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EM1
ENGINE
ON-VEHICLE INSPECTION
Intelligent Tester
DLC3
CAN VIM
B127989E03
1.
2.
3.
INSPECT BATTERY
4.
5.
6.
7.
EM
EM2
A112264
CG
EM
DLC3
TC
H100769E05
8.
Intelligent Tester
DLC3
CAN VIM
B127989E03
EM3
TAC
DLC3
H100769E32
9.
SST
Compression Gauge
A013304E05
INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the No. 1 engine under cover.
(c) Remove the 4 ignition coils (see page IG-9).
(d) Remove the 4 spark plugs.
(e) Disconnect the 4 fuel injector connectors.
(f)
EM
EM4
EM
HC
Problems
Causes
Normal
High
Rough idle
1. Faulty ignition:
- Incorrect timing
- Plugs are contaminated, shorted,
or gaps are defective
2. Incorrect valve clearance
3. Leaks in intake and exhaust
valve
4. Leaks in cylinders
Low
High
Rough idle
(Fluctuating HC reading)
1. Vacuum leakage:
- Ventilation hoses
- Intake manifold
- Throttle body
- Brake booster line
2. Lean mixture causing misfire
High
High
Rough idle
(Black smoke from exhaust)
EM5
DRIVE BELT
2AZ-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
EM
96 (979, 71)
96 (979, 71)
EM6
ON-VEHICLE INSPECTION
INCORRECT
1.
A058797E02
EM
CORRECT
INCORRECT
A087787E03
EM6
DRIVE BELT
2GR-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
EM
5.0 (51, 44 in.*lbf)
95 (969, 70)
EM7
ON-VEHICLE INSPECTION
INCORRECT
1.
A058797E02
CORRECT
INCORRECT
EM
A087787E03
REMOVAL
A124838
Front
A129514E01
1.
2.
3.
4.
EM8
5.
A137895
EM
A095070E01
INSTALLATION
1.
A137895
Generator
Water Pump
Idler
Tensioner
Crankshaft
EM9
A/C Compressor
A139509E01
2.
Front
3.
4.
5.
A129514E01
A124838
EM
EM7
REMOVAL
19 mm Socket
Wrench
1.
2.
3.
4.
5.
SST
A114351E01
19 mm Socket
Wrench
INSTALLATION
1.
2.
3.
4.
5.
SST
A114351E01
EM
EM8
VALVE CLEARANCE
ADJUSTMENT
EM
1.
2.
3.
4.
5.
6.
7.
8.
9.
IN
EX
Item
Standard Condition
Intake
Exhaust
A098170E04
IN
Item
EX
A098171E06
Standard Condition
Intake
Exhaust
EM9
A001082E01
Item
Specification
Intake
Exhaust
(f)
42
A126901E01
EM
EM10
Measured clearance
mm (in.)
Installed lifter
thickness
mm (in.)
EM
5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.210 (0.2051)
5.220 (0.2055)
5.230 (0.2059)
5.240 (0.2063)
5.250 (0.2067)
5.260 (0.2071)
5.270 (0.2075)
5.280 (0.2079)
5.290 (0.2083)
5.300 (0.2087)
5.310 (0.2091)
5.320 (0.2094)
5.330 (0.2098)
5.340 (0.2102)
5.350 (0.2106)
5.360 (0.2110)
5.370 (0.2114)
5.380 (0.2118)
5.390 (0.2122)
5.400 (0.2126)
5.410 (0.2130)
5.420 (0.2134)
5.430 (0.2138)
5.440 (0.2142)
5.450 (0.2146)
5.460 (0.2150)
5.470 (0.2154)
5.480 (0.2157)
5.490 (0.2161)
5.500 (0.2165)
5.510 (0.2169)
5.520 (0.2173)
5.530 (0.2177)
5.540 (0.2181)
5.550 (0.2185)
5.560 (0.2189)
5.570 (0.2193)
5.580 (0.2197)
5.590 (0.2201)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260)
06
06 08
06 08 10
06 08 10 12
06 08 10 12 14
06 08 10 12 14 16
06 08 10 12 14 16 18
06 08 10 12 14 16 18 20
06 08 10 12 14 16 18 20
06 08 10 12 14 16 18 20
08 10 12 14 16 18 20 22
06 08 10 12 14 16 18 20 22
06 10 12 14 16 18 20 22 24
08 10 12 14 16 18 20 22 24
08 12 14 16 18 20 22 24 26
10 12 14 16 18 20 22 24 26
10 14 16 18 20 22 24 26 28
12 14 16 18 20 22 24 26 28
12 16 18 20 22 24 26 28 30
14 16 18 20 22 24 26 28 30
14 18 20 22 24 26 28 30 32
16 18 20 22 24 26 28 30 32
16 20 22 24 26 28 30 32 34
18 20 22 24 26 28 30 32 34
18 22 24 26 28 30 32 34 36
20 22 24 26 28 30 32 34 36
20 24 26 28 30 32 34 36 38
22 24 26 28 30 32 34 36 38
22 26 28 30 32 34 36 38 40
24 26 28 30 32 34 36 38 40
24 28 30 32 34 36 38 40 42
26 28 30 32 34 36 38 40 42
26 30 32 34 36 38 40 42 44
28 30 32 34 36 38 40 42 44
28 32 34 36 38 40 42 44 46
30 32 34 36 38 40 42 44 46
30 34 36 38 40 42 44 46 48
32 34 36 38 40 42 44 46 48
32 36 38 40 42 44 46 48 50
34 36 38 40 42 44 46 48 50
34 38 40 42 44 46 48 50 52
36 38 40 42 44 46 48 50 52
36 40 42 44 46 48 50 52 54
38 40 42 44 46 48 50 52 54
38 42 44 46 48 50 52 54 56
40 42 44 46 48 50 52 54 56
40 44 46 48 50 52 54 56 58
42 46 48 50 52 54 56 58 60
44 48 50 52 54 56 58 60 62
46 50 52 54 56 58 60 62 64
48 52 54 56 58 60 62 64 66
50 54 56 58 60 62 64 66 68
52 56 58 60 62 64 66 68 70
54 58 60 62 64 66 68 70 72
12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
50 52 54 56 58 60 62 64 66 68 70 72 74 74
50 52 54 56 58 60 62 64 66 68 70 72 74 74
52 54 56 58 60 62 64 66 68 70 72 74 74
52 54 56 58 60 62 64 66 68 70 72 74 74
54 56 58 60 62 64 66 68 70 72 74 74
54 56 58 60 62 64 66 68 70 72 74 74
56 58 60 62 64 66 68 70 72 74 74
56 58 60 62 64 66 68 70 72 74 74
58 60 62 64 66 68 70 72 74 74
58 60 62 64 66 68 70 72 74 74
60 62 64 66 68 70 72 74 74
60 62 64 66 68 70 72 74 74
62 64 66 68 70 72 74 74
62 64 66 68 70 72 74 74
64 66 68 70 72 74 74
64 66 68 70 72 74 74
66 68 70 72 74 74
66 68 70 72 74 74
68 70 72 74 74
70 72 74 74 74
72 74 74 74
74 74 74
74 74
74
A126931E02
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
06
5.060 (0.1992)
30
5.300 (0.2087)
54
5.540 (0.2181)
EM11
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
08
5.080 (0.2000)
32
5.320 (0.2094)
56
5.560 (0.2189)
10
5.100 (0.2008)
34
5.340 (0.2102)
58
5.580 (0.2197)
12
5.120 (0.2016)
36
5.360 (0.2110)
60
5.600 (0.2205)
14
5.140 (0.2024)
38
5.380 (0.2118)
62
5.620 (0.2213)
16
5.160 (0.2031)
40
5.400 (0.2126)
64
5.640 (0.2220)
18
5.180 (0.2039)
42
5.420 (0.2134)
66
5.660 (0.2228)
20
5.200 (0.2047)
44
5.440 (0.2142)
68
5.680 (0.2236)
22
5.220 (0.2055)
46
5.460 (0.2150)
70
5.700 (0.2244)
24
5.240 (0.2063)
48
5.480 (0.2157)
72
5.720 (0.2252)
26
5.260 (0.2071)
50
5.500 (0.2165)
74
5.740 (0.2260)
28
5.280 (0.2079)
52
5.520 (0.2173)
EM
EM12
Measured clearance
clearance
Measured
mm (in.)
mm (in.)
Installed lifter
thickness
Installed lifter thickness
mm (in.)mm (in.)
5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.210 (0.2051)
5.220 (0.2055)
5.230 (0.2059)
5.240 (0.2063)
5.250 (0.2067)
5.260 (0.2071)
5.270 (0.2075)
5.280 (0.2079)
5.290 (0.2083)
5.300 (0.2087)
5.310 (0.2091)
5.320 (0.2094)
5.330 (0.2098)
5.340 (0.2102)
5.350 (0.2106)
5.360 (0.2110)
5.370 (0.2114)
5.380 (0.2118)
5.390 (0.2122)
5.400 (0.2126)
5.410 (0.2130)
5.420 (0.2134)
5.430 (0.2138)
5.440 (0.2142)
5.450 (0.2146)
5.460 (0.2150)
5.470 (0.2154)
5.480 (0.2157)
5.490 (0.2161)
5.500 (0.2165)
5.510 (0.2169)
5.520 (0.2173)
5.530 (0.2177)
5.540 (0.2181)
5.550 (0.2185)
5.560 (0.2189)
5.570 (0.2193)
5.580 (0.2197)
5.590 (0.2201)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260)
EM
06
06 08
06 08 10
06 08 10 12
06 08 10 12 14
06 08 10 12 14 16
06 08 10 12 14 16 18
06 08 10 12 14 16 18 20
06 08 10 12 14 16 18 20
06 08 10 12 14 16 18 20 22
06 08 10 12 14 16 18 20 22
06 08 10 12 14 16 18 20 22 24
06 08 10 12 14 16 18 20 22 24
06 08 10 12 14 16 18 20 22 24 26
06 08 10 12 14 16 18 20 22 24 26
06 08 10 12 14 16 18 20 22 24 26 28
06 08 10 12 14 16 18 20 22 24 26 28
06 08 10 12 14 16 18 20 22 24 26 28 30
06 08 10 12 14 16 18 20 22 24 26 28 30
06 08 10 12 14 16 18 20 22 24 26 28 30 32
06 08 10 12 14 16 18 20 22 24 26 28 30 32
06 08 10 12 14 16 18 20 22 24 26 28 30 32 34
06 08 10 12 14 16 18 20 22 24 26 28 30 32 34
08 10 12 14 16 18 20 22 24 26 28 30 32 34 36
08 10 12 14 16 18 20 22 24 26 28 30 32 34 36
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68
42 44 46 48 50 52 54 56 58 60 62 64 66 68 70
44 46 48 50 52 54 56 58 60 62 64 66 68 70 72
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
52 54 56 58 60 62 64 66 68 70 72 74 74 74
52 54 56 58 60 62 64 66 68 70 72 74 74 74
54 56 58 60 62 64 66 68 70 72 74 74 74
54 56 58 60 62 64 66 68 70 72 74 74 74
56 58 60 62 64 66 68 70 72 74 74 74
56 58 60 62 64 66 68 70 72 74 74 74
58 60 62 64 66 68 70 72 74 74 74
58 60 62 64 66 68 70 72 74 74 74
60 62 64 66 68 70 72 74 74 74
60 62 64 66 68 70 72 74 74 74
62 64 66 68 70 72 74 74 74
62 64 66 68 70 72 74 74 74
64 66 68 70 72 74 74 74
64 66 68 70 72 74 74 74
66 68 70 72 74 74 74
68 70 72 74 74 74
70 72 74 74 74
72 74 74 74
74 74 74
74 74
74
A114356E01
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
06
5.060 (0.1992)
30
5.300 (0.2087)
54
5.540 (0.2181)
EM13
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
Lifter No.
Thickness
mm (in.)
08
5.080 (0.2000)
32
5.320 (0.2094)
56
5.560 (0.2189)
10
5.100 (0.2008)
34
5.340 (0.2102)
58
5.580 (0.2197)
12
5.120 (0.2016)
36
5.360 (0.2110)
60
5.600 (0.2205)
14
5.140 (0.2024)
38
5.380 (0.2118)
62
5.620 (0.2213)
16
5.160 (0.2031)
40
5.400 (0.2126)
64
5.640 (0.2220)
18
5.180 (0.2039)
42
5.420 (0.2134)
66
5.660 (0.2228)
20
5.200 (0.2047)
44
5.440 (0.2142)
68
5.680 (0.2236)
22
5.220 (0.2055)
46
5.460 (0.2150)
70
5.700 (0.2244)
24
5.240 (0.2063)
48
5.480 (0.2157)
72
5.720 (0.2252)
26
5.260 (0.2071)
50
5.500 (0.2165)
74
5.740 (0.2260)
28
5.280 (0.2079)
52
5.520 (0.2173)
(i)
Timing Mark
A098176E03
A098177E03
EM
EM14
No. 1
3
10
A098177E06
Paint Mark
EM
Timing Mark
A098178E03
A052473E01
A098174E05
(f)
7
8
10
No. 2
A098174E07
EM15
Tighten
Hold
A098173E04
7 Links
Paint Mark
Paint Mark
(h) Check that the paint marks on the chain are aligned
with the timing marks on the camshaft timing gear
and camshaft timing sprocket. Also, check that the
crankshaft pulley groove is aligned with the timing
mark "0" of the timing chain cover.
EM
Timing Mark
Timing Mark
Groove
A098180E04
Raise
Push
Pin
Hook
A098376E03
(b) Install a new gasket and the chain tensioner with the
2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
NOTICE:
When installing the chain tensioner, set the
hook again if the hook releases the plunger.
Engine Front
A098377E02
EM16
Disconnect
Hook
Turn
Pin
A112204E02
EM
Plunger
Turn
EM10
ENGINE ASSEMBLY
2GR-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
HOOD SUB-ASSEMBLY
V-BANK COVER SUB-ASSEMBLY
RADIATOR RESERVOIR
TANK ASSEMBLY
13 (133, 10)
EM
5.0 (51, 44 in.*lbf)
EM11
x3
EM
ECM
BATTERY CLAMP
SUB-ASSEMBLY
BATTERY
BATTERY TRAY
20 (204, 15)
20 (204, 15)
BATTERY BRACKET
REINFORCEMENT
EM12
EM
35 (357, 26)
x4
35 (357, 26)
x4
37 (377, 27)
x2
CENTER EXHAUST
PIPE ASSEMBLY
GASKET
GASKET
EXHAUST PIPE
SUPPORT
GASKET
62 (632, 46)
GASKET
43 (440, 32)
21 (214, 16)
62 (632, 46)
EXHAUST PIPE
SUPPORT
TAILPIPE ASSEMBLY
COMPRESSION SPRING
43 (440, 32)
A138034E01
EM13
64 (653, 47)
64 (653, 47)
92 (938, 68)
EM
64 (653, 47)
COTTER PIN
FRONT DRIVE SHAFT LH
49 (500, 36)
74 (755, 55)
92 (938, 68)
A138038E01
EM14
for 4WD
FRONT AXLE HUB NUT RH
92 (938, 68)
EM
64 (653, 47)
64 (653, 47)
COTTER PIN
49 (500, 36)
92 (938, 68)
A138039E01
EM15
95 (969, 70)
x2
ENGINE MOUNTING
INSULATOR RH
56 (571, 41)
52 (530, 38)
EM
ENGINE MOUNTING INSULATOR LH
FRONT SUSPENSION
MEMBER BRACE REAR RH
FRONT SUSPENSION
CROSSMEMBER
SUB-ASSEMBLY
95 (969, 70)
35 (357, 26)
95 (969, 70)
95 (969, 70)
95 (969, 70)
FRONT CROSSMEMBER
SUB-ASSEMBLY
93 (948, 69)
145 (1,479, 107)
95 (969, 70)
145 (1,479, 107)
95 (969, 70)
A138146E01
EM16
for 2WD
WIRE HARNESS
EM
41 (418, 30)
x3
64 (653, 47)
FLYWHEEL HOUSING
UNDER COVER
x7
GENERATOR ASSEMBLY
O-RING
x3
x2
37 (377, 27)
37 (377, 27)
O-RING
AUTOMATIC TRANSAXLE ASSEMBLY
Non-reusable part
A138147E01
EM17
69 (704, 51)
WIRE HARNESS
69 (704, 51)
41 (418, 30)
EM
69 (704, 51)
x3
TRANSFER ASSEMBLY
64 (653, 47)
FLYWHEEL HOUSING
UNDER COVER
x7
GENERATOR ASSEMBLY
O-RING
x3
x2
37 (377, 27)
37 (377, 27)
O-RING
AUTOMATIC TRANSAXLE ASSEMBLY
Non-reusable part
A138148E01
EM18
21 (214, 15) *1
EM
21 (214, 15) *1
21 (214, 15) *1
16 (163, 12)
18 (184, 13) *1
VACUUM HOSE
8.5 (87, 75 in.*lbf)
EM19
34 (347, 25)
4WD:
NO. 1 EXHAUST MANIFOLD STAY
EM
10 (102, 7)
10 (102, 7)
21 (214, 15)
21 (214, 15)
x4
WATER PUMP PULLEY
43 (438, 32)
43 (438, 32)
EM20
21 (214, 15)
INTAKE MANIFOLD
ENGINE COOLANT
TEMPERATURE SENSOR
NO. 2 INTAKE
MANIFOLD TO
HEAD GASKET
NO. 2 ENGINE
HANGER
20 (204, 14)
GASKET
KNOCK SENSOR
EM
KNOCK SENSOR
20 (204, 14)
178 (1,815, 132)
33 (337, 24)
REAR SPACER
x8
FRONT SPACER
NO. 2 OIL
DIPSTICK GUIDE
21 (214, 15)
O-RING
EM17
TIMING CHAIN
2AZ-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
EM
96 (979, 71)
96 (979, 71)
EM18
x2
x2
RADIATOR RESERVOIR
EM
60 (612, 44)
x2
95 (969, 70)
x4
IDLER PULLEY
ENGINE MOUNTING
INSULATOR RH
52 (530, 38)
8.4 (86, 74 in.*lbf)
9.8 (100, 7)
GASKET
52 (530, 38)
21 (215, 15)
GASKET
COMPRESSION SPRING
x2
GENERATOR ASSEMBLY
43 (438, 32)
43 (438, 32)
Non-reusable part
A124367E06
EM19
NO. 2 VENTILATION
HOSE
EM
11 (112, 8)
14 (143, 10)
11 (112, 8)
VENTILATION HOSE
GASKET
EM20
11 (112, 8)
EM
55 (561, 41)
x3
55 (561,41)
55 (561,41)
59.5 (607, 44)
CRANKSHAFT PULLEY
25 (255, 18)
x8
EM21
EM
CRANKSHAFT TIMING
SPROCKET
CHAIN SUB-ASSEMBLY
12 (122, 9)
GASKET
40 (408, 30)
x 12
x2
Non-reusable part
A114343E02
EM21
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
A137900
EM
EM22
A137899
Nut
EM
Bolt
A124917E01
A124918
A124919
EM23
EM
A137897
A137898
A124838
EM24
(b) 4WD:
Disconnect the control cable (see page AX-154).
31. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See
page EX-3)
32. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See
page EX-2)
33. REMOVE PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-3)
34. REMOVE FRONT WHEELS
35. REMOVE FRONT AXLE HUB NUT LH
(a) Remove the hub nut (see page AH-8).
36. REMOVE FRONT AXLE HUB NUT RH
(a) Remove the hub nut (see page AH-8).
37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY
LH (See page SP-30)
EM
for LH side
for RH side
No. 1
No. 2
A129635E02
Part Name
Part No.
12281-31120
12282-31100
Bolt
91671-10825
HINT:
Insert the claw of the hanger into hole of the
cylinder head.
Fit the fork part of the hanger onto the rib of the
cylinder head.
EM25
EM
A137896
(g) Remove the bolt and nut, and disconnect the engine
mounting insulator LH.
A139134
EM26
EM
A123580
A139135
for 2WD
for 4WD
A139136E01
EM27
SST
A076326E04
A129464
A139490
(f)
A129466
EM
EM28
A129467
EM
A129468
A076533E01
EM29
A129638
EM
A139521
A139522
EM30
A129647
EM
A129648
INSPECTION
1.
Item
Specified Condition
A137423E01
2.
A137425
EM22
REMOVAL
EM
A112206
1.
2.
3.
4.
5.
6.
7.
8.
9.
A124838
A098189E02
Wooden Block
EM23
A061184E04
A124843
Through Bolt
Nut
A124839E02
A124840
A114359
EM
EM24
A112209
EM
A112210E01
A112211
Item
Part No.
12281-28010
12282-28010
Bolt
91512-61020
A112213E01
EM25
A114333
SST
SST
A000019E05
Timing Mark
Timing Mark
Groove
A098345E09
SST
SST
A013697E02
EM
EM26
EM
A098348E01
A112212
Torx Socket
A014253E03
EM27
EM
A132568E01
A128179
A132571
EM28
A077243E01
EM
A128183
A128184
A128185
A128186
EM29
90
Groove
A098351E01
Groove
A098352E01
Bolt
Spring
INSPECTION
1.
Raise
Lock
Move
A098357E01
EM
EM30
2.
3.
4.
5.
6.
122.6 mm
16 Links
F050593E01
52.4 mm
EM
8 Links
A126891E01
A033838E01
A036686E01
A053035E01
EM31
8.
A053035E01
A053036E01
REPLACEMENT
1.
A032626E01
SST
A094547E01
EM
EM31
INSTALLATION
1.
2.
3.
A129648
A129647
4.
5.
6.
7.
8.
A129646
A139522
1
A
B
B
B
B
2
A139138E01
70 mm (2.76 in.)
EM
EM32
9.
35 mm (1.37 in.)
A129643
EM
Front
A129649E01
A139492
A139521
EM33
No. 2
No. 1
A129638E01
EM
Front
A129650E01
A139491
A076536E01
EM34
A076533E01
EM
A129468
A129467
A129466
EM35
A139490
Adhesive
A054047E01
SST
A076326E04
EM
EM36
(b) 4WD:
Install the automatic transaxle (see page AX-175).
26. INSTALL TRANSFER ASSEMBLY (for 4WD) (See
page TF-75)
27. INSTALL STARTER ASSEMBLY (See page ST-14)
28. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine.
29. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB-ASSEMBLY
(a) Attach the engine together with the transaxle to the
suspension crossmember and mounting.
(b) Install the bolt which secures the engine mounting
bracket to the mounting insulator.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
for 2WD
EM
for 4WD
A139136E01
A139135
EM37
EM
A123580
A139134
(f)
Bolt A
Bolt A
Nut A
Nut B
A137896E01
EM38
D
D
B
A
EM
A
A
A123580E01
EM39
(b) 4WD:
Connect the control cable (see page AX-154).
46. CONNECT RADIATOR HOSE INLET
47. CONNECT RADIATOR HOSE OUTLET
48. CONNECT OIL COOLER HOSE
49. CONNECT SUCTION HOSE SUB-ASSEMBLY (See
page AC-221)
50. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (See
page AC-221)
51. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY
(a) Install the reservoir tank with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the 2 hoses
52. INSTALL ECM (See page ES-471)
A124838
A137898
(b) Insert the hinge part of the air cleaner cap into the
air cleaner case, then hang the 2 hook clamps.
Hinge
A137901E01
EM
EM40
EM
A137897
A124919
EM41
EM
EM42
A137900
EM
A137899
EM32
INSTALLATION
1.
B011424E01
(c) Align the yellow mark links with the timing marks of
each gear as shown in the illustration.
(d) Install the sprockets onto the crankshaft and oil
pump shaft with the chain wrapped on the gears.
(e) Temporarily tighten the oil pump drive shaft sprocket
with the nut.
Mark Link
Timing Mark
EM
Oil Pump Drive
Shaft Sprocket
Oil Pump
Drive Sprocket
Timing Mark
Mark Link
A094198E06
(f)
Bolt
Spring
Chain Tensioner Plate
A090851E03
(g) Align the adjusting hole of the oil pump drive shaft
sprocket with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of
the oil pump drive shaft gear to lock the gear in
position, and then tighten the nut.
Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf)
Groove
A098352E01
EM33
2.
3.
A128186
EM
A132570
4.
Timing Mark
Timing Mark
A098367E01
A052505E01
EM34
Timing Mark
Mark Link
A094576E01
SST
EM
A098369E01
(d) Align the gold or yellow links with each timing mark
located on the camshaft timing gear and sprocket,
then install the chain.
Mark Link
Timing Mark
Timing Mark
A098370E01
5.
6.
Hold
A124787E01
A077243E01
EM35
7.
8.
A124770
Seal Packing
A094577E01
EM
EM36
Seal Diameter:
4.0 (0.175)
A
E
EM
Seal Diameter:
3.0 (0.118)
Seal Diameter:
2.5 to 3.0
(0.098 to 0.118)
17.5 (0.689)
13.0 (0.512)
Seal Diameter:
5.5 to 6.0
(0.217 to 0.236)
mm (in.)
4.0 (0.175)
Seal Diameter:
4.5 to 5.0
(0.177 to 0.197)
: Seal Packing
A132566E02
(d) Install the timing chain cover with the 12 bolts and 2
nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for bolt B
55 N*m (561 kgf*cm, 41 ft.*lbf) for bolt C
11 N*m (112 kgf*cm, 8 ft.*lbf) for nut
HINT:
Bolt length:
Nut
Nut
C
C
Bolt A
EM37
Bolt B
Bolt C
B
B
B
B
EM
B
B
A132568E03
(e) Using an E10 "torx" socket, install the stud bolt for
the V-ribbed belt tensioner.
Torque: 21.5 N*m (219 kgf*cm, 16 ft.*lbf)
Torx Socket
A014253E03
9.
Raise
Push
Pin
Hook
A098376E03
EM38
(b) Install a new gasket and the chain tensioner with the
2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
NOTICE:
When installing the chain tensioner, set the
hook again if the hook releases the plunger.
Engine Front
A098377E03
EM
A112212
A128165
SST
A098346E01
EM39
Disconnect
Hook
Turn
Pin
A112204E02
Plunger
Turn
Push
A112205E02
EM
EM40
9
1, 15
8
11
12
7
13
6
5
14
A114333E01
Wooden Block
EM
A061184E04
A094205E01
Nut
Nut
A094204E01
EM41
A112210
A112209
A114359
A124843E01
EM
EM42
A098189E01
EM
A124840
Through Bolt
Nut
A124839E02
EM43
EM
EM43
ENGINE UNIT
2GR-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
10 (102, 7)
18 (184, 13)
SPARK PLUG
VVT SENSOR
10 (102, 7)
21 (214, 15)
CAMSHAFT TIMING
CONTROL VALVE
x2
10 (102, 7)
x9
10 (102, 7)
GASKET
EM
10 (102, 7)
VVT SENSOR
OIL CONTROL VALVE
FILTER RH
GASKET
GASKET
65 (663, 48)
UNION BOLT
10 (102, 7)
65 (663, 48)
UNION BOLT
OIL PIPE
54 (551, 40)
Non-reusable part
A139487E01
EM44
18 (184, 13)
SPARK PLUG
CAMSHAFT TIMING
CONTROL VALVE
10 (102, 7)
10 (102, 7)
10 (102, 7)
10 (102, 7)
VVT SENSOR
OIL FILLER CAP
10 (102, 7)
27 (275, 20)
x8
VENTILATION VALVE
EM
GASKET
21 (214, 15)
10 (102, 7)
VVT SENSOR
CYLINDER HEAD COVER
GASKET
GASKET
GASKET
UNION BOLT
O-RING
x4
10 (102, 7)
x2
N*m (kgf*cm, ft.*lbf) : Specified torque
WATER OUTLET
GASKET
Non-reusable part
A134267E05
EM45
13 (133, 10)
25 (255, 18)
13 (133, 10)
PLUG
O-RING
30 (306, 22)
DRAIN COCK
WATER INLET
HOUSING
10 (102, 7)
x4
x2
10 (102, 7)
10 (102, 7)
25 (255, 18)
THERMOSTAT
13 (133, 10)
O-RING
GASKET
OIL STRAINER
WATER INLET
10 (102, 7)
CRANKSHAFT POSITION
SENSOR
EM
10 (102, 7)
GASKET
10 (102, 7)
21 (214, 15)
x7
10 (102, 7)
GASKET
10 (102, 7)
10 (102, 7)
x 12
21 (214, 15)
25 (255, 18)
O-RING
13 (127, 10)
10 (102, 7)
Non-reusable part
Precoated part
*1: Install as shown
A132208E02
EM46
GASKET
x4
9.0 (93, 81 in.*lbf)
x5
43 (438, 32)
WATER PUMP
GASKET
21 (214, 15)*1
x9
250 (2,549, 184)
EM
x 13
CRANKSHAFT PULLEY
TIMING CHAIN COVER OIL SEAL
21 (214, 15)
21 (214, 15)*1
10 (102, 7)
Non-reusable part
Precoated part
EM47
x8
x8
NO. 2 CHAIN
GASKET
EM
GASKET
NO. 1 CAMSHAFT
100 (1,020, 74)
28 (286, 21)
CAMSHAFT HOUSING
EM48
NO. 3 CAMSHAFT
1st: 10 (102, 7)
2nd: 16 (163,12)
GASKET
GASKET
CAMSHAFT TIMING GEAR
x8
x8
28 (286, 21)
NO. 2 CHAIN
EM
GASKET
NO. 4 CAMSHAFT
100 (1,020, 74)
21 (214, 15)
28 (286, 21)
x4
CAMSHAFT HOUSING
EM49
x8
PLATE WASHER
x2
30 (306, 22)
x8
VALVE LASH
ADJUSTER
PLATE WASHER
EM
CYLINDER HEAD
CLIP
EM50
COMPRESSION SPRING
VALVE STEM CAP
VALVE STEM OIL SEAL
VALVE SPRING RETAINER
VALVE SPRING SEAT
COMPRESSION SPRING
VALVE GUIDE BUSH
GASKET
EM
GASKET
80 (816, 59)
EXHAUST VALVE
INTAKE VALVE
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A132058E03
EM51
PISTON PIN
SNAP RING
SNAP RING
PISTON
CONNECTING
ROD
CONNECTING
ROD BEARING
SEAL WASHER
x8
52 (530, 38)
CRANKSHAFT
EM
EM44
CYLINDER HEAD
2AZ-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
EM
96 (979, 71)
96 (979, 71)
EM45
x2
NO. 1 ENGINE COVER
x2
RADIATOR RESERVOIR
EM
60 (612, 44)
x2
95 (969, 70)
x4
IDLER PULLEY
ENGINE MOUNTING
INSULATOR RH
52 (530, 38)
8.4 (86, 74 in.*lbf)
9.8 (100, 7)
43 (438, 32)
GASKET
52 (530, 38)
21 (215, 15)
GASKET
COMPRESSION SPRING
x2
GENERATOR ASSEMBLY
N*m (kgf*cm, ft.*lbf) : Specified torque
43 (438, 32)
43 (438, 32)
Non-reusable part
A124367E07
EM46
PURGE VSV
EM
AIR CLEANER CAP
A124373E03
EM47
30 (306, 22)
EM
x4
FUEL TUBE
THROTTLE BODY
NO. 1 THROTTLE BODY
HOSE
GASKET
EM48
EM
FUEL DELIVERY PIPE SUB-ASSEMBLY
20 (204, 15)
x2
FUEL TUBE
INJECTOR VIBRATION
INSULATOR
NO. 1 DELIVERY PIPE SPACER
x2
EM49
GASKET
30 (306, 22)
EM
30 (306, 22)
AIR-FUEL RATIO
SENSOR CONNECTOR
INTAKE MANIFOLD
INTAKE MANIFOLD INSULATOR
FUEL TUBE
EM50
EM
11 (112, 8)
14 (143, 10)
11 (112, 8)
VENTILATION HOSE
CYLINDER HEAD COVER SUB-ASSEMBLY
GASKET
EM51
11 (112, 8)
EM
x3
55 (561, 41)
55 (561, 41)
59.5 (607, 44)
CRANKSHAFT PULLEY
25 (255, 18)
x8
EM52
EM
CRANKSHAFT TIMING
SPROCKET
CHAIN SUB-ASSEMBLY
12 (122, 9)
40 (408, 30)
x 12
x2
Non-reusable part
A114343E03
EM53
OIL DIPSTICK
12 (122, 9)
12 (122, 9)
EM
O-RING
GASKET
12 (122, 9)
37 (377, 27)
x5
44 (449, 32)
MANIFOLD STAY
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A124374E03
EM54
x 16
NO. 1 CAMSHAFT
BEARING CAP
x2
NO. 3 CAMSHAFT BEARING CAP
NO. 3 CAMSHAFT BEARING CAP
NO. 1 CAMSHAFT
BEARING
54 (551, 40)
NO. 2 CAMSHAFT
EM
NO. 2 CAMSHAFT TIMING SPROCKET
CAMSHAFT TIMING
GEAR ASSEMBLY
54 (551, 40)
PLATE WASHER
EM55
EM
O-RING
19.6 (200, 14)
ENGINE COOLANT
TEMPERATURE
SENSOR
GASKET
10 (102, 7)
15 (153, 11)
EM56
VALVE LIFTER
VALVE LIFTER
VALVE SPRING RETAINER LOCK
VALVE SPRING RETAINER
EM
STUD BOLT
STUD BOLT
RING PIN
STUD BOLT
STUD BOLT
EXHAUST VALVE
INTAKE VALVE
EM52
DISASSEMBLY
EM
1.
2.
3.
4.
5.
A129676
A129677
6.
7.
A132173
A132119
EM53
8.
9.
A132070
EM
A132120
A129685
EM54
SST
SST
A132066E01
(b) Using the pulley set bolt and SST, remove the
crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
EM
SST
A132067E01
A129686
Pry
EM55
(b) Set the timing mark on the crank angle sensor plate
to the RH block bore center line (TDC /
compression).
Timing Mark
Center Line
Sensor Plate
A132112E01
Timing Mark
EM
Timing Mark
A132113E01
Push
EM56
10
Center Line
Timing Mark
Sensor Plate
A132114E01
for Bank 1:
EM
A132098E01
A129695
A131972
EM57
A132072E01
Hold
Turn
A132073E01
A132046
A132121
EM
EM58
Front View
45
Knock Pin
A132139E01
EM
A132122E01
4
7
6
10
12
2
11
A132123E01
A132124
EM59
Push
A132082E01
Turn
Hold
A132083E01
A132048
A132130
EM
EM60
Front View
Knock Pin
A132141E01
EM
4
A132131E01
8
11
13
2
10
4
12
3
A132132E01
A132084
EM61
1
A132143E03
A132144
2
A132145E03
EM
EM62
SST
EM
A131991E01
SST
A131992E01
A132167
EM63
for Bank 1:
for Bank 2:
EM
A131995E01
for Bank 2:
for Bank 1:
A131996E01
A129663
EM64
A131979
EM
Engine Front
Front Mark
A131980E01
(f)
Plastigage
A131982E01
EM65
(g) Check that the front mark of the connecting rod cap
is facing forward.
Front
Front Mark
A131983E01
EM
A131984
(i)
Painted Mark
90
Front
A101478E06
EM66
Plastigage
EM
1, 2, 3, or 4 Mark
Mark
Thickness
A131985E01
Thickness
A129720E01
A131934
5
8
7
2
EM67
3
4
1
A131935E01
2
10
14
16
4
12
13
9
1
11
15
7
3
A131936E01
EM
EM68
Joint Surface
EM
A131937E01
Plastigage
A131956E01
EM69
(k) Install the main bearing cap with your hand until the
clearance between the main bearing cap and the
cylinder block is less than 6 mm (0.23 in.) by
marking the 2 internal bearing cap bolts as a guide.
Bolt length:
100 to 102 mm (3.94 to 4.02 in.)
6 mm
100 to 102 mm
A131957E01
(l)
A131958
105.5 to 107.5 mm
A131959E01
EM
EM70
11
15
EM
16
4
12
13
9
1
(o) Step 1
(1) Install and uniformly tighten the 16 main
bearing cap bolts in the sequence shown in the
illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
HINT:
If any of the main bearing cap bolts does not
meet the torque specification, replace the main
bearing cap bolt.
NOTICE:
Do not turn the crankshaft.
(p) Step 2
(1) Mark the front of the bearing cap bolts with
paint.
10
6
14
A129722E04
Painted Mark
90
Front
A132155E01
1
2
6
5
8
A131961E01
(t)
No. 1
No. 2
Cylinder Block
Number Mark
No. 3
No. 4
Crankshaft
Number Mark
Use Bearing
0-5
No. 1
No. 2
6 - 11
No. 3
12 - 17
18 - 23
24 - 28
No. 4
EM71
EXAMPLE:
Cylinder block "11" + Crankshaft "06" = Total
number 17 (Use bearing "3")
Standard crankshaft main journal diameter
Number Mark
A131987E01
Mark
Specified Condition
00
01
02
03
04
05
06
07
08
09
10
11
Specified Condition
EM
EM72
Specified Condition
Specified Condition
EM
Mark
Specified Condition
Specified Condition
EM73
A132018
LH Side:
RH Side:
A132017E01
Piston Ring
Expander
A131938E01
EM
EM74
EM
A129726
80C
A129727E01
A129728
A131942
EM75
A131943
EM
A131944
EM57
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
A112218
A112193
EM
EM58
A112192
EM
A112189
A098744E01
A112190
A114348
EM59
Timing Mark
Timing Mark
Groove
A098345E09
EM
EM60
Paint Mark
Paint Mark
Timing Mark
Timing Mark
Groove
A098172E05
EM
A098348E03
Loosen
Hold
A098173E03
1
2
10
A098174E08
(f)
A052473E02
10
EM61
A098175E02
A090848E03
EM
EM62
A031032E02
EM
A032639E02
10
A126930
EM63
A126929
DISASSEMBLY
1.
EM
A112227
2.
3.
A114362
Gasket
SST
A114367E01
EM64
4.
5.
6.
7.
8.
A114368
EM
A013383E01
A114361
SST
A098132E01
Retainer
Spring
9.
Valve
A114364E01
SST
EM65
A098133E01
EM
Retainer
Spring
Valve
A114363E01
A014192E01
A013356E01
EM66
INSPECTION
1.
2.
3.
EM
Exhaust Manifold Side
A098134E01
A013365E01
Width
A062786E02
Item
Standard Condition
Intake
Exhaust
4.
Retard Side
Path
Advance
Side Path
Close
Open
Open
Close
Vinyl Tape
EM67
EM
Rubber
A062190E02
Retard
Side Path
Advance
Side Path
A062191E03
EM68
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.
5.
INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than the
maximum, replace the camshaft.
EM01628E01
EM
Specified Condition
No. 1
Other
A036688E01
EM01628E01
EM69
Specified Condition
No. 1
Other
A036688E01
Plastigage
A124775E01
Number Mark
Number Mark
Item
Standard Condition
Other journal
A013530E04
Standard Condition
Other journal
NOTICE:
Completely remove the Plastigage after the
measurement.
EM
EM70
Standard Condition
Mark 1
Mark 2
Mark 3
EM
Mark
Standard Condition
Mark 1
Mark 2
Mark 3
Item
Standard Condition
Intake
Exhaust
A036626E02
Standard Condition
Intake
Exhaust
9.
EM71
P016860E02
A013374E01
A051437E01
Deviation
A062784E02
EM
EM72
A126904
Overall Length
EM
EM02534E05
A032770E02
Margin Thickness
A062785E03
A126904
Overall Length
EM73
EM02534E05
A032770E02
Margin Thickness
A062785E03
A013367E01
EM
EM74
A013367E01
EM
Length
A094201E01
REPLACEMENT
1.
A124781
EM75
(c) Using SST and a hammer, tap out the guide bush.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
SST
A098136E01
EM
A124781
(f)
A124782
Condition
Specified Condition
STD
O/S
(0.05 mm)
SST
A098138E01
EM76
A124783
2.
EM
A124781
(c) Using SST and a hammer, tap out the guide bush.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
SST
A098137E01
A087006E03
(f)
A124782
EM77
Specified Condition
STD
O/S
(0.05 mm)
SST
EM
A098139E01
A124783
EM78
Front Side
Upper Side
EM
Intake Side
Exhaust Side
C
49.5 (1.949)
46.5 (1.831)
37.5 (1.476)
33.3 (1.311)
12.0 (0.472)
24.0 (0.949)
18.0 (0.701)
12.0 (0.472)
A (M6)
B (M6)
13.0 (0.512)
13.0 (0.512)
12.0 (0.472)
9.0 (0.354)
C (M8)
D (M8)
mm (in.)
A098141E04
4.
Upper Side
11 (0.43)
EM79
3 (0.12)
8 (0.32)
mm (in.)
A098140E04
EM
EM76
INSPECTION
1.
CORRECT
INCORRECT
SST
Taper Part
Plunger
Low Pressure
Chamber
EM
Checkball
High Pressure
Chamber
SST
A132092E01
2.
A131920
INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout
at the center journal.
Maximum circle runout:
0.04 mm (0.0016 in.)
If the circle runout is greater than the
maximum, replace the camshaft.
HINT:
Check the oil clearance after replacing the
camshaft.
EM77
Specified Condition
Intake
Exhaust
Specified Condition
Intake
Exhaust
A131921
Specified Condition
No. 1 journal
Other journal
Straight Pin
Key Groove
A131930E01
3.
A131931
EM
EM78
Retard
Side Path
Advance
Side Path
Close
EM
Open
Close
Open
Vinyl Tape
Rubber
A129734E01
Retard
Side Path
Advance
Side Path
A132075E01
Retard
Side Path
Decompress
Advance
Side Path
Hold Pressure
A132076E01
EM79
Straight Pin
Flange Bolt
A131933E01
Straight Pin
Key Groove
A131930E01
4.
A131940
EM
EM80
Retard
Side Path
Advance
Side Path
Open
Close
Close
EM
Open
Rubber
Vinyl Tape
A132169E01
Advance
Side Path
Retard
Side Path
A132078E01
Advance
Side Path
Retard
Side Path
Decompress
Hold Pressure
A132079E01
EM81
Straight Pin
Do Not Remove
Flange Bolt
A131939E01
Measuring Point
5.
6.
Elongated Thread
147 N
Measuring Area
12 3 4 5 6
16
A139523E01
EM
EM82
7.
8.
9.
Measuring Area
12 3 4 5 6
16
A139523E01
EM
A131945
A131946
A131949
A131955
Plunger
EM83
EM
Stopper Plate
A131960E01
Depth
Depth
A131966E01
Depth
Depth
A131967E01
EM84
Depth
A129744E02
Depth
EM
A129745E02
Depth
A129746E02
EM85
Specified Condition
Intake side
Exhaust side
Maximum warpage:
0.10 mm (0.0039 in.)
If the warpage is greater than the maximum, replace
the cylinder head.
EM
Intake Side:
Exhaust Side:
A132032E01
A132151
A131997
EM86
Margin Thickness
A131998E01
Overall Length
EM
A131999E01
A132000
Margin Thickness
A132001E01
Overall Length
A132002E01
Width
A132152E01
Width
A132152E01
EM87
A101392
Deviation
A101393E02
EM
EM88
Specified Condition
Intake
Exhaust
Specified Condition
Intake
Exhaust
HINT:
If the clearance is greater than the maximum,
replace the intake valve and intake guide bush.
If the clearance is greater than the maximum,
replace the exhaust valve and exhaust guide
bush.
EM
A132008
Plastigage
A132170E01
EM89
Specified Condition
No. 1 journal
Other journal
No. 1 Journal
Item
Specified Condition
No. 1 journal
Other journal
(i)
Plastigage
A132038E01
EM
EM90
(l)
Plastigage
Specified Condition
No. 1 journal
Other journal
Other Journal
EM
No. 1 Journal
Item
Specified Condition
No. 1 journal
Other journal
Other Journal
A132010E01
A131819
A131820
EM91
10 mm
(0.39 in.)
EM
A131994E01
Distance: 9.8 mm
A131969E02
EM92
Specified Condition
No. 1
No. 2
Oil
A131948
EM
Piston Ring
110 mm
A132059E01
Specified Condition
No. 1
No. 2
Oil
Specified Condition
No. 1
A101491
No. 2
Oil
Piston Pin
Hole Inside
Diameter
Mark
EM93
Front Mark
Connecting Rod
Bush Inside
Diameter Mark
Front Mark
EM
A131950E01
Specified Condition
A131823
Specified Condition
5 mm (0.20 in.)
28 mm (1.10 in.)
5 mm (0.20 in.)
A132060E01
EM94
(f)
A132061
EM
Mark
Specified Condition
A132172
Measuring Point
A132062E01
EM95
A131952
A131953
40 mm (1.57 in.)
A132156E02
EM
EM96
REPLACEMENT
1.
A131832
EM
A131833
2.
Wooden
Block
A131834E03
SST
A131835E01
(c) Using SST, tap in a new oil seal until its surface is
flush with the oil seal retainer edge.
SST 09223-15030
NOTICE:
Keep the lip free from foreign matter.
Do not tap on the oil seal at an angle.
3.
SST
EM97
A132154E01
(b) Align the oil holes of the new bush and connecting
rod.
Oil Hole
EM
A132157E01
A132154E01
(d) Using a pin hole grinder, hone the bush to obtain the
standard specified clearance between the bush and
piston pin.
A132159
(e) Coat the piston pin with engine oil. Push the piston
pin into the connecting rod with your thumb to check
that the piston pin fits at normal room temperature.
4.
A132160
EM98
(c) Using SST and a hammer, tap out the valve guide
bush.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
SST
A132034E01
EM
A132005
Bush Size
Specified Condition
Use STD
(f)
HINT:
If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), machine
the bush bore diameter to between 10.383 to
10.394 mm (0.4088 to 0.4092 in.).
If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), replace the
cylinder head.
Heat the cylinder head to approximately 80 to
100C (176 to 212F).
SST
Height
A132035E01
EM99
A132036
(c) Using SST and a hammer, tap out the valve guide
bush.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
SST
EM
A132004E01
A132006
Bush Size
Specified Condition
Use STD
(f)
HINT:
If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), machine
the bush bore diameter to between 10.383 to
10.394 mm (0.4088 to 0.4092 in.).
If the bush bore diameter of the cylinder head is
greater than 10.344 mm (0.4072 in.), replace the
cylinder head.
Heat the cylinder head to approximately 80 to
100C (176 to 212F).
EM100
SST
Height
EM
A132037E01
A132007
Adhesive
A132063E01
EM101
RH Side:
LH Side:
A131963E01
7.
A
B
52 mm (2.05 in.)
34 mm (1.34 in.)
B
A131965E01
8.
EM
EM102
Item
Specified Condition
Pin A
23 mm (0.91 in.)
Pin B
6 mm (0.24 in.)
Pin C
11 mm (0.43 in.)
Pin D
9 mm (0.35 in.)
EM
C
A
B
B
Cylinder Block Upper:
A
B
6 mm
(0.24 in.)
C
11 mm
(0.43 in.)
9 mm
(0.35 in.)
B
A131964E01
9.
EM103
for Bank 1:
for Bank 2:
2.5 to 3.5 mm
(0.10 to 0.14 in.)
A132011E01
EM
EM104
C
B
for Bank 2 Intake Side:
EM
B
35 mm (1.38 in.)
34 mm (1.34 in.)
27 mm (1.06 in.)
C
A132039E01
EM80
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all
sliding and rotating surfaces.
Replace oil seals with new ones.
1.
SST
EM
A124784E02
HINT:
The intake valve oil seal is gray and the exhaust
valve oil seal is black.
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
installation problems later.
Exhaust
Intake
Mark
NOK
Gray
Black
A124785E01
2.
Retainer
Spring
Seat
Valve
A126924E02
SST
A098132E01
EM81
Valve Stem
A112168E04
(b) Install the valve, seat, spring and retainer onto the
cylinder head.
Retainer
Valve
EM
Spring
Seat
A126925E02
SST
A098133E01
Vinyl Tape
4.
5.
Valve Stem
A098144E07
EM82
(b) Align the bearing claw with the claw groove of No. 1
and No. 2 bearing cap, and push in the No. 1
camshaft bearing.
6.
A124773
EM
A013383E01
7.
8.
A114368
Gasket
SST
A114367E01
9.
EM83
A114362
EM
A112227
INSTALLATION
Lot No.
A126929E01
10
7 F050595E03
1.
2.
EM84
(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts by 90 as shown
in the illustration.
(e) Check that the paint mark is now at a 90 angle to
the front.
90
Engine Front
Paint Mark
A098364E01
3.
4.
5.
INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion
of the camshaft.
Straight Pin
EM
Key Groove
A098365E02
A032167E01
F050592E01
EM85
F050591E01
No. 1
10
17
18
13
14
15
16
No. 2
7 4
3 12 11 20 19
F050596E02
6.
7.
8.
9.
EM
EM86
EM
A098748E01
A114348
2
4
3
1
A112190E01
A098744E01
EM87
A112189
EM
A112192
New O-Ring
A112218E01
EM88
EM
REPAIR
75 45
1.
30
Width
A128227E01
Item
Standard Condition
Intake
Exhaust
EM88
ENGINE ASSEMBLY
2AZ-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
HOOD SUB-ASSEMBLY
EM
13 (133, 10)
13 (133, 10)
96 (979, 71)
96 (979, 71)
EM89
PURGE VSV
x3
AIR CLEANER
ASSEMBLY
BATTERY TRAY
EM
x4
FRONT BATTERY
CARRIER
20 (204, 15)
x2
BATTERY BRACKET
REINFORCEMENT
20 (204, 15)
RADIATOR GRILL
EM90
19 (194, 14)
EM
UNION TO CONNECTOR
TUBE HOSE
19 (194, 14)
RADIATOR RESERVOIR
UPPER RADIATOR SUPPORT BRACKET
NO. 2 FAN
SHROUD
NO. 1
TRANSMISSION
OIL COOLER
HOSE
(for Automatic
Transaxle)
NO. 1 RADIATOR
HOSE
A126875E03
EM91
x4
30 (306, 22)
EM
FUEL TUBE
THROTTLE BODY
NO.1 THROTTLE
BODY HOSE
GASKET
EM92
EM
20 (204, 15)
x2
x4
FUEL TUBE
EM93
GASKET
EM
30 (306, 22)
INTAKE MANIFOLD
HEATED OXYGEN SENSOR
CONNECTOR
EM94
CLIP
GENERATOR WIRE
ECM CONNECTOR
EM
52 (530, 38)
21 (214, 15)
ECM
GENERATOR ASSEMBLY
EM95
64 (653, 47)
x3
SNAP RING
x2
EM
SNAP RING
FLEXIBLE HOSE
FRONT DRIVE SHAFT
ASSEMBLY LH
HEATED OXYGEN
SENSOR CONNECTOR
49 (500, 36)
92 (938, 68)
GASKET
43 (438, 32)
43 (438, 32)
EM96
for 4WD
x6
69 (704, 51)
x4
35 (357, 26)
35 (357, 26)
x4
x2
x2
EM
37 (377, 27)
TRANSFER ASSEMBLY
95 (969, 70)
95 (969, 70)
52 (530, 38)
x2
95 (969, 70)
for 4WD
ENGINE MOUNTING
INSULATOR RR
x2 x2
95 (969, 70)
95 (969, 70)
x2
x2
A126920E04
EM97
EM
x6
x8
41 (418, 30)
64 (653, 47)
46 (469, 34)
46 (469, 34)
STARTER ASSEMBLY
x2
37 (377, 27)
EM98
REMOVAL
EM
1.
2.
3.
4.
5.
6.
REMOVE BATTERY
7.
8.
9.
A124838
EM99
A112221
EM
A124827
A124828
A124829
A124830
EM100
A124832
EM
EM101
A124834
EM
A124847
A124835
A124836
(f)
A124837
EM102
(b) Remove the front drive shaft (for 4WD) (see page
DS-40).
42. REMOVE PROPELLER SHAFT ASSEMBLY (for 4WD)
(See page PR-3)
43. REMOVE ENGINE MOUNTING INSULATOR FR
(a) Remove the through bolt and nut.
A124839
EM
A124840
A124841
A124842
EM103
Item
Part No.
12281-28010
12282-28010
Bolt
91512-61020
A112213E01
A114336
A124843
A124844
EM
EM104
A124845
EM
A098759E01
A114345
SST
A126932E01
EM105
A112224
EM
for Bank 1:
EM105
for Bank 2:
34 mm
(1.34 in.)
18.0 to 19.0 mm
(0.71 to 0.75 in.)
A132040E01
REASSEMBLY
1.
EM
A129732
2.
Adhesive
A076531E01
EM106
RH Side:
20
12
LH Side:
EM
45
15
A131970E01
3.
Service Hole
A131876E01
80C
A131877E01
EM107
Front Mark
A131968E01
EM
A129725
(f)
Service Hole
4.
A131879E01
Piston Ring
Expander
Side Rail
Upper
No. 1 Ring
No. 2 Ring
Side Rail Lower
Oil Ring
A131971E01
EM108
(c) Position the piston rings so that the ring ends are as
shown in the illustration.
NOTICE:
Do not align the ring ends.
5.
Front Mark
Oil Ring
Expander
No. 1 Ring
EM
Upper Bearing
CORRECT INCORRECT
A132043E01
Vernier
Caliper
Mark 1, 2, 3, 4 or 5
EM109
A
B
A131826E02
6.
INSTALL CRANKSHAFT
(a) Install the 2 thrust washers under the No. 2 journal
position of the cylinder block with the oil grooves
facing outward.
(b) Apply engine oil to the upper bearing, then place the
crankshaft on the cylinder block.
Oil Groove
A132044E01
A131988
6 mm
100 to 102 mm
A131957E01
EM
EM110
A131958
(i)
(j)
EM
105.5 to 107.5 mm
A131959E01
(k) Step 1
(1) Install and uniformly tighten the 16 main
bearing cap bolts in the sequence shown in the
illustration.
Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
If any of the main bearing cap bolts does not
meet the specified torque, replace it.
15
7
11
8
16
12
13
2
10
14
A131936E02
EM111
(l)
Step 2
(1) Mark the front of the bearing cap bolts with
paint.
(2) Tighten the bearing cap bolts another 90 in the
order shown in step 1.
(3) Check that the painted mark is now at a 90
angle to the front.
(m) Check that the crankshaft turns smoothly.
Painted Mark
90
Front
A132155E01
4
1
7
6
5
8
7.
A131935E02
8.
Vernier Caliper
A132045E01
EM
EM112
(b) Position the piston rings so that the ring ends are as
shown in the illustration.
NOTICE:
Do not align the ring ends.
No. 1 Ring
Side Rail Upper
A131881E01
EM
Engine Front
Front Mark
A131886E01
(d) Check that the front mark of the connecting rod cap
is facing forward.
(e) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod cap bolts.
(f) Install the connecting cap bolts.
HINT:
The connecting cap bolts are tightened in 2
progressive steps.
Engine Front
Front Mark
A131980E01
(g) Step 1
(1) Install and alternately tighten the bolts of the
connecting rod cap in several steps.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
A131887
EM113
(h) Step 2
(1) Mark the front side of each connecting cap bolt
with paint.
(2) Tighten the cap bolts another 90 as shown in
the illustration in the order in step 1.
(3) Check that the painted mark is now at a 90
angle to the front.
(i) Check that the crankshaft turns smoothly.
Painted Mark
90
Front
A132064E01
9.
EM
A129663
for Bank 2:
for Bank 1:
A131996E01
EM114
for Bank 1:
for Bank 2:
EM
A131995E01
Exhaust Side
Intake Side
White
Black
A131926E01
SST
A132014E01
EM115
SST
A131991E01
EM
A132015
A132042E01
SST
A131992E01
EM116
A129713
Lot No.
EM
Engine Front
A132135E01
A132143E04
(f)
90
90
Front
Painted Mark
A132162E01
Step 2
(1) Mark the cylinder head bolt head with paint as
shown in the illustration.
(2) Tighten the cylinder heads bolts another 90 in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90 in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
EM117
Lot No.
A132137E01
8
A132145E04
(f)
90
90
Front
Painted Mark
A132162E01
Step 2
(1) Mark the cylinder head bolt heads with paint as
shown in the illustration.
(2) Tighten the cylinder head bolts another 90 in
the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional
90 in the sequence shown in step 1.
(2) Check that the painted mark is now facing
rearward.
(h) Install the 2 bolts in the order shown in the
illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
A132144E02
EM
EM118
Lash
Adjuster
Valve Stem
A132090E01
EM
A132125
A132126E01
: Seal Packing
A132127E01
12
10
EM119
11
Front View
45
Knock Pin
A132140E01
A132122E03
A132121
EM
EM120
8
2
4
A132086E01
EM
: Seal Packing
A132133E01
12
10
5
2
8
13
11
Front View
Knock Pin
A132142E01
A132131E03
EM121
A132130
EM
A132023
Timing Mark
Mark Plate
A132080E01
Hold
Turn
A132073E01
EM122
A132024
Timing Mark
EM
Mark Plate
A132087E01
Turn
Hold
A132083E01
A131972
EM123
(b) Temporarily install the No. 1 idle gear shaft and idle
sprocket with the No. 2 idle gear shaft while aligning
the knock pin of the No. 1 idle gear shaft with the
knock pin groove of the cylinder block.
NOTICE:
Be careful of the idle gear direction.
(c) Using a 10 mm hexagon wrench, tighten the No. 2
idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
Knock Pin
A132222E01
Timing Mark
A132115E01
EM
EM124
Align
EM
Chain
Plate
Mark
Chain Plate
A122184E05
Mark Plate
Timing Mark
A132116E01
Timing Mark
Center Line
Sensor Plate
A132112E01
EM125
Stopper Plate
Plunger
A131974E01
EM
A132020
EM126
EM
Timing Mark
Timing Mark
A132117E01
: Seal Packing
A131897E03
EM127
A129686E01
SST
EM
A132068E01
A136827
EM128
: Seal Packing
A132236E01
12
EM
8
A
11
10
9
A132119E01
A
A132173E01
: Seal Packing
A132237E01
8
9
6
1
11
10 12
EM129
(c) Install the head cover with the 12 bolts in the order
in the illastration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
10 N*m (102 kgf*cm, 7 ft.*lbf) for except
bolt A
HINT:
Make sure the tightening torque of bolts 1 and 10 is
correct.
3
A132120E01
A132070
A129677
(c) Install the water outlet with the 2 bolts and 4 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
A129676
EM
EM130
for Bank 1:
for Bank 2:
EM
A131977E01
for Bank 1:
for Bank 2:
A131976E01
EM106
INSTALLATION
1.
SST
EM
A126932E01
A114342
(e) Install the drive plate and rear spacer onto the
crankshaft.
Drive Plate
Transaxle
Rear Spacer
Transaxle
A129332E01
(f)
1
2.
3.
4.
5.
6.
7.
8.
EM107
5
A112224E01
A098759E01
A114345
A114375E02
ITEM
Part No.
12281-28010
12282-28010
Bolt
91512-61020
EM
EM108
(b) Attach the sling device and the engine with the
chain block.
9.
A114336
EM
A114337
A124845
Nut
Through Bolt
A124844E01
A124843E01
EM109
A112213E01
A124842
A124841
A124840
EM
EM110
Through Bolt
Nut
A124839E02
EM
A124837
A124836
A124835
EM111
A124834
A124847
A124831
EM
EM112
A124832
EM
A124830
A124829
A124828
EM113
A112221
A124838
EM
EM114
EM
EM114
ENGINE UNIT
2AZ-FE ENGINE MECHANICAL
ENGINE
COMPONENTS
EM
GASKET
9.0 (92, 80 in.*lbf)
GASKET
PLATE WASHER
29.5 (301, 22)
EM115
THERMOSTAT
60 (612, 44)
x2
GASKET
WATER INLET
IDLER PULLEY
OIL DIPSTICK
EM
9.0 (92, 80 in.*lbf)
12 (122, 9)
37 (337, 27)
MANIFOLD STAY
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A124382E03
EM116
EM
CAMSHAFT POSITION
SENSOR
KNOCK SENSOR
20 (204, 15)
O-RING
GASKET
15 (153, 11)
EM117
x2
19 (194, 14)
VENTILATION VALVE
SUB-ASSEMBLY
11 (112, 8)
x2
11 (112, 8)
EM
x6
SPARK PLUG
43 (438, 32)
55 (561, 41)
A132514E01
EM118
CRANKSHAFT POSITION
SENSOR BRACKET
EM
9.0 (92, 80 in.*lbf)
x2
x4
26 (265, 19)
x4
WATER PUMP PULLEY
CRANKSHAFT PULLEY
OIL PAN SUB-ASSEMBLY
GASKET
40 (408, 30)
x2
x 12
EM119
19 (194, 14)
EM
GASKET
CRANKSHAFT TIMING
SPROCKET
TIMING CHAIN GUIDE
OIL PUMP
ASSEMBLY
x3
19 (194, 14)
11 (112, 8)
x2
GASKET
9.0 (92, 80 in.*lbf)
x2
x3
x8
25 (255, 18)
A124384E03
EM120
x 16
NO. 1 CAMSHAFT
BEARING CAP
x2
NO. 3 CAMSHAFT BEARING CAP
NO. 3 CAMSHAFT BEARING CAP
NO. 1 CAMSHAFT
BEARING
54 (551, 40)
NO. 2 CAMSHAFT
EM
CAMSHAFT TIMING
GEAR ASSEMBLY
PLATE WASHER
EM121
30 (306, 22)
PLUG
GASKET
EM
ENGINE REAR OIL SEAL
STIFFENING CRANKCASE
ASSEMBLY
x5
24 (245, 18)
24 (245, 18)
x6
25 (255, 18)
x8
1st: 21.6 (220, 16)
Non-reusable part
Precoated part
2nd: Turn 90
EM122
PISTON
PISTON PIN HOLE SNAP RING
PISTON PIN
CONNECTING ROD SUB-ASSEMBLY
EM
CONNECTING ROD BEARING
CRANKSHAFT BEARING
NO. 1 OIL NOZZLE
SUB-ASSEMBLY
CRANKSHAFT
7.0 (71, 62 in.*lbf)
A124761E02
EM123
DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
REMOVE THERMOSTAT
A112226
EM
EM124
A132575
EM
A128158
A128159
A128166
12 mm
Hexagon
wrench
EM125
A132571
A128185
A128186
No. 1
5
6
17
9
2
10
18
13
14
15
16
No. 2
7 4
3 12 11 20 19
F050596E02
EM
EM126
A126929
EM
A128208
A128209
A128210
A128196
EM127
A128197E01
A132569E01
(f)
Length
A131575E01
Plastigage
A090849E04
A128197E03
EM
EM128
New O-ring
A037134E02
EM
Item
Specified Condition
Mark 1
Mark 2
Mark 3
Item
Specified Condition
Mark 1
Mark 2
Mark 3
A132569E01
EM129
EM
A128204E01
Cut Position
A098356E01
5 9 11
8
4
3
2
10
A112229E01
EM130
EM
A128205
A128206
A112172
EM131
Matchmark
A063893E01
EM
A013397E01
A013400E01
(f)
Front Mark
A036691E01
(i)
(j)
90
Paint Mark
Engine Front
A101478E03
EM132
Plastigage
Diameter Mark
EM
Mark
Specified Condition
Mark 1
Mark 2
Mark 3
A129453E01
Specified Condition
Mark 1
Mark 2
Mark 3
A112232
EM133
EM
A112234
A112235
A112236
A112237
EM134
HINT:
The thrust washer thickness is 1.93 to 1.98 mm
(0.0760 to 0.0780 in.).
65. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE:
Do not turn the crankshaft during the measurement.
1
EM
10
A087780E03
Plastigage
A087782E03
Front Mark
A098155E01
(j)
EM135
10
A087780E04
Paint
Mark
90
(k) Mark the front of the bearing cap bolts with paint.
(l) Retighten the 10 bearing cap bolts by 90.
(m) Check that the paint marks are at a 90 angle to the
front.
EM
Engine Front
A098354E01
10
A087780E03
EM136
EM
Cylinder block
+ Crankshaft
0 to 2
3 to 5
6 to 8
9 to 11
Use bearing
"1"
"2"
"3"
"4"
EXAMPLE
Imprinted number on the cylinder block is 3.
Imprinted number on the crankshaft is 4.
3+4=7
Select the bearing marked "3".
Standard cylinder block journal bore diameter
Diameter Mark
A129506E01
Mark
Specified Condition
Specified Condition
EM137
Mark
Specified Condition
Mark
Specified Condition
10
A087780E02
A013501E02
A063901E01
EM
EM138
A063902E01
EM
A112263E01
INSPECTION
1.
A112240
2.
EM139
Thrust Direction
Front
Axial Direction
A
B
EM
10 mm
(0.39 in.)
A112241E01
3.
INSPECT PISTON
(a) Using a gasket scraper, remove the carbon from the
piston top.
A126913
A126914
A126915
EM140
4.
5.
A112242E01
EM
Item
Specified Condition
No. 1 ring
No. 2 ring
Oil ring
A126911
110 mm
Piston Ring
A098149E01
Specified Condition
No. 1 ring
No. 2 ring
Oil ring
Specified Condition
No. 1 ring
EM02552E01
Specified Condition
No. 2 ring
Oil ring
EM141
Item
Specified Condition
A112243
Specified Condition
Specified Condition
A001185E01
EM
EM142
Front Mark
Connecting Rod
Small End Bore
Diameter Mark
Front Mark
EM
A112244E01
8.
Z000064E03
Z000065E02
9.
A001470E02
EM143
A013491E01
No. 1
No. 2
No. 3
No. 4
No. 5
A098151E01
ZF06928E02
Mark
Specified Condition
EM
EM144
EM
EM131
REPAIR
1.
45
30
Width
A132153E01
60
45
2.
Width
A132003E02
Width
A132153E01
75
45
Width
A132003E01
EM
EM145
REPLACEMENT
1.
A112248
SST
A112249E02
Cut Position
A077418E02
SST
A077419E02
EM
EM146
2.
Cut Position
A098356E01
EM
3.
SST
A077422E01
Item
Specified Condition
EM147
Front Side
Right Side
C
B
A
D
Left Side
EM
16.0 (0.630)
15.0 (0.591)
84.0 (3.307)
12.0 (0.472)
52.5 (2.067)
12.0 (0.472)
33.3 (1.311)
20.0 (0.787)
27.5 (1.083)
9.0 (0.354)
A
10.0 (0.394)
9.0 (0.354)
mm (in.)
A112253E01
4.
Adhesive
A058129E01
Item
Specified Condition
EM148
Front Side
Rear Side
B
A098152E01
EM
5.
Item
Specified Condition
Upper Side
Lower Side
B
14.0 (0.551)
13.0 (0.512)
B
Protrusion Height
12.0 (0.472)
12.0 (0.472)
mm (in.)
A112251E01
EM149
6.
Item
Specified Condition
Front Side
Lower Side
EM
B
A
B
Rear Side
Right Side
C
D
A
18.0 (0.709)
8.0 (0.315)
15.0 (0.591)
8.0 (0.315)
22.0 (0.866) D
10.0 (0.394)
Protrusion Height
14.0 (0.551)
7.0 (0.276)
mm (in.)
A112252E01
EM150
REASSEMBLY
1.
A032958E02
Front Mark
EM
INSTALL PISTON
(a) Using a small screwdriver, install a new snap ring
onto one end of the piston pin hole.
HINT:
Make sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
(b) Gradually heat the piston up to 80 to 90C (176 to
194F).
Front Mark
A098154E01
2.
Oil Ring
Oil Ring
(Expander)
Oil Ring
(Expander)
Oil Ring
A131712E01
EM151
Upward
No. 1
EM
Paint Mark
No. 2
(c) Position the piston rings so that the ring ends are as
shown in the illustration.
Front Mark
3.
A112263E01
EM152
4.
5.
6.
7.
8.
INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, and install the
crankshaft onto the cylinder block.
A112265
EM
A053029E02
A033379E01
Oil Groove
A013501E01
Front Mark
A098155E01
EM153
10
A087780E04
(e) Mark the front of the bearing cap bolts with paint.
(f) Retighten the 10 bearing cap bolts by 90 in the
same sequence.
(g) Check that the paint marks are now at a 90 angle
to the front.
(h) Check that the crankshaft turns smoothly.
Paint
Mark
90
Engine Front
A098354E01
9.
Claw
A098158E01
Front Mark
EM
EM154
Front Mark
Hammer
Handle
Front
A112258E01
Front Mark
EM
A098145E01
90
Paint Mark
(d) Check that the front mark of the connecting rod cap
is facing in the correct direction.
NOTICE:
Match the numbered connecting rod cap with
the connecting rod.
(e) Apply a light coat of engine oil to the threads and
under the heads of the connecting rod bolts.
(f) Using a 12 mm socket wrench, tighten the bolts in
several passes to the specified torque.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
(g) Mark the front of the connecting rod bolts with paint.
(h) Retighten the cap bolts 90 as shown in the
illustration.
(i) Check that the crankshaft turns smoothly.
Engine Front
A101478E03
Stiffening Crankcase
A128204E01
Timing Mark
EM155
Rotating Direction
A090850E02
(b) Confirm that the timing marks on the No. 1 and No.
2 driven gears are aligned.
EM
Timing Mark
A128214E01
No. 1
Timing Mark
No. 2
A131707E01
(f)
5
A128197E03
(i)
New O-ring
A037134E02
EM156
New O-Ring
A112261E02
EM
No. 1
Crank Pin
Adjusting Hole
A091021E02
A
C
D
B
7.5 mm
(0.295 in.)
7.5 mm
(0.295 in.)
C, D
4.0 mm
(0.158 in.)
A112260E01
EM157
Item
Specified Condition
For bolt A
(12 mm head)
For bolt B
(12 mm head)
35 mm (1.38 in.)
11
7 3
B
A112229E02
(f)
EM
9
10
A112229E03
Timing Mark
Key
A094194E01
(b) Using SST and hammer, tap in the new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
Wipe any extra grease off the crankshaft.
Do not tap the oil seal at an angle.
SST
A077422E01
Gasket
Plug
A128210E01
EM158
A076531E04
EM
45
45
A098363E01
O-ring
A090053E02
(b) Install the camshaft timing oil control valve with the
bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
20. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY (See
page EM-83)
21. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET (See
page EM-84)
A128171
EM159
A128176
12 mm
Hexagon
wrench
EM
EM160
A128166
EM
A128159
A128158
A132575
EM161
Adhesive
A092670E03
A098067E01
A126940
EM
EM162
EM