14–5

ENGINE MECHANICAL – PARTIAL ENGINE ASSY

141BY–01

OVERHAUL

1. REMOVE OIL FILLER CAP SUB–ASSY

A77358

2. REMOVE OIL FILLER CAP GASKET

A77361

3. REMOVE VENTILATION VALVE SUB–ASSY

A77357

4. REMOVE SPARK PLUG

(a) Using a 16 mm plug wrench, remove the spark plugs.
16 mm Plug Wrench

A77236

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

5. REMOVE OIL FILTER SUB–ASSY

(a) Using SST, remove the oil filter.
SST 09228–06501

SST

A77425

6. REMOVE OIL FILTER UNION

(a) Using a 12 mm socket hexagon wrench, remove the oil fil-
ter union.
12 mm
Hexagon
Wrench

A77239

7. REMOVE CYLINDER HEAD COVER SUB–ASSY

(a) Remove 9 bolts and 2 nuts from the cylinder head cover.
(b) Remove the cylinder head cover.

A64640

8. REMOVE CYLINDER HEAD COVER GASKET

9. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and the camshaft position sensor.

A77356

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

Timing Marks 10. REMOVE CRANKSHAFT PULLEY

(a) Set No. 1 cylinder to TDC/ compression.
(1) Turn the crankshaft pulley, and align its groove with
the timing mark ”0” of the timing chain cover.
(2) Check that the timing marks of the camshaft timing
sprockets are aligned with the timing marks of the
No. 1 bearing cap as shown in the illustration.
Timing Marks If not, turn the crankshaft 1 revolution (360
) and align the mark
as above.

Groove A77426

(b) Remove the crankshaft pulley.

(1) Using SST, fix the crankshaft pulley and loosen the
pulley set bolt.
SST
SST 09213–54015 (91651–60855), 09330–00021,

A77380

(2)Using the pulley set bolt and SST, remove the

crankshaft pulley.
SST 09950–50013 (09951–05010, 09952–05010,
09953–05020, 09954–05021)
SST

A77381

11. REMOVE CHAIN TENSIONER ASSY NO.1

NOTICE:
Do not turn the crankshaft.
(a) Separate a clamp.

12. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the 2 bolts and the crankshaft position sensor.

A77359

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13. REMOVE WATER PUMP PULLEY

(a) Using SST, remove the 4 bolts and the water pump pulley.
SST 09960–10010 (09962–01000, 09963–00700)


A77427

14. REMOVE WATER PUMP ASSY

(a) Remove the 4 bolts, 2 nuts and clamp.
(b) Using a screw driver, pry between the water pump and
cylinder block, and then remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.
Pry
A64711

15. REMOVE OIL PAN DRAIN PLUG

A77360

16. REMOVE OIL PAN SUB–ASSY

(a) Remove the 12 bolts and 2 nuts.

A64641

(b) Insert the blade of SST between the crank case, timing
chain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST 09032–00100
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, crank case and oil pan.

A00019

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17. REMOVE TIMING CHAIN OR BELT COVER

SUB–ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Using a screwdriver, pry between the timing chain cover
and cylinder head or cylinder block.
(c) Remove the timing chain cover.
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, cylinder head and cylinder block.

Pry
A64642

18. REMOVE TIMING GEAR CASE OR TIMING CHAIN

CASE OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.

A77242

19. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1

20. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.

21. REMOVE CHAIN VIBRATION DAMPER NO.1

(a) Remove the 2 bolts and the chain vibration damper No.
1.

A77355

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

22. REMOVE TIMING CHAIN GUIDE

(a) Remove the bolt and the timing chain guide.

A77243

23. REMOVE CHAIN SUB–ASSY

24. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

90
25. REMOVE NO.2 CHAIN SUB–ASSY

(a) Turn the crankshaft counterclockwise 90
, and align ad-
Groove justing hole of the oil pump drive shaft gear with the
groove of the oil pump.

A77382

(b) Insert a 4 mm diameter bar in the adjusting hole drive

shaft gear to lock in position, and remove the nut.

Groove
A77383

(c) Remove the bolt, chain tensioner and spring.

(d) Remove the oil pump drive shaft gear and chain No.2.

A66833

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

26. REMOVE OIL PUMP ASSY

(a) Remove the 3 bolts, the remove then oil pump and gas-
ket.

A77354

1 3 5 4 2 27. REMOVE NO.2 CAMSHAFT

(a) Remove the No. 2 and No. 3 camshaft bearing caps in the
sequence shown in the illustration.
(b) Remove the No. 2 camshaft.

A77428

28. REMOVE CAMSHAFT

(a) Remove the No. 1 and No. 3 camshaft bearing caps in the
sequence shown in the illustration.
(b) Remove the camshaft.

1 3 5 4 2 A77429

29. REMOVE CAMSHAFT BEARING NO.1

30. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

(a) Clamp the No. 2 camshaft in a vise, and remove the cam-
shaft timing gear.
NOTICE:
Be careful not to damage the No. 2 camshaft.

A64874

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

31. REMOVE CAMSHAFT TIMING GEAR ASSY

Advance
(a) Clamp the camshaft in a vise, and make sure the cam-
Angle Port shaft timing gear assembly does not move.
NOTICE:
Be careful not to damage the camshaft.
(b) Cover all the oil ports with vinyl tape expect the advance
angle port as shown in the illustration.

A77413

(c) Put air pressure into the oil port with 150 kPa (1.5 kgf/cm2
21 psi), and turn the camshaft timing gear assembly to the
advance direction (counterclockwise) by force.
NOTICE:
Some oil spraying will occur. Be prepared to catch the
spray with a shop rag.
HINT:
Depending on the pressure, the VVT timing sprocket may turn
A31032 to the advance angle side without applying force by hand. Also,
if the pressure can be hardly applied because of the air leakage
from the port, it might be difficult to get the lock–pin to release.

(d) Remove the flange bolt from the camshaft timing gear as-
Straight Pin sembly.
NOTICE:
S Be sure not to remove the other 4 bolts.
S In case of reusing the camshaft timing gear assembly,
release the straight pin lock first, and then install the
gear.
Flange Bolt
A32639

32. REMOVE CAMSHAFT BEARING NO.2

A32664

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33. REMOVE CAMSHAFT HOUSING PLUG

A64712

3 7 9 6 2 34. REMOVE CYLINDER HEAD SUB–ASSY

(a) Using several steps, loosen the 10 cylinder head bolts
with a 10 mm bi–hexagon wrench uniformly in the se-
quence shown.
(b) Remove 10 cylinder head bolts and plate washers.
NOTICE:
S Be careful not to drop washers into the cylinder head.
S Head warpage or cracking could result from remov-
1 5 10 8 4 ing bolts in an incorrect order.
A77430

35. REMOVE CYLINDER HEAD GASKET

36. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB–ASSY
37. REMOVE OIL CONTROL VALVE FILTER
(a) Using a 12 mm hexagon wrench, remove the plug, gasket and oil control valve filter.

38. REMOVE ENGINE REAR OIL SEAL

Tape (a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After the removal, check the crankshaft is not damaged. If
Cut Position
it is damaged, smooth the surface with 400 grit sand paper.

A77244

3 7 9 10 5 1 39. REMOVE STIFFENING CRANKCASE ASSY

(a) Loosen and remove the 11 bolts uniformly in several
steps, in the sequence shown.
(b) Using a screw driver, remove the crankcase by prying the
between the crankcase and cylinder block.
NOTICE:
Be careful not to damage the contact surfaces of the crank-
case and cylinder block.
4 8 11 6 2 A77431 (c) Remove the O–ring from the cylinder block.

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

40. INSPECT OIL PUMP DRIVE GEAR

(a) Wrap the chain around the drive gear.
(b) Using vernier calipers, measure the drive gear diameter
with the chain wrapped.
NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.
Minimum gear diameter (w/chain): 48.2 mm (1.898 in.)
EM2378 If the diameter is less than minimum, replace the chain and
drive gear.
41. INSPECT OIL PUMP DRIVE SHAFT GEAR
(a) Wrap the chain around the drive shaft gear.
(b) Using vernier calipers, measure the drive shaft gear diam-
eter with the chain wrapped.
NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.
Minimum gear diameter (w/chain): 48.2 mm (1.898 in.)
A53036 If the diameter is less than minimum, replace the chain and
drive shaft gear.
42. INSPECT CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the timing gear.
(b) Using vernier calipers, measure the timing gear diameter
with the chain wrapped.
NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.
EM2378 Minimum gear diameter (w/chain): 51.6 mm (2.031 in.)
If the diameter is less than minimum, replace the chain and tim-
ing gear.

43. INSPECT CHAIN TENSIONER SLIPPER

(a) Measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the chain tension-
er slipper.

A33838

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

44. INSPECT CHAIN VIBRATION DAMPER NO.1

(a) Measure the chain vibration damper No. 1 wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the chain vibration
damper No. 1

A36686

45. INSPECT CYLINDER HEAD SET BOLT

(a) Using vernier calipers, measure the length of head bolts
Overall Length from the seat to the end.
Standard bolt length:
161.3 to 162.7 mm (6.350 to 6.406 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the bolt.

A77407

46. INSPECT CHAIN TENSIONER ASSY NO.1

Raise (a) Check the plunger moves smoothly when the ratchet pawl
is raised, and when the ratchet pawl is released, the
Move
plunger is locked in place.
Lock (b) Replace the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushing with your finger.

A77432

47. INSPECT CHAIN SUB–ASSY

115.4 mm (a) Using vernier calipers, measure length of the 15 links with
(4.543 in.) the chain dully stretched.
Maximum chain elongation: 115.4 mm (4.543 in.)
If the elongation is greater than maximum, replace the chain.
NOTICE:
Make the same measurements pulling at 3 or more random
15 Links places to obtain an average length.
A57478

48. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET

(a) Wrap the chain around the timing sprocket.
(b) Using vernier calipers, measure the timing sprocket diam-
eter with the chain wrapped.
Minimum sprocket diameter (w/ chain):
97.3 mm (3.831 in.)
If the diameter is less than minimum, replace the chain and tim-
ing sprocket.
A30206

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.

49. INSPECT CAMSHAFT

(a) Inspect the camshaft for runout.
(1) Place the camshaft on V–blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
EM1628

(b) Inspect cam lobe height.

(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
45.510 to 45.610 mm (1.7917 to 1.7957 in.)
Minimum cam lobe height: 45.400 mm (1.7874 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.

A36687

(c) Inspect camshaft journals.

(1) Using a micrometer, measure the journal diameter.
Journal diameter:
No. 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Others 22.959 to 22.975 mm (0.9040 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clear-
ance.

A36688

50. INSPECT NO.2 CAMSHAFT

(a) Inspect the No. 2 camshaft for runout.
(1) Place the No. 2 camshaft on V–blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, replace the No. 2
camshaft.
EM1628

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(b) Inspect cam lobe height.

(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
45.983 to 46.083 mm (1.8106 to 1.8143 in.)
Minimum cam lobe height: 45.873 mm (1.8060 in.)
If the cam lobe height is less than minimum, replace the No. 2
camshaft.

A36687

(c) Inspect camshaft journals.

(1) Using a micrometer, measure the journal diameter.
Journal diameter:
No. 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Others 22.959 to 22.975 mm (0.9040 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clear-
ance.

A36688

51. INSTALL STIFFENING CRANKCASE ASSY

Seal packing (a) Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to
0.118 in.)) of seal packing on the places shown in the il-
lustration.
Seal Packing: Part No. 08826 – 00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
S Install the crankcase within 3 minutes after applying
seal packing.
S Do not start the engine within 2 hours after installing.

(mm) A77245

(b) Install a new O–ring to the place shown in the illustration.

A37779

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

9 5 3 2 7 11 (c) Tighten the 11 bolts in several steps in the sequence

shown in the illustration.
Torque: 33 N
m (332 kgf
cm, 24 ft
lbf)

8 4 1 6 10 A77433

52. INSTALL ENGINE REAR OIL SEAL

(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign material.
(b) Using SST and a hammer, equally tap the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223–15030, 09950–70010 (09951–07100)
NOTICE:
SST A77434 Wipe off extra grease on the crankshaft.

53. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign material on the mesh part of the fil-
ter.
(b) Using a 6 mm socket hexagon wrench, install the oil con-
Mesh Part trol valve filter with a new gasket.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)

A77435

54. INSTALL CYLINDER BLOCK WATER DRAIN COCK

SUB–ASSY
(a) Install the water drain cock sub assembly within the range
shown in the illustration.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)

45
45

A77436

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

55. INSTALL CYLINDER HEAD GASKET

Lot No.
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
S Remove any oil from contact surface.
S Be careful of the installation direction.
S Place the cylinder head carefully in order not to dam-
age the gasket with the bottom part of the head.

A77408

56. INSTALL CYLINDER HEAD SUB–ASSY

HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a continuous bead (Diameter 2.5 to 3.0 mm (0.098
Cylinder Head to 0.118 in.)) of seal packing on the places as shown in the
Cylinder
2.5 to 3 mm illustration.
Head Gasket Seal Packing: Part No. 08826 – 00080, or equivalent.
12.5 to 1.5 mm
NOTICE:
Cylinder Block S Remove any oil from the contact surface.
S Install the cylinder head within 3 minutes after apply-
ing seal packing.
S Do not start the engine within 2 hours after installing.
(b) Apply a light coat of engine oil on the threads of the cylin-
Seal Packing der head bolts.
A77437

(c) Install the bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.

9 3 2 6 8 (d) Using several steps tighten each bolt with a 10 mm bi–

hexagon wrench uniformly in the sequence shown in the
illustration.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)

7 5 1 4 10
A77438

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(e) Mark each cylinder head bolt head on the front side with
paint.
90_
(f) Retighten the cylinder head bolts by 90_ in the same se-
quence shown as step (b).
Engine (g) Check that each painted mark is now at a 90_ angle to the
Front front.
Paint Mark

A00976 A77411

57. INSTALL CAMSHAFT HOUSING PLUG

(a) Apply engine oil to a new O–ring, and install the camshaft
housing plug.
NOTICE:
S Install the plug with its flange portions faced the man-
ifold.
S Insert the plug into the cylinder head until its flange
portions reach the installation surface of the cylinder
head.
Flange

A77247

58. INSTALL CAMSHAFT BEARING NO.2

59. INSTALL CAMSHAFT TIMING GEAR ASSY

Straight Pin (a) Align the key groove of the camshaft timing gear with the
straight pin located on the camshaft, then fit the timing
gear into place.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) while pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
Key Groove A77248 CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear’s
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N
m (551 kgf
cm, 49 ft
lbf)
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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(e) Check that the camshaft timing gear assembly can move
to the retard angle side (the right direction), and is locked
at the most retarded position.

60. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET

(a) Clamp the camshaft No. 2 in a vise, and install the cam-
shaft No. 2 timing gear.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the No. 2 camshaft.

A64874

61. INSTALL CAMSHAFT BEARING NO.1

62. INSTALL CAMSHAFT

(a) Place the camshaft on the cylinder head as shown in the
illustration.
(b) Tighten the camshaft bearing cap No. 1 and No. 3 in the
sequence shown in the illustration.
Torque:
Bearing cap No. 1 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9 N
m (92 kgf
cm, 80 in.
lbf)
5 3 1 2 4 NOTICE:
S Tighten the bolts after deciding the position for the
thrust direction of the camshaft by bearing cap No. 1.
S Install the camshaft with its timing mark of camshaft
timing gear upward.
No. 1 cylinder A77439

63. INSTALL NO.2 CAMSHAFT

No. 1 cylinder
(a) Place the No. 2 camshaft on the cylinder head as shown
in the illustration.
(b) Tighten the camshaft bearing cap No. 2 and No. 3 in the
sequence shown in the illustration.
Torque:
5 3 1 2 4
Bearing cap No. 2 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
S Tighten the bolts after deciding the position for the
thrust direction of the camshaft by bearing cap No. 2.
S Install the camshaft with its timing mark of camshaft
timing gear upward.
A77440

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64. INSTALL OIL PUMP ASSY

(a) Install the oil pump assembly with the 3 bolts and a new gasket.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)

65. INSTALL NO.2 CHAIN SUB–ASSY

(a) Set the crankshaft key in the left side position.
(b) Turn the flat portion of the drive shaft upward.

B11424

Mark Link (c) Align the mark links (yellow colored links) with the timing
marks of the gears as shown in the illustration.
Timing Mark
(d) With the chain wrapped, insert the gears to the crankshaft
and oil pump shaft.
(e) Temporarily secure the oil pump drive shaft gear with a
nut.

Timing Mark
Mark Link A77384

(f) Insert the damper spring into the adjusting hole of the cyl-
inder block, and install the chain tensioner plate with the
bolt.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)

Groove

A77385

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(g) Align the adjusting hole of the sprocket with the groove of
the oil pump.
(h) Put a 4 mm diameter bar into the adjusting hole to lock in
position, and assemble the nut.
Torque: 30 N
m (301 kgf
cm, 22 ft
lbf)

Groove
A77386

(i) Rotate the crankshaft 90
clockwise, and position the key
of the crankshaft upward.
90

A77387

66. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

67. INSTALL CHAIN SUB–ASSY

(a) Set No. 1 cylinder to TDC/ compression.
(1) Align the timing marks of the camshaft timing
sprockets with the timing marks located on the No.
1 bearing caps.
Timing Marks

Timing Marks
A77441

(2) Using the crankshaft pulley bolt, turn the crankshaft

and set the key on the crankshaft upward.

A52505

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(b) Align the mark link (blue or orange colored link) with the
timing mark located on the crankshaft timing gear.
Timing Mark

Mark Link

A77442

(c) Using SST, install the sprocket.

SST 09309–37010

SST

A77443

Mark Links (d) Align the mark links (gold or yellow colored links) with
Timing Marks Timing Mark
each timing mark located on the camshaft timing gear,
and on the timing sprocket to install the chain.

A77389

68. INSTALL TIMING CHAIN GUIDE

Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
69. INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
70. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)

71. INSTALL CRANKSHAFT POSITION SENSOR PLATE

NO.1
(a) Install the crankshaft position sensor plate with the ”F”
mark facing forward.

A32629

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

72. INSTALL TIMING GEAR CASE OR TIMING CHAIN

CASE OIL SEAL


 (a) Using SST, tap in a new oil seal until its surface is flush
with the timing chain cover edge.
SST 09223–22010
(b) Apply a light coat of MP grease to the lip of a new oil seal.
NOTICE:
Keep the lip free of foreign material.
A77444

73. INSTALL TIMING CHAIN OR BELT COVER SUB–ASSY

NOTICE:
S Remove any oil from the contact surface.
S Install the chain cover within 3 minutes after applying
seal packing.
S Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
Seal Packing
A77445 chain cover, cylinder head and cylinder block.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of
seal packing as shown in the illustration.
Seal packing: Part No. 08826 – 00080 or equivalent

(c) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to

Seal Packing 0.157 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 – 00080 or equivalent

4mm

A
A

2.5 mm

3 to 4 mm
A A A77391

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in.
lbf)
Nut Nut
C Bolt B 21 N
m (214 kgf
cm, 15 ft
lbf)
C Bolt C 43 N
m (438 kgf
cm, 32 ft
lbf)
C
Nut 9.0 N
m (92 kgf
cm, 80 in.
lbf)
C C
A

B B

B
B

B
B

A77251

74. INSTALL OIL PAN SUB–ASSY

NOTICE:
S Remove any oil from the contact surface.
S Install the oil pan within 3 minutes after applying seal
packing.
S Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the cylinder
block and oil pan.
6mm (b) Apply a continuous bead (Diameter 3 mm to 4 mm (0.079
to 0.118 in.)) of seal packing as shown in the illustration,
and install the oil pan.
Seal Packing Seal packing: Part No. 08826 – 00080 or equivalent
A77392

(c) Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

A64641

75. INSTALL OIL PAN DRAIN PLUG

(a) Install the oil pan drain plug and a new gasket.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

76. INSTALL WATER PUMP ASSY

(a) Clean the contact surface of the cylinder block.
(b) Apply a continuous bead (Diameter 2.2 to 2.5 mm(0.087
to 0.098in.)) of seal packing to the outside edge of the wa-
ter pump.
Seal packing: Part No. 08826 – 00100 or equivalent
Seal Width NOTICE:
2.2 to 2.5 mm S Remove any oil from the contact surface.
A77446 S Install the water pump within 5 minutes after applying
seal packing.
S Do not start the engine within 2 hours after installing.

(c) Install the clamp and the water pump assembly with the
4 bolts and 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
Tighten the outside bolts and nuts.

A64722

77. INSTALL WATER PUMP PULLEY

(a) Using SST, install the water pump pulley with the 4 bolts.
SST 09960–10010 (09962–01000, 09963–00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)

͓͓͔
A77447

78. INSTALL CRANKSHAFT POSITION SENSOR

Wire Harness
(a) Apply a light coat of engine oil to the O–ring.
(b) Install the crankshaft position sensor with the bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(c) Confirm the wire harness of the crankshaft position sen-
sor is placed as shown in the illustration.
Clamp

Rib
A77448

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

79. INSTALL CRANKSHAFT PULLEY

(a) Using SST, tighten the set bolt.
SST 09213–54015 (91651–60855), 09330–00021
SST
Torque: 170 N
m (1,733 kgf
cm, 125 ft
lbf)

A77393

80. INSTALL CHAIN TENSIONER ASSY NO.1

(a) Release the ratchet pawl, fully push in the plunger and ap-
Raise ply the hook to the pin so that the plunger is locked in the
position.

Push

Hook
Pin
A77394

(b) Install a new gasket and the chain tensioner with the 2
nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is disengaged while installing, re–apply the
hook and then insert the chain tensioner.

Engine
Front

A77395

(c) Turn the crankshaft pulley counterclockwise, and check

that the plunger knock pin is free from the hook.

Disconnect

Pin
Hook Turn
A77396

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(d) Turn the crankshaft clockwise, and check that the plunger
is extended.

Plunger

Push
Turn A77397

Timing Marks 81. INSPECT VALVE CLEARANCE

(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the timing chain cover.
(b) Check that the timing marks of the camshaft timing
sprockets are aligned with the timing marks located on the
No. 1 bearing cap as shown in the illustration.

Timing Marks

Groove A77449

No. 1 Cylinder TDC/Compression (c) Check only the valve indicated as shown in the illustra-
IN tion.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and the camshaft.
(2) Record the our–of–specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifter.
EX Valve clearance (cold):
A77378 Intake 0.19 to 0.29 mm (0.007 to 0.011 in.)
Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.)
(d) Turn the crankshaft 1 revolution (360
) clockwise, and set
the No. 4 cylinder to TDC/compression.

No. 4 Cylinder TDC/Compression

(e) Check only the valve indicated as shown in the illustra-
tion.
IN
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and the camshaft.
(2) Record the out–of–specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifter.
Valve clearance (cold):
EX
A77379 Intake 0.19 to 0.29 mm (0.007 to 0.011 in.)
Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.)
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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

Paint Mark Paint Mark 82. ADJUST VALVE CLEARANCE

NOTICE:
Do not turn the crankshaft without the chain tensioner.
(a) Turn the crankshaft 1 revolution (360
) clockwise, and set
the No. 1 cylinder to TDC/compression.
Timing Mark (b) Place matchmarks on the timing chain and camshaft tim-
Timing Mark
ing gear.
Groove
(c) Remove the 2 bolts and the chain tensioner.
A77450

Loosen Hold (d) Fix the camshaft with a wrench, then loosen the camshaft
timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.

A77412

(e) Using several steps, loosen the camshaft bearing cap

bolts on the No. 2 camshaft in the sequence shown in the
illustration, and then remove the bearing caps.

1 3 5 4 2 A77451

(f) Raising the No. 2 camshaft, remove the set bolt.

(g) Remove the timing chain sprocket from the No. 2 cam-
shaft with the timing chain assembled.
(h) Remove the timing chain sprocket from the timing chain.

A52473

1 3 5 4 2
(i) Using several steps, loosen the camshaft bearing cap
bolts on the camshaft in the sequence shown in the il-
lustration, then remove the bearing caps.
(j) Remove the intake camshaft.

A77452

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(k) Tie the timing chain with a string.

A32556

(l) Using a micrometer, measure the thickness of the re-

moved lifter.
(m) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified valve.
A Thickness of the new lifter
B Thickness of the used lifter
C Measured valve clearance

Valve clearance:
A01082 Intake A = B + (C – 0.24 mm (0.0094 in.))
Exhaust A = B + (C – 0.35 mm (0.0138 in.))

EXAMPLE: (Intake)
Measure valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) – 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.)
(Measured – Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. ”50”

HINT:
S Select a new lifter with a thickness as close as possible
to the calculated values.
S Lifter are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.)
S Refer to new Lifter Thickness table on the following 2
pages.

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Valve Lifter Selection Chart (Intake)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

ENGINE MECHANICAL
–

New Lifter Thickness mm (in.)

Lifter Lifter Lifter
Thickness Thickness Thickness
No. No. No.

06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)

08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)

10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)

PARTIAL ENGINE ASSY

12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)

14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)

16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)

18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)

Intake valve clearance (Cold): 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
0.19 to 0.29 mm (0.008 to 0.011 in.)
EXAMPLE: 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
The 5.250 mm (0.2067 in.) lifter is installed, and 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter. 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)

28 5.280 (0.2079) 52 5.520 (0.2173)

A77296
 Valve Lifter Selection Chart (Exhaust)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

ENGINE MECHANICAL
–

New lifter thickness mm (in.)

Lifter Lifter Lifter
No. Thickness Thickness Thickness
No. No.

06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)

08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)

10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)

PARTIAL ENGINE ASSY

12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)

14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)

16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)

18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)

20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)

Exhaust valve clearance (Cold):
0.30 to 0.40 mm (0.0118 to 0.0157 in.) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
EXAMPLE:
24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
The 5.340 mm (0.2102 in.) lifter is installed, and
the measured clearance is 0.440 mm (0.0173 in.). 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
Replace the 5.340 mm (0.2102 in.) lifter with a new No. 44 lifter.
28 5.280 (0.2079) 52 5.520 (0.2173)

A77297
14–33
14–34
ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(n) Install the timing chain on the camshaft timing gear, with
Paint Mark
the painted links aligned with the timing marks on the
camshaft timing sprockets.

Timing Mark

A77254

5 3 1 2 4 (o) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 1 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)

Bearing Cap No. 3

Bearing Cap No. 1 A77415

Paint Mark (p) Put the camshaft No. 2 on the cylinder head with the
painted links of chain aligned with the timing mark on the
camshaft timing sprockets.

Timing Mark A77453

(q) Raising the No. 2 camshaft, tighten the set bolt temporari-
ly.

A52473

Bearing Cap No. 2 Bearing Cap No. 3
(r) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)

5 3 1 2 4 A77416

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

Tighten Hold (s) Fix the camshaft with a wrench, then tighten the camshaft
timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the valve lifter.

A77417

(t) Check that each pair of the matchmarks are aligning as

shown in the illustration.
HINT:
7 Links There are 7 links between the two paint marks.
Paint Mark Paint Mark

Timing Marks Timing Mark

Groove

A77454

(u) Install the chain tensioner.

(1) Release the ratchet pawl, fully push in the plunger
Raise and apply the hook to the pin so that the plunger is
locked in the position.

Push

Hook
Pin
A77394

(2) Install a new gasket and the chain tensioner with the
2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is disengaged from the pin, re–apply the hook
then resume installation.

Engine
Front

A77395

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

(3) Turn the crankshaft counterclockwise, and disen-

gage the hook from the pin to free the plunger.

Disconnect

Pin
Hook Turn
A77396

(4) Turn the crankshaft clockwise, and check that the

plunger is pushed by the slipper.

Plunger

Push
Turn
A77510

83. INSTALL CAMSHAFT POSITION SENSOR

Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
84. INSTALL CYLINDER HEAD COVER GASKET
85. INSTALL CYLINDER HEAD COVER SUB–ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations shown in the illustra-
Seal Packing tion.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
S Install the cylinder head cover within 5 minutes after
applying seal packing.
S Do not expose seal packing to engine oil 2 hours after
A77399 installing.

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
A A C C Torque:
A
Bolt A 11 N
m (112 kgf
cm, 8 ft
lbf)
B B Bolt B 14 N
m (143 kgf
cm, 10 ft
lbf)
Bolt C 21 N
m (214 kgf
cm, 15 ft
lbf)
Nut 11 N
m (112 kgf
cm, 8 ft
lbf)

A Nut
Nut A A77346

86. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY

87. INSTALL OIL FILTER SUB–ASSY

(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228–06501
SST

A77425

88. INSTALL SPARK PLUG

Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
89. INSTALL VENTILATION VALVE SUB–ASSY
(a) Apply adhesive on the threads of the ventilation valve.
Torque: 15 N
m (153 kgf
cm, 11 ft
lbf)
Adhesive: Part No. 08833–00070 THREE BOND 1324 or equivalent
90. INSTALL OIL FILLER CAP GASKET
91. INSTALL OIL FILLER CAP SUB–ASSY

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)