2tr-Fe Engine Mechanical

01_007-2TR-FE ENGINE MECHANICAL.
book Page i Thursday, August 7, 2008 3:02 PM
ENGINE
2TR-FE ENGINE MECHANICAL
ENGINE
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-1
DRIVE BELT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-7
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-9
CAMSHAFT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EM-14
EM-18
EM
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-21
ENGINE ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-51
ENGINE UNIT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-61
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-68
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-86
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-103
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-107
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-140
01_007-2TR-FE ENGINE MECHANICAL.book Page ii Thursday, August 7, 2008 3:02 PM
EM
01_007-2TR-FE ENGINE MECHANICAL.book Page 1 Thursday, August 7, 2008 3:02 PM
2TR-FE ENGINE MECHANICAL – ENGINE EM–1
ENGINE
ON-VEHICLE INSPECTION
1. INSPECT AIR CLEANER FILTER ELEMENT
(a) Remove the air filter.
(b) Visually check that the air filter is not excessively
damaged or oily.
If necessary, replace the air filter.
2. INSPECT V-RIBBED BELT TENSIONER
(a) Idle the engine and then stop the engine. Check that
Turn
the drive belt is between the edges of the tensioner
pulley.
(b) Remove the drive belt from the tensioner pulley.
(c) Turn the pulley, and check that the tensioner
bearing moves smoothly and quietly.
If necessary, replace the tensioner.
(d) Install the drive belt.
EM
G035187E01
3. INSPECT NO. 1 IDLER PULLEY

Turn (a) Idle the engine and then stop the engine. Check that
the drive belt is between the edges of the idler
pulley.
(b) Remove the drive belt from the idler pulley.
(c) Turn the pulley, and check that the idler bearing
moves smoothly and quietly.
If necessary, replace the idler pulley.
(d) Install the drive belt.
G035186E01
4. CHECK VALVE LASH ADJUSTER NOISE
(a) Rev up the engine several times. Check that the
engine does not emit unusual noises.
(b) If unusual noises occur, warm up the engine and
idle it for over 30 minutes. Then repeat the step
above.
HINT:
If any defects or problems are found during the
inspection above, perform a lash adjuster inspection
(see page EM-18).
5. INSPECT IGNITION TIMING
(a) Warm up the engine and stop the engine.
NOTICE:
A warmed up engine should have an engine
coolant temperature of over 80°C (176°F), have
an engine oil temperature of 60°C (140°F), and
the engine rpm should be stabilized.
EM–2 2TR-FE ENGINE MECHANICAL – ENGINE
(b) When using the intelligent tester:

Intelligent Tester
Check the ignition timing.
(1) Connect the intelligent tester to the DLC3.
(2) Start the engine at idle.
(3) Turn the intelligent tester main switch ON.
(4) Enter the following item: Powertrain / Engine
and ECT / Data List / IGN Advance.
Standard ignition timing:
0 to 20° BTDC @ idle
HINT:
Please refer to the intelligent tester operator's
DLC3 manual for further details.
C108852E03
EM (c) When not using the intelligent tester:

Tachometer Check the ignition timing.
(1) Using SST, connect tachometer probe to
terminal TAC of the DLC3.
TAC SST 09843-18030
NOTICE:
• Confirm the terminal numbers before
DLC3 SST connecting them. Connection with a
Battery wrong terminal can damage the engine.
G039759E01 • Turn off all electrical systems before
connecting the terminals.
(2) Clamp the tester probe of a timing light to the 4
lead wires or green-red lead wire of the ignition
coil connector for No. 1 cylinder.
(3) Start the engine.
Green-red Lead Wire

A099874E01
(4) Using SST, connect terminals TC and CG of

TC
the DLC3.
SST 09843-18040
NOTICE:
CG When checking the ignition timing, the
transmission should be in the neutral
position.
SST
DLC3
G039758E01
HINT:
Engine
Speed Approx. 1,000 to 1,500 rpm • After connecting terminals (TC and CG),
engine rpm changes to approximately 1,000
to 1,500 rpm for 5 seconds, then returns to
Idle Speed idle speed. Because the ECM checks that
5 sec. the ISC (idle speed control system) operates
properly.
• Perform the inspection of the ignition timing
Connect Terminals TC and CG after engine rpm is returned to idle speed.
A099876E01
(5) Using a timing light, measure the ignition

timing.
(6) Remove the SST from terminals 13 (TC) and 4
(CG) of the DLC3.
(7) Check the ignition timing. EM
A099880E01 (8) Confirm that ignition timing moves to the
advanced angle side when the engine speed is
increased.
(9) Remove the timing light.
6. INSPECT ENGINE IDLE SPEED
(a) Warm up and stop the engine.
NOTICE:
(b) When using the intelligent tester:
Intelligent Tester
Check the idle speed.
(1) Connect the intelligent tester to the DLC3.
HINT:
Please refer to the intelligent tester II operator's
manual for further details.
(3) Turn the intelligent tester main switch ON.
(4) Enter the following item: Powertrain / Engine
and ECT / Data List / Engine SPD.
Standard idle speed:
DLC3 600 to 700 rpm
NOTICE:
• When checking the idle speed, the
C108852E03
position.
• Switch off all accessories and air
conditioning before connecting the
intelligent tester.
(c) When not using the intelligent tester:

Tachometer Check the idle speed.
(1) Using SST, connect tachometer tester probe to
terminal 9 (TAC) of the DLC3.
TAC SST 09843-18030
(3) Check the idle speed.
DLC3 SST Standard idle speed:
Battery 600 to 700 rpm
G039759E01
7. INSPECT IDLE SPEED CONTROL SYSTEM
(a) Warm up and stop the engine.
NOTICE:
EM TC
(b) Check the idle speed control system.
(1) Using SST, connect terminals TC and CG of
the DLC3.
SST 09843-18040
CG (2) Start the engine at idle.
NOTICE:
• Confirm the terminal numbers before
SST connecting them. Connection with a
DLC3
wrong terminal can damage the engine.
G039758E01 • Turn off all electrical systems before
connecting the terminals.
• When checking ISC function, the
position.
(3) After connecting terminals (TC and CG), check
Engine
Approx. 1,000 to 1,500 rpm that the engine speed changes to
Speed
approximately 1,000 to 1,500 rpm for 5
seconds, and then returns to idle speed.
Idle Speed If the result is not as specified, check the
5 sec. throttle body, DTC (see page ES-226) and wire
harness.
8. INSPECT COMPRESSION
Connect Terminals TC and CG (a) Warm up and stop the engine.
A099876E01
NOTICE:
the engine speed should be stabilized.
(b) Disconnect the injector connectors.
(c) Remove the ignition coils.
(d) Remove the spark plugs.
(e) Check the cylinder compression pressure.

(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.
(3) While cranking the engine, measure the
compression pressure.
Standard compression pressure:
1230 kPa (12.5 kgf/cm2, 178 psi)
Minimum pressure:
880 kPa (9 kgf/cm2, 128 psi)
A099130E01
Difference between each cylinder:

68 kPa (0.7 kgf/cm2, 10 psi)
NOTICE:
• Always use a fully charged battery to
obtain an engine speed of 250 rpm or
more.
• Check the other cylinders' compression EM
pressure in the same way.
• This measurement must be done as
quickly as possible.
If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through
the spark plug hole and inspect again.
HINT:
• If adding oil increases the compression, the
piston rings and/or cylinder bore may be
worn or damaged.
• If pressure stays low, a valve may be stuck
or seated improperly, or there may be
leakage in the gasket.
9. CHECK CO/HC
(a) Start and warm up the engine.
(b) Run the engine at 2,500 rpm for approximately 180
seconds and idle the engine.
(c) Insert CO/HC meter testing probe at least 40 cm
(1.3 ft.) into the tailpipe.
(d) Check CO/HC concentration at idle.
CO/HC Meter Idle CO concentration:
0 to 0.5%
Idle HC concentration:
Applicable local regulation
(e) If the CO/HC concentration is not as specified,
perform troubleshooting in the order given below.
G038860E01 (1) Check the heated oxygen sensor operation
(see page ES-279).
(2) See the table below for possible causes, and

then inspect and repair the applicable causes if
necessary.
CO HC Problems Causes
Normal High Rough idle 1. Faulty ignitions:
– Incorrect timing
– Plugs are contaminated, shorted or gaps are defective
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Low High Rough idle 1. Vacuum leaks:
(Fluctuating HC – Ventilation hoses
reading) – Intake manifold
– Throttle body
– Brake booster line
2. Lean mixture causing misfire
High High Rough idle 1. Restricted air filter
(Black smoke from 2. Plugged ventilation valve
exhaust) 3. Faulty SFI system:
EM – Faulty pressure regulator
– Defective ECT sensor
– Defective Mass Air Flow (MAF) meter
– Faulty ECM
– Faulty injectors
– Faulty throttle position sensor
2TR-FE ENGINE MECHANICAL – DRIVE BELT EM–7
DRIVE BELT
ENGINE
COMPONENTS
DRIVE BELT
EM
A116947E01
EM–8 2TR-FE ENGINE MECHANICAL – DRIVE BELT
ON-VEHICLE INSPECTION
INCORRECT
1. INSPECT DRIVE BELT
(a) Check the belt for wear, cracks or other signs of
damage.
If any of the following defects is found, replace the
drive belt.
• The belt is cracked.
• The belt is worn out to the extent that the cords
A058797E02
are exposed.
• The belt has chunks missing from the ribs.
(b) Check that the belt fits properly in the ribbed groves.
HINT:
Check with your hand to confirm that the belt has
not slipped out of the groove on the bottom to the
pulley. If it has slipped out, replace the drive belt.
Install a new drive belt correctly.
EM CORRECT INCORRECT
A087787E04
(c) Check that the tensioner indicator mark is within

Bracket Side range A shown in the illustration.
Indicator If the mark is not within range A, replace the drive
belt.
Drive Belt
A
Arm Side Indicator
Tensioner
G038478E02
REMOVAL
1. REMOVE DRIVE BELT
(a) Use the hexagon-shaped part indicated by the
arrow in the illustration to move the tensioner pulley
downward and decrease the tension in the drive
belt. Then remove the drive belt.
NOTICE:
When removing the drive belt, do not use the
A099194E01
idle pulley's bolt.
HINT:
After removing the drive belt, move the tensioner
upward to the maximum amount.
2TR-FE ENGINE MECHANICAL – DRIVE BELT EM–9
INSTALLATION
1. INSTALL DRIVE BELT
(a) Install the drive belt to the pulleys except the drive
belt tensioner pulley.
(b) Use the hexagon-shaped part indicated by the
arrow in the illustration to move the tensioner pulley
downward and then install the drive belt to the
tensioner pulley.
NOTICE:
• The backside of the drive belt should face the
w/ A/C
Fan Pulley
tensioner pulley.
Idler Pulley
• Check that the drive belt is properly set to
Vane Pump each pulley.
Generator
EM
Tensioner
Pulley
Crankshaft
Pulley
A/C
Compressor
w/o A/C
Idler Pulley
Vane Pump
Generator
Tensioner
Pulley
Crankshaft
Pulley
A097752E02
(c) After a new belt has been installed, check that the
Bracket Side tensioner indicator mark is within range A shown in
Indicator the illustration.
Drive Belt
A
Arm Side Indicator
Tensioner
G038479E01
EM–10 2TR-FE ENGINE MECHANICAL – CAMSHAFT
CAMSHAFT
ENGINE
COMPONENTS
DRIVE BELT
EM
A116947E02
2TR-FE ENGINE MECHANICAL – CAMSHAFT EM–11
8.0 (82, 71 in.*lbf)
NO. 2 VENTILATION HOSE
EM
INTAKE AIR CONNECTOR
5.0 (51, 44 in.*lbf)
VACUUM HOSE
N*m (kgf*cm, ft.*lbf) : Specified torque
A111864E01
9.0 (92, 80 in.*lbf)
IGNITION COIL
9.0 (92, 80 in.*lbf)

OIL FILLER CAP
x8
EM 9.0 (92, 80 in.*lbf) x 11
CYLINDER HEAD COVER

VENTILATION HOSE
CYLINDER HEAD COVER GASKET
NO. 2 CYLINDER HEAD COVER GASKET
A113348E06
15.5 (158, 11) x4
12 (122, 9)
OIL DELIVERY PIPE
O-RING
15.5 (158, 11)

15.5 (158, 11) x 12
NO. 2 CAMSHAFT BEARING CAP
EM
CAMSHAFT TIMING SPROCKET
10 (102, 7)
NO. 2 CAMSHAFT
NO. 1 CAMSHAFT
O-RING
CAMSHAFT TIMING GEAR
78 (795, 58)
VALVE ROCKER ARM
TIMING CHAIN TIMING CHAIN GUIDE
Non-reusable part
A113349E10
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag activation.
2. REMOVE DRIVE BELT (See page EM-8)
3. REMOVE INTAKE AIR CONNECTOR (See page EM-
43)
4. REMOVE IGNITION COIL
(a) Remove the bolt and ignition coil.
5. REMOVE CYLINDER HEAD COVER
(a) Disconnect the wire harness from the 6 clamps.
EM (b) Remove the 19 bolts, 2 nuts, cylinder head cover
and 2 gaskets.
G035202E03
6. REMOVE TIMING CHAIN GUIDE

(a) Remove the 2 bolts, chain guide and O-ring.
O-Ring
G037278E02
7. REMOVE CAMSHAFT TIMING SPROCKET

13°47' *
(a) Turn the crankshaft pulley, and align its groove with
timing mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing
gear and sprocket are aligned with the timing marks
of the No. 1 bearing cap, as shown in the illustration.
*
*:
Timing
Mark
6°37'
EM
Groove
G038864E01
(c) Place paint marks on the timing chain and camshaft

Paint Mark timing gear/sprocket.
Timing Mark
A097862E04
(d) Fix the camshaft with a wrench and then loosen the
Loosen sprocket bolt.
Fix
NOTICE:
Be careful not to damage the oil delivery pipe.
A097863E01
(e) Using a 10 mm socket hexagon wrench, remove the

timing chain cover plug.
A086539E01
(f) Using a screwdriver, access the tensioner stopper

plate through the chain tensioner service hole.
Move the stopper plate upward to release the lock.
Then hold the plate in that position as shown in the
illustration.
HINT:
If the stopper plate's lock is difficult to release,
slightly rotate the camshaft's hexagon-shaped part
to the left and right.
Stopper
Plate
A097864E01
EM (g) With the stopper plate's lock released, slightly rotate

the camshaft to the right. Then maintain that
position.
Turn
NOTICE:
Be careful not to damage the oil delivery pipe.
HINT:
Rotating the camshaft to the right will cause
pressure to be applied to the tensioner plunger.
Plunger
A097865E01
(h) Remove the screwdriver from the chain tensioner

service hole. Move the stopper plate to the position
shown in the illustration. Then insert a hexagon
wrench into the hole.
HINT:
• If the wrench cannot fit into the hole, slightly
rotate the camshaft to the left and then to the
right. Then insert the wrench.
• To prevent the wrench from falling out, use tape
1.27 mm to fix the wrench in place.
Hexagon (i) Remove the camshaft timing sprocket from the
Wrench
camshaft.
A086542E01
8. REMOVE CAMSHAFT
3 12 20 16 8 (a) Uniformly loosen the 21 bearing cap bolts in several
passes in the sequence shown in the illustration.
5 (b) Remove the 9 bearing caps, oil delivery pipe, O-ring
13
and camshaft.
21 17 9
11 15 7
NOTICE:
1 19
4 • Place the camshaft on a flat surface, maintain
this position and loosen the bolts uniformly.
2 • Do not pry the camshaft with a tool by
10 18 14 6
A097866E01 applying excessive force to it.
• Do not damage the reception part of exhaust
on the cylinder head side.
(c) Remove the camshaft while holding the timing
chain.
EM
A086544E01
(d) Tie the timing chain with a string as shown in the

illustration.
NOTICE:
Be careful not to drop anything inside the timing
chain cover.
9. REMOVE VALVE ROCKER ARM
HINT:
Each rocker arm must be reinstalled to its original
location.
A086545E01
10. REMOVE VALVE LASH ADJUSTER

HINT:
Each lash adjuster must be reinstalled to its original
location.
11. REMOVE CAMSHAFT TIMING GEAR
Do Not Remove Straight Pin (a) Remove the flange bolt of the camshaft timing gear.
NOTICE:
• Be sure not to remove the other 3 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
Flange Bolt 12. REMOVE VALVE STEM CAP
HINT:
A097871E01
Each stem cap must be reinstalled to its original
locations.
CORRECT INCORRECT
INSPECTION
1. INSPECT VALVE LASH ADJUSTER
SST NOTICE:
• Keep the lash adjuster free from foreign matter.
Tapered Part
• Only use clean engine oil.
(a) Place the lash adjuster into a container full of engine
Plunger oil.
(b) Insert SST's tip into the lash adjuster's plunger and
Low Pressure use the tip to press down on the checkball inside the
Chamber plunger.
SST 09276-75010
(c) Squeeze the SST and lash adjuster together to
Check Ball
move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed air.
High Pressure
OK:
Chamber
Plunger moves up and down.
EM SST NOTICE:
When bleeding high-pressure air from the
compression chamber, make sure that the tip of
the SST is actually pressing the checkball as
shown in the illustration. If the checkball is not
pressed, air will not bleed.
(e) After bleeding air, remove SST. Then, try to quickly
and firmly press the plunger with a finger.
OK:
A097867E01 Plunger is difficult to move.
If the result is not as specified, replace the lash
adjuster.
2. INSPECT CAMSHAFT TIMING GEAR
Retard Side (a) Check the lock of the camshaft timing gear.
Path (1) Clamp the camshaft in a vise, and confirm that
the camshaft timing gear is locked.
NOTICE:
Advance
Be careful not to damage the camshaft.
Side Path (b) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
2 advance side paths are provided in the
groove of the camshaft. Plug one of the paths
Close Open with a rubber piece.
(2) Break through the tape of the advance side
Open Close
path and the retard side path on the opposite
side of the groove.
Vinyl Tape Rubber
A062190E02
(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28

Retard Advance psi) of air pressure to the paths whose tape
Side Path Side Path was broken in the procedure above.
CAUTION:
Some oil spraying will occur. Contain the
spray with a shop rag.
A062191E03
(4) Check that the camshaft timing gear revolves in

Retard Advance the advance direction when weakening the air
Side Path Side Path pressure of the retard side path.
OK:
Gear rotates in advance direction.
HINT:
Decompress This operation releases the lock pin for the EM
extreme retard position.
Hold Pressure (5) When the camshaft timing gear reaches the
A062192E04 extreme advance position, remove the air gun
from the retard side path and advance side
path, in that order.
NOTICE:
Do not remove the air gun from the advance
side path first. The gear may abruptly shift
in the retard direction and break the lock
pin.
(c) Check for smooth rotation.
(1) Rotate the camshaft timing gear within its
movable range several times, but do not turn it
to the extreme retard position. Check that the
gear rotates smoothly.
OK:
Gear rotates in advance direction.
NOTICE:
Do not use an air gun to perform the
smooth operation check.
(d) Check the lock in the extreme retard position.
(1) Confirm that the camshaft timing gear is locked
at the extreme retard position.
3. INSPECT NO. 1 CAMSHAFT
(a) Check 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:
0.03 mm (0.0012 in.)
If the circle runout is greater than the
maximum, replace the camshaft.
A086996E01
(b) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:
42.855 to 42.955 mm (1.6872 to 1.6911 in.)
Minimum cam lobe height:
42.855 mm (1.6872 in.)
If the cam lobe height is less than the minimum,
replace the camshaft.
A034310E01
(c) Using a micrometer, measure the journal diameter.

Standard journal diameter
Item Specified Condition
No. 1 journal 35.949 to 35.965 mm (1.4153 to
1.4159 in.)
EM Other journal 26.959 to 26.975 mm (1.0614 to

1.0620 in.)
If the journal diameter is not as specified, check the

A034311E01
oil clearance.
4. INSPECT NO. 2 CAMSHAFT

(a) Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
0.03 mm (0.0012 in.)
maximum, replace the camshaft.
A086997E01
(b) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:
42.854 to 42.954 mm (1.687 to 1.6911 in.)
Minimum cam lobe height:
42.854 mm (1.6872 in.)
If the cam lobe height is less than the minimum,
replace the camshaft.
A034310E02
(c) Using a micrometer, measure the journal diameter.

1.4159 in.)
Other journal 26.959 to 26.975 mm (1.0614 to
1.0620 in.)
If the journal diameter is not as specified, check the

A034311E01
oil clearance.
INSTALLATION
Straight Pin 1. INSTALL CAMSHAFT TIMING GEAR
(a) Put the camshaft timing gear and camshaft together
by aligning the key groove and straight pin.
(b) Check that there is no gap between the gear's
flange and the camshaft.
Key Groove
(c) With the camshaft timing gear fixed in place, tighten
the flange bolt.
A097872E01
Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
2. INSTALL VALVE STEM CAP
(a) Apply clean engine oil to the valve stem tip, and
install the valve stem cap.
NOTICE:
Install the cap to the same place it was removed
from.
3. INSTALL VALVE LASH ADJUSTER EM
NOTICE:
• Keep the lash adjuster free from dirt and foreign
objects.
• Only use clean engine oil.
CORRECT INCORRECT oil.
SST
use the tip to press down on the checkball inside the
Tapered Part plunger.
SST 09276-75010
(c) Squeeze the SST and lash adjuster together to
Plunger
Low Pressure OK:
Chamber
NOTICE:
Check Ball When bleeding high-pressure air from the
High Pressure the SST is actually pressing the checkball as
Chamber shown in the illustration. If the checkball is not
SST (e) After bleeding air, remove SST. Then, try to quickly
OK:
Plunger is very difficult to move.
adjuster.
(f) Install the lash adjuster.
HINT:
Repeat the same procedures and install the
A097867E01
remaining lash adjusters.
NOTICE:
Install the lash adjuster to the same place it was
removed from.
4. INSTALL VALVE ROCKER ARM

(a) Apply clean engine oil to the valve lash adjuster tips
and valve stem cap surfaces. Then install the valve
rocker arms.
NOTICE:
Install the valve stem cap and valve rocker arm
to the same place it was removed from.
5. INSTALL CAMSHAFT
Timing Mark Paint Mark (a) Apply clean engine oil to the camshaft's cam portion
and the cylinder head journals.
(b) Install the timing chain on the camshaft timing gear,
with the painted mark of the link aligned with the
timing mark of the camshaft timing gear.
EM A097873E01
(c) Set the 2 camshafts as shown in the illustration.

A C NOTICE:
• Align the paint mark and timing mark before
setting the camshaft.
B D
B
A
D
C
A097874E01
• Before and after setting the camshaft and No.

2 camshaft, check that the rocker arm is
firmly set to the lash adjuster.
Stem End Cap Rocker Arm
CORRECT INCORRECT
Lash Adjuster
A110967E01
(d) Loosely install the No. 1 camshaft bearing cap. EM

(e) Check the proper location of each camshaft bearing
cap and install each one.
G037331E01
(f) Install a new O-ring to the No. 1 camshaft bearing

cap.
O-Ring (g) Temporarily install the oil delivery pipe.
G037284E01
(h) Tighten the 21 bolts and 20 washers in the order

20
shown in the illustration.
12 4 8 16 Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt A
15.5 N*m (158 kgf*cm, 11 ft.*lbf) for
18 except bolt A
21 A 11 3 7 15
17 9 1 5 13
19 10 2 6 14
G037283E01
6. INSTALL CAMSHAFT TIMING SPROCKET

Timing Mark (a) Rotate the camshaft so that the camshaft's timing
mark and the No. 2 camshaft knock pin are as
Timing Mark
(b) Turn the crankshaft pulley, and align its groove with
Knock Pin Timing Mark
Groove
A097877E01
EM Paint Mark
(c) Install the timing chain on the camshaft timing
sprocket, with the paint mark aligned with the timing
marks on the camshaft timing sprocket.
(d) Align the No. 2 camshaft knock pin and camshaft
timing sprocket's pin hole. Then install the camshaft
timing sprocket to the No. 2 camshaft.
NOTICE:
If the knock pin and pin hole are difficult to
Timing Mark align, slightly rotate the No. 2 camshaft to the
A097878E01 left and right using the camshaft's hexagon-
shaped part. Then attempt alignment again.
(e) Fix the camshaft with a wrench, and then tighten the
sprocket bolt.
Tighten Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
Fix (f) Remove the hexagon wrench from the chain
tensioner.
A097863E02
(g) Apply adhesive to 2 or 3 threads of the timing chain

Adhesive cover plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or equivalent
NOTICE:
Remove any oil from the bolt hole.
(h) Using a 10 mm socket hexagon wrench, install the
timing gear case plug.
A058128E03 Torque: 16.6 N*m (169 kgf*cm, 12 ft.*lbf)
7. INSTALL TIMING CHAIN GUIDE

(a) Install a new O-ring to the camshaft bearing cap.
(b) Install the timing chain guide with the 2 bolts.
O-Ring
G037278E02
8. INSTALL CYLINDER HEAD COVER

(a) Install the 2 gaskets to the cylinder head cover.
(b) Remove any old packing (FIPG) material.
(c) Apply seal packing to 2 locations as shown in the
illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three EM
Bond 1207B or equivalent
NOTICE:
Seal Packing A097879E02 • Remove any oil from the contact surface.
• Install the cylinder head cover within 3
minutes after applying seal packing.
• Do not apply engine oil for at least 2 hours
after installing.
(d) Loosely install the head cover with the 19 bolts and
17 18 19 20
21 2 nuts.
(e) Uniformly tighten the 19 bolts and 2 nuts in the
2 3 6 7 sequence shown in the illustration.
16 9 Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(f) In numerical order, confirm that the bolts labeled 1
to 18 are tightened to the torque specification.
1 4 5 8
Tighten the bolts as necessary.
10 (g) Connect the wire harness to the 6 clamps.
15 13 12 11
14 G035202E01
9. INSTALL IGNITION COIL
(a) Install the ignition coil with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
10. INSTALL INTAKE AIR CONNECTOR (See page EM-
60)
11. INSTALL DRIVE BELT (See page EM-9)
12. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
13. PERFORM INITIALIZATION
(a) Perform initialization (see page IN-18).
NOTICE:
Certain systems need to be initialized after
disconnecting and reconnecting the cable from
the negative (-) battery terminal.
14. CHECK FOR ENGINE OIL LEAKS
(a) Start the engine, and check that there are no oil
leaks after performing maintenance.
15. CHECK FOR ENGINE COOLANT LEAKS (See page

CO-1)
16. CHECK IGNITION TIMING (See page EM-1)
17. CHECK IDLE SPEED (See page EM-3)
18. CHECK CO/HC (See page EM-5)
19. CHECK FUNCTION OF THROTTLE BODY (See page
ES-376)
EM
2TR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–27
ENGINE ASSEMBLY
ENGINE
COMPONENTS
14 (143, 10)
8.0 (82, 71 in.*lbf)
5.0 (51, 44 in.*lbf)
INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY

ENGINE ROOM RELAY
AIR PUMP INLET BLOCK COVER (UPPER)
(w/ Secondary Air Injection System)
EM
8.5 (87, 75 in.*lbf)
RADIATOR RESERVOIR
RADIATOR INLET HOSE

5.0 (51, 44 in.*lbf)
x4 ENGINE ROOM RELAY

BLOCK COVER (UPPER)
FAN PULLEY DRIVE BELT

12 (122, 9) 25 (255, 18)
FAN SHROUD FAN AND

COUPLING
RADIATOR ASSEMBLY

A116946E14
EM–28 2TR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
HOOD ASSEMBLY
13 (133, 10)
OIL DIPSTICK GUIDE
VANE PUMP
EM 21 (214, 15)
WASHER NOZZLE HOSE
OIL DIPSTICK
25 (250, 18)
O-RING
8.0 (82, 71 in.*lbf)
COOLER COMPRESSOR
RADIATOR GRILLE
RADIATOR SIDE
DEFLECTOR RH
RADIATOR SIDE
DEFLECTOR LH
ENGINE SIDE
COVER RH
28 (286, 21) NO. 1 ENGINE UNDER COVER
28 (286, 21) ENGINE SIDE COVER LH
Non-reusable part
A116945E12
LHD
Engine Compartment Side
13 (133, 10)
EM
AIR INJECTION DRIVER
CONNECTOR
(w/ Secondary Air Injection
System)
GROUND WIRE
GLOVE COMPARTMENT DOOR
ECM CONNECTOR
A120550E06
RHD
Engine Compartment Side
GROUND WIRE
EM WIRE CLAMP
13 (133, 10)
ECM CONNECTOR
GLOVE COMPARTMENT DOOR

A116943E05
POSITIVE NEGATIVE GROUND WIRE

BATTERY BATTERY
CABLE CABLE
31 (316, 23)
NO. 1 FUEL
HOSE
PURGE VSV HOSE

NO. 2 FUEL
VACUUM HOSE HOSE
31 (316, 23) EM
w/ Secondary Air Injection System 13 (133, 10)
ENGINE ROOM
JUNCTION BLOCK
CONNECTOR
WIRE CLAMP
AIR HOSE
WIRE CLAMP
SUCTION HOSE
13 (133, 10)
13 (133, 10)
SENSOR CLAMP GROUND WIRE

5.0 (51, 44 in.*lbf) 31 (316, 23)
A116944E05
88 (897, 65)
EM
PROPELLER SHAFT WITH

CENTER BEARING
ASSEMBLY (for 2WD)
EXHAUST SUPPORT
36 (367, 27)
48 (489, 35)
REAR PROPELLER
SHAFT ASSEMBLY
(for 4WD)
88 (897, 65)
GASKET
GASKET
FRONT EXHAUST PIPE

43 (438, 32)
COMPRESSION SPRING
N*m (kgf*cm, ft.*lbf) : Specified torque FRONT EXHAUST PIPE

(w/o Secondary Air Injection System)
Non-reusable part
A116941E14
MT for 4WD
UPPER CONSOLE SHIFT LEVER KNOB

PANEL ASSEMBLY
TRANSFER
SHIFT LEVER
EM
CONSOLE BOX ASSEMBLY SHIFT LEVER BOOT ASSEMBLY
TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY
FLOOR SHIFT SHIFT LEVER ASSEMBLY
SNAP RING
A114538E13
MT for 2WD
SHIFT LEVER KNOB
CONSOLE PANEL UPPER
CONSOLE BOX
EM
SHIFT LEVER BOOT
FLOOR SHIFT LEVER
A113352E10
18 (184, 13)
72 (730, 53)
x3 TRANSFER CASE
37 (377, 27) LOWER PROTECTOR
STARTER
EM
37 (377, 27) MANUAL TRANSMISSION UNIT
CLUTCH RELEASE CYLINDER

37 (377, 27)
12 (122, 9)
88 (897, 65)
FRONT PROPELLER SHAFT

ASSEMBLY
ENGINE MOUNTING
INSULATOR REAR
47 (479, 35)
50 (510, 37)
NO. 3 FRAME CROSSMEMBER
27 (275, 20)
A120551E08
MT for 2WD
72 (730, 53)
x3
STARTER 37 (377, 27)
MANUAL
TRANSMISSION
EM UNIT
37 (377, 27)
12 (122, 9)
37 (377, 27)
CLUTCH RELEASE CYLINDER
ENGINE MOUNTING
INSULATOR REAR
47 (479, 35)
NO. 3 FRAME
CROSSMEMBER
ASSEMBLY
50 (510, 37)
27 (275, 20)
A120552E04
A/T for 4WD

TRANSMISSION OIL LEVEL GAUGE
5.0 (51, 44 in.*lbf) TRANSMISSION OIL FILLER TUBE
OIL COOLER INLET TUBE
CLAMP
OIL COOLER OUTLET TUBE
17 mm Head: 71 (724, 52) x3

14 mm Head: 37 (377, 27) x4 12 (122, 9)
EXHAUST MANIFOLD
44 (449, 32)
STAY
O-RING
EM
AUTOMATIC TRANSMISSION
TORQUE ASSEMBLY
CONVERTER
CLUTCH
x6 28 (286, 21)
41 (418, 30)
TRANSMISSION
CONTROL CABLE
BRACKET
FLYWHEEL HOUSING
DUST SEAL
88 (897, 64)
STARTER FRONT PROPELLER

SHAFT ASSEMBLY
88 (897, 64)
NO. 1 ENGINE MOUNTING 47 (479, 35)

INSULATOR REAR
50 (510, 37)
NO. 3 FRAME
CROSSMEMBER
N*m (kgf*cm, ft.*lbf) : Specified torque 27 (275, 20)
Non-reusable part
A116942E09
A/T for 2WD
TRANSMISSION
OIL DIPSTICK
5.0 (51, 44 in.*lbf)
TRANSMISSION
CLAMP OIL FILLER TUBE
12 (122, 9)
OIL COOLER INLET TUBE
O-RING
EM
OIL COOLER OUTLET TUBE
44 (449, 32)
17 mm head: 71 (724, 52) x3 28 (286, 21)
14 mm head: 37 (377, 27) x4
EXHAUST MANIFOLD STAY
TORQUE
CONVERTER
CLUTCH
41 (418, 30) x6 AUTOMATIC TRANSMISSION CONTROL

TRANSMISSION CABLE BRACKET
ASSEMBLY
47 (479, 35)
FLYWHEEL HOUSING NO. 1 ENGINE MOUNTING

DUST SEAL INSULATOR REAR
NO. 3 FRAME CROSSMEMBER 50 (510, 37)
27 (275, 20)
Non-reusable part
A120836E19
M/T
38 (388, 28)
ENGINE ASSEMBLY
EM
19 (195, 14)
1st: 26.5 (270, 20)
2nd: Turn 90° x6

18 (184, 13)
REAR END PLATE
x 10
CLUTCH COVER
FLYWHEEL CLUTCH DISC

HOUSING DUST
SEAL
FLYWHEEL
Precoated part
A121158E26
A/T
ENGINE ASSEMBLY
38 (388, 28) 18 (184, 13) 74 (755, 55)
x 10
EM
DRIVE PLATE
SPACER REAR
DRIVE PLATE
DRIVE PLATE
SPACER FRONT
REAR END PLATE
Precoated part
A117753E26
12 (122, 9)
x5
EXHAUST MANIFOLD HEAT INSULATOR DELIVERY PIPE SPACER
12 (122, 9)
w/ Secondary Air Injection System
GASKET
FUEL DELIVERY PIPE
20 (204, 15) O-RING
9.0 (92, 80 in.*lbf)

INTAKE PIPE INJECTOR
INSULATOR AIR SWITCHING VALVE
EM
EXHAUST MANIFOLD INJECTOR VIBRATION
SPACER
x8
THROTTLE BODY 25 (255, 18)
O-RING
36 (367, 27) GASKET GASKET
x2
9.0 (92, 80 in.*lbf)
EXHAUST MANIFOLD
x6
GASKET
IGNITION COIL
x5
SPARK PLUG 25 (255, 18)
INTAKE MANIFOLD
36 (367, 27) GASKET
18 (184, 13)
VENTILATION PIPE
Non-reusable part
A121408E03
43 (438, 32) GENERATOR
V-RIBBED BELT TENSIONER

NO. 1 IDLER PULLEY
15 (153, 11)
PULLEY
PLATE ENGINE OIL PRESSURE SWITCH
SPACER
CAMSHAFT TIMING OIL CONTROL VALVE
43 (438, 32)
8.0 (82, 71 in.*lbf)
40 (408, 30) ENGINE COOLANT

EM 43 (438, 32)
TEMPERATURE SENSOR
21 (214, 15)
O-RING WATER
8.5 (87, 75 in.*lbf) BY-PASS
HOSE
17.5 (178, 13)
CAMSHAFT POSITION SENSOR
COMPRESSOR MOUNTING
BRACKET
(w/ Air Conditioning System) NO. 1 WATER BY-PASS PIPE
GASKET
20 (204, 15)
45 (459, 33)
GASKET KNOCK SENSOR
THERMOSTAT
24.5 (250, 18)
FRONT ENGINE GASKET WATER INLET

MOUNTING
45 (459, 33)
BRACKET RH
20 (204, 15)
51 (520, 38) 51 (520, 38) CRANKSHAFT POSITION SENSOR

8.5 (87, 75 in.*lbf)
Non-reusable part
FRONT ENGINE MOUNTING
BRACKET LH
Precoated part
A113072E34
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-12)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag pretensioner activation.
3. REMOVE NO. 1 ENGINE UNDER COVER
(a) Remove the 4 bolts and under cover.
(b) Remove the 3 clips, 3 bolts and side cover RH.
(c) Remove the 3 clips, 3 bolts and side cover LH.
4. DRAIN ENGINE COOLANT (See page CO-2)
5. DRAIN ENGINE OIL (See page LU-4) EM
6. REMOVE INTAKE AIR CONNECTOR AND AIR
CLEANER ASSEMBLY
(a) Disconnect the vacuum hose.
(b) Disconnect the No. 2 ventilation hose.
(c) Disconnect the MAF meter connector and wire
harness clamps.
(d) Loosen the hose clamp and remove the 4 bolts, air
cleaner and intake air connector assembly.
7. REMOVE RADIATOR GRILLE (See page ET-39)
A099871E01
8. DISCONNECT RADIATOR INLET HOSE

9. DISCONNECT RADIATOR OUTLET HOSE
10. REMOVE DRIVE BELT (See page EM-8)
11. REMOVE FAN SHROUD (See page CO-22)
12. REMOVE FAN PULLEY
13. REMOVE RADIATOR ASSEMBLY (See page CO-23)
14. DISCONNECT HOSE
(a) Disconnect the vacuum hose (from brake master
cylinder).
(b) Disconnect the hose from the purge VSV.
15. DISCONNECT FUEL HOSE (See page FU-13)
G039232E01
16. DISCONNECT ENGINE WIRE

(a) Disconnect the ECM connectors from the cabin.
(1) Remove the glove compartment door.
(2) Disconnect the 4 ECM connectors.
(b) w/ Secondary air injection system:
Disconnect the air injection driver connector.
(c) Remove the bolt and clamp, and disconnect the
ground wire.
(d) Remove the bolt and disconnect the ground wire
A111959 from the frame.
(e) Pull out the engine wire from the cabin.
(f) Remove the engine room relay block cover (upper).
(g) Remove the engine room relay block cover (side).
(1) Using a screwdriver, detach the 4 claws and
remove the relay block cover.
HINT:
EM Pull Tape the screwdriver tip before use.
(h) Remove the nut and disconnect the cable from the
Pull
engine room junction block.
(i) Disconnect the 2 engine room junction block
connectors and disconnect the wire clamp.
(j) Remove the bolt and disconnect the wire clamp
from the front engine mounting bracket LH.
(k) Remove the bolt and disconnect the sensor clamp.
G038830E06
17. DISCONNECT VANE PUMP

(a) Disconnect the oil pressure switch connector.
(b) Remove the 2 bolts and disconnect the vane pump
from the engine.
(c) Support the vane pump securely.
18. REMOVE OIL DIPSTICK
(a) Remove the bolt, dipstick guide and O-ring.
HINT:
Cover the dipstick guide hole to prevent foreign
A099199
matter from entering it.
19. REMOVE OIL DIPSTICK GUIDE
20. DISCONNECT COOLER COMPRESSOR FROM
ENGINE (w/ Air Conditioning System)
(a) Disconnect the compressor connector.
(b) Remove the 2 bolts and disconnect the suction hose

from the engine.
A099198E01
(c) Remove the 4 bolts and disconnect the compressor

from the engine.
(d) Support the cooler compressor securely.
EM
A099200
21. REMOVE HOOD ASSEMBLY

(a) Disconnect the washer nozzle hose.
(b) Remove the 4 bolts and hood.
NOTICE:
Be careful not to damage the vehicle.
22. REMOVE FRONT EXHAUST PIPE (See page EX-4)
23. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(for 4WD) (See page PR-3)
G037191E01
24. REMOVE PROPELLER SHAFT WITH CENTER
BEARING ASSEMBLY (for 2WD) (See page PR-10)
25. REMOVE REAR PROPELLER SHAFT ASSEMBLY (for
4WD) (See page PR-22)
26. REMOVE STARTER (See page ST-16)
27. REMOVE CLUTCH RELEASE CYLINDER (for Manual
Transmission) (See page CL-28)
28. REMOVE MANUAL TRANSMISSION UNIT
(a) Remove the manual transmission unit from the
vehicle.
If necessary, refer to the corresponding manual
transmission section, and perform the work by
following the removal procedures for the manual
transmission assembly.
29. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
(a) Remove the automatic transmission assembly from
the vehicle.
If necessary, refer to the corresponding automatic
following the removal procedures for the automatic
30. REMOVE CLUTCH COVER (for Manual

Transmission) (See page CL-36)
31. REMOVE CLUTCH DISC (for Manual Transmission)
(See page CL-36)
32. REMOVE FLYWHEEL (for Manual Transmission)
(a) Fix the crankshaft in place with SST.
SST 09213-54015 (91651-60855), 09330-00021
SST
A099210E01
(b) Remove the 10 bolts and flywheel.

EM
G035062E01
33. REMOVE DRIVE PLATE (for Automatic

Transmission)
(a) Fix the crankshaft in place with SST.
SST 09213-54015 (91651-60855), 09330-00021
SST
A099210E01
(b) Remove the 10 bolts, rear spacer, drive plate and

front spacer.
34. REMOVE REAR END PLATE
(a) Remove the bolt and rear end plate.
A099868E01
35. REMOVE ENGINE ASSEMBLY

for Rear Side: for Front Side:
(a) Install the 2 engine hangers as shown in the
illustration.
Item Part No.

Engine hanger 12281-0C010
Bolt 90105-T0129

(b) Attach the engine sling device and chain block to
A099202E01
the engine hangers.
(c) Remove the 4 bolts and 4 nuts holding the engine
mounting bracket and frame.
EM
A117895
(d) Lift the engine out of the vehicle slowly and

carefully.
NOTICE:
Lift
Make sure to disconnect all the wires, hoses and
cables from the engine. Keep the disconnected
wires, hoses and cables off of the engine.
36. INSTALL ENGINE TO ENGINE STAND
(a) Place the engine assembly onto the stand.
A117894E01 37. REMOVE IGNITION COIL
(a) Disconnect the 4 ignition coil connectors and
remove the 4 bolts and 4 ignition coils.
38. REMOVE SPARK PLUG
39. REMOVE VENTILATION PIPE
(a) Remove the bolt and ventilation pipe.
40. REMOVE GENERATOR (See page CH-9)
41. REMOVE ENGINE WIRE
(a) Disconnect the oil pressure sensor connector.
(b) Disconnect the noise filter connector
(c) Disconnect the camshaft position sensor connector.
(d) Disconnect the 4 injector connectors.
(e) Disconnect the crankshaft position sensor
connector.
(f) Disconnect the oil control valve connector.
(g) Disconnect the throttle body connector.
(h) Disconnect the engine coolant temperature sensor
connector.
(i) Disconnect the knock sensor connector.
(j) Disconnect the wire harness from the clamps.
(k) Remove the 2 bolts and wire harness from the
engine.
42. REMOVE THROTTLE BODY (See page ES-376)

43. REMOVE FUEL DELIVERY PIPE (See page FU-13)
44. REMOVE INJECTOR (See page FU-14)
45. REMOVE INTAKE MANIFOLD
(a) Disconnect the crankshaft position sensor from the
clamp.
(b) Remove the 5 bolts, 2 nuts, intake manifold and
gasket.
G036020E01
46. REMOVE EXHAUST MANIFOLD HEAT INSULATOR

EM (w/o Secondary Air Injection System)
(a) Remove the 5 bolts and heat insulator.
A099875E01
47. REMOVE EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 5 bolts and heat insulator.
G037181E01
48. REMOVE AIR SWITCHING VALVE (w/ Secondary Air

Injection System)
(a) Remove the 4 nuts, intake pipe insulator and 2
gaskets.
G037182E01
(b) Remove the 2 nuts and air switching valve.
G037183E01
49. REMOVE EXHAUST MANIFOLD (w/o Secondary Air

Injection System)
(a) Remove the 6 nuts, exhaust manifold and gasket.
EM
A099195E01
50. REMOVE EXHAUST MANIFOLD (w/ Secondary Air

Injection System)
(a) Remove the 8 nuts, exhaust manifold and gasket.
G037180E01
51. REMOVE COMPRESSOR MOUNTING BRACKET (w/

Air Conditioning System)
(a) Remove the 5 bolts and compressor mounting
bracket.
A099203E02
52. REMOVE V-RIBBED BELT TENSIONER

(a) Remove the 3 bolts and belt tensioner.
53. REMOVE WATER INLET
(a) Remove the bolt, 2 nuts, water inlet and gasket.
54. REMOVE THERMOSTAT
(a) Remove the thermostat and gasket.
G035081E01
55. REMOVE NO. 1 IDLER PULLEY

(a) Remove the bolt, pulley plate, idler pulley and
spacer.
56. REMOVE OIL PRESSURE SWITCH
(a) Using a 24 mm deep socket wrench, remove the oil
pressure switch.
G035185E01
57. REMOVE NO. 1 WATER BY-PASS PIPE

(a) Remove the 2 nuts, water by-pass pipe and gasket.
58. REMOVE KNOCK SENSOR
(a) Remove the bolt and sensor.
59. REMOVE ENGINE COOLANT TEMPERATURE
EM SENSOR
(a) Using a 19 mm deep socket wrench, remove the
sensor.
G037195E01
60. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt, sensor and O-ring.
61. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-392)
G035088E01
62. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE

(a) Remove the bolt, oil control valve and O-ring.
A099883E01
63. REMOVE FRONT ENGINE MOUNTING BRACKET RH

(a) Remove the 4 bolts and mounting bracket.
A099873E01
64. REMOVE FRONT ENGINE MOUNTING BRACKET LH

(a) Remove the 4 bolts and mounting bracket.
A099872E01
INSTALLATION
1. INSTALL FRONT ENGINE MOUNTING BRACKET LH
(a) Install the mounting bracket with the 4 bolts.
EM
A099872E01
2. INSTALL FRONT ENGINE MOUNTING BRACKET RH

(a) Install the mounting bracket with the 4 bolts.
A099873E01
3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE

(a) Apply a coat of engine oil to a new O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
4. INSTALL CRANKSHAFT POSITION SENSOR (See
page ES-393)
A099883E01
5. INSTALL CAMSHAFT POSITION SENSOR

(a) Apply a coat of engine oil to the O-ring.
(b) Install a new O-ring to the sensor.
(c) Install the sensor with the bolt.
6. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using a 19 mm deep socket wrench, install a new
gasket and the sensor.
G035088E01
7. INSTALL KNOCK SENSOR (See page ES-402)

8. INSTALL NO. 1 WATER BY-PASS PIPE

(a) Install a new gasket and the water by-pass pipe with
the 2 nuts.
Torque: 17.5 N*m (178 kgf*cm, 13 ft.*lbf)
9. INSTALL ENGINE OIL PRESSURE SWITCH (See page
LU-2)
G037195E01
10. INSTALL NO. 1 IDLER PULLEY

(a) Install the spacer, idler pulley and pulley plate with
the bolt.
11. INSTALL THERMOSTAT (See page CO-12)
EM 12. INSTALL WATER INLET (See page CO-12)
G035185E01
13. INSTALL V-RIBBED BELT TENSIONER

(a) Temporarily install the belt tensioner with the 3 bolts.
3 HINT:
Make sure the flanges of the bolts are contacting the
1
tensioner surface.
(b) Install the tensioner by tightening the 3 bolts in the
order shown in the illustration.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) for bolt 1
2
21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt 2
G035081E02 43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt 3
14. INSTALL COMPRESSOR MOUNTING BRACKET (w/
Air Conditioning System)
NOTICE:
In order to prevent misalignment, which causes belt
rattle, the 5 bolts must be tightened exactly as
described in the procedures below.
(a) Temporarily install the mounting bracket with the 3

B bolts labeled A.
A
HINT:
Make sure the flanges of the bolts are contacting the
bracket surface.
(b) Make sure there is no clearance between the
A cylinder block and bracket as shown in the
A illustration. Then install the bolt labeled B.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) for bolt B
Engine Front
No Clearance
Bolt B
EM
Mounting Bracket
A113390E01
(c) Tighten the bolts labeled A and install the bolt

A
labeled C.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) for bolt A
24.5 N*m (250 kgf*cm, 18 ft.*lbf) for bolt
C
A
C
A
A113788E01
15. INSTALL EXHAUST MANIFOLD (w/o Secondary Air

Injection System)
(a) Install a new gasket and the exhaust manifold with
the 6 nuts.
A099195E01
16. INSTALL EXHAUST MANIFOLD (w/ Secondary Air

Injection System)
(a) Install a new gasket and the exhaust manifold with
the 8 nuts.
G037180E01
17. INSTALL AIR SWITCHING VALVE (w/ Secondary Air

Injection System)
(a) Install the air switching valve with 2 new nuts.
G037183E01
(b) Install 2 new gaskets and the intake pipe insulator

with 4 new nuts.
(c) Check that the nuts are tightened to the torque
specification.
NOTICE:
EM Tightening the nuts only once is not enough to
tighten them to the torque specification.
G037182E01
18. INSTALL EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the heat insulator with the 5 bolts.
G037181E01
19. INSTALL EXHAUST MANIFOLD HEAT INSULATOR

(w/o Secondary Air Injection System)
(a) Install the heat insulator with the 5 bolts.
A099875E01
20. INSTALL INTAKE MANIFOLD

(a) Install a new gasket and the intake manifold with the
5 bolts and 2 nuts.
(b) Connect the crankshaft position sensor to the
clamp.
21. INSTALL INJECTOR (See page FU-17)
22. INSTALL FUEL DELIVERY PIPE (See page FU-17)
G036020E01
23. INSTALL THROTTLE BODY (See page ES-377)
24. INSTALL ENGINE WIRE

(a) Connect the wire harness (engine ground wire) to
INCORRECT
the engine rear side with the 2 bolts so that it is
within the specified range shown in the illustration.
(b) Connect the oil pressure sensor connector.
60°
(c) Connect the noise filter connector.
45°
(d) Connect the camshaft position sensor connector.
Do not Overlap (e) Connect the 4 injector connectors.
G038850E02 (f) Connect the crankshaft position sensor connector.
(g) Connect the oil control valve connector.
(h) Connect the purge VSV connector.
(i) Connect the throttle body connector.
(j) Connect the engine coolant temperature sensor
connector.
(k) Connect the knock sensor connector.
(l) Connect the wire harness to the clamps.
EM
25. INSTALL GENERATOR (See page CH-15)
26. INSTALL VENTILATION PIPE
(a) Install the ventilation pipe with the bolt.
27. INSTALL SPARK PLUG
28. INSTALL IGNITION COIL
(a) Install the ignition coil with the bolt.
(b) Connect the 4 ignition coil connectors.
29. REMOVE ENGINE FROM ENGINE STAND
30. INSTALL ENGINE ASSEMBLY
(a) Attach the engine sling device and chain block to
Lower
the engine hangers.
(b) Slowly lower the engine assembly into the engine
compartment.
A117894E02
(c) Install the engine mounting brackets with the 4 bolts

and 4 nuts.
31. INSTALL REAR END PLATE
(a) Install the end plate with the 2 bolts.
G037190E01
32. INSTALL FLYWHEEL (for Manual Transmission)

Adhesive HINT:
• The mounting bolts are tightened in 2 progressive
steps.
• If any of the mounting bolts is broken or deformed,
replace it.
(a) Apply adhesive to 2 or 3 threads of the mounting
bolt end.
Adhesive:
A004869E02 Toyota Genuine Adhesive, Three Bond 1324, or
equivalent
(b) Install the flywheel.
(c) Fix the crankshaft in place with SST.
SST 09213-54015 (91651-60855), 09330-00021
EM
SST
A099210E02
(d) Install and uniformly tighten the 10 mounting bolts in

7 several passes in the order shown in the illustration.
4 Torque: 26.5 N*m (270 kgf*cm, 20 ft.*lbf)
2
10 If any of the mounting bolts does not meet the
torque specification, replace the mounting bolts.
5
6
9 1
3 8 G035062E02
(e) Mark the mounting bolts with paint.

(f) Retighten the mounting bolts by 90° in the numerical
90°
order shown in the illustration.
: Paint Mark G035063E01

(g) Check that the painted marks are now at a 90°

7 angle to the position.
4
2
10
5
6
9 1
3 8 G035062E02
33. INSTALL DRIVE PLATE (for Automatic Transmission)

Adhesive HINT:
• The mounting bolts are tightened in 2 progressive
steps.
• If any of the mounting bolts is broken or deformed,
replace it.
(a) Apply adhesive to 2 or 3 threads of the mounting EM
bolt end.
Adhesive:
A004869E02 Toyota Genuine Adhesive, Three Bond 1324, or
equivalent
(b) Install the drive plate.
(c) Fix the crankshaft in place with SST.
SST 09213-54015 (91651-60855), 09330-00021
SST
A099210E02
(d) Install and uniformly tighten the 10 mounting bolts in

several passes in the order shown in the illustration.
If any of the mounting bolts does not meet the
2 7 torque specification, replace the mounting bolts.
5 4
34. INSTALL CLUTCH DISC (for Manual Transmission)
9 10 (See page CL-39)
3 6
1 35. INSTALL CLUTCH COVER (for Manual Transmission)
8
A099868E04 (See page CL-39)
36. INSTALL MANUAL TRANSMISSION UNIT
(a) Install the manual transmission unit from the
vehicle.
If necessary, refer to the corresponding manual
following the installation procedures for the manual
37. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) Install the automatic transmission assembly from
the vehicle.
If necessary, refer to the corresponding automatic
following the installation procedures for the
automatic transmission assembly.
38. INSTALL STARTER (See page ST-25)
39. INSTALL REAR PROPELLER SHAFT (for 4WD) (See
page PR-26)
40. INSTALL PROPELLER SHAFT WITH CENTER
BEARING ASSEMBLY (for 2WD) (See page PR-19)
41. INSTALL FRONT PROPELLER SHAFT (for 4WD) (See
page PR-7)
EM 42. INSTALL FRONT EXHAUST PIPE (See page EX-4)

43. INSTALL HOOD
44. INSTALL COOLER COMPRESSOR (w/ Air
2
Conditioning System)
(a) Loosely install the bolt labeled A to install the
compressor.
4 (b) Install the compressor completely by tightening the
1
4 bolts in the order shown in the illustration.
A Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
NOTICE:
3
In order to prevent misalignment, which causes
A099200E01 belt rattle, tightening of the bolts must be
performed in the order shown.
(c) Connect the suction hose with the 2 bolts.
(d) Connect the compressor connector.
45. INSTALL OIL DIPSTICK GUIDE
(a) Install a new O-ring and the dipstick guide with the
bolt.
46. INSTALL OIL DIPSTICK
A099198E01
47. INSTALL VANE PUMP

(a) Install the vane pump with the 2 bolts.
(b) Connect the PS oil pressure switch connector.
A099199E01
48. CONNECT ENGINE WIRE

(a) Connect the 2 engine room junction block
connectors and connect the wire clamp.
(b) Connect the cable to the engine room junction block
with the nut.
(c) Install the engine room relay block cover (upper).
(d) Install the engine room relay block cover (side).
(e) Connect the ground wire with the bolt and clamp.
G038831E01 Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf)
(f) Connect the ground wire to the frame with the bolt
45° 45° so that it is within the range shown in the illustration.
(g) w/ Secondary air injection system:
Connect the injection driver connector.
(h) Push the engine wire through the dash panel into
the cabin. The wire should be within the range EM
(i) Connect the sensor clamp with the bolt.
45°
A112963E01
(j) Connect the ECM connectors.

(1) Connect the 4 ECM connectors.
(2) Install the glove compartment door.
(k) Connect the wire clamp to the engine mounting
bracket front LH with the bolt.
49. CONNECT FUEL HOSE (See page FU-18)
A111959
50. CONNECT HOSE

(a) Connect the vacuum hose (for brake master
cylinder).
(b) For unleaded gasoline specification vehicle:
Connect the hose to the purge VSV.
51. INSTALL RADIATOR (See page CO-28)
52. INSTALL FAN PULLEY
53. INSTALL FAN SHROUD (See page CO-28)
G039232E01
54. INSTALL DRIVE BELT (See page EM-9)

55. CONNECT RADIATOR OUTLET HOSE

56. CONNECT RADIATOR INLET HOSE
57. INSTALL RADIATOR GRILLE (See page ET-41)
58. INSTALL INTAKE AIR CONNECTOR AND AIR
CLEANER ASSEMBLY
(a) Install the air cleaner and intake air connector
assembly with the 4 bolts, and tighten the hose
clamp.
Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) for air
cleaner
8.0 N*m (82 kgf*cm, 71 in.*lbf) for intake
air connector
A099871E01 5.0 N*m (51 kgf*cm, 44 in.*lbf) for hose
clamp
(b) Connect the MAF meter connector and harness
EM clamps.
(c) Connect the No. 2 ventilation hose.
(d) Connect the vacuum hose.
59. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
60. ADD ENGINE OIL (See page LU-4)
61. ADD ENGINE COOLANT (See page CO-2)
62. CHECK FOR FUEL LEAKS (See page FU-19)
63. CHECK FOR OIL LEAKS
(a) Start the engine, and check that there are no oil
leaks after performing maintenance.
64. CHECK FOR COOLANT LEAKS (See page CO-3)
65. INSTALL NO. 1 ENGINE UNDER COVER
(a) Install the No. 1 under cover with the 4 bolts.
(b) Install the side cover RH with the 2 clips and 2 bolts.
(c) Install the side cover LH with the 2 clips and 2 bolts.
66. INSPECT IGNITION TIMING (See page EM-1)
67. CHECK IDLE SPEED (See page EM-3)
68. CHECK CO/HC (See page EM-5)
69. CHECK FUNCTION OF THROTTLE BODY (See page
ES-377)
70. PERFORM INITIALIZATION
(a) Perform initialization (see page IN-18).
NOTICE:
Certain systems need to be initialized after
disconnecting and reconnecting the cable from
the negative (-) battery terminal.
2TR-FE ENGINE MECHANICAL – ENGINE UNIT EM–61
ENGINE UNIT
ENGINE
COMPONENTS
9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf)
OIL FILLER CAP

x8
5.0 (51, 44 in.*lbf)
9.0 (92, 80 in.*lbf)
x 11
VENTILATION VALVE
CYLINDER HEAD COVER
EM
NO. 2 CYLINDER HEAD COVER GASKET CYLINDER HEAD COVER
GASKET
CAMSHAFT POSITION
SENSOR
8.5 (87, 75 in.*lbf)
CAMSHAFT TIMING
OIL CONTROL
WATER PUMP GASKET VALVE
WATER PUMP
8.0 (82, 71 in.*lbf)

26 (265, 19)
x8
13 (133, 10)
CRANKSHAFT POSITION
260 (2651, 192) CRANKSHAFT PULLEY SENSOR
8.5 (87, 75 in.*lbf)
Non-reusable part Precoated part

A112911E18
EM–62 2TR-FE ENGINE MECHANICAL – ENGINE UNIT
24.5 (250, 18)

OIL FILTER BRACKET UNION
24.5 (250, 18) 13 (133, 10)

OIL FILTER BRACKET 49 (500, 36)
NO. 1 TAPER SCREW PLUG
25 (255, 18)
25 (255, 18)
GASKET x6
49 (500, 36)
EM GASKET ENGINE REAR

OIL SEAL
43 (438, 32) O-RING
OIL FILTER UNION
OIL BRACKET
GASKET ENGINE REAR OIL
SEAL RETAINER
17.2 (175, 13)

OIL FILTER
O-RING
NO. 1 OIL PAN
x7 26 (265, 19)
x 11
GASKET
26 (265, 19)
OIL STRAINER
20 (204, 15)
20 (204, 15)
9.0 (92, 80 in.*lbf)

NO. 2 OIL PAN
x 20
9.0 (92, 80 in.*lbf)
37.5 (382, 28)

OIL PAN DRAIN PLUG
Non-reusable part
GASKET
MP grease
A112912E09
TIMING CHAIN COVER

O-RING
x8
60 (612, 44) O-RING
x7
21 (214, 15)
O-RING
16.6 (169, 12)
TIMING CHAIN 21 (214, 15)
COVER PLUG
21 (214, 15)
TIMING CHAIN
COVER OIL SEAL
EM
CHAIN TENSIONER GASKET
10 (102, 7)
10 (102, 7)
TIMING CHAIN GUIDE
O-RING
TIMING CHAIN
NO. 1 TIMING CHAIN

TENSIONER
21 (214, 15)
21 (214, 15)
CHAIN TENSIONER 21 (214, 15)
SLIPPER
21 (214, 15)
CRANKSHAFT TIMING SPROCKET
Non-reusable part CHAIN VIBRATION DAMPER

Precoated part
A112913E08
15.5 (158, 11)
x4
12 (122, 9)
OIL DELIVERY PIPE
O-RING
15.5 (158, 11)
15.5 (158, 11) x 12

EM
NO. 2 CAMSHAFT
CAMSHAFT TIMING SPROCKET
78 (795, 58) NO. 1 CAMSHAFT
VALVE ROCKER ARM
x8
x8
CAMSHAFT TIMING GEAR
Non-reusable part
A112914E04
VALVE STEM CAP VALVE STEM CAP
VALVE LASH
VALVE LASH ADJUSTER
ADJUSTER
VALVE SPRING RETAINER LOCK

VALVE SPRING RETAINER
LOCK
RETAINER
RETAINER
COMPRESSION SPRING
COMPRESSION SPRING
VALVE STEM OIL SEAL

EM
VALVE STEM OIL SEAL
VALVE SPRING SEAT

VALVE SPRING SEAT
EXHAUST VALVE GUIDE BUSH
INTAKE VALVE
GUIDE BUSH
EXHAUST VALVE
INTAKE VALVE
44 (449, 32)
NO. 1 STRAIGHT SCREW PLUG
GASKET
GASKET
140 (1428, 103)

NO. 2 STRAIGHT
SCREW PLUG
OIL CONTROL VALVE FILTER
N*m (kgf*cm, ft.*lbf) : Specified torque 30 (306, 22)
Non-reusable part GASKET
A113384E08
1st: 39 (398, 29)

2nd: Turn 90°
3rd: Turn 90°
x 10
CYLINDER HEAD SET BOLT

PLATE WASHER
CYLINDER HEAD
EM
CYLINDER HEAD GASKET
NO. 2 CHAIN VIBRATION DAMPER BALANCE SHAFT DRIVE GEAR
27 (270, 20)
BALANCE SHAFT
DRIVE GEAR SHAFT
NO. 2 CHAIN 25 (255, 18)
NO. 4 CHAIN VIBRATION DAMPER

18 (184, 13)
NO. 2 CRANKSHAFT CRANKSHAFT

TIMING SPROCKET PULLEY SET KEY
18 (184, 13)
NO. 2 CHAIN TENSIONER
NO. 3 CHAIN VIBRATION DAMPER
18 (184, 13)
Non-reusable part
A112915E09
NO. 1 COMPRESSION RING
NO. 2 COMPRESSION RING
OIL RING EXPANDER

OIL RING
OIL RING RAIL
PISTON PIN SNAP RING

PISTON
SNAP RING
13 (130, 9)
CYLINDER BLOCK WATER CONNECTING ROD

DRAIN COCK PLUG
EM
CONNECTING ROD BEARING
19.6 (200, 15)

CONNECTING ROD CAP
WATER DRAIN COCK NO. 1 BALANCE SHAFT
THRUST PLATE
1st: 24.5 (250, 18)
2nd: Turn 90°
18 (184, 13)
36 (367, 27)
NO. 1 BALANCE SHAFT
SLIDING KEY BALANCE SHAFT THRUST SPACER
NO. 1 BALANCE SHAFT DRIVEN GEAR

NO. 2 BALANCE SHAFT
18 (184, 13)
OIL NOZZLE
x4
CRANKSHAFT UPPER
36 (367, 27) THRUST WASHER 7.0 (71, 62 in.*lbf)
NO. 2 BALANCE SHAFT CRANKSHAFT

CRANKSHAFT
DRIVEN GEAR UPPER BEARING
CRANKSHAFT LOWER
THRUST WASHER
NO. 2 BALANCE SHAFT THRUST PLATE
CRANKSHAFT LOWER BEARING
N*m (kgf*cm, ft.*lbf) : Specified torque CRANKSHAFT BEARING CAP
Non-reusable part 1st: 39 (398, 29)

2nd: Turn 90°
Precoated part
A112916E09
DISASSEMBLY
1. REMOVE OIL FILLER CAP
(a) Remove the oil filler cap from the head cover.
2. REMOVE VENTILATION VALVE
(a) Remove the ventilation valve from the head cover.
G037256E01
3. REMOVE CYLINDER HEAD COVER

(a) Remove the 19 bolts, 2 nuts, cover and 2 gaskets.
EM
G035202E05
4. REMOVE CRANKSHAFT PULLEY

13° 47’ Timing Mark (a) Turn the crankshaft pulley, and align its groove with
(b) Check that the timing marks of the camshaft timing
gear and sprocket are aligned with the timing marks
of the No. 1 bearing cap, as shown in the illustration.
Timing Mark
Timing Mark
Groove
A097861E04
(c) Using SST, hold the crankshaft pulley and remove

the pulley set bolt.
SST SST 09213-54015 (91651-60855), 09330-00021
Loosen
Fix
A099211E01
(d) Using the pulley set bolt and SST, remove the
Fix pulley.
SST 09950-50013 (09951-05010, 09952-05010,
09953-05010, 09954-05021)
SST EM
G035121E01
5. REMOVE NO. 2 OIL PAN

(a) Remove the drain plug and gasket.
(b) Remove the 20 bolts and 2 nuts.
A099214E02
(c) Insert the blade of oil pan seal cutter between the oil
pans. Cut through the applied sealer and remove
the oil pan.
NOTICE:
Be careful not to damage the contact surface of
the oil pans.
6. REMOVE OIL STRAINER
(a) Remove the bolt, 2 nuts, oil strainer and gasket.
A099215
7. REMOVE NO. 1 OIL PAN

(a) Remove the 16 bolts and 2 nuts.
A099220E02
(b) Remove the oil pan by prying between the oil pan
and cylinder block with a screwdriver.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Protective Be careful not to damage the contact surface of
Tape the cylinder block and oil pan.
G036411E01
(c) Remove the O-ring.
EM
G037271E01
8. REMOVE TIMING CHAIN COVER

(a) Remove the 19 bolts and 2 nuts as shown in the
illustration.
A088529E01
(b) Remove the timing chain cover by prying between

Protective Tape
the timing chain cover and cylinder head or cylinder
block with a screwdriver.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Be careful not to damage the contact surface of
the cylinder head, cylinder block and timing
chain cover.
Protective Tape
G037273E01
(c) Remove the 3 O-rings.
G037274E01
(d) Using a 10 mm socket hexagon wrench, remove the

EM
G036021E01
9. REMOVE WATER PUMP

(a) Remove the 8 bolts, water pump and gasket.
10. REMOVE TIMING CHAIN COVER OIL SEAL (See
page EM-103)
11. REMOVE OIL PUMP RELIEF VALVE (See page LU-29)
A087223E01
12. REMOVE TIMING CHAIN GUIDE

(a) Remove the 2 bolts, timing chain guide and O-ring.
O-Ring
G037278E02
13. REMOVE NO. 1 TIMING CHAIN TENSIONER

NOTICE:
Upward
Plunger • When the chain tensioner is removed, do not
rotate the crankshaft.
• When the chain is removed and the camshaft
needs to be rotated, rotate the crankshaft 90° to
the right.
(a) Move the stopper plate upward to release the lock,
Stopper Plate and push the plunger deep into the tensioner.
Downward
A097899E02
(b) Move the stopper plate downward to set the lock,

and insert a hexagon wrench into the stopper plate's
hole.
(c) Remove the bolt, nut, chain tensioner and gasket.
G039810E01
14. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and tensioner slipper.
EM
G037281E01
15. REMOVE NO. 1 VIBRATION DAMPER

(a) Remove the bolt, nut and vibration damper.
16. REMOVE TIMING CHAIN
G037280E01
17. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the
crankshaft.
18. REMOVE CRANKSHAFT POSITION SENSOR PLATE
G037282E01
19. REMOVE CAMSHAFT

3 12 20 16 8 (a) Uniformly loosen the 21 bearing cap bolts in the
several passes in the order shown in the illustration.
5 (b) Remove the 9 bearing caps, oil delivery pipe, O-ring
13
and 2 camshafts.
21 17 9
11 15 7
NOTICE:
1 19
4 • Place the camshaft on a flat surface, maintain
this position and loosen the bolts uniformly.
2 • Do not pry the camshaft with a tool by
10 18 14 6
A097866E01 applying excessive force to it.
• Do not damage the reception part of the
exhaust on the cylinder head side.
(c) Remove the oil delivery pipe and O-ring from the
bearing caps.
O-Ring
EM
G037284E04
(d) Remove the 9 bearing caps.

(e) Remove the 2 camshafts.
G037285E01
20. REMOVE CAMSHAFT TIMING SPROCKET

(a) Fix the camshaft with a vise, and then remove the
sprocket bolt and camshaft timing sprocket.
NOTICE:
Be careful not to damage the camshaft.
A086867E01
21. REMOVE CAMSHAFT TIMING GEAR

Do Not Remove Straight Pin (a) Remove the flange bolt of the camshaft timing gear.
NOTICE:
• Be sure not to remove the other 3 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
Flange Bolt
A097871E01
22. REMOVE CYLINDER HEAD

3 5 10 8 2
(a) Using a 10 mm bi-hexagon wrench, uniformly
loosen the 10 bolts in the sequence shown in the
illustration. Remove the 10 cylinder head bolts and
plate washers.
NOTICE:
EM • Be careful not to drop washers into the
cylinder head.
1 7 9 6 4 • Head warpage or cracking could result from
A097901E01 removing bolts in an incorrect order.
(b) Remove the cylinder head and gasket.
23. REMOVE NO. 2 CHAIN VIBRATION DAMPER
Upward (a) Move the stopper plate downward to release the
Plunger lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate upward to set the lock, and
insert a hexagon wrench into the stopper plate's
Downward hole.
Stopper Plate
G037294E01
(c) Remove the bolt and chain vibration damper.
G037295E01

(a) Remove the 2 bolts and chain vibration damper.
G037296E01
25. REMOVE NO. 2 CHAIN TENSIONER

(a) Remove the hexagon wrench from the tensioner.
(b) Remove the nut and chain tensioner.
G037297E01
26. REMOVE NO. 2 CHAIN

(a) Remove the bolt, balance shaft drive gear shaft and
balance shaft drive gear.
(b) Remove the No. 2 crankshaft timing sprocket and
chain.
EM
G037298E01

(a) Remove the 2 bolts and No. 4 vibration damper.
G037299E01
28. REMOVE CRANKSHAFT PULLEY SET KEY

(a) Remove the 2 pulley set keys from the crankshaft.
G037300E01
29. REMOVE OIL FILTER

(a) Using SST, remove the oil filter.
SST 09228-07501
SST
A097902E01
30. REMOVE OIL FILTER UNION

(a) Using a 27 mm socket wrench, remove the oil filter
union.
G037462E03
31. REMOVE OIL FILTER BRACKET

(a) Remove the 2 screw plugs and 2 gaskets from the
oil filter bracket.
Screw Plug (b) Remove the 2 bolts, nut and oil filter bracket.
Screw Plug
EM
G037304E03
(c) Remove the gasket and O-ring.
O-Ring
Oil Filter Bracket Gasket
G037305E04
(d) Using a 14 mm hexagon wrench, remove the oil

filter bracket union.
A101977E01
32. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.
(b) Using a screwdriver with its tip taped, pry out the oil
seal retainer.
33. REMOVE VALVE ROCKER ARM
HINT:
Protective Each rocker arm must be reinstalled to its original
Tape
location.
A097903E01 34. REMOVE VALVE STEM CAP
HINT:
Each valve stem cap must be reinstalled to its original
location.
35. REMOVE VALVE LASH ADJUSTER
HINT:
Each lash adjuster must be reinstalled to its original
location. EM
36. REMOVE INTAKE VALVE
(a) Using SST and wooden blocks, compress the
SST compression spring and remove the valve retainer
locks.
SST 09202-70020 (09202-00010)
A097931E01
(b) Remove the retainer, compression spring, valve,

valve spring and spring seat.
HINT:
Each intake valve must be reinstalled to its original
location.
A121457E01
37. REMOVE EXHAUST VALVE

SST
(a) Using SST and wooden blocks, compress the
compression spring and remove the valve retainer
locks.
A097932E01
(b) Remove the retainer, compression spring, valve,

valve spring and spring seat.
HINT:
Each exhaust valve must be reinstalled to its
original location.
A121461
38. REMOVE VALVE STEM OIL SEAL

(a) Using needle-nose pliers, remove the oil seal.
EM
G037403E01
39. REMOVE OIL CONTROL VALVE FILTER

(a) Using an 8 mm hexagon wrench, remove the screw
plug.
(b) Remove the oil control valve filter and gasket.
G037445E01
40. REMOVE NO. 1 STRAIGHT SCREW PLUG

for Upper Side: (a) Using a 10 mm hexagon wrench, remove the 3
screw plugs.
No. 1 Screw Plug

A097933E01
41. REMOVE NO. 2 STRAIGHT SCREW PLUG

for Front Side: (a) Using a 9 mm hexagon wrench, remove the screw
plug.
No. 2 Screw Plug

A097934E01
42. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.35 mm (0.006 to 0.014 in.)
Maximum thrust clearance:
0.40 mm (0.016 in.)
If the thrust clearance is greater than the maximum,
replace the connecting rod assembly(s). If
G037344E01 necessary, replace the crankshaft.
43. INSPECT CONNECTING ROD OIL CLEARANCE

Front Mark
(a) Check that the front mark on the connecting rod and
cap are aligned to ensure the correct reassembly.
HINT:
The front mark on the connecting rods and caps are
for ensuring the correct reassembly.
EM
A097980E01
(b) Remove the 2 connecting rod cap bolts.

(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 to the connecting
rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and
G037345E01 scratches.
(f) Lay a strip of Plastigage on the crank pin.

Plastigage (g) Install the connecting rod cap.
NOTICE:
Do not turn the crankshaft.
(1) Match the numbered connecting rod cap with
the connecting rod.
(2) Align the pins of the connecting rod cap with
the pin holes of the connecting rod, and install
the connecting rod cap.
G037346E02
(3) Check that the front mark of the connecting rod

Front Mark cap is facing forward.
(h) Install the connecting rod cap bolts.
HINT:
• The connecting rod cap bolts are tightened in 2
progressive steps.
• If any connecting rod bolt is broken or deformed,
replace it.
(1) Apply a light coat of engine oil on the threads
G037347E01 and under the heads of the connecting rod cap
bolts.
(2) Install and alternately tighten the bolts of the

connecting rod cap in several passes.
If any one of the connecting rod cap bolts does
not meet the torque specification, replace the
cap bolts.
(3) Mark the front of the connecting rod cap bolts
Paint Mark
90° with paint.
(4) Retighten the connecting rod cap bolts 90° as
shown.
(5) Check that the painted mark is now at a 90°
angle to the front.
Engine Front (i) Remove the 2 bolts and connecting rod cap.
A099641E01
EM (j) Measure the Plastigage at its widest point.

Plastigage Standard oil clearance:
0.039 to 0.066 mm (0.0015 to 0.0026 in.)
If the crank pin or bearing is damaged, replace the
bearings. If necessary, replace the crankshaft.
HINT:
If replacing a bearing, replace it with one that has
the same number as its respective connecting rod
cap. Each bearing's standard thickness is indicated
by a 4, 5 or 6 mark on its surface.
Standard bearing center wall thickness
Mark Specified Condition
4 1.484 to 1.487 mm (0.0584 to 0.0585
in.)
5 1.488 to 1.490 mm (0.0586 to 0.0587
in.)
6 1.491 to 1.493 mm (0.0587 to 0.0588
in.)
(k) Completely remove the Plastigage.

4, 5 or 6 Mark
G039628E01
44. REMOVE PISTON WITH CONNECTING ROD

(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:
• Keep the bearing, connecting rod and cap
together.
Ridge Reamer • Arrange the piston and connecting rod
G035191E03 assemblies in the correct order.
45. INSPECT CRANKSHAFT THRUST CLEARANCE

while prying the crankshaft back and forth with a
screwdriver.
0.020 to 0.220 mm (0.0008 to 0.0087 in.)
0.30 mm (0.0118 in.)
G037352E01 replace the thrust washers as a set.
Thrust washer thickness:
2.440 to 2.490 mm (0.0961 to 0.0980 in.)
46. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Uniformly loosen the 10 bearing cap bolts in several
passes in the sequence shown in the illustration.
4 8 10 6 2
HINT:
• Keep the lower bearings and crankshaft bearing
caps together.
EM
• Arrange the thrust washers in the correct order.
3 7 9 5 1 (b) Clean each main journal and bearing.
(c) Check each main journal and bearing for pitting and
A097951E03 scratches.
If the journal or bearing is damaged, replace the
bearings. If necessary, grind or replace the
crankshaft.
(d) Place the crankshaft on the cylinder block.
(e) Lay a strip of Plastigage across each journal.
Plastigage
G037376E01
(f) Install the 5 crankshaft bearing caps in their proper

Engine Front
locations.
NOTICE:
Do not turn the crankshaft.
G037377E01
(g) Install the crankshaft bearing cap bolts.

HINT:
• The main bearing cap bolts are tightened in 2
7 3 1 5 9
progressive steps.
• If any of the main bearing cap bolts are broken or
deformed, replace as necessary.
(1) Install and uniformly tighten the 10 main
8 4 2 6 10 bearing cap bolts in the sequence shown in the
illustration.
A097951E01 Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
If any one of the main bearing cap bolts does
main bearing cap bolt.
(2) Mark the front of the bearing cap bolts with
Paint Mark
90° paint.
(3) Retighten the bearing cap bolts by 90° in the
EM numerical order above.
angle to the front.
Engine Front (h) Remove the 10 bolts and 5 crankshaft bearing caps.
A099641E01
(i) Measure the Plastigage at its widest point.

Plastigage Standard oil clearance
No. 3 journal 0.030 to 0.055 mm (0.0012 to 0.0022
in.)
Other journal 0.024 to 0.049 mm (0.0009 to 0.0019
in.)
Maximum oil clearance:

0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum,
replace the crankshaft bearings. If necessary,
replace the crankshaft.
HINT:
If replacing the cylinder block, the bearing standard
clearance will be 0.030 to 0.055 mm (0.0012 to
0.0022 in.).
HINT: EM
If replacing a bearing, first check the number on the
cylinder block for the bearing's respective journal.
Then replace the bearing with one that has the
No. 3 same number. Each bearing's standard thickness is
indicated by a 1, 2 or 3 mark on its surface.
Cylinder block main journal bore diameter
(Reference):
No. 1 No. 5
No. 2 No. 4
1 64.004 to 64.010 mm (2.5198 to
2.5201 in.)
2 64.011 to 64.016 mm (2.5201 to
2.5203 in.)
Mark 1, 2 or 3 3 64.017 to 64.022 mm (2.5203 to
2.5206 in.)
G039585E04
Standard bearing center wall thickness

(Reference)
1 1.987 to 1.990 mm (0.0782 to 0.0783
in.)
2 1.990 to 1.993 mm (0.0783 to 0.0785
in.)
3 1.993 to 1.996 mm (0.0785 to 0.0786
in.)
(j) Completely remove the Plastigage.

47. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
HINT:
Keep the upper crankshaft bearings and upper
thrust washers together with the cylinder block.
48. REMOVE PISTON WITH PIN

(a) Check fit between the piston and piston pin.
(1) 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.
G035197E02
(b) Remove the piston rings.

(1) Using a piston ring expander, remove the 2
compression rings.
(2) Remove the rail and expander by hand.
HINT:
Arrange the piston rings in the correct order
EM only.
A087190E01
(c) Disconnect the connecting rod from the piston.

(1) Using a small screwdriver, pry off the snap ring
from the piston.
Service Hole
G035729E01
(2) Gradually heat the piston to approximately 80

to 90°C (176 to 194°F).
A001178E02
(3) Using a brass bar and plastic-faced hammer,

lightly tap out the piston pin and remove the
connecting rod.
HINT:
• The piston and pin are a matched set.
• Arrange the pistons, pins, rings, connecting
rods and bearings in the correct order.
49. REMOVE CYLINDER BLOCK WATER DRAIN COCK
G036556E01
50. REMOVE OIL NOZZLE

(a) Using a 5 mm hexagon wrench, remove the oil
nozzle.
51. INSPECT BALANCE SHAFT THRUST CLEARANCE
while moving the balance shaft back and forth.
0.07 to 0.13 mm (0.0027 to 0.0051 in.)
0.20 mm (0.0079 in)
replace the balance shaft thrust washer. If
G037388E01 necessary, replace the balance shaft.
52. REMOVE NO. 1 BALANCE SHAFT

(a) Remove the bolt.
EM
G037389E01
(b) Remove the balance shaft from the cylinder block.

NOTICE:
When removing the balance shaft, make sure to
support the balance shaft with both hands and
avoid scratching the balance shaft bearing on
the cylinder block side.
G037390E01
53. REMOVE NO. 1 BALANCE SHAFT DRIVEN GEAR

B
C (a) Mount the head portion of the balance shaft in a
vise.
NOTICE:
Be careful not to damage the balance shaft.
A D (b) Remove the bolt.
(c) Remove the No. 1 balance shaft driven gear (A),
sliding key (B), No. 1 balance shaft thrust washer
(C) and balance shaft thrust spacer (D).
G037391E01
54. REMOVE NO. 2 BALANCE SHAFT

(a) Remove the 2 bolts.
G037392E01
(b) Remove the balance shaft from the cylinder block.

NOTICE:
When removing the balance shaft, make sure to
EM
G037393E01
55. REMOVE NO. 2 BALANCE SHAFT DRIVEN GEAR

B (a) Mount the head portion of the balance shaft in a
vise.
NOTICE:
A (b) Remove the bolt.
(c) Remove the No. 2 balance shaft driven gear (A) and
No. 2 balance shaft thrust washer (B).
G037394E01
INSPECTION
1. INSPECT OIL NOZZLE
(a) Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
2. INSPECT CHAIN
147 N (a) Pull the chain with a force of 147 N (15 kgf, 33 lbf)
as shown in the illustration.
(b) Using a vernier caliper, measure the length of 16
links.
Measuring Area Maximum chain elongation:
147.5 mm (5.807 in.)
If the elongation is greater than the maximum,
1 234 56 16 replace the chain.
A097900E03 NOTICE:
Make the same measurement pulling at 3 or
more places selected at random. Average the
measurements.
3. INSPECT NO. 2 CHAIN

147 N (a) Pull the chain with a force of 147 N (15 kgf, 33 lbf)
(b) Using a vernier caliper, measure the length of 16
links.
Measuring Area Maximum chain elongation:
123.6 mm (4.866 in.)
If the elongation is greater than the maximum,
1 234 56 16 replace the chain.
A097900E03 NOTICE:
Make the same measurement pulling at 3 or
more places selected at random. Average the
measurements.
4. INSPECT CAMSHAFT TIMING GEAR (VVT
CONTROLLER) (See page EM-18)
5. INSPECT NO. 1 CAMSHAFT (See page EM-19)
6. INSPECT NO. 2 CAMSHAFT (See page EM-20)
EM
7. INSPECT NO. 1 CHAIN TENSIONER
(a) Move the stopper plate upward to release the lock.
Plunger Push the plunger and check that it moves smoothly.
Stopper Plate
A097905E03
8. INSPECT NO. 2 CHAIN TENSIONER

Stopper Plate (a) Move the stopper plate downward to release the
Plunger lock.
Push the plunger and check that it moves smoothly.
G037464E02
9. INSPECT CAMSHAFT TIMING SPROCKET

(a) Measure the distance between the most worn out
sprocket tip and the beginning of the worn area
below the tip.
Minimum distance:
Worn Area 1.0 mm (0.039 in.)
If the distance is less than the minimum, replace the
sprocket.
HINT:
A097906E03 If the worn area is too small or difficult to distinguish
from a normal area, perform the steps below.
(b) Wrap the chain around the sprocket.
(c) Using a vernier caliper, measure the sprocket

diameter with the chain.
Minimum sprocket diameter (with chain):
113.8 mm (4.480 in.)
HINT:
The vernier caliper must contact the chain rollers for
the measurement.
If the diameter is less than the minimum, replace the
chain and sprocket.
10. INSPECT CAMSHAFT TIMING GEAR
timing gear tip and the beginning of the worn area
below the tip.
Minimum distance:
Worn Area 1.0 mm (0.039 in.)
If the distance is less than the minimum, replace the
EM timing gear.
HINT:
(b) Wrap the chain around the timing gear.
113.8 mm (4.480 in.)
HINT:
the measurement.
chain and timing gear.
11. INSPECT CRANKSHAFT TIMING SPROCKET
sprocket tip and the beginning of the worn area
below the tip.
Minimum distance:
1.0 mm (0.039 in.)
Worn Area If the distance is less than the minimum, replace the
sprocket.
HINT:
(b) Wrap the chain around the drive sprocket.
59.4 mm (2.358 in.)
HINT:
the measurement.
chain and sprocket.
12. INSPECT CHAIN TENSIONER SLIPPER

(a) Using a vernier caliper, measure the tensioner
2.0 mm slipper wear.
Maximum wear:
2.0 mm (0.079 in.)
If the wear is greater than the maximum, replace the
tensioner slipper.
A097909E02
13. INSPECT CHAIN VIBRATION DAMPER

(a) Using a vernier caliper, measure the vibration
2.0 mm damper wear.
Maximum wear:
2.0 mm (0.079 in.)
vibration damper. EM
A097910E02
14. INSPECT TIMING CHAIN GUIDE

(a) Using a vernier caliper, measure the chain guide
Wear wear.
Maximum wear:
0.5 mm (0.020 in.)
0.5 mm timing chain guide.
A097911E02
15. INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET

(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket
96.7 mm (3.807 in.)
HINT:
the measurement.
G038149E01 If the diameter is less than the minimum, replace the
chain and sprocket.
16. INSPECT BALANCE SHAFT DRIVE GEAR
(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket
75.9 mm (2.988 in.)
HINT:
the measurement.
G038148E01

chain and sprocket.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER
(a) Using a vernier caliper, measure the No. 2 vibration
damper wear.
Maximum wear:
Wear 1.0 mm (0.039 in.)
vibration damper.
G037311E02

damper wear.
EM
Wear
Maximum wear:
1.0 mm (0.039 in.)
vibration damper.
A068741E02

Wear damper wear.
Maximum wear:
1.0 mm (0.039 in.)
vibration damper.
A068742E02
20. INSPECT CYLINDER HEAD SET BOLT

Measuring Point:
20 mm (0.79 in.) (a) Using a vernier caliper, measure the minimum
Elongated diameter of the elongated thread at the measuring
Thread point.
Standard outside diameter:
10.76 to 10.97 mm (0.4236 to 0.4319 in.)
Minimum outside diameter:
10.40 mm (0.4094 in.)
HINT:
G035889E02 If a visual check reveals no excessively thin areas,
check the center of the bolt (see illustration) and find
the area that has the lowest diameter.
cylinder head bolt.
21. INSPECT VALVE LASH ADJUSTER (See page EM-18)
22. INSPECT CYLINDER HEAD FOR FLATNESS

(a) Using a precision straightedge and feeler gauge,
measure the surface contacting the cylinder block
and manifold for warpage.
Maximum warpage:
0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace
the cylinder head.
for Cylinder Block Side:
EM
for Intake Manifold Side:
for Exhaust Manifold Side:
A097935E01
23. INSPECT CYLINDER HEAD FOR CRACKS

(a) Using a dye penetrant, check the intake ports,
exhaust ports and cylinder surface for cracks.
If cracked, replace the cylinder head.
A086993E01
24. INSPECT INTAKE VALVE SEAT

(a) Apply a light coat of Prussian blue (or white lead) to
the valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat according to
Width the following procedures.
(1) If blue appears 360° around the valve face, the
valve face is concentric. If not, replace the
valve.
A099448E01
(2) If blue appears 360° around the valve seat, the

guide and valve face are concentric. If not,
resurface the valve seat.
(3) Check that the valve seat contact is in the
middle of the valve face with the width between
1.0 to 1.4 mm (0.039 to 0.055 in.).
25. INSPECT EXHAUST VALVE SEAT
the valve face.
(c) Check the valve face and valve seat according to
Width the following procedures.
(1) If blue appears 360° around the valve face, the
valve.
A099449E01 (2) If blue appears 360° around the valve seat, the
EM guide and valve face are concentric. If not,
1.0 to 1.4 mm (0.039 to 0.055 in.).
26. INSPECT CAMSHAFT THRUST CLEARANCE
while moving the camshaft back and forth.
0.10 to 0.24 mm (0.004 to 0.009 in.)
0.26 mm (0.010 in.)
replace the cylinder head. If the thrust surface is
A086998E01 damaged, replace the camshaft.
27. INSPECT CAMSHAFT OIL CLEARANCE

Plastigage (a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the
camshaft journals.
(d) Install the bearing caps (see page EM-130).
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
A086999E02
(f) Measure the Plastigage at its widest point.

Standard oil clearance
No. 1 journal 0.035 to 0.072 mm
(0.0014 to 0.0029 in.)
Other journal 0.025 to 0.062 mm
(0.0010 to 0.0028 in.)

A087000E01
0.08 mm (0.0031 in.)
If the oil clearance is greater than the maximum,

replace the camshaft. If necessary, replace the
cylinder head.
(g) Completely remove the Plastigage.
28. INSPECT COMPRESSION SPRING
(a) Using a vernier caliper, measure the free length of
the inner compression spring.
Standard free length:
48.53 mm (1.9106 in.)
If the free length is not as specified, replace the
spring.
A051437E01
(b) Using a steel square, measure the deviation of the

Deviation inner compression spring.
Maximum deviation:
EM
1.5 mm (0.059 in.)
Maximum angle (reference):
2°
If the deviation is greater than the maximum,
replace the spring.
A062784E01
29. INSPECT INTAKE VALVE

(a) Using a vernier caliper, measure the valve's overall
length.
Standard overall length:
Overall Length 106.26 mm (4.1835 in.)
Minimum overall length:
105.96 mm (4.1716 in.)
If the overall length is less than the minimum,
replace the valve.
EM02534E01
(b) Using a micrometer, measure the diameter of the

valve stem.
Standard valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
A087001E01
(c) Using a vernier caliper, measure the valve head

margin thickness.
Standard margin thickness:
1.05 to 1.45 mm (0.0413 to 0.0571 in.)
Minimum margin thickness:
0.50 mm (0.0197 in.)
Margin Thickness If the margin thickness is less than the minimum,
replace the valve.
A099452E01
30. INSPECT EXHAUST VALVE

(a) Using a vernier caliper, measure the valve's overall
length.
Standard overall length:
Overall Length 106.74 mm (4.2024 in.)
Minimum overall length:
EM 106.44 mm (4.1905 in.)
If the overall length is less than the minimum,
replace the valve.
EM02534E01
(b) Using a micrometer, measure the diameter of the

valve stem.
Standard valve stem diameter:
5.465 to 5.480 mm (0.2151 to 0.2157 in.)
A087003E01
(c) Using a vernier caliper, measure the valve head

margin thickness.
Standard margin thickness:
1.2 to 1.6 mm (0.0472 to 0.0630 in.)
Minimum margin thickness:
0.50 mm (0.0197 in.)
Margin Thickness If the margin thickness is less than the minimum,
replace the valve.
A099453E01
31. INSPECT INTAKE VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the inside diameter
of the guide bush.
Bush inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement
from the guide bush inside diameter measurement.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 in.)
A087005E01 Maximum oil clearance:
0.08 mm (0.0032 in.)
If the clearance is greater than the maximum,

replace the valve and guide bush.
32. INSPECT EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the inside diameter
of the guide bush.
Standard bush inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement
from the guide bush inside diameter measurement.
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
G035204E01 Maximum oil clearance:
0.10 mm (0.0039 in.)
If the clearance is greater than the maximum,
replace the valve and guide bush.
33. INSPECT NO. 1 BALANCE SHAFT
B
(a) Inspect the diameter of the journal. EM
(1) Using a micrometer, measure the diameter of
A the balance shaft main journals.
Standard main journal diameter
A 37.969 to 37.985 mm (1.4948 to
1.4955 in.)
B 37.449 to 37.465 mm (1.4744 to
G037395E01 1.4750 in.)
(b) Inspect the diameter of bearing.

B (1) Using a cylinder gauge, measure the inside
A diameter of the balance shaft bearings.
Standard bearing inside diameter
A 38.025 to 38.045 mm (1.4970 to
1.4978 in.)
B 37.525 to 37.545 mm (1.4774 to
1.4781 in.)
G037397E01
(c) Inspect the oil clearance.
(1) Subtract the balance shaft main journal
diameter measurement from the balance shaft
bearing inside diameter measurement.
A 0.040 to 0.076 mm (0.0016 to 0.0030
in.)
B 0.060 to 0.096 mm (0.0024 to 0.0038
in.)

0.15 mm (0.0059 in.)
If the oil clearance is greater than the
maximum, replace the cylinder block and
balance shaft.
34. INSPECT NO. 2 BALANCE SHAFT

(a) Inspect the diameter of the journal.
B (1) Using a micrometer, measure the diameter of
the balance shaft main journals.
Standard main journal diameter
A
A 37.969 to 37.985 mm (1.4948 to
1.4955 in.)
B 37.449 to 37.465 mm (1.4744 to
G037396E01 1.4750 in.)
(b) Inspect the diameter of the bearing.

B (1) Using a cylinder gauge, measure the inside
A diameter of the balance shaft bearings.
Standard bearing inside diameter
EM A 38.025 to 38.045 mm (1.4970 to

1.4978 in.)
B 37.525 to 37.545 mm (1.4774 to
1.4781 in.)
G037398E01
(c) Inspect the oil clearance.
(1) Subtract the balance shaft main journal
diameter measurement from the balance shaft
bearing inside diameter measurement.
A 0.040 to 0.076 mm (0.0016 to 0.0030
in.)
B 0.060 to 0.096 mm (0.0024 to 0.0038
in.)

0.15 mm (0.0059 in.)
maximum, replace the cylinder block and
balance shaft.
35. INSPECT CYLINDER BLOCK

(a) Inspect for flatness.
(1) Using a precision straightedge and feeler
gauge, measure the surface contacting the
cylinder head gasket for warpage.
Maximum warpage:
0.05 mm (0.0020 in.)
If the warpage is greater than the maximum,
replace the cylinder block.
EM
G037356E01
(b) Visually check the cylinder for vertical scratches.

If deep scratches are present, rebore all the 4
cylinders. If necessary, replace the cylinder block.
G035190E01
(c) Inspect the cylinder bore diameter.

(1) Using a cylinder gauge, measure the cylinder
bore diameter at position A in the thrust and
axial directions.
Standard diameter:
94.990 to 95.003 mm (3.7398 to 3.7403 in.)
If the diameter is greater than the maximum,
rebore all the 4 cylinders. If necessary, replace
the cylinder block.
Thrust Direction
Front
Axial Direction
70 mm
(2.76 in.)
G037358E01
(d) Inspect the cylinder ridge.

(1) If the wear is less than 0.2 mm (0.008 in.),
using a ridge reamer, grind the top of the
cylinder.
Ridge Reamer
G035191E04
36. INSPECT PISTON WITH PIN

(a) Inspect the piston oil clearance.
(1) Using a micrometer, measure the piston
diameter at right angles to the piston center
line, the indicated distance from the piston end.
Standard distance:
EM 13.8 mm (0.543 in.)
Standard piston diameter
Distance: 13.8 mm
A097953E04
Standard side 94.940 to 94.950 mm (3.7378 to
3.7382 in.)
O/S 0.50 95.440 to 95.450 mm (3.7575 to
3.7579 in.)
(2) Measure the cylinder bore diameter in the

thrust directions.
(3) Subtract the piston diameter measurement
from the cylinder bore diameter measurement.
0.019 to 0.052 mm (0.0007 to 0.0020 in.)
If the oil clearance is greater than the standard,
replace all the 4 pistons and rebore all the 4
cylinders. If necessary, replace the cylinder
block.
(b) Inspect the piston pin fit.
(1) At 60°C (140°F), check that the piston pin can
be pushed into the piston pin hole with your
thumb.
G035195E02
(c) Inspect the piston pin diameter.

Piston Size Mark A, B or C
HINT:
There are 3 piston pin sizes, which are indicated by
an A, B or C mark on its surface.
(1) Using a micrometer, measure the piston pin
diameter.
Front Mark Standard piston pin diameter
A 21.997 to 22.000 mm
(0.8660 to 0.8661 in.)
B 22.001 to 22.003 mm
(0.8662 to 0.8663 in.)
C 22.004 to 22.006 mm
(0.8663 to 0.8664 in.)
D 22.007 to 22.009 mm
(0.8664 to 0.8665 in.)
If the diameter is not as specified, replace the

piston pin and piston as a set.
EM
G035891E01
37. INSPECT PISTON RING SET

(a) Using a feeler gauge, measure the clearance
between a new piston ring and the wall of the ring
groove.
Standard ring groove clearance
No. 1 ring 0.020 to 0.075 mm (0.0008 to 0.0030
in.)
No. 2 ring 0.020 to 0.065 mm (0.0008 to 0.0026
A087192E01 in.)
Oil ring 0.020 to 0.070 mm (0.0008 to 0.0028
in.)
If the clearance is not as specified, replace the

piston.
(b) 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
beyond the bottom of the ring travel, 110 mm
(4.33 in.) from the top of the cylinder block.
110 mm
Piston Ring
A097954E01
(3) Using a feeler gauge, measure the end gap.

Standard end gap
No. 1 ring 0.22 to 0.34 mm (0.0087 to 0.0134 in.)
No. 2 ring 0.45 to 0.57 mm (0.0177 to 0.0224 in.)
Oil ring 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Maximum end gap

A050189E01
No. 1 ring 0.90 mm (0.0354 in.)
No. 2 ring 1.36 mm (0.0535 in.)
Oil ring 0.75 mm (0.0295 in.)
If the end gap is greater than the maximum,

replace the piston ring. If the end gap is greater
than the maximum, even with a new piston ring,
EM rebore all the 4 cylinders or replace the cylinder
block.
38. INSPECT CONNECTING ROD
(a) Using a rod aligner and feeler gauge, check the
connecting rod alignment.
(1) Check for bend.
Maximum bend:
0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum,
replace the connecting rod.
A054727E01
(2) Check for twist.

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum,
replace the connecting rod.
A054728E01
39. INSPECT PISTON PIN OIL CLEARANCE

(a) Inspect the piston pin oil clearance.
HINT:
There are 3 connecting rod bush sizes, which are
Connecting Rod Bush
Inside Diameter Mark indicated by an A, B or C mark on its surface.
A, B or C Front Mark (1) Using a caliper gauge, measure the inside
diameter of the connecting rod bush.
Standard bush inside diameter
A 22.005 to 22.008 mm (0.86633 to
0.86645 in.)
B 22.008 to 22.011 mm (0.86645 to
0.86657 in.)
C 22.011 to 22.014 mm (0.86657 to
0.86669 in.)
(2) Subtract the piston pin diameter measurement

from the bush inside diameter measurement. EM
0.001 to 0.007 mm (0.00004 to 0.00028 in.)
G035892E02
0.01 mm (0.00039 in.)
maximum, replace the connecting rod. If
necessary, replace the piston and piston pin as
a set.
40. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion
diameter of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter:
7.0 mm (0.276 in.)
Tension Portion If the diameter is less than the minimum, replace the
bolt.
A054729E03
41. INSPECT CRANKSHAFT

(a) Inspect for circle runout.
(1) Place the crankshaft on V-blocks.
0.03 mm (0.0012 in.)
Center Journal
maximum, replace the crankshaft.
A013859E01
(b) Inspect the main journals.

No. 1 No. 2 No. 3 No. 4 No. 5 (1) Using a micrometer, measure the diameter of
each main journal.
2.3620 in.)
Journal Diameter Except No. 3 journal 59.987 to 60.000 mm (2.3229 to
2.3622 in.)
If the diameter is not as specified, check the oil

clearance. If necessary, replace the crankshaft.
(2) Check each main journal for taper and out-of-
round as shown in the illustration.
Maximum taper and out-of-round:
G037369E01 0.005 mm (0.0002 in.)
If the taper and out-of-round is greater than the
EM maximum, replace the crankshaft.
(c) Inspect the crank pin.
(1) Using a micrometer, measure the diameter of
each crank pin.
Diameter:
52.989 to 53.002 mm (2.0862 to 2.0867 in.)
If the diameter is not as specified, check the oil
clearance (see "INSPECT CONNECTING
Crank Pin Diameter ROD OIL CLEARANCE" procedures). If
necessary, replace the crankshaft.
(2) Check each crank pin for taper and out-of-
round as shown in the illustration.
Maximum taper and out-of-round:
0.003 mm (0.0001 in.)
If the taper and out-of-round is greater than the
maximum, replace the crankshaft.
G037370E01
42. INSPECT CRANKSHAFT BEARING CAP SET BOLT

Measuring Point:
(a) Using a vernier caliper, measure the minimum
27 mm (1.06 in.)
diameter of the elongated thread at the measuring
Elongated
Thread
point.
Standard outside diameter:
10.76 to 10.97 mm (0.4236 to 0.4319 in.)
Minimum outside diameter:
10.66 mm (0.4197 in.)
G035889E03 crankshaft bearing cap bolt.
REPLACEMENT
1. REPLACE TIMING CHAIN COVER OIL SEAL
Protective (a) Place the timing chain cover on wooden blocks.
Tape (b) Using a screwdriver with its tip taped, pry out the oil
seal.
Wooden
Block
A097898E01
(c) Using SST and a hammer, tap in a new oil seal until
SST its surface is flush with the timing chain cover edge.
SST 09223-75010, 09950-70010 (09951-07150)
NOTICE:
• Keep the lip free from foreign matter.
• Do not tap the oil seal at an angle.
EM
SST
HINT:
When installing the crankshaft pulley, check the
shape of the pulley. The correct pulley has a groove
(See page EM-139).
(d) Apply a light coat of MP grease to a new oil seal lip.
A172563E01
2. REPLACE ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.
(b) Using a screwdriver with its tip taped and hammer,
tap out the oil seal.
Protective Tape
Wooden
Block
A097904E01
(c) Place the oil seal retainer on wooden blocks.

(d) Using SST and hammer, tap in the oil seal until its
SST
surface is flush with the oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07150)
SST NOTICE:
• Keep the lip free from foreign matter.
• Do not tap the oil seal at an angle.
G039580E01
3. REPLACE INTAKE VALVE GUIDE BUSH

(a) Heat the cylinder head to 80 to 100°C (176 to
212°F).
A087006E03
(b) Place the cylinder head on wooden blocks.

SST (c) Using SST and a hammer, tap out the guide bush.
SST 09201-01055, 09950-70010 (09951-07100)
EM
A097936E01
(d) Using a caliper gauge, measure the bush bore

diameter of the cylinder head.
Standard cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
(e) Select a new guide bush (STD or O/S 0.05).
Bush Bore Diameter Bush Size
10.285 to 10.306 mm (0.4049 to 0.4057 Use STD
in.)
10.335 to 10.356 mm (0.4069 to 0.4077 Use O/S 0.05
A087011E01 in.)
If the bush bore diameter of the cylinder head is

greater than 10.306 mm (0.4057 in.), machine the
bush bore to the dimension of 10.335 to 10.356 mm
(0.4069 to 0.4077 in.) to install a O/S 0.05 valve
guide bush.
greater than 10.356 mm (0.4077 in.), replace the
cylinder head.
(f) Heat the cylinder head to 80 to 100°C (176 to
212°F).
A087006E03
(g) Place the cylinder head on wooden blocks.

(h) Using SST and a hammer, tap in a new valve guide
SST bush to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Protrusion height:
9.8 to 10.2 mm (0.3858 to 0.4016 in.)
(i) Using a sharp 5.5 mm reamer, ream the valve guide
bush to obtain the standard specified clearance.
Wooden Block Standard oil clearance:
A097938E01 0.025 to 0.060 mm (0.0010 to 0.0023 in.)
4. REPLACE EXHAUST VALVE GUIDE BUSH

SST
(a) Heat the cylinder head to 80 to 100°C (176 to
212°F).
(b) Place the cylinder head on wooden blocks.
(c) Using SST and a hammer, tap out the guide bush.
SST 09201-01055, 09950-70010 (09951-07100)
EM
A097937E01
(d) Using a caliper gauge, measure the bush bore

diameter of the cylinder head.
Standard cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
(e) Select a new guide bush (STD or O/S 0.05).
Bush Bore Diameter Bush Size
10.285 to 10.306 mm (0.4049 to 0.4057 Use STD
in.)
10.335 to 10.356 mm (0.4069 to 0.4077 Use O/S 0.05
A087009E01 in.)

greater than 10.306 mm (0.4057 in.), machine the
bush bore to the dimension of 10.335 to 10.356 mm
(0.4069 to 0.4077 in.) to install a O/S 0.05 valve
guide bush.
greater than 10.356 mm (0.4077 in.), replace the
cylinder head.
(f) Heat the cylinder head to 80 to 100°C (176 to
212°F).
A087006E04
(g) Place the cylinder head on the wooden blocks.

SST
(h) Using SST and a hammer, tap in a new valve guide
bush to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Protrusion height:
7.6 to 8.0 mm (0.2992 to 0.3150 in.)
(i) Using a sharp 5.5 mm reamer, ream the valve guide
bush to obtain the standard specified clearance.
A097939E01 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
5. REPLACE CONNECTING ROD SMALL END BUSH

(a) Using SST and a press, press out the bush.
SST
SST 09222-30010
EM
A054717E04
(b) Align the oil holes of a new bush and the connecting
rod.
Oil Hole
A054732E03
(c) Using SST and a press, press in the bush.

SST 09222-30010
SST
A054717E05
(d) Using a pin hole grinder, hone the bush to obtain the
standard specified clearance between the bush and
piston pin.
(e) Check that the piston pin fits at normal room
temperature.
(1) Coat the piston pin with engine oil, and push it
into the connecting rod with your thumb.
A054733E01
REASSEMBLY
Adhesive
1. INSTALL TIGHT PLUG
(a) Apply adhesive around the tight plugs.
Adhesive:
1324 or equivalent
A058129E03
(b) Using SST and a hammer, tap in new tight plugs as

(1) Using SST, tap in the 8 tight plugs A and C.
SST SST 09950-60010 (09951-00300), 09950-
70010 (09951-07100, 09951-00350,
09951-00400)
(2) Using SST, tap in the tight plug B. EM
SST 09950-60010 (09951-00300), 09950-
70010 (09951-07100, 09951-00350,
G037381E01 09951-00400)
(3) Using SST, tap in the 3 tight plugs D.
SST 09950-60010 (09951-00300), 09950-
70010 (09951-07100, 09951-00350,
09951-00400)
Front Side Intake Side

B A
EM Rear Side
D
Exhaust Side
C
1.0 mm
(0.039 in.)
G037382E01
2. INSTALL STUD BOLT

(a) Using an E7 "TORX" socket wrench, install the stud
bolts B and D.
Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) for stud
bolt B and D
(b) Using an E8 "TORX" socket wrench, install the stud
bolts A.
bolt A
(c) Apply adhesive to the hole for the stud bolt C on the
cylinder block. Using an E7 "TORX" socket wrench,
install the stud bolt C.
bolt C
NOTICE:
If the stud bolt is deformed or the threads are
damaged, replace it.
for Front Side: A for Lower Side:

D
16 mm
(0.63 in.) EM
for Exhaust Side:
C
89 mm (3.50 in.)
12 mm
(0.47 in.)
18 mm
25 mm (0.71 in.)
(0.98 in.)
55 mm 60 mm 22.5 mm
(2.17 in.) (2.36 in.) (0.89 in.)
37.5 mm
(1.48 in.)
12 mm 12 mm 13 mm
(0.47 in.) (0.47 in.) (0.51 in.)
B C D
G037383E04
3. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap in new straight
pins to the cylinder block.
A: 10 mm (0.39 in.)
B: 6 mm (0.24 in.)
A
A: 22 mm (0.87 in.) A: 13 mm (0.51 in.)

B: 14 mm (0.55 in.) B: 5.5 mm (0.217 in.)
A B
A113461E03
4. INSTALL RING PIN

(a) Using a plastic-faced hammer, tap in new ring pins
EM to the cylinder block.
for Front Side: for Lower Side:
C
A
A
14 mm
11 mm (0.55 in.)
(0.43 in.)
C 20 mm
A 9 mm (0.787 in.)
for Upper Side:
(0.354 in.)
A: 3.5 to 4.5 mm
15 mm (0.138 to 0.177 in.)
(0.59 in.) B: 7.5 to 9.5 mm
(0.295 to 0.374 in.)
14 mm
B C: 7.0 to 9.0 mm
(0.55 in.)
(0.276 to 0.354 in.)
A113462E02
5. INSTALL NO. 2 BALANCE SHAFT DRIVEN GEAR

A (a) Mount the head portion of the balance shaft in a
vise.
NOTICE:
B (b) Install the No. 2 balance shaft thrust washer
(labeled A) and balance shaft No. 2 driven gear
(labeled B).
(c) Install and torque the bolt.
G037394E03 Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
6. INSTALL NO. 2 BALANCE SHAFT

(a) Install the balance shaft to the cylinder block.
NOTICE:
When installing the balance shaft, make sure to
the cylinder block side. EM
G037393E01
(b) Install the 2 bolts.

G037392E01
7. INSTALL NO. 1 BALANCE SHAFT DRIVEN GEAR

C (a) Mount the head portion of the balance shaft in a
B
vise.
NOTICE:
D A (b) Install the balance shaft thrust spacer (labeled A),
No. 1 balance shaft thrust washer (labeled B),
sliding key (labeled C) and No. 1 balance shaft
driven gear (labeled D).
G037391E02 (c) Install the bolt.
8. INSTALL NO. 1 BALANCE SHAFT
(a) Install the No. 1 balance shaft to the cylinder block.
NOTICE:
When installing the balance shaft, make sure to
G037390E01
(b) Install and torque the bolt.

9. CHECK BALANCE SHAFT THRUST CLEARANCE
(See page EM-85)
G037389E01
10. INSTALL OIL NOZZLE

(a) Using an E7 "TORX" socket wrench, install the oil
nozzle.
EM
G037357E01
11. INSTALL CYLINDER BLOCK WATER DRAIN COCK

(a) Apply adhesive around the drain cock.
Adhesive:
1324 or equivalent
G037320E01
(b) Install the cylinder block water drain cock as shown

in the illustration.
(c) Install the water drain cock plug to the water drain
cock.
Upper Side
Front
30°
60°
Permit Direction Target Direction
G037321E03
12. INSTALL PISTON WITH PIN

(a) Assemble the piston and connecting rod.
(1) Using a small screwdriver, install a new snap
ring at one end of the piston pin hole.
Service Hole
G035729E01
(2) Gradually heat the piston to approximately 80

to 90°C (176 to 194°F).
EM
A087202E02
(3) Coat the piston pin with engine oil.

Front Mark (4) Align the front marks of the piston and
connecting rod, and push in the piston pin with
your thumb.
HINT:
The piston and pin are a matched set.
Front Mark
A097972E01
(5) Check the fit between the piston and piston pin
by trying to move the piston back and forth on
the piston pin.
G035197E02
(6) Using a small screwdriver, install a new snap

ring at the other end of the piston pin hole.
Service Hole
G035729E01
(b) Install the piston rings.

(1) Install the oil ring expander and 2 side rails by
hand.
(2) Using a piston ring expander, install the 2
compression rings with the painted mark as
HINT:
• Install the No. 1 compression ring with the
code mark (1N) facing upward.
• Install the No. 2 compression ring with the
code mark (2N) facing upward.
Upward
Code Mark (1N) Code Mark (2N)
EM No. 1
No. 2
G036557E01
(c) Position the piston rings so that the ring ends are as
Expander
No. 2 Compression shown in the illustration.
NOTICE:
Oil Ring Rail
Do not align the ring ends.
Front 45°
No. 1
Compression
A097974E02
13. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the groove of the
Claw connecting rod or connecting cap.
(b) Install the bearings in the connecting rod and
connecting rod cap.
NOTICE:
Clean the backside of the bearing and the
bearing surface of the connecting rod. The
surface should be free of dust and oil.
A097986E01
14. INSTALL CRANKSHAFT BEARING
NOTICE:
Do not apply engine oil to the bearing's contact area
and backside.
(a) Clean the main journal, and the interior and exterior
of the bearing.
(b) Install the upper bearing.

(1) Install the upper bearing to the cylinder block
so that the upper bearing's lubrication hole is
centered within the cylinder block's lubrication
hole, as shown in the illustration.
Reference (Difference in dimension of
cylinder block and upper bearing)
# 1, 5 journal 3.75 mm (0.1476 in.)
# 3 journal 1.75 mm (0.0689 in.)
# 2, 4 journal 2.75 mm (0.1083 in.)
Bearing’s Hole NOTICE:

Do not apply engine oil to the bearing's
contact area and backside.
CORRECT INCORRECT
EM
G038408E01
(c) Install the lower bearing.

Lower Bearing (1) Install the lower bearing to the bearing cap.
(2) Using a vernier caliper, measure the distance
A between the bearing cap's edge and the lower
bearing's edge.
Standard dimension (A - B):
B 0.3 mm (0.0118 in.) or less
Reference: (Dimension of A or B)
Bearing Cap
A097958E01
# 1, 5 journal 3.83 mm (0.1508 in.)
# 3 journal 1.74 mm (0.0685 in.)
# 2, 4 journal 2.75 mm (0.1083 in.)
NOTICE:
Do not apply engine oil to the bearing's
contact area and backside.
(d) With the upper bearing and lower bearing installed,
use a plastic-faced hammer to install the bearing
caps to the cylinder block.
NOTICE:
Make sure the bearing cap's front mark and
journal number are correct.
(e) Using a vernier caliper, measure the amount of

misalignment between the upper bearing and lower
bearing, as shown in the illustration.
Standard value:
0.9 mm (0.035 in.) or less
(f) Remove the bearing cap.
15. INSTALL CRANKSHAFT
NOTICE:
The crankshaft bearing cap bolt is tightened in 2
Misalignment
progressive steps.
A097959E01
EM (a) Install the crankshaft thrust washer upper to the

cylinder block.
(1) Install the 2 thrust washers under the No. 3
journal position of the cylinder block with the oil
grooves facing outward.
NOTICE:
Be careful when installing the thrust
bearing upper and lower as they are similar
Oil Groove but cannot be interchanged.
A097960E01
(b) Install the 2 thrust washers on the No. 3 bearing cap

Lower Bearing Claw
with the grooves facing outward.
Has Claw
NOTICE:
Be careful when installing the thrust bearing
upper and lower as they are similar but cannot
be interchanged. The lower bearing has a claw
Oil Groove (c) Apply engine oil to the upper bearing, then place the
crankshaft on the cylinder block.
A097961E01 (d) Apply engine oil to the lower bearing.
(e) Install the 5 crankshaft bearing caps in their proper

Engine Front locations.
G037377E05
(f) Install the crankshaft bearing cap bolts.

HINT:
• The main bearing cap bolts are tightened in 2
7 3 1 5 9
progressive steps.
• If any of the main bearing cap bolts are broken or
deformed, replace as necessary.
(1) Install and uniformly tighten the 10 main
8 4 2 6 10 bearing cap bolts in the sequence shown in the
illustration.
A097951E01 Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
If any one of the main bearing cap bolts does
main bearing cap bolt.
(2) Mark the front of the bearing cap bolts with
Paint Mark
90° paint.
(3) Retighten the bearing cap bolts by 90° in the
numerical order above.
EM
angle to the front.
Engine Front (g) Check that the crankshaft turns smoothly.
16. CHECK CRANKSHAFT THRUST CLEARANCE (See
page EM-81)
A099641E01
17. INSTALL PISTON WITH CONNECTING ROD

Front Mark (a) Using a piston ring compressor, push the correctly
numbered piston and connecting rod assembly into
the cylinder with the front mark of the piston facing
forward.
(1) Match the numbered connecting rod cap with
the connecting rod.
Front (2) Align the pins of the connecting rod cap with
the pin holes of the connecting rod, and install
G037400E01 the connecting rod cap.
(3) Check that the front mark of the connecting rod

Front Mark cap is facing forward.
G037347E01
(b) Install the connecting rod cap bolts.

HINT:
• The connecting rod cap bolts are tightened in 2
progressive steps.
• If any connecting rod bolt is broken or deformed,
replace it.
(1) Apply a light coat of engine oil on the threads
and under the heads of the connecting rod cap
bolts.
G037348E01 (2) Install and alternately tighten the bolts of the
connecting rod cap in several passes.
If any one of the connecting rod cap bolts does
cap bolts.
(3) Mark the front of the connecting rod cap bolts
EM
Paint Mark
90° with paint.
(4) Retighten the connecting rod cap bolts 90° as
shown.
angle to the front.
Engine Front (c) Check that the crankshaft turns smoothly.
18. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM-79)
A099641E01
19. INSTALL RING PIN

(a) Using a plastic-faced hammer, tap in a new ring pin
until the pin stops.
Ring Pin 2.5 to 3.8 mm

(0.10 to 0.15 in.)
10 mm
(0.39 in.)
7 mm
(0.28 in.)
Until Pin Stops
G035306E01
20. INSTALL NO. 1 STRAIGHT SCREW PLUG

for Upper Side:
(a) Using a 10 mm hexagon wrench, install a new
gasket and the straight screw plug.
Screw Plug
A099454E01
21. INSTALL NO. 2 STRAIGHT SCREW PLUG

for Front Side: (a) Using a 19 mm hexagon wrench, install a new
gasket and the straight screw plug.
Screw Plug
A099455E01
22. INSTALL TIGHT PLUG

(a) Apply adhesive to the tight plug hole of the cylinder
head.
Adhesive Adhesive:
1324 or equivalent
EM
A058129E04
(b) Using SST and a hammer, tap in a new tight plug to

for Rear Side: the cylinder head as shown in the illustration.
SST 09950-60010 (09951-00250), 09950-70010
(09951-07100)
1.5 mm
Tight Plug (0.059 in.)
SST
A097941E01
23. INSTALL STUD BOLT

(a) Using E5 and E7 "TORX" socket wrenches, install
the stud bolts.
for Head Upper Side: for Intake Side:
B (for Intake Manifold)
for Exhaust Side:
EM A (for Cylinder Head Cover)
for Head Front Side:
C (for Exhaust Manifold)

A (for Chain Tensioner)
19 mm
28.5 mm
A (0.75 in.)
34 mm B (1.12 in.) 49.5 mm
(1.34 in.) (1.95 in.)
9 mm 13 mm
(0.35 in.) (0.51 in.)
27 mm
(1.06 in.) 42 mm
C
(1.65 in.)
13 mm
(0.51 in.)
G037444E11

bolt A
7.5 N*m (76 kgf*cm, 66 in.*lbf) for stud
bolt B and C
24. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign matter is on the mesh part of
the filter.
If foreign objects are present, clean the part
thoroughly.
(b) Using a 6 mm hexagon wrench, install a new gasket
and the oil control valve filter with the screw plug.
Mesh Part
25. INSTALL VALVE SPRING SEAT
A097943E01
26. INSTALL VALVE STEM OIL SEAL

White Black (a) Apply a light coat of engine oil on a new oil seal.
NOTICE:
Pay close attention when installing the intake
and exhaust oil seals. For example, installing
the intake oil seal into the exhaust or installing
the exhaust oil seal to the intake can cause EM
Intake Side Exhaust Side installation problems later.
HINT:
A097944E01 The intake valve oil seal is white and the exhaust
valve oil seal is black.
(b) Using SST, push in the oil seal.
Oil Seal SST 09201-41020
NOTICE:
Failure to use SST will cause the seal to be
damaged or improperly seated.
SST
SST
A099457E01
27. INSTALL INTAKE VALVE

(a) Apply plenty of engine oil to the tip area of the intake
valve indicated in the illustration.
30 mm (1.18 in.) or more

A097945E01
(b) Install the valve, spring seat, compression spring

and spring retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to the original locations.
A121457E01
(c) Using SST and wooden blocks, compress the

spring and install the 2 retainer locks.
SST SST 09202-70020 (09202-00010)
A097931E01
(d) Using a 5 mm pin punch and plastic-faced hammer,

lightly tap the valve stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
EM
5 mm
Pin Punch
A099458E01
28. INSTALL EXHAUST VALVE

(a) Apply plenty of engine oil to the tip area of the
exhaust valve indicated in the illustration.
30 mm (1.18 in.) or more

A099459E01
(b) Install the valve, spring seat, compression spring

and spring retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination
to the original locations.
A121461
(c) Using SST and wooden blocks, compress the

SST spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)
A097946E01
(d) Using a 5 mm pin punch and plastic-faced hammer,

lightly tap the valve stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
29. INSTALL VALVE LASH ADJUSTER
NOTICE:
• Keep the lash adjuster free from dirt and foreign
objects.
5 mm Pin Punch • Only use clean engine oil.
A097947E01

CORRECT INCORRECT oil.
SST
use the tip to press down on the checkball inside the
Tapered Part plunger.
SST 09276-75010
Plunger
(c) Squeeze the SST and lash adjuster together to EM
Low Pressure OK:
Chamber
NOTICE:
Check Ball When bleeding high-pressure air from the
High Pressure the SST is actually pressing the checkball as
Chamber shown in the illustration. If the checkball is not
SST (e) After bleeding air, remove SST. Then, try to quickly
OK:
Plunger is very difficult to move.
adjuster.
NOTICE:
Install the lash adjuster to the same place it was
removed from.
A097867E01
30. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem
cap.
(b) Install the valve stem cap to the cylinder head.
31. INSTALL VALVE ROCKER ARM
Stem End Cap Rocker Arm (a) Apply clean engine oil to the valve lash adjuster tip
and valve stem cap surface. Then install the valve
rocker arm.
NOTICE:
Install the valve stem cap, lash adjuster and
CORRECT INCORRECT valve rocker arm to the same place it was
Lash Adjuster
removed from.
G035211E01
32. INSTALL CRANKSHAFT PULLEY SET KEY

(a) Install the 2 pulley keys to the crankshaft.
G037300E01
33. INSTALL NO. 4 CHAIN VIBRATION DAMPER

(a) Install the No. 4 vibration damper with the 2 bolts.
34. INSTALL NO. 2 CHAIN
NOTICE:
EM Check that the No. 1 cylinder is at TDC and that the
weights of the No. 1 and No. 2 balance shafts are at
the bottom side.
G037299E01
(a) Install the No. 2 timing sprocket as shown in the

illustration.
HINT:
Install the sprocket with the front mark facing
forward.
G038150E01
(b) As shown in the illustration, install the chain on the

Mark Plate
sprocket and gear with the mark plates aligned with
the timing marks on the sprocket and gear.
Timing Mark
Mark Plate
G037313E01
(c) Fit the other mark plate of the balance shaft drive
gear behind the large timing mark of the balance
shaft drive gear.
(d) Insert the balance shaft drive gear shaft through the
balance shaft drive gear so that it fits into the thrust
plate hole.
Mark Plate
Large Timing Mark

G037314E04
(e) Align the small timing mark of the balance shaft

Large timing Mark drive gear with the timing mark of the balance shaft
timing gear.
Small Timing Mark
(f) Install the bolt to the balance shaft drive gear and
tighten it.
EM
Mark Plate
G037315E02
(g) Check that each timing mark is matched with the

Mark Plate corresponding mark plate.
Large Timing Mark NOTICE:
Check that the No. 1 cylinder is at TDC and that
Small Timing Mark the weights of the No. 1 and No. 2 balance shafts
are at the bottom side.
Timing Mark
Mark Plate Mark Plate

G037316E01
35. INSTALL NO. 2 CHAIN TENSIONER

(a) Install the No. 2 chain tensioner with the nut.
NOTICE:
Assemble the chain tensioner with the pin
installed, then remove the pin after assembly.
When doing this, avoid pushing the vibration
damper against the chain.
G037297E01
(b) Move the stopper plate downward to release the

Upward lock, and push the plunger deep into the tensioner.
Plunger (c) Move the stopper plate upward to set the lock, and
insert a hexagon wrench into the stopper plate's
hole.
Downward
Stopper Plate
G037294E03

(a) Install the No. 3 chain vibration damper with the 2
bolts.
EM
G037296E01

(a) Install the No. 2 chain vibration damper with the
bolt.
(b) Remove the hexagon wrench from the No. 2 chain
tensioner and release the plunger.
G037295E01
38. INSTALL ENGINE REAR OIL SEAL RETAINER

(a) Apply seal packing in a continuous line to the places
Seal packing:
Toyota Genuine Seal Packing Black, Three
Standard seal diameter:
2 to 3 mm (0.079 to 0.118 in.)
NOTICE:
: Seal Packing
A097914E02 • Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
applying seal packing.
• Do not start the engine for at least 2 hours
after installing.
(b) Install the oil seal retainer with the 6 bolts.
39. INSTALL OIL FILTER BRACKET

(a) Using a 14 mm hexagon wrench, install the oil filter
bracket union.
A101977E01
(b) Install a new gasket to the oil filter bracket.

NOTICE:
Apply a light coat of engine oil to the new
gasket.
O-Ring (c) Install a new O-ring and gasket to the oil filter
bracket union bolt.
NOTICE: EM
Apply a light coat of engine oil to the new O-
ring.
Oil Filter Bracket Gasket
G037305E04
(d) Install the oil filter bracket with the 2 bolts and nut.
(e) Install 2 new gaskets and 2 screws to the oil filter
Screw Plug bracket.
Screw Plug
G037304E03
40. INSTALL OIL FILTER UNION

(a) Using a 27 mm socket wrench, install the oil filter
union.
G037462E03
41. INSTALL OIL FILTER

(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 the oil filter.
SST 09228-07501
SST (1) When using a torque wrench:
A097902E01 Using a torque wrench to tighten the oil filter.
(2) When not using a torque wrench:
Tighten the oil filter a 3/4 turn by a common
wrench.
42. INSTALL CYLINDER HEAD GASKET
15 (a) Apply seal packing to the cylinder block upper side
EM (0.591) and cylinder head gasket upper side as shown in
the illustration.
15 (0.591)
Seal packing:
Toyota Genuine Seal Packing 1282B, Three
15 (0.591) Bond 1282B or equivalent
15 (0.591) 4 to 7 mm (0.15 to 0.28 in.)
mm (in.) A097915E03 NOTICE:
• Remove any oil from the contact surface.
• Install the cylinder head gasket within 3
minutes after applying the seal packing.
• Install the cylinder head bolt within 15
minutes after applying the seal packing.
• Do not put into engine oil within 4 hours of
installation.
(b) Place a new cylinder head gasket on the cylinder
Cylinder Head Gasket Upper Side block surface with the Lot No. stamp upward.
Lot No. NOTICE:
• Make sure the installation direction is correct.
• Place the cylinder head gently to avoid
damaging the gasket with the bottom part of
the head.
43. INSTALL CYLINDER HEAD
Front HINT:
A097916E03
The cylinder head bolts are tightened in 3 progressive
steps.
(a) Place the cylinder head on the cylinder block.
(b) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(c) Using a 10 mm bi-hexagon wrench, install and

8 6 1 3 9 uniformly tighten the 10 cylinder head bolts with the
plate washers, in several passes, in the sequence
shown.
10 4 2 5 7
A097901E03
(d) Mark the front of the cylinder head bolt head with
paint.
90° 90° (e) Retighten the cylinder head bolts by 90° in the
numerical order shown.
(f) Retighten the cylinder head bolts by an additional
Engine 90°.
Front (g) Check that the painted mark is now facing rearward. EM
Painted Mark
A097917E03
(h) Seal packing will seep out on the engine's front side.
for Engine Front Side: Thoroughly wipe clean any seal packing.
Cylinder Head
Cylinder Head
Gasket
Wipe clean
Cylinder Block
A097918E02
44. INSTALL CAMSHAFT TIMING GEAR

Straight Pin (a) Put the camshaft timing gear and camshaft together
by aligning the key groove and straight pin.
(b) Check that there is no gap between the gear's
flange and the camshaft.
(c) With the camshaft timing gear fixed in place, tighten
Key Groove the flange bolt.
A097872E03
45. INSTALL CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise and then install the
camshaft timing sprocket to the camshaft with the
sprocket bolt.
NOTICE:
Be careful not to damage the camshaft in the
vise.
A086867E01
46. INSTALL CAMSHAFT

A C (a) Apply clean engine oil to the camshaft's cam portion
and the cylinder head journals.
(b) Set the camshaft and No. 2 camshaft as shown in
the illustration.
NOTICE:
Before and after setting the camshaft and No. 2
B D camshaft, firmly set the rocker arm to the lash
adjuster.
B
A
D
EM C
Stem End Cap Rocker

Arm
CORRECT INCORRECT
Lash Adjuster
G039613E02
(c) Loosely install the No. 1 camshaft bearing cap.

(d) Check the proper location of each No. 2 camshaft
bearing cap and install each one.
G037331E01
(e) Install a new O-ring to the No. 1 camshaft bearing

cap.
O-Ring (f) Loosely install the oil delivery pipe.
G037284E01
(g) Tighten the 21 bolts and 20 washers in the order

20
12 4 8 16 Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt A
15.5 N*m (158 kgf*cm, 11 ft.*lbf) for
18 except bolt A
21 A 11 3 7 15
17 9 1 5 13
19 10 2 6 14
G037283E01
47. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the timing sprocket as shown in the
illustration.
EM
G037282E01
48. INSTALL CHAIN VIBRATION DAMPER

(a) Install the vibration damper with the bolt and nut.
G037280E01
49. INSTALL CHAIN

13q47’ Timing Mark (a) As shown in the illustration, install the chain on the
sprocket and gear with the painted marks aligned
with the timing marks on the sprocket and gear.
HINT:
• The camshaft mark plate is yellow.
• The crankshaft mark plate is orange.
Mark Timing Mark Mark
Plate Plate
Timing Mark
Mark Plate
A097920E01
(b) Use a rope to tie the chain of the crankshaft timing

sprocket. Tie the rope near the sprocket.
NOTICE:
After the chain tensioner has been installed, the
rope must be removed.
HINT:
The rope is tied so that the chain will not jump a
tooth.
G037333E01
50. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the tensioner slipper with the bolt.
EM
G037281E01
51. INSTALL CHAIN TENSIONER

Plunger (a) Move the stopper plate upward to release the lock,
Upward and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock,
and insert a 1.27 mm hexagon wrench into the
stopper plate's hole.
Downward Stopper Plate

G037277E02
(c) Install a new gasket and the chain tensioner with the
bolt and nut.
New Gasket (d) Remove the hexagon wrench.
G039810E02
52. INSTALL TIMING CHAIN GUIDE

(a) Install a new O-ring and the chain guide with the 2
bolts.
53. INSTALL OIL PUMP RELIEF VALVE (See page LU-31)
O-Ring
G037278E03
54. INSTALL WATER PUMP

(a) Install a new gasket and the water pump with the 8
bolts.
55. INSTALL TIMING CHAIN COVER OIL SEAL (See page
EM-103)
A087223E02
56. INSTALL TIMING CHAIN COVER

(a) Install 3 new O-rings to the timing chain cover as
New O-Ring
EM
A097922E03
(b) Apply adhesive to the timing gear case plug.

Adhesive Adhesive:
1324 or equivalent
A058128E03
(c) Using a 10 mm socket hexagon wrench, install the

(d) Apply seal packing in a continuous to the places
Seal packing:
Standard seal diameter
G036021E01
Position Specified Condition
A - A, C - C 2.5 to 3.0 mm (0.098 to 0.118 in.)
B - B, D - D 4.0 to 4.5 mm (0.157 to 0.177 in.)
E 3.0 to 3.5 mm (0.118 to 0.138 in.)
NOTICE:
• Install the crankcase within 3 minutes and
tighten the bolts within 15 minutes after
after installing.
Seal Packing
Seal Packing
A
A
B B D
D
E E
C C 20 mm 20 mm
(0.787 in.) (0.787 in.)
C C
EM Seal Diameter: 2.5 to 3.0 mm
C-C
O-ring
1.0 mm 4 mm
Seal Diameter: (0.157 in.)
(0.039 in.) 2.5 to 3.0 mm
D-D
A-A Seal Diameter: 4.0 to 4.5 mm
2.0 mm
(0.079 in.) Seal Diameter:
4.0 to 4.5 mm Seal Diameter:
3.0 to 3.5 mm
Cylinder Head
B-B
E
Cylinder Block
G038474E03
(e) Align the oil pump's drive rotor spline and the
Driver Rotor Spline crankshaft as shown in the illustration. Install the
spline and chain cover to the crankshaft.
(f) Loosely install the timing chain cover with the 19
bolts and nut, but do not tighten the bolts and nuts
yet.
(g) Excluding bolt A and bolt C, fully tighten the bolts
and nuts in this order: Area 1, Area 2 and Area 3.
Crankshaft Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
G037336E01 HINT:
Bolt length:
75 mm (2.95 in.) for bolt A
75 mm (2.95 in.) for bolt B
87 mm (3.43 in.) for bolt C
95 mm (3.74 in.) for bolt D
(h) Fully tighten the bolts labeled A in this order: Area 2

and Area 3.
(i) Fully tighten the bolts labeled C for Area 1.
(j) Fully tighten the bolts labeled E for Area 4.
HINT:
Bolt length:
35 mm (1.37 in.) for bolt E
B
Area 3
A
A
A Nut A
Area 1
EM
C
B
Area 4
A A
A E
D E Area 2
A
B B
G037337E01
57. INSTALL NO. 1 OIL PAN

(a) Install the stud bolt.
(1) Using an E5 "TORX" socket wrench, install the
stud bolts labeled A for the oil pan as shown in
the illustration.
(2) Using an E7 "TORX" socket wrench, install the
stud bolts labeled B for the oil strainer as
A (for Oil Strainer)
EM B (for Oil Pan)
22.5 mm
A (0.886 in.) 13 mm
B (0.512 in.)
22.5 mm
37.5 mm
13 mm 8 mm (0.886 in.)
(1.476 in.)
(0.512 in.) (0.315 in.)
G035730E01
(b) Install a new tight plug.

(1) Apply adhesive around a new tight plug.
Adhesive:
Adhesive Toyota Genuine Adhesive 1324, Three
Bond 1324 or equivalent
A058129E04
(2) Using SST and a hammer, tap in the tight plug

SST 09950-60010 (09951-00300), 09950-
70010 (09951-07100)
Depth:
1.5 mm (0.256 in.)
SST
EM
A099218E01
(c) Install a new O-ring.
G037271E01
(d) Apply seal packing in a continuous line to the places

Seal packing:
: Seal Packing Toyota Genuine Seal Packing Black, Three
A A C C 2 to 3 mm (0.08 to 0.12 in.)
NOTICE:
B • Install the crankcase within 3 minutes after
B • Do not start the engine for at least 4 hours
8.0 mm
after installing.
Seal (0.315 in.)
Seal 6.5 mm
Diameter: Diameter: (0.256 in.)
2 to 3 mm 2 to 3 mm
EM A-A B-B
Seal Diameter:
2 to 3 mm 8.0 mm (0.315 in.)
C-C
G038861E01
(e) Temporarily install the oil pan with the 16 bolts and 2
Nut Nut B nuts.
A A
HINT:
Bolt length:
9 1 10 11 12 13 14 20 mm (0.79 in.) for bolt A
8 15 A
7 16
40 mm (1.57 in.) for bolt B
6 5 4 3 2 18 17 (f) Uniformly tighten the 16 bolts and 2 nuts in the
sequence shown in the illustration.
B A Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
B A099220E01
58. INSTALL OIL STRAINER
(a) Install a new gasket and the oil strainer with the bolt
and 2 nuts.
59. INSTALL NO. 2 OIL PAN

(a) Apply seal packing in a continuous line to the places
A Seal packing:
A
2.5 to 3.5 mm (0.098 to 0.138 in.)
6.0 mm NOTICE:
(0.236 in.) • Remove any oil from the contact surface.
Seal diameter: • Install the crankcase within 3 minutes after
2.5 to 3.5 mm applying seal packing.
A-A
after installing.
: Seal Packing A099221E03
(b) Temporarily install the oil pan with the 20 bolts and 2 EM
20
21 22 4 nuts.
19 5
6 (c) Uniformly tighten the 20 bolts and 2 nuts in the
7 sequence shown in the illustration.
18 1
3 (d) Install a new gasket and the drain plug.
8
17 60. CHECK CRANKSHAFT PULLEY
9 (a) Check that the crankshaft pulley matches the pulley
16 14 2 13 12 11 10 labeled A in the illustration.
15 A099214E01
with Groove without Groove
A B
A170499E01
NOTICE:
If the crankshaft pulley matches the pulley
labeled B, replace the crankshaft pulley.
61. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the
pulley, and slide on the pulley.
(b) Using SST, install a new pulley bolt.

SST 09213-54015 (91651-60855), 09330-00021
SST
NOTICE:
Do not reuse the pulley bolt.
62. INSTALL CYLINDER HEAD COVER
(a) Install the 2 gaskets to the head cover.
A097885E01
(b) Apply seal packing to the places shown in the

illustration.
Seal packing:
NOTICE:
EM • Remove any oil from the contact surface.
• Install the crankcase within 3 minutes after
: Seal Packing A099825E02 • Do not start the engine for at least 2 hours
after installing.
(c) Temporarily install the cover with the 19 bolts and 2
17 18 19 20
21 nuts.
(d) Uniformly tighten the 19 bolts and 2 nuts in the
2 3 6 7 sequence shown in the illustration.
16 9 Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(e) In numerical order, confirm that the bolts labeled 1
to 8 are tighten to the torque specification. Tighten
1 4 5 8
the bolts as necessary.
10
15 13 12 11
14 G035202E01
63. INSTALL VENTILATION VALVE

(a) Install the ventilation valve to the head cover.
G037256E01
64. INSTALL OIL FILLER CAP
REPAIR
1. REPAIR INTAKE VALVE SEAT
NOTICE:
Keep the lip free from foreign matter.
G037255E01

the valve face.
(c) Check the valve seat according to the following
procedures.
Width (1) If blue appears 360° around the valve face, the
valve.
A099449E01 guide and valve face are concentric. If not,
1.0 to 1.4 mm (0.039 to 0.055 in.).
(d) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
45°
30°
EM
Width
A099450E01
(e) If the seating is too low on the valve face, use 60°
60° (f) Hand-lap the valve and valve seat with an abrasive
45°
compound.
(g) Check the valve seating position.
2. REPAIR EXHAUST VALVE SEAT
NOTICE:
Keep the lip free from foreign matter.
Width
A099451E01

the valve face.
(c) Check the valve seat according to the following
procedures.
Width (1) If blue appears 360° around the valve face, the
valve.
A099449E01 guide and valve face are concentric. If not,
1.0 to 1.4 mm (0.039 to 0.055 in.).
(d) If the seating is too high on the valve face, use 30°
45°
30°
Width
A099450E01
(e) If the seating is too low on the valve face, use 60°
60° (f) Hand-lab the valve and valve seat with an abrasive
45°
compound.
(g) Check the valve seating position.
EM 3. BORE CYLINDER
HINT:
• Bore all the 4 cylinders for the O/S piston outside
Width
diameter.
A099451E01
• Replace all the piston rings with ones to match the O/
S pistons.
(a) Keep 4 new O/S pistons.
O/S 0.50 piston diameter:
95.441 to 95.451 mm (3.7575 to 3.7579 in.)
(b) Using a micrometer, measure the piston diameter at
right angles to the piston center line, the indicated
distance from the piston end.
Standard distance:
11.4 mm (0.449 in.)
Distance: 11.4 mm (c) Calculate how much each cylinder needs to be
A097953E01 rebored:
Size to be rebored = P + C - H:
P = Piston diameter
C = Piston clearance: 0.019 to 0.052 mm
(0.0007 to 0.0020 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.

2tr-Fe Engine Mechanical

Uploaded by

Document Information

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

2tr-Fe Engine Mechanical

Uploaded by

Copyright:

Available Formats

01_007-2TR-FE ENGINE MECHANICAL.

book Page i Thursday, August 7, 2008 3:02 PM

2TR-FE ENGINE MECHANICAL

2TR-FE ENGINE MECHANICAL – ENGINE EM–1

3. INSPECT NO. 1 IDLER PULLEY

EM–2 2TR-FE ENGINE MECHANICAL – ENGINE

(b) When using the intelligent tester:

EM (c) When not using the intelligent tester:

Green-red Lead Wire

(4) Using SST, connect terminals TC and CG of

2TR-FE ENGINE MECHANICAL – ENGINE EM–3

(5) Using a timing light, measure the ignition

EM–4 2TR-FE ENGINE MECHANICAL – ENGINE

(c) When not using the intelligent tester:

2TR-FE ENGINE MECHANICAL – ENGINE EM–5

(e) Check the cylinder compression pressure.

Difference between each cylinder:

EM–6 2TR-FE ENGINE MECHANICAL – ENGINE

(2) See the table below for possible causes, and

2TR-FE ENGINE MECHANICAL – DRIVE BELT EM–7

EM–8 2TR-FE ENGINE MECHANICAL – DRIVE BELT

(c) Check that the tensioner indicator mark is within

2TR-FE ENGINE MECHANICAL – DRIVE BELT EM–9

Arm Side Indicator

EM–10 2TR-FE ENGINE MECHANICAL – CAMSHAFT

2TR-FE ENGINE MECHANICAL – CAMSHAFT EM–11

8.0 (82, 71 in.*lbf)

NO. 2 VENTILATION HOSE

INTAKE AIR CONNECTOR

5.0 (51, 44 in.*lbf)

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

EM–12 2TR-FE ENGINE MECHANICAL – CAMSHAFT

9.0 (92, 80 in.*lbf)

9.0 (92, 80 in.*lbf)

CYLINDER HEAD COVER

CYLINDER HEAD COVER GASKET

NO. 2 CYLINDER HEAD COVER GASKET

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

2TR-FE ENGINE MECHANICAL – CAMSHAFT EM–13

15.5 (158, 11) x4

15.5 (158, 11)

NO. 1 CAMSHAFT BEARING CAP

CAMSHAFT TIMING SPROCKET

CAMSHAFT TIMING GEAR

VALVE ROCKER ARM

TIMING CHAIN TIMING CHAIN GUIDE

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

EM–14 2TR-FE ENGINE MECHANICAL – CAMSHAFT

6. REMOVE TIMING CHAIN GUIDE

2TR-FE ENGINE MECHANICAL – CAMSHAFT EM–15

7. REMOVE CAMSHAFT TIMING SPROCKET

(c) Place paint marks on the timing chain and camshaft

(e) Using a 10 mm socket hexagon wrench, remove the

EM–16 2TR-FE ENGINE MECHANICAL – CAMSHAFT

(f) Using a screwdriver, access the tensioner stopper

EM (g) With the stopper plate's lock released, slightly rotate

(h) Remove the screwdriver from the chain tensioner

2TR-FE ENGINE MECHANICAL – CAMSHAFT EM–17

(d) Tie the timing chain with a string as shown in the

10. REMOVE VALVE LASH ADJUSTER

EM–18 2TR-FE ENGINE MECHANICAL – CAMSHAFT

Vinyl Tape Rubber

2TR-FE ENGINE MECHANICAL – CAMSHAFT EM–19

(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque

Nm (kgfcm, ft.*lbf) : Specified torque FRONT EXHAUST PIPE