold, and remove the VSV for EVAP.
(c) Remove the bolt, 2 unions, 4 gaskets and front fuel pipe
(c)
from the intake manifold.
(d) Remove the throttle body (see page SF−44).
(c)
A23330
(e) Remove the bolt and VSV for ACIS from the intake man-
ifold.
B17510
(f) Disconnect the fuel return hose from the fuel pressure
regulator.
(g) Remove the 3 bolts and fuel return pipe from the intake
manifold.
(h) Remove the 2 bolts, fuel pressure regulator and O−ring.
(i) Remove the fuel pressure pulsation damper and 2 gas-
kets.
(j) Remove the 2 delivery pipes and 8 injectors (see page
A23331 SF−27).
EM−39
16. REMOVE WATER INLET AND INLET HOUSING AS-

SEMBLY (See page CO−6)
17. REMOVE AIR PUMP ASSEMBLY (See page EC−23)
18. REMOVE NO.2 AIR SWITCHING VALVES
(See page EC−23)
19. REMOVE FRONT WATER BYPASS JOINT

Front Water Bypass Joint Remove the 4 nuts, water bypass joint and 2 gaskets.
cardiagn.com
A23332
Rear Water Bypass Joint 20. REMOVE REAR WATER BYPASS JOINT
Remove the 4 nuts, water bypass joint and 2 gaskets.
21. REMOVE ENGINE HANGERS
A23333
22. REMOVE CYLINDER HEAD COVERS

Remove the 18 bolts, seal washers, RH and LH cylinder head
covers and 2 gaskets.
23. IF NECESSARY, REMOVE SEMI−CIRCULAR PLUGS
AND CAMSHAFT HOUSING PLUGS
24. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
A05564 camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
EM−40
(a) Check the crankshaft pulley position.

Check that the timing mark of the crankshaft pulley is
No.2 Idler
Pulley Bolt aligned with the centers of the crankshaft pulley bolt and
idler pulley bolt.
NOTICE:
Having the crankshaft pulley at the wrong angle can cause
Timing
Mark the piston head and valve head to come into contact with
Crankshaft each other when you remove the camshaft, causing dam-
Pulley Bolt
A04456 age. So always set the crankshaft pulley at the correct
angle.
Movement Oil Control Valve (b) Release the oil from the front bearing caps.
(25°) Installation Hole Using SST, rotate the camshaft timing tube from left to
right 2 to 3 times within its VVT−i range (25°) and use a
waste cloth to collect the oil from the camshaft timing oil
SST control valve installation hole.
SST 09960−10010 (09962−01000, 09963−00400)
NOTICE:
cardiagn.com
Approximately 20 cc (1.2 cu in.) of oil will be ejected. Take
A23334 care not to spill it.
(c) Remove the LH camshafts.

(1) Bring the service bolt hole of the sub−gear upward
by turning the hexagon head portion of the exhaust
camshaft with a wrench.
(2) Secure the sub−gear to the main gear with a service
bolt.
Recommended service bolt:
Service Bolt Thread diameter 6 mm
A23335
Thread pitch 1.0 mm
Bolt length 16 to 20 mm (0.63 to 0.79 in.)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub−gear has been eliminated by the above
operation.
(3) Align the timing mark (2−dot mark) of the camshaft

drive gear by turning the hexagon head portion of
the exhaust camshaft with a wrench.
A23336
EM−41
2 (4) Uniformly loosen the 22 bearing cap bolts in several

22 steps, in the sequence shown.
21 13
17
(5) Remove the 22 bearing cap bolts, 4 seal washers,
20
14 9 oil feed pipe, 9 bearing caps, camshaft housing
18 11
19 6 10 plug, oil control valve filter and 2 camshafts.
1 16
4 12
5
15 8
3
7 A23337
(d) Remove the RH camshafts.

Service Bolt (1) Bring the service bolt hole of the sub−gear upward
by turning the hexagon head portion of the exhaust
camshaft with a wrench.
(2) Secure the sub−gear to the main gear with a service
bolt.
Recommended service bolt:
cardiagn.com
Thread diameter 6 mm
A23338
Thread pitch 1.0 mm
Bolt length 16 to 20 mm (0.63 to 0.79 in.)
HINT:
When removing the camshafts, make sure that the torsional
spring force of the sub−gear has been eliminated by the above
operation.
(3) Set the timing mark (1−dot mark) of the camshaft

main gear at approx. 10° angle by turning the hexa-
gon head portion of the exhaust camshaft with a
wrench.
Approx.
10°
A23339
2 (4) Uniformly loosen the 22 bearing cap bolts in several

21
steps, in the sequence shown.
22
11 (5) Remove the 22 bearing cap bolts, 4 seal washers,
17
15 18 12
20 oil feed pipe, 9 bearing caps, camshaft housing
9 8 19 plug, strainer and 2 camshafts.
16 4
14 1 HINT:
10
7 Arrange the bearing caps for RH and LH sides.
6 3
13
5 A23340
EM−42
25. DISASSEMBLE EXHAUST CAMSHAFTS

(a) Mount the hexagon head portion of the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
A02859
(b) Using SST, turn the sub−gear clockwise, and remove the
Service Bolt
service bolt.
SST 09960−10010 (09962−01000, 09963−00500)
Turn
SST
cardiagn.com
A02850
(c) Using snap ring pliers, remove the snap ring.

(d) Remove the wave washer.
(e) Remove the camshaft sub−gear.
(f) Remove the camshaft gear spring.
NOTICE:
A02861
26. REMOVE CAMSHAFT TIMING TUBE FROM INTAKE

CAMSHAFT
(a) Mount the hexagon head portion of the intake camshaft
in a vise.
NOTICE:
Do Not Remove
The 4 bolts shown in the illustration determine back-
lash of the gear in the timing tube, so do not remove
A23341 them. If any of the 4 bolts are removed, install a new
timing tube assembly.
(b) Remove the screw plug and seal washer.
(c) Using a 10 mm hexagon wrench, and remove the bolt.
(d) Pull out the timing tube and drive gear assembly from the
camshaft.
10 mm
Hexagon
Wrench
A23342
EM−43
(e) Using SST and a 5 mm hexagon wrench, remove the 4

bolts, drive gear and oil seal.
SST SST 09960−10010 (09962−01000, 09963−00500)
NOTICE:
Be careful not to damage the timing tube.
27. REMOVE SPARK PLUGS
5 mm Hexagon Wrench A23343
RH Bank 28. REMOVE CYLINDER HEAD AND EXHAUST MAN-

4 6 9 7
IFOLD ASSEMBLIES
1
(a) Uniformly loosen the 10 cylinder head bolts on one side
of each cylinder head in several steps, in the sequence
shown, then perform the same procedure to the other
side as shown. Remove the 20 cylinder head bolts and
plate washers.
cardiagn.com
NOTICE:
2 8 10 5 3
Cylinder head warpage or cracking could result from
removing bolts in incorrect order.
LH Bank
2 8 10 5 3
4 6 9 7 1
B02642
B02644 A04229
Do not drop the plate washer for cylinder head bolt

RH Bank
Portion A into portion A of the cylinder head. If dropped into
portion A, the plate washer will pass through the cyl-
inder head and cylinder block into the oil pan.
LH Bank
Portion A
B02643
B02645 A04230
EM−44
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the 2 cylinder heads on wooden blocks
on a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the
A02871 cylinder head and cylinder block.
The cylinder head should not be tilted so as to secure
the valve lifter. If the cylinder head is tilted, remove
the valve lifter and check that the adjusting shim is
set correctly.
cardiagn.com
29. REMOVE RH EXHAUST MANIFOLD FROM CYLINDER
HEAD
(a) Remove the 4 bolts and heat insulator.
(b) Remove the 8 nuts, exhaust manifold and gasket.
A23344
30. REMOVE LH EXHAUST MANIFOLD FROM CYLINDER

HEAD
(a) Remove the 4 bolts and heat insulator.
(b) Remove the 8 nuts, exhaust manifold and gasket.
A23345
EM−45
EM0L1−09
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in correct order.
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST SST 09202−70020 (09202−00010)
A03191
(b) Remove the spring retainer, the valve spring, the valve
and the spring seat.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers incorrect order.
cardiagn.com
(c) Using needle−nose pliers, remove the oil seal.
A03192
EM−46
EM1X1−02
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
A03194
(b) Using a surface contacting gasket scraper, remove all the

gasket materials from the cylinder block.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high pressure compressed
air.
cardiagn.com
A03193
2. REMOVE GASKET MATERIAL

Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the surface contacting the cylin-
der block.
EM6323
3. CLEAN COMBUSTION CHAMBERS

Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the surface contacting the cylin-
der block.
EM6324
4. CLEAN VALVE GUIDE BUSHINGS

Using a valve guide bushing brush and solvent, clean all the
guide bushings.
P21861
EM−47
5. CLEAN CYLINDER HEAD

Using a soft brush and solvent, thoroughly clean the cylinder
head.
EM6325
6. INSPECT FOR FLATNESS

Using a precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder block and the manifolds for
warpage.
Maximum warpage: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
cardiagn.com
A05592
7. INSPECT FOR CRACKS

Using a dye penetrate, check the combustion chamber, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
EM6327
8. INSPECT CYLINDER HEAD BOLT

Using vernier calipers, measure the thread outside diameter of
the cylinder head bolt.
Standard outside diameter:
9.810 to 9.960 mm (0.3862 to 0.3921 in.)
Minimum outside diameter: 9.70 mm (0.3819 in.)
Measuring 50 mm If the diameter is less than minimum, replace the bolt.
Point (1.96 in.)
A21018
EM−48
9. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.
EM0580
10. INSPECT VALVE STEMS AND GUIDE BUSHINGS

(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
cardiagn.com
A04091 A04087 A04236
(b) 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 0.2157 in.)
(c) Subtract the valve stem diameter measurement from the

guide bushing inside diameter measurement.
Standard oil clearance:
Z00052
Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing. (See page EM−56)
11. INSPECT AND GRIND VALVES

(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
44.5°
Z00054
EM−49
(c) Check the valve head margin thickness.

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 minimum, replace the valve.
Margin Thickness
EM0181
(d) Check the valve overall length.

Standard overall length:
Intake 95.05 mm (3.7421 in.)
Exhaust 95.10 mm (3.7441 in.)
Overall Length
Minimum overall length:
Intake 94.55 mm (3.7224 in.)
cardiagn.com
Exhaust 94.60 mm (3.7244 in.)
EM2534
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
EM0255
12. INSPECT AND CLEAN VALVE SEATS

45° Carbide Cutter (a) Using a 45° carbide cutter, resurface the valve seats. Re-
move only metal enough to clean the seats.
EM6330
(b) Check the valve seating position.

Apply a light coat of Prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate the valve.
Width
Z00055
EM−50
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
30° concentric. If not, replace the valve.
45°
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
1.0 − 1.4 mm valve face with the following width:
Z03988 1.0 to 1.4 mm (0.039 to 0.055 in.)
If not, correct the valve seats as follows:
If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
cardiagn.com
If the seating is too low on the valve face, use 60°
60° 45°
and 45° cutters to correct the seat.
1.0 − 1.4 mm
Z03989
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.
EM6331
13. INSPECT VALVE SPRINGS

Deviation
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
EM0988
EM−51
(b) Using vernier calipers, measure the free length of the

valve spring.
Free length: 54.1 mm (2.130 in.)
If the free length is not as specified, replace the valve spring.
EM0801
(c) Using a spring tester, measure the tension of the valve

spring at the specified installed length.
Installed tension:
210 to 226 N (21.4 to 23.0 kgf, 47.2 to 50.7 lbf)
at 35.0 mm (1.378 in.)
If the installed tension is not as specified, replace the valve
spring.
cardiagn.com
EM0281
14. INSPECT CAMSHAFT FOR RUNOUT

(a) Place the camshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
A05912
15. INSPECT CAM LOBES

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 42.61 to 42.71 mm (1.6776 to 1.6815 in.)
Minimum cam lobe height:
Intake 42.46 mm (1.6717 in.)
Exhaust 42.48 mm (1.6724 in.)
EM2011
If the cam lobe height is less than minimum, replace the cam-
shaft.
EM−52
16. INSPECT CAMSHAFT JOURNALS

Using a micrometer, measure the journal diameter.
Journal diameter:
26.954 to 26.970 mm (1.0612 to 1.0618 in.)
If the journal diameter is not as specified, check the oil clear-
ance (see step 20).
A04022
17. INSPECT CAMSHAFT TIMING TUBE

(a) Using a micrometer, measure the journal diameter.
Journal diameter:
39.955 to 39.964 mm (1.5730 to 1.5734 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
cardiagn.com
A23346
(b) Install the timing tube to the intake camshaft, and check
Turn the timing tube turns smoothly.
If necessary, replace the timing tube and intake camshaft.
A23347
18. INSPECT CAMSHAFT GEAR SPRING

Using vernier calipers, measure the free distance between the
spring ends.
Free distance: 18.2 to 18.8 mm (0.717 to 0.740 in.)
If the free distance is not as specified, replace the gear spring.
19. INSPECT CAMSHAFT BEARINGS
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
EM3322 inder head as a set.
20. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE

Plastigage (a) Install the camshaft timing tube to the intake camshaft
(see page EM−58).
(b) Clean the bearing caps and camshaft journals.
(c) Place the camshafts on the cylinder head.
(d) Lay a strip of Plastigage across each of the camshaft jour-
nals.
A04083
EM−53
(e) Install the bearing caps (see page EM−60).

Torque:
7.5 N·m (76 kgf·cm, 66 in.·lbf) for bolt A
16 N·m (160 kgf·cm, 12 ft·lbf) for others
A NOTICE:
Do not turn the camshaft.
(f) Remove the bearing caps.
A
A04099
(g) Measure the Plastigage at its widest point.

Camshaft journal 0.030 to 0.071 mm (0.0012 to 0.0028 in.)
Camshaft timing tube
journal 0.036 to 0.057 mm (0.0014 to 0.0022 in.)

Camshaft journal 0.100 mm (0.0039 in.)
cardiagn.com
Camshaft timing tube 0.075 mm (0.0030 in.)
A04084
journal
If the oil clearance is greater than the maximum, replace the

camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
(h) Completely remove the Plastigage.
(i) Remove the camshafts.
(j) Remove the camshaft timing tube from the intake cam-
shaft.
21. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshaft timing tube to the intake camshaft
(see page EM−58).
(b) Install the camshaft (see page EM−58).
(c) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
Intake 0 to 0.040 mm (0 to 0.0016 in.)
A23348
Maximum thrust clearance:

Intake 0.12 mm (0.0047 in.)
Exhaust 0.10 mm (0.0039 in.)
If the thrust clearance is greater than the maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
(d) Remove the camshafts.
(e) Remove the camshaft timing tube from the intake cam-
shaft.
EM−54
22. INSPECT CAMSHAFT GEAR BACKLASH

(a) Install the drive gear to the camshaft timing tube
(See page EM−58).
(b) Install the camshaft timing tube to the intake camshaft
(See page EM−58).
(c) Install the camshafts without installing the exhaust cam-
shaft sub−gear and front bearing cap
(See page EM−58).
A04082 (d) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 to 0.200 mm (0.0008 to 0.0079 in.)
Maximum backlash: 0.30 mm (0.0118 in.)
If the backlash is greater than the maximum, replace the intake
camshaft drive gear and exhaust camshaft.
(e) Remove the camshafts.
(f) Remove the camshaft timing tube from the intake cam-
shaft.
cardiagn.com
(g) Remove the drive gear from the camshaft timing tube.
23. INSPECT VALVE LIFTERS AND LIFTER BORES

(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 to 31.016 mm (1.2205 to 1.2211 in.)
A03209
(b) Using a micrometer, measure the lifter diameter at the

valve lifter center line, 12.3 to 12.7 mm (0.484 to 0.500 in.)
12.3 to 12.7 mm
from the valve lifter head.
Lifter diameter:
30.968 to 30.976 mm (1.2192 to 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
A03201 0.024 to 0.050 mm (0.0009 to 0.0020 in.)
0.07 mm (0.0028 in.)
If the oil clearance is greater than the maximum, replace the lift-
er. If necessary, replace the cylinder head.
EM−55
24. INSPECT EXHAUST MANIFOLDS

Using a precision straight edge and feeler gauge, measure the
warapage of the surface that is in contact with the cylinder
head.
If warpage is greater than maximum, replace the manifold.
A23376
cardiagn.com
EM−56
EM0L3−10
80 to 100°C REPLACEMENT
1. REPLACE VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 to 100°C (176 to
212°F).
A03195
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201−01055, 09950−70010 (09951−07100)
SST
cardiagn.com
A05708
(c) Using a caliper gauge, measure the bushing bore diame-

ter of the cylinder head.
A03197
Both intake and exhaust (d) Select a new guide bushing (STD or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
Bushing bore diameter
Bushing size 10.306 mm (0.4057 in.), machine the bushing bore to the fol-
mm (in.)
lowing dimension:
10.285 to 10.306
Use STD 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
(0.4049 to 0.4057)
10.335 to 10.356
If the bushing bore diameter of the cylinder head is greater than
Use O/S STD 10.356 mm (0.4077 in.), replace the cylinder head.
(0.4069 to 0.4077)
Intake Exhaust HINT:

Different the bushings are used for the intake and exhaust.
(e) Gradually heat the cylinder head to 80 to 100°C (176 to
212°F).
40.5 mm
34.5 mm (1.594 in.)
(1.358 in.)
P21844
EM−57
(f) Using SST and a hammer, tap in a new guide bushing to

SST the specified protrusion height.
Protrusion height:
Intake 9.2 to 9.8 mm (0.362 to 0.386 in.)
SST 09201−01055, 09950−70010 (09951−07100)
A05709
Sharp 5.5 mm Reamer (g) Using a sharp 5.5 mm reamer, ream the guide bushing
to obtain the standard specified clearance (see page
EM−46) between the guide bushing and valve stem.
cardiagn.com
A03199 A03200
2. REPLACE SPARK PLUG TUBE GASKETS

(a) Bend the 4 ventilation case claws installed on the cylinder
head cover to an angle of 90° or more.
(b) Using a screwdriver, pry out the gasket.
NOTICE:
Be careful not to damage the cylinder head cover. Tape the
Bend Pry screwdriver tip.
Claw A04107
(c) Using SST and a hammer, tap in a new gasket until its sur-
SST
face is flush with the upper edge of the cylinder head cov-
er.
SST 09950−60010 (09951−00240, 09951−00440,
09952−06010), 09950−70010 (09951−07100)
NOTICE:
Return Be careful of the installation direction.
SST
(d) Apply a light coat of MP grease to the gasket lip.
Claw Downward A04108 (e) Return the 4 ventilation case claws to its original position.
EM−58
EM0L4−10
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES

Adhesive
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Apply adhesive to the end of the spark plug tube.
Adhesive:
Part No. 08833−00070, THREE BOND 1324
cardiagn.com
or equivalent
15 mm (0.59 in.)
P08885
(b) Using a wooden block and hammer, tap in a new spark

tube until there is 40.9 − 42.1 mm (1.610 − 1.658 in.) pro-
truding from the camshaft bearing cap installation surface
Protrusion of the cylinder head.
NOTICE:
Avoid tapping a new spark plug tube too far for measuring
the amount of the protrusion while tapping.
A03212
2. INSTALL VALVES
SST (a) Using SST, push in a new oil seal.
SST 09201−41020
A05710
(b) Install the valve (1), spring seat (2), valve spring (3) and
(4)
spring retainer (4).
(3)
(2)
(1)
A05711
EM−59
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
SST
A05712
(d) Using a plastic−faced hammer and the valve stem (not in

use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
3. INSTALL SHIMS AND VALVE LIFTERS
Vinyl Tape (a) Install the shim and valve lifter.
cardiagn.com
(b) Check that the valve lifter rotates smoothly by hand.
A07306
EM−60
EM1X2−02
INSTALLATION
1. INSTALL RH EXHAUST MANIFOLD TO CYLINDER
HEAD
(a) Place a new gasket on the cylinder head.
A23349
(b) Install the exhaust manifold with 8 new nuts. Uniformly

tighten the nuts in several steps.
cardiagn.com
A23344
(c) Install the heat insulator with the 4 bolts.

A23351
2. INSTALL LH EXHAUST MANIFOLD TO CYLINDER

HEAD
(a) Place a new gasket on the cylinder head.
A23350
(b) Install the exhaust manifold with 8 new nuts. Uniformly

tighten the nuts in several steps.
A23345
EM−61
(c) Install the heat insulator with the 4 bolts.

A23352
RH Cylinder Head 3. PLACE CYLINDER HEADS ON CYLINDER BLOCK

(a) Place 2 new cylinder head gaskets in the positions on the
cylinder block.
HINT:
On the rear side of the cylinder head gasket are marked to dis-
tinguish the LH and RH banks, a ”2UR” mark for the RH bank
2UR and a ”2UL” mark for the LH bank.
cardiagn.com
NOTICE:
Be careful of the installation direction.
LH Cylinder Head (b) Place the 2 cylinder heads in the positions on the cylinder
head gaskets.
2UL A05563
RH Bank 4. INSTALL CYLINDER HEAD BOLTS

7 5 2 4 10 HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (c) and (e)).
If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil to the threads and under
the heads of the cylinder head bolts.
9 3 1 6 8
(b) Install the plate washer to the cylinder head bolt.
(c) Install and uniformly tighten the 10 cylinder head bolts on
LH Bank
one side of the cylinder head in several steps in the se-
9 3 1 6 8 quence shown, then perform the same procedure to the
other side as shown.
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
7 5 2 4 10
B02642
B02644 A04229
EM−62
RH Bank NOTICE:
Portion A Do not drop the plate washer for cylinder head bolt into por-
tion A of the cylinder head. If dropped into portion A, the
plate washer will pass through the cylinder head and cylin-
der block into the oil pan.
LH Bank
Portion A
cardiagn.com
B02643
B02645 A04230
90° Painted Mark (d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90° in the numerical
order shown.
90° (f) Check that the painted mark is now at a 90° angle to front.
Front 5. INSTALL SPARK PLUGS
A04093
6. ASSEMBLE EXHAUST CAMSHAFT

Camshaft Gear Spring (a) Install the camshaft gear spring, camshaft sub−gear and
wave washer.
HINT:
Attach the pin on the gear to the gear spring end.
Camshaft Sub−gear
Wave Washer
A02888
(b) Using snap ring pliers, install the snap ring.
A02861
EM−63
(c) Mount the hexagon wrench head portion of the camshaft

in a vise.
NOTICE:
A02859
Service Bolt (d) Using SST, align the holes of the camshaft main gear and
Sub Gear sub−gear by turning the camshaft sub−gear counter-
SST clockwise, and temporarily install a service bolt.
SST 09960−10010 (09962−01000, 09963−00500)
Main Gear (e) Align the gear teeth of the main gear and sub−gear, and
tighten the service bolt.
cardiagn.com
Turn
A02889
7. INSTALL CAMSHAFT TIMING TUBE TO INTAKE CAM-

SHAFT
(a) Place a new oil seal to the timing tube.
NOTICE:
Front
A23353
(b) Align the timing tube knock pin with the knock pin groove
of the drive gear, and temporarily install the drive gear
with the 4 bolts.
SST (c) Using SST and a 5 mm hexagon wrench, uniformly tight-
en the 4 bolts in several steps.
SST 09960−10010 (09962−01000, 09963−00500)
5 mm Hexagon NOTICE:
Wrench A23343 Be careful not to damage the timing tube.
(d) Mount the hexagon head portion of the camshaft in a vise.

NOTICE:
A03173
EM−64
(e) Align the camshaft knock pin with the knock pin groove of
the timing tube, and push the timing tube by hand until you
it touches the bottom.
(f) Using a 10 mm hexagon wrench, install the bolt.
(g) Install the seal washer and screw plug.
10 mm Hexagon
Wrench
8. INSTALL CAMSHAFTS
A23342 NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
cardiagn.com
(a) Set the crankshaft pulley position.
Timing Mark Idler Pulley Bolt
Turn the pulley clockwise or counterclockwise, and align
the timing mark of the crankshaft pulley with the centers
of the crankshaft pulley bolt and idler pulley bolt.
NOTICE:
Having the crankshaft pulley at the wrong angle can cause
the piston head and valve head to come into contact with
Crankshaft each other when you install the camshaft, causing dam-
Pulley Bolt Turn
A14399 age. So always set the crankshaft pulley at the correct
angle.
(b) Install the LH camshafts.
(1) Apply MP grease to the thrust portion of the intake
and exhaust camshafts.
(2) Align the timing marks (2−dot mark) of the camshaft
drive and driven main gears, and place the intake
A23354
(3) Apply seal packing to the camshaft housing plug.

Remove the old packing material (FIPG).
Seal Packing
Apply seal packing to the housing plug.
Seal packing: Part No. 08826−00080 or equivalent
B02636
EM−65
(4) Install the camshaft housing plug to the cylinder

head as shown in the illustration.
(5) Install the strainer to the cylinder head.
NOTICE:
A23355
Seal Packing (6) Apply seal packing to the front bearing cap.
Remove any old packing material (FIPG) and
be careful not to drop any oil on the contact
surfaces of the bearing cap and cylinder
head.
Using a razor blade and gasket scraper, re-
move all the old packing material (FIPG) from
cardiagn.com
Seal Width the gasket surfaces and groove.
1.5 mm A16831 Thoroughly clean all components to remove
all the loose material.
Using a non−residue solvent, clean both
sealing surfaces.
Apply seal packing to the bearing cap as
Install a nozzle that has been cut to a 1.5 mm
(0.059 in.) opening.
Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
Immediately remove the nozzle from the tube
and reinstall cap.
NOTICE:
Do not apply seal packing to the front bearing cap grooves.
(7) Install the front bearing cap.

HINT:
Installing the front bearing cap will determine the thrust portion
of the camshaft.
(8) Install the other bearing caps in the sequence
shown with the arrow mark facing forward.
A23356
EM−66
(9) Push in the camshaft oil seal.
Push
A23357
C (10) Install 4 new seal washers to the bearing cap bolts

A (A and B).
A E
D
(11) Apply a light coat of engine oil to the threads and un-
B E E der the heads of the bearing cap bolts (D and E).
B E E E NOTICE:
E E
C Do not apply engine oil under the heads of the bearing cap
E E
E E bolts (A), (B) and (C).
D
cardiagn.com
HINT:
E
E
A23337 Each bolt length is indicated in the illustration.
Bolt length:
94 mm (3.70 in.) for A with seal washer
72 mm (2.83 in.) for B with seal washer
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E
(12) Install the oil feed pipe and the 22 bearing cap bolts
as shown in the illustration.
21 (13) Uniformly tighten the 22 bearing cap bolts in several

1 steps, in the sequence shown.
2 10
6
Torque:
3 9 14 7.5 N·m (76 kgf·cm, 66 in.·lbf) for bolt C
4 5 12 16 N·m (160 kgf·cm, 12 ft·lbf) for others
17 7 13
22
11
18 19 15
8
20 16
A23337
(14) Remove the service bolt.
Service Bolt
A23335
EM−67
(c) Install the RH camshafts.

Approx. 10° (1) Apply MP grease to the thrust portions of the intake
(2) Align the timing marks (1−dot mark) of the camshaft
drive and driven main gears, and place the intake
(3) Set the timing mark (1−dot mark) of the camshaft
drive and driven main gears at approx. 10° angle.
A23358
(4) Apply seal packing to the camshaft housing plug.

Seal Packing Remove the old packing material (FIPG).
Apply seal packing to the housing plug.
cardiagn.com
B02636
(5) Install the camshaft housing plug to the cylinder

head as shown in the illustration.
(6) Install the strainer to the cylinder head.
NOTICE:
A23359
EM−68
Seal Packing (7) Apply seal packing to the front bearing cap.
Remove any old packing material (FIPG) and
be careful not to drop any oil on the contact
surfaces of the bearing cap and cylinder
head.
Using a razor blade and gasket scraper, re-
move all the old packing material (FIPG) from
Seal Width the gasket surfaces and groove.
1.5 mm A16832 Thoroughly clean all components to remove
all the loose material.
Using a non−residue solvent, clean both
sealing surfaces.
Apply seal packing to the bearing cap as
Install a nozzle that has been cut to a 1.5 mm
(0.059 in.) opening.
Parts must be assembled within 5 minutes of
cardiagn.com
application. Otherwise the material must be
removed and reapplied.
Immediately remove the nozzle from the tube
and reinstall cap.
NOTICE:
Do not apply seal packing to the front bearing cap grooves.
(8) Install the front bearing cap.

HINT:
Installing the front bearing cap will determine the thrust portion
of the camshaft.
(9) Install the other bearing caps in the sequence
shown with the arrow mark facing forward.
A23360
(10) Push in the camshaft oil seal.
Push
A23361
EM−69
C (11) Install 4 new seal washers to the bearing cap bolts

A
(A and B).
E A
(12) Apply a light coat of engine oil on the threads and
E
D
E
E B under the heads of the bearing cap bolts (D and E).
E
E
B
NOTICE:
E E
E
Do not apply engine oil under the heads of the bearing cap
E E C
E bolts (A), (B) and (C).
E
D HINT:
E Each bolt length is indicated in the illustration.
A23340
Bolt length:
94 mm (3.70 in.) for A with seal washer
72 mm (2.83 in.) for B with seal washer
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E
(13) Install the oil feed pipe and the 22 bearing cap bolts
as shown in the illustration.
cardiagn.com
21 (14) Uniformly tighten the 22 bearing cap bolts in several
2
steps, in the sequence shown.
6 12 1 Torque:
8 11 3 7.5 N·m (76 kgf·cm, 66 in.·lbf) for bolt C
14 7 5 16 N·m (160 kgf·cm, 12 ft·lbf) for others
4
15
13 19
9 16 22
17 20
10
18 A23340
(15) Remove the service bolt.

Service Bolt 9. CHECK AND ADJUST VALVE CLEARANCE
(See page EM−4)
Turn the camshaft so that the cam lobe faces upward, and
check and adjust the valve clearance.
10. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
(See page SF−50)
A23338
11. INSTALL SEMI−CIRCULAR PLUGS

(a) Remove any old packing material (FIPG).
Seal Packing (b) Apply seal packing to the semi−circular plug grooves.
Seal packing:
Part No. 08826−00080 or equivalent
EM7143
EM−70
RH Bank (c) Install the 4 semi−circular plugs to the cylinder heads as

LH Bank
cardiagn.com
A23362
12. INSTALL LH CYLINDER HEAD COVER

(b) Apply seal packing to the cylinder heads as shown in the
illustration.
: Seal Packing A23363
(c) Install the gasket to the cylinder head cover.

(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts. Uniformly
tighten the bolts in several steps.
A14369
13. INSTALL RH CYLINDER HEAD COVER

(b) Apply seal packing to the cylinder heads as shown in the
illustration.
: Seal Packing A23364

EM−71
(c) Install the gasket to the cylinder head cover.

(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts. Uniformly
tighten the bolts in several steps. Install the 2 cylinder
head covers.
Wire (f) Install the wire clamp bracket on the engine wire to the
Clamp
Bracket
camshaft bearing cap.
A04015 14. INSTALL ENGINE HANGERS
15. INSTALL VVT SENSORS (See page SF−79)
16. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
17. INSTALL OIL DIPSTICK AND GUIDE FOR A/T
18. INSTALL IGNITION COILS (See page IG−6)
cardiagn.com
Rear Water Bypass Joint 19. INSTALL REAR WATER BYPASS JOINT
(a) Install 2 new gaskets to the cylinder head.
(b) Install the the water bypass joint with the 4 nuts to the cyl-
inder heads. Alternately tighten the nuts.
20. INSTALL NO.2 AIR SWITCHING VALVES
(See page EC−27)
21. INSTALL AIR PUMP ASSEMBLY (See page EC−27)
A23333
22. INSTALL FRONT WATER BYPASS JOINT

Front Water Bypass Joint Install 2 new gaskets and the water bypass joint with the 4 nuts.
Alternately tighten the nuts.
23. INSTALL WATER INLET AND INLET HOUSING AS-
SEMBLY (See page CO−8)
A23332
24. ASSEMBLE INTAKE MANIFOLDS

(a) Install the 2 delivery pipes and 8 injectors (see page
SF−31).
(b) Install 2 new gaskets and fuel pulsation damper.
(c) Install a new O−ing and fuel pressure regulator with the
2 bolts.
(d) Install the fuel return pipe to the intake manifold with the
3 bolts.
A23331 (e) Connect the fuel return hose to the fuel pressure regula-
tor.
EM−72
(f) Install the VSV for ACIS with the bolt.

(g) Install the throttle body (See page SF−45).
B17510
(h) Install 4 new gaskets and front fuel pipe with the bolt and
(j)
(j) 2 unions to the intake manifold.
Torque:
(h) (i) 39 N·m (400 kgf·cm, 29 ft·lbf) for union bolts
7.5 N·m (80 kgf·cm, 66 in.·lbf) for bolt
(h) (i) Install the VSV for EVAP with the bolt to the intake man-
ifold and connect the EVAP hose.
cardiagn.com
(h)
A23330 (j) Install the 2 VSVs for air injection system with the 2 bolts.
25. INSTALL INTAKE MANIFOLD ASSEMBLY

(a) Place 2 new gaskets on the intake manifold.
A23365
(b) Place the intake manifold assembly on the cylinder

heads.
(c) Install and uniformly tighten the 6 bolts and 4 nuts in sev-
eral steps.
A23329
EM−73
(d) Install the throttle body cover bracket to the intake man-
ifold.
(e) Install the wire bracket to the intake manifold with the bolt.
(f) Connect the engine wire to the engine hanger and wire
bracket.
(g) Install the engine wire to the LH No.1 timing belt rear
A23328 plate.
(h) Connect the wire protector to the intake manifold and cyl-
inder heads with the 2 bolts.
(i) Install the 2 ground cables with the 2 bolts to the RH and
LH cylinder heads.
cardiagn.com
A23327
(j) Connect the 2 water bypass hoses to the throttle body.
A23325
(k) Connect the 2 wire clamps to the wire clamp bracket on

the RH delivery pipe.
Wire Clamp
A23326
EM−74
26. CONNECT HOSES TO INTAKE MANIFOLD

(d) (a) Connect the vacuum hose to the fuel pressure regulator.
(b) Connect the PCV hose to the PCV valve on the LH the cyl-
inder head.
(c) Connect the EVAP hose (from charcoal canister) to the
VSV for EVAP.
(d) Connect the 2 vacuum hoses to the VSV for the air injec-
tion system.
(e) Connect the brake booster tube.
(a) 27. CONNECT CONNECTORS TO INTAKE MANIFOLD
(a) Connect the throttle control connector.
(c)
(b) Connect the 2 VSV connectors for the air injection sys-
tem.
(c) Connect the VSV connector for the EVAP.
(d) Connect the 8 injector connectors.
(e) Connect the ECT sensor connector.
(f) Connect the 2 air fuel ratio sensor connectors.
cardiagn.com
(b) 28. CONNECT FUEL INLET HOSE (See page SF−31) AND
A23324 FUEL RETURN HOSE
29. INSTALL TIMING BELT REAR PLATES
(a) Install the RH No.1 timing belt rear plates.
Install the RH No.1 timing belt rear plates to the cylinder
head with the 3 bolts and stud bolt.
(b) Install the LH No.1 timing belt rear plates.
(1) Connect the wire clamp to the No.1 timing belt rear
plate.
(2) Install the LH No.1 timing belt rear plates to the cyl-
inder head with the 3 bolts and stud bolt.
31. INSTALL IGNITION COILS (See page IG−6)
32. INSTALL OIL DIPSTICK AND GUIDE FOR A/T
33. INSTALL FRONT EXHAUST PIPE (See page EM−127)
34. INSTALL PS PUMP (See page EM−83)
35. INSTALL CAMSHAFT POSITION SENSOR
(See page IG−9)
36. INSTALL CAMSHAFT TIMING PULLEYS
(See page EM−23)
37. CONNECT TIMING BELT TO CAMSHAFT TIMING PUL-
LEYS (See page EM−23)
38. CHECK ENGINE OIL LEVEL
EM−75
ENGINE MECHANICAL (2UZ−FE) − ENGINE UNIT (2WD)
ENGINE UNIT (2WD)

EM11Z−08
COMPONENTS
MAF Meter Wire
MAF Meter Connector A/C Suction Hose
Vacuum Hose
Hood
PS Air Hose
PCV Hose
Air Filter
Air Cleaner Cap and
Assembly Throttle Body Cover
Clip
Clip
cardiagn.com
Air Cleaner Case
Radiator Assembly
No. 2 Fan Shroud
Windshield Washer Hose
Fan Pulley
Drive Belt
12 (200, 15)
29 (296, 21) A/T Oil Cooler Hose
Fan with Fluid Coupling Assembly
Engine Under Cover

A19397
EM−76
Heater to Register Dust
Lower No. 2 Finish Panel
ECM and Bracket Assembly
cardiagn.com
ECM Connector
Wire Harness Connector
(Cassette Connector)
Glove Compartment Door
B16538
Ground Strap Heater Hose

w/o Hydraulic Brake Booster:
Engine Wire Clamp Heater Hose Brake Booster Tube
Engine Wire
EVAP Hose
Generator
Connector Fuel Return
Hose
Fuel Inlet Battery
Hose Negative
(−) Cable
Generator Wire
Battery
Clamp Positive (+)
Terminal
A23366
EM−77
Engine and
PS Pump Propeller Shaft
Transmission
Assembly
74 (750, 54)
62 (632, 46)
Rear Engine Mounting Bracket
65 (663, 48)
cardiagn.com
38 (388, 28)
Frame Crossmember
Transmission 72 (730, 53)

38 (388, 28) Control Cable
A/C Compressor
RH Front Exhaust Pipe
Gasket
13 (130, 9)
A/C Compressor
62 (632, 46)
Gasket
19 (190, 14) Gasket Gasket
Retainer
Bushing 62 (632, 46)
LH Front Exhaust Pipe
62 (632, 46)
Stabilizer Bar Turn Pressure

Tube 29 (290, 21)
37 (377, 27)
37 (377, 27)
Pressure
Feed Tube

EM−78
Stay Stay Stay
Connector
Clamp
Oil Cooler Pipe for Transmission

Connector
Connector
Transmission
(with Torque
Converter Clutch)
cardiagn.com
Oil Dipstick and Guide
for Transmission
x 10
37 (380, 27) for 14 mm Head

72 (730, 53) for 17 mm Head
O−Ring
See page EM−83
1st :49 (500, 36)
Engine Unit Assembly 2nd: Turn 90°
Front Spacer
x8
Rear Spacer
x6
48 (490, 35)
Drive Plate
Flywheel Housing Under Cover

Non−reusable part
Precoated part
A19393
EM−79
EM120−05
REMOVAL
1. REMOVE ENGINE HOOD
TOR ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Loosen the 3 bolts, and remove the air cleaner case.
(c) Remove the A/C suction hose from the intake air connec-
tor.
(d) Disconnect the PS air hose, air inlet hose for EVAP, PCV
hose and MAF meter wire from the air intake connector.
(e) Disconnect the intake air connector from the throttle body.
7. DISCONNECT BATTERY CABLES
(a) Disconnect the clamp on battery negative (−) cable from
cardiagn.com
the No. 2 relay box.
(b) Disconnect the battery positive (+) terminal cable.
(c) Disconnect battery negative (−) cable from the left fender
apron.
FAN PULLEY
bracket.
(b) Remove the drive belt (See page CH−7 or CH−19).
fan pulley.
9. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the glove compartment door.
(b) Remove the lower No. 2 panel.
(c) Remove the 3 screws, and disconnect the ECM from the
body bracket.
(d) Disconnect the 3 wire harness connectors from the ECM.
(e) Disconnect the 2 wire harness connectors (cassette con-
nector).
(f) Disconnect the engine wire from the engine wire bracket
and remove the bolt, 2 nuts and bracket.
(g) Pull out the engine wire from the cowl panel.
10. DISCONNECT HOSES, WIRES, CONNECTORS,
CLAMPS, GROMMET AND CABLES
Disconnect (a) Disconnect the 2 PS air hoses from hose clamp on the No.
3 RH timing belt cover.
(b) Disconnect the generator wire.
B07536 (c) Disconnect the generator connector.
(d) Disconnect the hose clamp for the PS air hose.
EM−80
(e) Disconnect the PS air hose from the upper intake man-
ifold.
(f) Disconnect the 2 heater hoses.
(g) Disconnect the ground strap from the cowl panel.
(h) Disconnect the fuel inlet hose and clamps.
(i) Disconnect the fuel return hose and clamp.
(j) Disconnect the air inlet hose from the charcoal canister.
(k) Disconnect the EVAP hose from the VSV for EVAP.
(l) w/o Hydraulic brake booster:
Disconnect the brake booster tube.
11. REMOVE FRONT EXHAUST PIPES (See page
EM−125)
12. REMOVE PROPELLER SHAFT (See page PR−3)
13. REMOVE FRONT STABILIZER BAR (See page
SA−89)
14. DISCONNECT POWER STEERING GEAR PIPES
Disconnect the pressure feed tube, turn tube and pressure
cardiagn.com
tubes from the PS gear assembly (See page SR−73).
15. REMOVE TRANSMISSION CONTROL CABLE

(a) Remove the 2 bolts and control cable bracket from the
transmission.
(b) Remove the control cable from the control shift lever.
A09151

(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.
A08905

Remove the 3 bolts, and disconnect the PS pump from the en-
gine.
HINT:
A08907
EM−81
18. REMOVE ENGINE MOUNTING BRACKETS

(a) Attach the engine chain hoist to the engine hangers.
(b) Remove the 4 nuts and 4 bolts holding the engine mount-
ing brackets to the frame brackets.
19. PLACE JACK UNDER TRANSMISSION
A09147
20. REMOVE ENGINE REAR MOUNTING BRACKET

(a) Remove the 8 bolts, 2 nuts and frame crossmember.
cardiagn.com
A08804
(b) Remove the 4 bolts and engine rear mounting bracket

from the transmission.
A08906
21. REMOVE ENGINE AND TRANSMISSION ASSEMBLY

Lift FROM VEHICLE
(a) Lift the engine out of the vehicle slowly and carefully.
HINT:
Down
Make sure the engine is clear of all wiring, hoses and cables.
(b) Place the engine and transmission assembly onto the
stand.
22. DISCONNECT ENGINE WIRE FROM TRANSMISSION
A08805 (a) Disconnect the 5 connectors.
(b) Disconnect the 2 wire clamps.
23. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR
TRANSMISSION
(a) Disconnect the 2 breather hoses from the dipstick guide.
(b) Remove the 2 bolts.
(c) Pull out the dipstick guide and dipstick from the dipstick
tube of transmission.
(d) Remove the O−ring from the dipstick guide.
24. REMOVE OIL COOLER PIPES FOR TRANSMISSION
(a) Remove the 3 bolts and 3 stays.
EM−82
(b) Loosen the 2 union nuts, and remove the 2 oil cooler
pipes.
25. REMOVE TORQUE CONVERTER CLUTCH BOLTS

(a) Remove the 2 bolts and flywheel housing under cover.
cardiagn.com
A08806
(b) Turn the crankshaft pulley bolt to gain access to each bolt.
(c) Hold the crankshaft pulley bolt with a wrench, and remove
the 6 bolts.
A08900
26. REMOVE TRANSMISSION

(a) Remove the 10 bolts.
(b) Remove the transmission together with the torque con-
verter clutch from the engine.
A08901
27. REMOVE DRIVE PLATE

Remove the 8 bolts, front spacer, drive plate and rear spacer.
A04857
EM−83
EM121−08
INSTALLATION
1. INSTALL DRIVE PLATE
HINT:
The mounting bolts are tightened in 2 progressive steps
(steps (c) and (e)).
If any one 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
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent
cardiagn.com
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 passes, in the sequence shown.
3 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
If any one of the mounting bolts does not meet the torque speci-
4
7 fication, replace the mounting bolt.
6
2
A04857
(d) Mark the mounting bolt with paint.

(e) Retighten the mounting bolts by 90° in the numerical or-
der shown.
(f) Check that the painted mark is now at a 90° angle to (e).
Painted
Mark
90°
90°
A05137
2. INSTALL TRANSMISSION TO ENGINE

(a) Check the torque converter clutch installation (See page
AT−38).
(b) Attach the transmission to the engine.
(c) Install the 10 bolts.
Torque:
37 N·m (380 kgf·cm, 27 ft·lbf) for 14 mm head
72 N·m (730 kgf·cm, 53 ft·lbf) for 17 mm head
A08901
EM−84
3. INSTALL TORQUE CONVERTER CLUTCH BOLTS

Adhesive (a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
lent
P18747
(b) Hold the crankshaft pulley bolt with a wrench, and install
the 6 bolts evenly.
HINT:
First install the black colored bolt, install the other bolts.
cardiagn.com
A08900
(c) Install the flywheel housing under cover with the 2 bolts.
4. INSTALL OIL COOLER PIPE FOR TRANSMISSION
5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR
TRANSMISSION
(a) Install a new O−ring to the dipstick guide.
(b) Apply soapy water to the O−ring.
(c) Connect the dipstick guide end to the dipstick tube of the
A08806 oil pan.
(d) Install the dipstick guide with the bolt.
(e) Install the dipstick.
(f) Connect the 2 breather hoses to the dipstick guide.
6. CONNECT ENGINE WIRE TO TRANSMISSION
(a) Connect the 5 connectors.
(b) Connect the 2 wire clamps.
7. INSTALL ENGINE AND TRANSMISSION ASSEMBLY

Lower
IN VEHICLE
Up (b) Slowly lower the engine and transmission assembly into
the engine compartment.
(c) Attach the engine mounting brackets to the frame brack-
ets.
A08931
EM−85
(d) Keep the engine level with a jack.
A09149
8. INSTALL ENGINE REAR MOUNTING BRACKET

(a) Install the engine rear mounting bracket to the transmis-
sion with the 4 bolts.
cardiagn.com
A08906
(b) Install the frame crossmember with the 8 bolts and 4 nuts.
Torque:
18 N·m (183 kgf·cm, 13 ft·lbf) for bolts (A)
72 N·m (730 kgf·cm, 53 ft·lbf) for nuts (B)
A
B B
A08804
9. INSTALL ENGINE MOUNTING BRACKETS

(a) Install the engine mounting brackets to the frame brack-
ets with the 2 nuts and 4 bolts.
(b) Remove the engine chain hoist.
A09147
10. INSTALL PS PUMP

A08907
EM−86
11. INSTALL A/C COMPRESSOR

(a) Install the A/C compressor with the 3 bolts.
(b) Connect the A/C compressor connector.
A08905
12. INSTALL TRANSMISSION CONTROL CABLE

(a) Install the control cable to the control shift lever.
(b) Install the control cable bracket to the transmission with
(a)
the 2 bolts.
13. CONNECT POWER STEERING GEAR PIPES
Connect the pressure feed tube, turn tube and turn pressure
cardiagn.com
tubes to the PS gear assembly (See page SR−88).
A09151 14. INSTALL FRONT STABILIZER BAR
(See page SA−91)
15. INSTALL PROPELLER SHAFT (See page PR−8)
16. INSTALL FRONT EXHAUST PIPES
(See page EM−125)
17. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS,
GROMMET AND CABLES
(a) Connect the 2 PS air hoses to hose clamp on the No. 3
RH timing belt cover.
(b) Connect the generator wire.
(c) Connect the generator connector.
(d) Connect the hose clamp for the PS air hose.
(e) Connect the PS air hose to the upper intake manifold.
(f) Connect the 2 heater hoses.
(g) Connect the ground strap connector.
(h) Connect the fuel inlet hose and clamps.
(i) Connect the fuel return hose and clamp.
(j) Connect the air inlet hose to the charcoal canister.
(k) Connect the EVAP hose to the VSV for EVAP.
(l) w/o Hydraulic brake booster:
Connect the brake booster tube.
18. CONNECT ENGINE WIRE TO CABIN

(a) Push into 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.
Connect
(c) Connect the 2 wire harness connectors (cassette con-
nector).
(d) Connect the 3 connectors to the ECM.
(e) Install the ECM with the 3 screws.
A09152 (f) Install the lower No. 2 panel.
(g) Install the glove compartment door.
EM−87
19. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND

DRIVE BELT
(a) Temporarily install the fan pulley, the fan and fluid cou-
pling assembly with the 4 nuts.
(b) Install the drive belt (See page CH−16 or CH−28).
(c) Tighten the 4 nuts holding the fluid coupling to the fan
bracket.
20. INSTALL BATTERY CABLES
(a) Connect the clamp on battery negative (−) cable to No.2
relay box.
(b) Connect the battery positive (+) terminal cable.
(c) Connect the battery negative cable to the left fender
apron.
21. INSTALL AIR CLEANER AND INTAKE AIR CONNEC-
TOR ASSEMBLY
(a) Install the air cleaner with the 3 bolt.
Torque: 5 N·m (51 kgf·cm, 44 in.·lbf)
cardiagn.com
(b) Connect the intake air connector to the throttle body.
(c) Connect the MAF meter connector.
(d) Install the A/C suction hose to the intake air connector.
(e) Connect the PS air hose, air inlet hose for EVAP, PCV
hose and MAF meter wire to the air intake connector.
24. FILL WITH ENGINE COOLANT (See page CO−2)
25. FILL WITH ENGINE OIL (See page LU−2)
27. INSTALL ENGINE UNDER COVER
28. INSTALL HOOD
29. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
30. RECHECK ENGINE COOLANT AND OIL LEVELS
EM−88
ENGINE UNIT (4WD)

EM1XC−01
COMPONENTS
MAF Meter Wire
Vacuum Hose
MAF Meter Connector A/C Suction Hose
Hood
PS Air Hose
PCV Hose
Air Filter
Air Cleaner
Cap and
Throttle Body Cover
Intake Air Clip
Connector Clip
Assembly
cardiagn.com
Air Cleaner Case
Radiator Assembly
No. 2 Fan Shroud
Windshield Washer Hose
Fan Pulley
Drive Belt
12 (200, 15)
29 (296, 21) A/T Oil Cooler Hose
Fan with Fluid Coupling Assembly
Engine Under Cover

A19396
EM−89
Heater to Register Dust
Lower No. 2 Finish Panel
ECM and Bracket Assembly
cardiagn.com
ECM Connector
Wire Harness Connector
(Cassette Connector)
Glove Compartment Door
B16538
Ground Strap Heater Hose

w/o Hydraulic Brake Booster:
Engine Wire Clamp Heater Hose Brake Booster Tube
Engine Wire
EVAP Hose
Generator
Connector Fuel Return
Hose
Fuel Inlet Battery
Hose Negative
(−) Cable
Generator Wire
Battery
Clamp Positive (+)
Terminal
A23366
EM−90
88 (897, 65)
Rear Propeller Shaft
88 (897, 65)
40 (410, 30)
34 (346, 25) Transmission and
Transfer
12 (122, 9)
71 (724, 52)
Clamp
Oil Cooler Pipe
Torque
Converter
Clutch 14.5 (148, 11)
48 (490, 35)
x6
cardiagn.com
Rear End Plate 19.5 (199, 14)
18 (185, 13) 37 (377, 27)
32 (326, 24)
Front Exhaust Pipe RH
48 (490, 35)
Engine Rear
88 (897, 65)
Mounting Insulator
Gasket Front Propeller Shaft
Clamp
88 (897, 65)
Gasket Gasket
65 (660, 48)
16 (164, 12)
Gasket
72 (734, 53)
62 (630, 46)
Heat Insulator
Front Exhaust Pipe LH
62 (630, 46)
Crossmember
37 (377, 27)
No. 1 Engine Under Cover

Bushing
Stabilizer Bar Stabilizer Bar Bracket

Non−reusable part D14121
EM−91
Stay
Stay
Stay
PS Pump
Oil Cooler Pipe

for Transmission
17 (175, 13)
17 (175, 13)
cardiagn.com
Engine Unit Assembly Drive Plate
Rear Spacer
Front Spacer
x8
38 (388, 28)
See page EM−95

1st 49 (500, 36)
2nd Turn 90°
38 (388, 28)
A/C Compressor
A/C Compressor 49 (500, 36)

Connector

EM−92
EM11X−08
REMOVAL
1. REMOVE FRONT EXHAUST PIPES
(See page EM−125)
2. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR−10)
3. REMOVE FRONT STABILIZER BAR
(See page SA−89)
4. REMOVE TRANSMISSION (See page AT−34)
5. REMOVE ENGINE HOOD
TOR ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Loosen the 3 bolts, and remove the air cleaner case.
cardiagn.com
(c) Remove the A/C suction hose from the intake air connec-
tor.
(d) Disconnect the PS air hose, air inlet hose for EVAP, PCV
hose and MAF meter wire from the air intake connector.
(e) Disconnect the intake air connector from the throttle body.
11. DISCONNECT BATTERY CABLES
(a) Disconnect the clamp on battery negative (−) cable from
the No. 2 relay box.
(b) Disconnect the battery positive (+) terminal cable.
(c) Disconnect the battery negative (−) cable from the left
fender apron.
FAN PULLEY
bracket.
(b) Remove the drive belt (See page CH−7 or CH−19).
fan pulley.
13. DISCONNECT ENGINE WIRE FROM CABIN

(a) Remove the glove compartment door.
(b) Remove the lower No. 2 panel.
(c) Remove the 3 screws, and disconnect the ECM from the
body bracket.
Disconnect
(d) Disconnect the 3 wire harness connectors from the ECM.
(e) Disconnect the 2 wire harness connectors (cassette con-
nector).
B07536 (f) Disconnect the engine wire from the engine wire bracket
and remove the 2 nuts, bolt and bracket.
EM−93
(g) Pull out the engine wire from the cowl panel.
14. DISCONNECT HOSES, WIRES, CONNECTORS,
CLAMPS, GROMMET AND CABLES
(a) Disconnect the accelerator cable from the engine.
(b) Disconnect the 2 PS air hoses from hose clamp on the No.
3 RH timing belt cover.
(c) Disconnect the generator wire.
(d) Disconnect the generator connector.
(e) Disconnect the hose clamp for the PS air hose.
(f) Disconnect the PS air hose from the upper intake man-
ifold.
(g) Disconnect the 2 heater hoses.
(h) Disconnect the ground strap from the cowl panel.
(i) Disconnect the fuel inlet hose and clamps.
(j) Disconnect the fuel return hose and clamp.
(k) Disconnect the air inlet hose from the charcoal canister.
(l) Disconnect the EVAP hose from the VSV for EVAP.
cardiagn.com
(m) w/o Hydraulic brake booster:
Disconnect the brake booster tube.

(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.
A08905

Remove the 3 bolts, and disconnect the PS pump from the en-
gine.
HINT:
17. REMOVE OIL COOLER PIPES FOR TRANSMISSION
(a) Remove the 3 bolts and 3 stays.
(b) Loosen the 2 union nuts, and remove the 2 oil cooler
A08907 pipes.
18. REMOVE ENGINE ASSEMBLY FROM VEHICLE

(b) Remove the 4 bolts holding the engine mounting brackets
to the frame brackets.
A08936
EM−94
(c) Lift the engine out of the vehicle slowly and carefully.
Lift HINT:
Make sure the engine is clear of all wiring, hoses and cables.
(d) Place the engine and transmission assembly onto the
stand.
A08932
19. REMOVE DRIVE PLATE

Remove the 8 bolts, front spacer, drive plate and rear spacer.
cardiagn.com
A04857
EM−95
EM11Y−08
INSTALLATION
Adhesive 1. INSTALL DRIVE PLATE
HINT:
The mounting bolts are tightened in 2 progressive steps
(steps (c) and (e)).
If any one of the mounting bolts is broken or deformed, re-
place it.
(a) Apply adhesive to 2 or 3 threads of the mounting bolt end.
A04869
Adhesive:
lent
(b) Install the front spacer, drive plate and rear spacer on the
crankshaft.
cardiagn.com
(c) Install and uniformly tighten the 8 mounting bolts in sever-
al passes, in the sequence shown.
5
8 If any one of the mounting bolts does not meet the torque speci-
3 fication, replace the mounting bolt.
4
7
6 2
A04857
(d) Mark the mounting bolt with paint.

(e) Retighten the mounting bolts by 90° in the numerical or-
der shown.
(f) Check that the painted mark is now at a 90° angle to (e).
Painted
Mark
90°
90°
A05137
2. INSTALL ENGINE ASSEMBLY IN VEHICLE

Lower
(b) Slowly lower the engine assembly into the engine
compartment.
(c) Attach the engine mounting brackets to the frame brack-
ets.
A08933
EM−96
(d) Install the engine mounting brackets to the frame brack-

ets with the 2 nuts and 4 bolts.
(e) Remove the engine chain hoist.
A08936
3. INSTALL PS PUMP
cardiagn.com
A08907
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 accelerator cable to the engine.
(b) Connect the 2 PS air hoses to hose clamp on the No.3 RH
A08905 timing belt cover.
(c) Connect the generator wire.
(d) Connect the generator connector.
(e) Connect the hose clamp for the PS air hose.
(f) Connect the PS air hose to the upper intake manifold.
(g) Connect the 2 heater hoses.
(h) Connect the ground strap to the cowl panel.
(i) Connect the fuel inlet hose and clamps.
(j) Connect the fuel return hose and clamp.
(k) Connect the air inlet hose to the charcoal canister.
(l) Connect the EVAP hose to the VSV for EVAP.
(m) w/o Hydraulic brake booster:
Connect the brake booster tube.
EM−97
6. CONNECT ENGINE WIRE TO CABIN

(a) Push into 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.
Connect (c) Connect the 3 connectors to the ECM.
(d) Connect the 2 wire harness connectors (cassette con-
nector).
(e) Install the ECM with the 3 screws.
A09152 (f) Install the lower No. 2 panel.
(g) Install the glove compartment door.
7. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND
DRIVE BELT
(a) Temporarily install the fan pulley, the fan and fluid cou-
pling assembly with the 4 nuts.
(b) Install the drive belt (See page CH−16 or CH−28).
(c) Tighten the 4 nuts holding the coupling to the fan bracket.
8. INSTALL BATTERY CABLES
cardiagn.com
(a) Connect the battery positive (+) terminal cable.
(b) Connect the battery negative (−) cable to the battery and
left fender apron.
(c) Connect the clamp on battery negative (−) cable to No. 2
relay box.
9. INSTALL AIR CLEANER AND INTAKE AIR CONNEC-
TOR PIPE ASSEMBLY
(a) Install the air cleaner case with the 3 bolts.
Torque: 5 N·m (51 kgf·cm, 44 in.·lbf)
(b) Connect the intake air connector to the throttle body.
(c) Connect the MAF meter connector.
(d) Install the A/C suction hose to the intake air connector.
(e) Connect the PS air hose, air inlet hose for EVAP, PCV
hose and MAF meter connector to the intake air connec-
tor.
11. INSTALL TRANSMISSION (See page AT−38)
13. INSTALL FRONT STABILIZER BAR
(See page SA−91)
14. INSTALL FRONT AND REAR PROPELLER SHAFTS
(See page PR−15)
15. INSTALL FRONT EXHAUST PIPES
(See page EM−125)
16. FILL WITH ENGINE COOLANT (See page CO−2)
17. FILL WITH ENGINE OIL (See page LU−2)
19. INSTALL ENGINE UNDER COVERS
20. INSTALL HOOD
21. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
22. RECHECK ENGINE COOLANT AND OIL LEVELS
EM−98
ENGINE MECHANICAL (2UZ−FE) − CYLINDER BLOCK
CYLINDER BLOCK
EM0E9−18
COMPONENTS
Engine Wire Protector

Water Bypass Pipe
Starter
O−Ring
Water Pump
Knock Sensor 2
x5 Gasket
Engine Mounting Bracket

36 (370, 27)
VVT Sensor 2 Knock Sensor 1
cardiagn.com
Connector
Oil Pump Engine Coolant
30.5 (310, 22)
Drain Union VVT
Engine Sensor 1
Wire
O−Ring
Crankshaft
Front Oil Engine
Seal Wire
Cover
Engine Coolant
15.5 (160, 11) Drain Union
Gasket
Engine
Crankshaft Position Mounting
Engine Bracket
Sensor Connector
Wire
7.5 (76, 66 in.·lbf)
7.5 (76, 66 in.·lbf)
Oil Strainer
Oil Pressure Tape
Sender Gauge 7.5 (76, 66 in.·lbf)
Connector Clamp
28 (290, 21) x4
No.1 Oil Pan
28 (290, 21)
7.5 (76, 66 in.·lbf)
28 (290, 21) x8
Oil Pan Baffle Plate 7.5 (76, 66 in.·lbf)
No.2 Oil Pan
Gasket
N·m (kgf·cm, ft·lbf) : Specified torque x 20 39 (400, 29)
Non−reusable part
Precoated part 7.5 (76, 66 in.·lbf)
A23375
EM−99
No.1 Piston Ring

No.2 Piston Ring
Side Rail
Oil Ring Expander
Side Rail
Piston
Snap Ring Snap Ring
Piston Pin
Connecting Rod
Connecting Rod Bushing
Connecting Rod Bearing

See page EM−118
1st 24.5 (250, 18)
Connecting Rod Cap
2nd Turn 90°
cardiagn.com
Crankshaft
O−Ring Rear Oil Seal
Cylinder Block
x7
8.0 (80, 71 in.·lbf)
Rear Oil Seal Retainer
Upper Crankshaft
Thrust Washer
Upper Main Bearing
Crankshaft
Lower Main Bearing Lower Crankshaft

Thrust Washer
Main Bearing Cap
See page EM−118

1st 27 (275, 20)
2nd Turn 90°
EM−100
EM122−06
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND
2. REMOVE TIMING BELT AND PULLEYS
(See page EM−16)
3. REMOVE CYLINDER HEAD (See page EM−36)
4. REMOVE WATER BYPASS PIPE

Pull (a) Disconnect the wire clamp (for knock sensor 1, 2) from
Wire bracket of the water bypass pipe.
Clamp (b) Remove the bolt.
(c) Pull out the water bypass pipe from the water pump.
O−Ring (d) Remove the O−ring from the water bypass pipe.
5. REMOVE STARTER (See page ST−6)
cardiagn.com
6. REMOVE KNOCK SENSORS (See page SF−70)
A05112 7. REMOVE VVT SENSORS (See page SF−79)
LH Side 8. DISCONNECT ENGINE WIRE FROM LH SIDE OF CYL-

INDER BLOCK
(a) Remove the 2 bolts and engine wire cover from the LH
side of the cylinder block.
(b) Remove the 2 bolts, disconnect the brackets on the en-
gine wire from the cylinder block and engine mounting
bracket.
9. REMOVE OIL COOLER PIPE BRACKET FOR A/T
A08472 Remove the bolt and bracket.
10. REMOVE ENGINE MOUNTING BRACKETS
Remove the 4 bolts and mounting bracket. Remove the 2
mounting brackets.
11. REMOVE WATER PUMP (See page CO−6)
12. REMOVE NO.2 OIL PAN (See page LU−8)
13. REMOVE OIL PAN BAFFLE PLATE
14. REMOVE NO.1 OIL PAN (See page LU−8)
15. REMOVE OIL STRAINER
16. REMOVE OIL PUMP (See page LU−8)
17. REMOVE ENGINE COOLANT DRAIN UNIONS
Remove the 2 drain unions.
EM−101
18. REMOVE REAR OIL SEAL RETAINER

(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portion between the oil seal retainer and main bearing
cap.
pry (c) Remove the O−ring.
A05086
19. CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back an forth.
0.160 to 0.290 mm (0.0063 to 0.0114 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
cardiagn.com
connecting rod assembly(s). If necessary, replace the crank-
A05100 shaft.
Connecting rod thickness:
22.880 to 22.920 mm (0.9008 to 0.9024 in.)
20. REMOVE CONNECTING ROD CAPS AND CHECK OIL

CLEARANCE
(a) Check the matchmarks on the connecting rod and see it
cap to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
A05104
(c) Using the 2 removed connecting rod cap bolts, remove

the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for peeling and
scratches.
A05105 If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
EM−102
Plastigage (f) Lay a strip of Plastigage across the crank pin.
A05102
(g) Install the connecting rod cap with the 2 bolts.

(see page EM−118)
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure (b) and (c) above)
cardiagn.com
A05101
(i) Measure the Plastigage at its widest point.

0.021 to 0.047 mm (0.0008 to 0.0019 in.)
Maximum oil clearance: 0.059 mm (0.0023 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.
A05103
HINT:
If using a standard bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
Number
Mark printed on the connecting rod cap and crankshaft, then select-
ing the bearing with the same number as the total. There are 6
No.4 sizes of standard bearings, marked ”2”, ”3”, ”4”, ”5”, ”6” and ”7”.
No.3
No.1 Number mark
No.2 Connecting rod cap 1 1 2 1 2 3 2 3 4 3 4 4
Crankshaft 1 2 1 3 2 1 3 2 1 3 2 3
Number Use bearing 2 3 4 5 6 7
Mark EXAMPLE:
Number Connecting rod cap ”3” + Crankshaft ”1”
Mark = Total number 4 (Use bearing ”4”)
A05852
A05087
A05853 A05175
EM−103
Reference
Connecting rod big end inside diameter:
Mark ”1” 55.000 to 55.006 mm (2.1654 to 2.1656 in.)
Mark ”2” 55.006 to 55.012 mm (2.1656 to 2.1658 in.)
Mark ”3” 55.012 to 55.018 mm (2.1658 to 2.1661 in.)
Mark ”4” 55.018 to 55.024 mm (2.1661 to 2.1663 in.)
Crankshaft crank pin diameter:
Mark ”1” 51.994 to 52.000 mm (2.0470 to 2.0472 in.)
Mark ”2” 51.988 to 51.994 mm (2.0468 to 2.0470 in.)
Mark ”3” 51.982 to 51.988 mm (2.0465 to 2.0468 in.)
Standard sized bearing center wall thickness:

Mark ”2” 1.487 to 1.490 mm (0.0585 to 0.0587 in.)
Mark ”3” 1.490 to 1.493 mm (0.0587 to 0.0588 in.)
Mark ”4” 1.493 to 1.496 mm (0.0588 to 0.0589 in.)
Mark ”5” 1.496 to 1.499 mm (0.0589 to 0.0590 in.)
cardiagn.com
Mark ”6” 1.499 to 1.502 mm (0.0590 to 0.0591 in.)
Mark ”7” 1.502 to 1.505 mm (0.0591 to 0.0593 in.)
(j) Completely remove the Plastigage.
21. REMOVE PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Ridge Keep the bearings, connecting rod and cap together.
Reamer A04852 Arrange the piston and connecting rod assemblies in cor-
rect order.
22. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
A05096 Thrust washer thickness:
2.440 to 2.490 mm (0.0961 to 0.0980 in.)
23. REMOVE MAIN BEARING CAPS AND CHECK OIL
3
7 CLEARANCE
9 (a) Uniformly loosen and remove the 10 main bearing cap
5
1 4 bolts in several passes, in the sequence shown.
8
10
6
2
A05095
EM−104
(b) Using 2 screwdrivers, pry out the main bearing cap, and
remove the 5 main bearing caps, 5 lower bearings and 2
lower thrust washers (No.3 main bearing cap only).
NOTICE:
Be careful not to damage the cylinder block.
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
A05093 in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and upper thrust washers together
with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for peelings and
scratches.
If the journal or bearing is damaged, replace the bearings. If
cardiagn.com
necessary, replace the crankshaft.
Plastigage (f) Place the crankshaft on the cylinder block.

(g) Lay a strip of Plastigage across each journal.
A05097
(h) Install the main bearing caps. (See page EM−118)

NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) above)
A05095
(j) Measure the Plastigage at its widest point.

Standard clearance:
No.1, No.5
0.028 to 0.046 mm (0.0011 to 0.0018 in.)
Others
0.040 to 0.058 mm (0.0016 to 0.0023 in.)
Maximum clearance: 0.065 mm (0.0026 in.)
If the oil clearance is greater than maximum, replace the bear-
A05098 ings. If necessary, replace the crankshaft.
EM−105
No.3 No.4 No.5 HINT:

If using a standard bearing, replace it with one having the same
Number Mark
number. If the number of the bearing cannot be determined, se-
No.2 lect the correct bearing by adding together the numbers im-
No.1
printed on the cylinder block and crankshaft, then refer to the
Number table below for the appropriate bearing number. There are 5
Mark sizes of the standard bearings. For No.1 and No.5 position
bearings, use bearings marked ”3”, ”4”, ”5”, ”6” and ”7”. For oth-
ers position bearings, use bearings marked ”1”, ”2”, ”3”, ”4” and
”5”.
No.5 No.1, No.5
No.2 Mark Use bearing
No.1 0 to 5 3
Cylinder block (A) 6 to 11 4
No.3 No.4 + 12 to 17 5
Crankshaft (B) 18 to 23 6
Number 24 to 28 7
Mark EXAMPLE:
cardiagn.com
A05089 Cylinder block ”08” + Crankshaft ”06”
A05088
A05090 A05176 = Total number 14 (Use bearing ”5”)
Others
Mark Use bearing
0 to 5 1
Cylinder block (A) 6 to 11 2
+ 12 to 17 3
Crankshaft (B) 18 to 23 4
24 to 28 5
EXAMPLE:
Cylinder block ”08” + Crankshaft ”06”
= Total number 14 (Use bearing ”3”)
Reference
Cylinder block main journal bore diameter (A):
Mark ”00” 72.000 mm (2.8346 in.)
Mark ”01” 72.001 mm (2.8347 in.)
Mark ”02” 72.002 mm (2.8347 in.)
Mark ”03” 72.003 mm (2.8348 in.)
Mark ”04” 72.004 mm (2.8348 in.)
Mark ”05” 72.005 mm (2.8348 in.)
Mark ”06” 72.006 mm (2.8349 in.)
Mark ”07” 72.007 mm (2.8349 in.)
Mark ”08” 72.008 mm (2.8350 in.)
Mark ”09” 72.009 mm (2.8350 in.)
Mark ”10” 72.010 mm (2.8350 in.)
Mark ”11” 72.011 mm (2.8351 in.)
Mark ”12” 72.012 mm (2.8351 in.)
Mark ”13” 72.013 mm (2.8352 in.)
Mark ”14” 72.014 mm (2.8352 in.)
EM−106
Mark ”15” 72.015 mm (2.8352 in.)

Mark ”16” 72.016 mm (2.8353 in.)
Crankshaft main journal diameter (B):
Mark ”00” 67.000 mm (2.6378 in.)
Mark ”01” 66.999 mm (2.6378 in.)
Mark ”02” 66.998 mm (2.6377 in.)
Mark ”03” 66.997 mm (2.6377 in.)
Mark ”04” 66.996 mm (2.6376 in.)
Mark ”05” 66.995 mm (2.6376 in.)
Mark ”06” 66.994 mm (2.6376 in.)
Mark ”07” 66.993 mm (2.6375 in.)
Mark ”08” 66.992 mm (2.6375 in.)
Mark ”09” 66.991 mm (2.6374 in.)
Mark ”10” 66.990 mm (2.6374 in.)
Mark ”11” 66.989 mm (2.6374 in.)
cardiagn.com
Mark ”12” 66.988 mm (2.6373 in.)
Standard bearing center wall thickness:
No.1 and No.5
Mark ”3” 2.487 to 2.490 mm (0.0979 − 0.0980 in.)
Mark ”4” 2.490 to 2.493 mm (0.0980 − 0.0981 in.)
Mark ”5” 2.493 to 2.496 mm (0.0981 − 0.0983 in.)
Mark ”6” 2.496 to 2.499 mm (0.0983 − 0.0984 in.)
Mark ”7” 2.499 to 2.502 mm (0.0984 − 0.0985 in.)
Others
Mark ”1” 2.481 to 2.484 mm (0.0977 − 0.0978 in.)
Mark ”2” 2.484 to 2.487 mm (0.0978 − 0.0979 in.)
Mark ”3” 2.487 to 2.490 mm (0.0979 − 0.0980 in.)
Mark ”4” 2.490 to 2.493 mm (0.0980 − 0.0981 in.)
Mark ”5” 2.493 to 2.496 mm (0.0981 − 0.0983 in.)
(k) Completely remove the Plastigage.
24. REMOVE CRANKSHAFT
(a) Lift up the crankshaft.
(b) Remove the 5 upper main bearings and 2 upper thrust
washers from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
correct order.
25. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
A04862
EM−107
26. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the piston rings in correct order only.
A04873
27. DISCONNECT CONNECTING ROD FROM PISTON

(a) Using a small screwdriver, pry out the 2 snap rings.
cardiagn.com
A04860
(b) Gradually heat the piston to approx. 60°C (140°F).
A04887
(c) Using a plastic−faced hammer and brass bar, lightly tap

out the piston pin and 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 correct order.
A04888
EM−108
EM0EB−20
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Using a soft brush and solvent, thoroughly clean the cylin-
der block.
A04849
2. INSPECT CYLINDER BLOCK

(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head and main
bearing cap for warpage.
If warpage is greater than maximum, replace the cylinder block.
cardiagn.com
Cylinder Block Side
Main Bearing Cap Side
A04850
A04210
A04212 A05178
(b) Visually check the cylinder for vertical scratches.

If deep scratches are present, rebore all the 8 cylinders and re-
place all the 8 pistons. (See page EM−115) If necessary, re-
place the cylinder block.
A04853
EM−109
(c) Inspect the cylinder bore diameter.

No.2 No.4 No.6 No.8 HINT:
There is 1 size of the standard cylinder bore diameter, marked
Front ”2” accordingly. The mark is stamped on the top of the cylinder
block.
No.1 No.3 No.5 No.7
: Mark 2 A04211
Thrust Using a cylinder gauge, measure the cylinder bore diame-

1
11 Direction ter at positions A and B in the thrust and axial directions.
Front 2 Standard diameter:
2 Axial
Direction
94.010 to 94.023 mm (3.7012 to 3.7017 in.)
Maximum diameter:
STD 94.223 mm (3.7096 in.)
10 mm
A (0.39 in.) O/S 0.50 94.723 mm (3.7292 in.)
cardiagn.com
If the diameter is greater than maximum, rebore all the 8 cylin-
B
ders and replace all the 8 pistons. (See page EM−115) If neces-
10 mm sary, replace the cylinder block.
(0.39 in.)
A04262
A04851 cmc0382
(d) Remove the cylinder ridge.

If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
Ridge
Reamer A04852
(e) Using vernier calipers, measure the thread outside diam-

eter of the main bearing cap bolt.
Standard diameter:
10.760 to 10.970 mm (0.4236 to 0.4319 in.)
Minimum diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the cap bolt.
50 − 64 mm (1.97 − 2.52 in.) A05138

EM−110
3. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
A04877
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
cardiagn.com
A04878
(c) Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.
A04879
4. INSPECT PISTON AND CONNECTING ROD

Mark 2
(a) Inspect the piston oil clearance.
HINT:
Front
Mark There is 1 size of the standard piston diameter, marked ”2” ac-
cordingly. The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 30.75 mm
30.75 mm (1.2106 in.) from the piston head.
A23611 Piston diameter:
STD Mark ”2” 93.912 to 93.940 mm (3.6973 to 3.6984 in.)
O/S 0.50 94.392 to 94.440 mm (3.7162 to 3.7181 in.)
(2) Measure the cylinder bore diameter in the thrust
directions (see step 2 above).
EM−111
(3) Subtract the piston diameter measurement from the

cylinder bore diameter measurement.
0.030 to 0.071 mm (0.0012 to 0.0028 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all the 8
pistons and rebore all the 8 cylinders. (See page EM−115) If
necessary, replace the cylinder block.
HINT
Cylinder Block Use a new cylinder block:
No.2 No.4 No.6
Use a piston with the same number mark as the cylinder
No.8
diameter number marked on the cylinder block.
Front
cardiagn.com
No.1 No.3 No.5 No.7
: Mark 2
Mark 2
A23615
(b) Inspect the piston 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 0.030 to 0.080 mm (0.0012 to 0.0031 in.)
No.2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
If the clearance is not as specified, replace the piston.
A04880
(c) Inspect the piston ring end gap.

(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little to the bot-
tom of the ring travel, 105 mm (4.13 in.) from the top
of the cylinder block.
105 mm
A04872
EM−112
(3) Using a feeler gauge, measure the end gap.

Standard end gap:
No.1 0.300 to 0.400 mm (0.0118 to 0.0157 in.)
No.2 0.450 to 0.600 mm (0.0177 to 0.0236 in.)
Oil (Side rail) 0.100 to 0.350 mm (0.0039 to 0.0138 in.)
Maximum end gap:
No.1 1.10 mm (0.0433 in.)
EM7639
No.2 1.30 mm (0.0512 in.)
Oil (Side rail) 0.75 mm (0.0295 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 8 cylinders (See page EM−115) or replace
the cylinder block.
cardiagn.com
(d) Inspect the piston pin fit.
60°C At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
A04048
(e) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
Z14454
(2) Check for twist.

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
Z14455
EM−113
(f) Inspect the piston pin oil clearance.

(1) 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.)
EM6525
(2) Using a micrometer, measure the piston pin diame-

ter.
Piston pin diameter:
21.997 to 22.009 mm (0.8660 to 0.8664 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
cardiagn.com
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
EM0227 Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.
(g) Using vernier calipers, measure the tension portion of the

connecting rod bolt.
Standard diameter:
7.200 to 7.300 mm (0.2835 to 0.2874 in.)
Minimum diameter: 7.00 mm (0.2756 in.)
If the diameter is less than the minimum, replace the bolt.
Tension
Portion
A04223
5. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
A05121
EM−114
(b) Inspect the main journals and crank pins.

(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
66.988 to 67.000 mm (2.6373 to 2.6378 in.)
Crank pin diameter:
51.982 to 52.000 mm (2.0465 to 2.0472 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−100). If necessary, replace the crankshaft.
(2) Check each main journal and crank pin for taper
and out−of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
cardiagn.com
A05122
A05854 A05169
EM−115
EM123−05
REPLACEMENT
1. REPLACE OVERSIZED (O/S) PISTONS FOR CYL-
INDER BORING
HINT:
Bore all the 8 cylinders to match the oversized piston out-
side diameter.
Replace all the piston rings with ones to match the over-
30.75 mm
sized pistons.
A23612
(a) Keep 8 new oversized pistons.
O/S 0.50 piston diameter:
94.392 to 94.440 mm (3.7162 to 3.7181 in.)
(b) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 30.75 mm (1.2106 in.)
from the piston head.
(c) Calculate the size to be rebored for each cylinder as fol-
lows:
Size to be rebored = P + C − H
cardiagn.com
P = Piston diameter
C = Piston clearance:
0.030 to 0.071 mm (0.0012 to 0.0028 in.)
H = Allowance for honing: 0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
2. REPLACE CONNECTING ROD BUSHINGS

(a) Using SST and a press, press out the bushing.
SST SST 09222−30010
P20665
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222−30010
Oil
Hole
P20666
EM−116
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM−100) be-
tween the bushing and piston pin.
P20667
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
3. REPLACE CRANKSHAFT FRONT OIL SEAL (See
page LU−13)
cardiagn.com
P20668
4. REPLACE CRANKSHAFT 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.
A04868
(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 09223−56010
(3) Apply MP grease to the oil seal lip.
SST
A04867
(b) If the rear oil seal retainer is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
Cut Position A04858

EM−117
(3)Apply MP grease to a new oil seal lip.

SST (4)Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223−56010
A04859
cardiagn.com
EM−118
EM124−08
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O−rings and oil seals with new ones.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a screwdriver, install a new snap ring on one side
A04861
of the piston pin hole.
(b) Gradually heat the piston to about 60°C (140°F).

60°C
cardiagn.com
A04876
(c) Coat the piston pin with engine oil.

(d) Position the piston so that the front mark and to the out-
side mark on the connecting rod face in the same direc-
tion as shown in the illustration.
Front Mark (e) Align the piston pin holes of the piston and connecting
rod, and push in the piston pin with your thumb.
Outside Mark
A23613
(f) Using a screwdriver, install a new snap ring on the other

side of the piston pin hole.
A04860
2. INSTALL PISTON RINGS

No.1 (a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings.
Code mark:
No.2 No.1 None
No.2 2R
Code Mark 2R
A21016
EM−119
No. 2 Compression (c) Position the piston rings so that the ring ends are as
Lower shown.
Side Expander
NOTICE:
Rail 60° 45°
Do not align the ring ends.
Front
Mark 45°
60°
Upper Side Rail No. 1 Compression A23614
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
cardiagn.com
EM6484
No.1 and No.5 Others 4. INSTALL MAIN BEARINGS

Upper HINT:
Main bearings are of 19.5 mm (0.768 in.) and 22.5 mm
(0.886 in.) in width. Install the 22.5 mm (0.886 in.) bear-
ings in the No.1 and No.5 cylinder block journal positions
with the main bearing cap. Install the 19.5 mm (0.768 in.)
Lower
bearings in the other positions.
22.5 mm 19.5 mm Upper bearings have an oil groove and oil holes, but lower
A04846 bearings do not.
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
A04216
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
Mark
1, 2, 3, 4, or 5
A04214
EM−120
5. INSTALL UPPER THRUST WASHERS

Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
A04215
7. PLACE MAIN BEARING CAPS AND LOWER THRUST

WASHERS ON CYLINDER BLOCK
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
cardiagn.com
A04217
(b) Install the 5 main bearing caps in their proper locations.

8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any one of the main bearing cap bolts is broken or de-
formed, replace it.
A05091
(a) Apply a light coat of engine oil to the threads and under
8
4 the main bearing cap bolts.
2
6 (b) Install and uniformly tighten the 10 main bearing cap bolts
10 7 in several steps, in the sequence shown.
1 If any of the main bearing cap bolts does not meet the torque
5
specification, replace the main bearing cap bolt.
9
A05095
(c) Mark the front of the main bearing cap bolt with paint.
90°
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
90°
(e) Check that the painted mark is now at a 90° angle to the
Front front.
(f) Check that the crankshaft turns smoothly.
Painted 9. CHECK CRANKSHAFT THRUST CLEARANCE
Mark
(See page EM−100)
A05094
EM−121
10. INSTALL PISTON AND CONNECTING ROD AS-

SEMBLIES
Using a piston ring compressor, push correctly the numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
Front Mark Front
cardiagn.com
A23616
11. PLACE CONNECTING ROD CAP ON CONNECTING

ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin groove of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod
cap.
A05106
LH Bank (c) Check that the outside mark of the connecting rod cap is
facing in correct direction.
12. INSTALL CONNECTING ROD CAP BOLTS
HINT:
Front
The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any one of the connecting rod cap bolts is broken or de-
formed, replace it.
Outside Mark
(Protrusion)
RH Bank
Front
Outside Mark
(Protrusion)
A05107
A05108 A05174
EM−122
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque: 24.5 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the connecting rod cap bolts.
A05101
(c) Mark the front of the connecting cap bolt with paint.
90° 90° (d) Retighten the cap bolts by 90° as shown.
Front (e) Check that the painted mark is now at a 90° angle to the
front.
Painted (f) Check that the crankshaft turns smoothly.
Mark 13. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM−100)
cardiagn.com
A05099
14. INSTALL REAR OIL SEAL RETAINER

(a) Remove any old packing (FIPG) material and be careful
A
not to drop any oil on the contacting surfaces of the oil
seal retainer and cylinder block.
B Using a razor blade and gasket scraper, remove all
the old packing (FIPG) materials from the gasket
surfaces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
A illustration.
Seal Width Seal packing: Part No. 08826−00080 or equivalent
3 − 4 mm Install a nozzle that has been cut to a 3 − 4 mm (0.12
− 0.16 in.) opening.
B Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
A04848 and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
EM−123
(c) Install a new O−ring to the cylinder block.

(d) Install the oil seal retainer with the 7 bolts.
New O−Ring Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf)
A04855
15. INSTALL ENGINE COOLANT DRAIN UNIONS

Seal Packing (a) Apply seal packing to 2 or 3 threads.
cardiagn.com
P12477
(b) Install the 2 drain unions.

HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing forward.
Port 16. INSTALL OIL PUMP (See page LU−15)
17. INSTALL OIL STRAINER (See page LU−15)
Front 18. INSTALL NO.1 OIL PAN (See page LU−15)
A04856 19. INSTALL OIL PAN BAFFLE PLATE
(See page LU−15)
20. INSTALL NO.2 OIL PAN (See page LU−15)
21. INSTALL WATER PUMP (See page CO−8)
22. INSTALL ENGINE MOUNTING BRACKETS
Install the mounting bracket with the 4 bolts. Install the 2 mount-
ing brackets.
LH Side 23. INSTALL ENGINE WIRE TO LH SIDE OF CYLINDER

BLOCK
(a) Install the brackets on the engine wire with the 2 bolts.
(b) Install the engine wire cover with the 2 bolts.
24. INSTALL OIL COOLER PIPE BRACKET FOR A/T
Install the bracket with the bolt.
25. INSTALL VVT SENSORS (See page SF−79)
26. INSTALL KNOCK SENSORS (See page SF−70)
A08472 27. INSTALL STARTER (See page ST−19)
EM−124
28. INSTALL WATER BYPASS PIPE

Push
(a) Install a new O−ring to the water bypass pipe.
Wire
Clamp (b) Apply soapy water to the O−ring.
(c) Push in the water bypass pipe end into the pipe hole of
the water pump.
New (d) Install the water bypass pipe with the bolt.
O−Ring
(e) Install the wire clamp to the bracket of the water bypass
A05132 pipe.
29. INSTALL CYLINDER HEADS (See page EM−60)
30. INSTALL TIMING BELT AND PULLEYS
(See page EM−23)
31. DISCONNECT ENGINE FROM ENGINE STAND
cardiagn.com
EM−125
ENGINE MECHANICAL (2UZ−FE) − EXHAUST SYSTEM
EXHAUST SYSTEM
EM0EE−21
COMPONENTS
C−Cab Ring Ring
No.4 Heat Insulator No.4 Heat Insulator
7.0 (71, 62 in.·lbf)
No.3 Heat Insulator Exhaust Tailpipe
7.0 (71, 62 in.·lbf)

Clamp
5.0 (51, 44 in.·lbf) Gasket
32 (326, 24)
cardiagn.com
Center Exhaust Pipe
Ring
48 (489, 35)
0 − 30°
Ring
48 (489, 35)
No.1 Heat Insulator
Heated Oxygen
Sensor
44 (450, 33)
RH Front Exhaust
5.0 (51, 44 in.·lbf)
Pipe
Gasket Heated Oxygen

Gasket No.2 Heat Sensor
Insulator 44 (450, 33)
Gasket
Ring
62 (632, 46) 5.0 (51, 44 in.·lbf)
4WD
5.0 (51, 44 in.·lbf)
LH Front Exhaust
No.2 Heat Insulator Pipe
Gasket
N·m (kgf·cm, ft·lbf) : Specified torque 62 (632, 46)

EM−126
EM1XD−01
REMOVAL
1. REMOVE HEATED OXYGEN SENSOR (BANK 1)
(a) Disconnect the heated oxygen sensor.
(b) Remove the heated oxygen sensor.
2. REMOVE HEATED OXYGEN SENSOR (BANK2)
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the heated oxygen sensor.
3. SEPARATE EXHAUST CENTER PIPE
Remove the 4 bolts and 2 gasket from the exhaust center pipe.
4. REMOVE RH FRONT EXHAUST PIPE
Remove the 3 nuts, gasket, and front exhaust pipe from the exhaust manifold.
5. REMOVE LH FRONT EXHAUST PIPE
Remove the 3 nuts, gasket, ring and front exhaust pipe from the exhaust manifold.
6. REMOVE CENTER EXHAUST PIPE
(a) Loosen the clamp bolt, disconnect the center exhaust pipe and remove the gasket from the exhaust
tailpipe.
(b) Remove the 2 rings and center exhaust pipe.
cardiagn.com
7. REMOVE EXHAUST TAILPIPE
(a) Remove the 3 rings and exhaust tailpipe.
8. REMOVE HEAT INSULATOR
(a) Remove the 5 bolts and No.1 heat insulator.
(b) Remove the 4 bolts and No.2 heat insulator.
(c) Remove the 3 bolts and No.3 heat insulator.
(d) Remove the 2 bolts and No.4 heat insulator.
EM−127
EM1XE−01
INSTALLATION
1. REMOVE HEAT INSULATOR
(a) Install the No.1 heat insulator with the 5 bolts.
(b) Install the No.2 heat insulator with the 4 bolts.
(c) Install the No.3 heat insulator with the 3 bolts.
(d) Install the No.4 heat insulator with the 2 bolts.
2. INSTALL EXHAUST TAIL PIPE
Install the 3 rings and exhaust tailpipe.
3. INSTALL CENTER EXHAUST PIPE
(a) Install the 2 rings and center exhaust pipe.
(b) Install a new gasket and connect the center exhaust pipe to the exhaust tailpipe with a new clamp.
4. INSTALL LH FRONT EXHAUST PIPE
cardiagn.com
(a) Install a new gasket and ring to the LH front exhaust pipe.
(b) Install the LH front exhaust pipe to the exhaust manifold with 3 new nuts.
5. INSTALL RH FRONT EXHAUST PIPE
(a) Install a new gasket to the RH front exhaust pipe.
(b) Install the RH front exhaust pipe to the exhaust manifold with 3 new nuts.
6. CONNECT EXHAUST CENTER PIPE
(a) Install a new gasket and connect the RH front exhaust pipe with the 2 bolts.
(b) Install a new gasket and connect the LH front exhaust pipe with the 2 bolts.
7. INSTALL HEATED OXYGEN SENSOR (BANK2)
(a) Install the heated oxygen sensor.
(b) Connect the heated oxygen sensor connector.
8. INSTALL HEATED OXYGEN SENSOR (BANK1)
(a) Install the heated oxygen sensor.
(b) Connect the heated oxygen sensor connector.

Toyota Tuntra Repair Manual

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Toyota Tuntra Repair Manual

Uploaded by

Copyright:

Available Formats

EM−1

ENGINE MECHANICAL (2UZ−FE) − CO/HC

4. INSERT CO/HC METER TESTING PROBE AT LEAST

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

Low High Rough idle 1. Vacuum leaks:

High High Rough idle 1. Restricted air filter

3. CHECK CYLINDER COMPRESSION PRESSURE

VALVE CLEARANCE EM0KS−10

8. SET NO.1 CYLINDER TO TDC/COMPRESSION

9. INSPECT VALVE CLEARANCE

LH Cylinder Head Front Exhaust 0.25 − 0.35 mm (0.010 − 0.014 in.)

10. ADJUST VALVE CLEARANCE

(d) Determine the replacement adjusting shim size according

ENGINE MECHANICAL (2UZ−FE)

Intake valve clearance (Cold):

ENGINE MECHANICAL (2UZ−FE)

Exhaust valve clearance (Cold):

IGNITION TIMING EM0KT−12

Hand−Held Tester 2. INSPECT IGNITION TIMING

(b) When not using a hand−held tester.

(2)Using SST, connect terminals TC and CG of the

(3) Using a timing light, check the ignition timing.

IDLE SPEED EM1X3−02

(b) When not using a hand−held tester.

(4) Disconnect the tachometer from the DLC3.

No. 2 Fan Shroud

A/T Oil Cooler Hose

Fan and Fluid Coupling

29 (296, 21) 2WD Engine Under Cover

Engine Under Cover (4WD)

RH No.3 Timing Belt Cover

7.5 (76, 66 in.·lbf)

Drive Belt Idler Pulley

Engine Wire 7.5 (76, 66 in.·lbf)

N·m (kgf·cm, ft·lbf) : Specified torque A23302

LH Camshaft Timing Pulley

RH Camshaft Timing Pulley

8.1 (83, 72 in.·lbf)

245 (2,500, 181)

Timing Belt Tensioner

Drive Belt Tensioner

No.1 Timing Belt Cover

39 (400, 29) 39 (400, 29)

Timing Belt No.1 Idler Pulley

34.5 (350, 25)

Crankshaft Timing Pulley

34.5 (350, 25)

Timing Belt Guide No.2 Idler Pulley

N·m (kgf·cm, ft·lbf) : Specified torque Timing Belt Cover Spacer

6. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND

9. REMOVE RH NO.3 TIMING BELT COVER

10. REMOVE LH NO.3 TIMING BELT COVER

(g) Remove the LH No.3 timing belt cover.

11. REMOVE NO.2 TIMING BELT COVER

13. REMOVE FAN BRACKET

14. IF RE−USING TIMING BELT, CHECK INSTALLATION

15. LOOSEN CRANKSHAFT PULLEY BOLT

16. SET NO.1 CYLINDER TO TDC/COMPRESSION

17. REMOVE TIMING BELT TENSIONER

When replacing the timing belt tensioner only:

18. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-

SST 19. REMOVE CAMSHAFT TIMING PULLEYS

22. REMOVE CRANKSHAFT PULLEY