1GR-FE Engine Mechanical PDF

EM-1
ENGINE MECHANICAL (1GR-FE)
CO/HC
CO/HC
EM0KQ-10
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1.
INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f)
SFI system wiring connectors fully plugged
(g) Correct ignition timing
(h) Transmission in neutral position
(i)
Tachometer and CO/HC meter calibrated by hand
2.
START ENGINE
3.
RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS
4.
CO/HC Meter
5.
INSERT CO/HC METER TESTING PROBE AT LEAST

40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow
the measurement orders prescribed by the applicable local regulations.
A19383
Author:
Date:
3209
EM-2
CO/HC
If the CO/HC concentration does not comply with regulations,

perform troubleshooting in the order given below.
(1) Check the A/F sensors and heated oxygen sensors
operation (See page DI-84 and DI-90 ).
(2) See the table below for possible causes, and then
inspect and correct the corresponding causes if
necessary.
CO
HC
Problems
Causes
Normal
High
Rough idle
1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
Low
High
Rough idle
(fluctuating HC reading)
1. Vacuum leaks:
PCV hose
Intake manifold
Throttle body
2. Lean mixture causing misfire
High
High
Rough idle
(Black smoke from exhaust)
1. Restricted air filter

2. Faulty SFI system:
Faulty pressure regulator
Defective ECT sensor
Faulty ECM
Faulty injectors
Faulty throttle position sensor
Faulty MAF meter
Author:
Date:
3210
EM-3
COMPRESSION
COMPRESSION
EM06C-06
INSPECTION
A22796
HINT:
If there is a lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1.
WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2.
REMOVE SPARK PLUGS
(a) Remove the V-bank cover.
(b) Remove the air cleaner.
(c) Remove the intake air surge tank (See page EM-62 ).
(d) Remove the 6 ignition coils.
(e) Remove the 6 spark plugs.
(f)
Disconnect the 6 injector connectors.
3.
CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain an engine speed
of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in the shortest possible
time.
Compression pressure:
1.3 MPa (13.3 kgf/cm2, 189 psi) or more
Minimum pressure: 1.0 MPa (10.2 kgf/cm2, 145 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm2, 15 psi) or less
(e) If the cylinder compression pressure in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a)
through (c) for cylinders with low compression pressure.

If adding oil improves the compression pressure, it
is likely that the piston rings and/or cylinder bore are
worn or damaged.

If compression pressure stays low, a valve may be
sticking, seating may be improper, or there may be
a leak past the gasket.
4.
REINSTALL SPARK PLUGS
(a) Connect the 6 injector connectors.
(b) Install the 6 spark plugs.
Torque: 20 Nm (200 kgfcm, 15 ftlbf)
(c) Install the 6 ignition coils.
(d) Install the intake air surge tank (See page EM-89 ).
(e) Install the air cleaner.
(f)
Install the V-bank cover.
Author:
Date:
3211
EM-1 11
CYLINDER BLOCK
CYLINDER BLOCK
EM1XY-01
COMPONENTS
Piston Ring (No. 1 Compression Ring)
Piston Ring (No. 2 Compression Ring)
Piston Ring (Expander)
Piston Ring (Side Rail)

Piston
Piston Pin Hole Snap Ring
Piston Pin
Water Outlet Pipe No.1
10 (102, 7)
Piston Pin Hole

Snap Ring
10 (102, 7)
Connecting Rod
Connecting Rod
Bearing
Connecting Rod
Cap
Knock Sensor
20 (204, 15)
20 (204, 15)
Knock Sensor
Water Drain Cock
Knock Sensor Wire

Engine Rear Oil
10 (102, 7)
Seal Retainer
Oil Seal
25 (255, 18)
See page EM-128

1st 25 (250, 18)
2nd Turn 90
x5
x2
Water Drain Cock
25 (255, 18)
9.0 (92, 80 in.lbf)
Crankshaft Bearing
x8
Oil Nozzle
Upper Crankshaft
Thrust Washer
25 (255, 18)
9.0 (92, 80 in.lbf)
Crankshaft
Lower Crankshaft Thrust Washer

Crankshaft Bearing Cap
Crankshaft Bearing
See page EM-128
Nm (kgfcm, ftlbf) : Specified torque

Non-reusable part
1st 61 (622, 45)

2nd Turn 90
A23200
Author:
Date:
3319
EM-1 12
CYLINDER BLOCK
EM1XZ-01
DISASSEMBLY
1.
(a)
(b)
REMOVE WATER OUTLET PIPE NO.1

Separate the knock sensor wire.
Remove the 3 bolts and water outlet pipe.
2.
(a)
(b)
3.
REMOVE KNOCK SENSOR

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

Remove the 5 bolts and 2 nuts.
Using a screwdriver, remove the oil seal retainer by prying
between the oil seal retainer and crankshaft bearing cap.
A22979
A22980
Pry
A22981
A23021
5.
INSPECT CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
6.
INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure correct reassembling.
(b) Using SST, remove the 2 connecting rod cap bolts.
SST 09011-38121
(c) Clean the crank pin, bearing and connecting rod.
(d) Check the crank pin and bearing for pits and scratches.
Author:
Date:
3320
EM-1 13
CYLINDER BLOCK
(e)
Lay a strip of Plastigage across the crank pin.
(f)
Check that the protrusion of the connecting rod cap is facing the correct direction.
Apply a light coat of engine oil to the threads of the connecting rod cap bolts.
Plastigage
A23022
(g)
Protrusion
A23023
(h)
Using SST, tighten the bolts alternately to the specified

torque.
SST 09011-38121
A23024
(i)
Mark the front side of each connecting cap bolt with paint.
(j)
Retighten the cap bolts 90 as shown in the illustration.
NOTICE:
Do not turn the crankshaft.
(k) Remove the 2 bolts, connecting rod cap and lower bearing.
Painted Mark
90
Front
90
A23025
(l)
Measure the Plastigage at its widest point.

Standard oil clearance:
0.026 to 0.046 mm (0.0010 to 0.0018 in.)
Maximum oil clearance: 0.066 mm (0.0025 in.)
NOTICE:
Completely remove the Plastigage.
A23026
Author:
Date:
3321
EM-1 14
Number Mark
(m)
Number Mark
CYLINDER BLOCK
If replacing a bearing, replace it with one that has the

same number marked on the connecting rod. There are
4 sizes of standard bearings, marked 1 , 2, 3 and 4
accordingly.
HINT:
Standard bearing center wall thickness
A23027
7.
(a)
(b)
Mark
mm (in.)
1.484 to 1.487 (0.0584 to 0.0585)
1.487 to 1.490 (0.0585 to 0.0587)
1.490 to 1.493 (0.0587 to 0.0588)
1.493 to 1.496 (0.0588 to 0.0589)
REMOVE PISTON W/CONNECTING ROD

Using a ridge reamer, remove all the carbon from the top
of the cylinder.
Push in the piston w/ connecting rod and upper bearing
through the top of the cylinder block.
HINT:

A23028
8.
9.
(a)
(b)
Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.
REMOVE CONNECTING ROD BEARING
REMOVE PISTON RING SET
Using a piston ring expander, remove the 2 compression
rings.
Remove the 2 side rails and oil ring by hand.
A23029
10. REMOVE PISTON PIN HOLE SNAP RING

Using a screwdriver, pry out the 2 snap rings.
A23030
Author:
Date:
3322
EM-1 15
80C
CYLINDER BLOCK
11.
(a)
REMOVE PISTON PIN

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

out the piston pin and remove the connecting rod.
A23031
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.
A23032
12.
(a)
A23033
INSPECT CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
If the thrust clearance is greater than the maximum, replace the
pair of the thrust washers or the crankshaft.
HINT:
Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780
in.)
13.
(a)
5
8
7
2
REMOVE CRANKSHAFT
Using several steps, uniformly loosen and remove the 8
main bearing cap bolts and seal washers in the sequence
as shown in the illustration.
4
1
A23034
Author:
Date:
3323
EM-1 16
(b)
4
12
16 11
14 15
7
10 13
5
9
1
8
CYLINDER BLOCK
Using several steps, uniformly loosen and remove the 16

main bearing cap bolts in the sequence as shown in the
illustration.
A23035
(c)
Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.
NOTICE:

Pull up the main bearing cap while turning it little by
little to the right and the left.
A23036
14.
15.
Main Bearing Cap
Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
REMOVE CRANKSHAFT THRUST WASTER SET
REMOVE CRANKSHAFT BEARING
Cylinder
Block
A23037
16. REMOVE OIL NOZZLE

Using a 5 mm socket hexagon wrench, remove the 3 oil
nozzles.
A23038
Author:
Date:
3324
EM-1 17
CYLINDER BLOCK
EM1Y0-01
INSPECTION
1.
INSPECT CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
flatness of the surface that is in contact with the cylinder head
gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than the maximum, replace the cylinder
block.
A23039
2.
INSPECT CYLINDER BORE
Using a cylinder gauge, measure the cylinder bore diameter at
positions A and B in the thrust and axial directions.
Standard diameter:
94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter: 94.132mm (3.7060 in.)
If the average diameter of the 4 positions is greater than the
maximum, replace the cylinder block.
Thrust Direction
Front
Axial Direction
10 mm
A23040
3.
INSPECT PISTON
Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 27.7 mm (1.091 in.) from the
piston head.
Piston diameter:
93.910 to 93.940 mm (3.6972 to 3.6984 in.)
27.7 mm
(1.091 in.)
A23041
Author:
Date:
3325
EM-1 18
CYLINDER BLOCK
4.
INSPECT PISTON OIL CLEARANCE
Subtract the piston diameter measurement from the cylinder
bore diameter measurement.
0.060 to 0.102 mm (0.0024 to 0.0040 in.)
If the oil clearance is greater than the maximum, replace all the
6 pistons. If necessary, replace the cylinder block.
5.
INSPECT CONNECTING ROD
Using a rod aligner and feeler gauge, check the connecting rod
alignment.
(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment is greater than the maximum, replace the connecting rod assembly.
Z00064
(2) Check twist.

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than the maximum, replace the connecting rod
assembly.
Z00065
6.
(a)
INSPECT PISTON PIN OIL CLEARANCE

Using a caliper gauge, measure the inside diameter of the
piston pin hole.
Piston pin hole inside diameter:
22.001 to 22.010 mm (0.8662 to 0.8665 in.)
HINT:
Piston pin hole inside diameter
A13490
Mark
mm (in.)
22.001 to 22.004 (0.8662 to 0.8663)
22.005 to 22.007 (0.8663 to 0.8664)
22.008 to 22.010 (0.8665 to 0.8665)
Author:
Date:
3326
EM-1 19
(b)
CYLINDER BLOCK
Using a micrometer, measure the piston pin diameter.

Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
HINT:
Piston pin diameter
EM0227
(c)
Mark
mm (in.)
21.997 to 22.000 (0.8660 to 0.8661)
22.001 to 22.003 (0.8661 to 0.8663)
22.004 to 22.006 (0.8663 to 0.8664)

connecting rod bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
HINT:
Bushing inside diameter
EM6525
22.005 to 22.008 (0.8663 to 0.8665)
22.009 to 22.011 (0.8665 to 0.8666)
22.012 to 22.014 (0.8666 to 0.8667)
Subtract the piston pin diameter measurement from the

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

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

Inside Diameter
Mark
Mark
(g)
Front Mark
A23042
Author:
Date:
3327
EM-120
CYLINDER BLOCK
7.
INSPECT RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between the new
piston ring and the wall of the ring groove.
Ring groove clearance:
No.1: 0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No.2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Oil: 0.07 to 0.15 mm (0.0028 to 0.0060 in.)
A23044
8.
(a)
INSPECT PISTON RING END GAP

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

Standard end gap:
No. 1: 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No. 2: 0.40 to 0.50 mm (0.0157 to 0.0197 in.)
Oil (Side rail): 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Maximum end gap:
No. 1: 1.0 mm (0.039 in.)
No. 2: 1.1 mm (0.043 in.)
Oil (Side rail): 1.0 mm (0.039 in.)
110 mm
A23045
EM7639
9.
INSPECT CONNECTING ROD BOLT
Using a vernier caliper, measure the tension portion diameter
of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.
A23046
10. INSPECT CRANKSHAFT BEARING CAP SET BOLT

Using a vernier caliper, measure the tension portion diameter
of the bolt.
Standard diameter:
10.0 to 10.2 mm (0.393 to 0.402 in.)
If the diameter is less than the minimum, replace the bolt.
A23046
Author:
Date:
3328
EM-121
CYLINDER BLOCK
11.
(a)
INSPECT CRANKSHAFT
Using a dial indicator and V-blocks, measure the runout
Maximum circle runout: 0.06 mm (0.0024 in.)
(b)
Using a micrometer, measure the diameter of each main

journal.
Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.)
Check each main journal for taper and out-of-round as
shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
A23047
(c)
A23048
(d)
(e)
Using a micrometer, measure the diameter of each crank

pin.
Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.)
Check each crank pin for taper and out-of-round as
shownin the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
A23049
No. 1 and No. 4
22.4 mm
No. 2 and No. 3
19.0 mm
12. INSPECT CRANKSHAFT OIL CLEARANCE

HINT:
Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4
mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the
No. 1 and No. 4 cylinder block journal positions with the main
bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
(a) Clean each main journal and bearing.
A23050
(b)
Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact surface.
A23051
Author:
Date:
3329
EM-122
CYLINDER BLOCK
(c)
Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 bottom bearings.
NOTICE:
Do not apply engine oil to the bearing or its contact surface.
HINT:
A number marked on each main bearing cap indicates the
installation position.
(d) Place the crankshaft on the cylinder block.
Mark
1, 2, 3, or 4
A23052
Plastigage
(e)
Lay a strip of Plastigage across each journal.
(f)
Examine the front marks and numbers and install the

bearing caps on the cylinder block.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
Temporarily install the 8 main bearing cap bolts to the inside positions.
A23053
(g)
(h)
A23054
(i)
Install the main bearing caps. Tighten the 2 bolts for each
bearing cap until the clearance between the bearing cap
and the cylinder block becomes less than 6 mm (0.23 in.).
(j)
Using a plastic-faced hammer, lightly tap the bearing cap

to ensure a proper fit.
Apply a light coat of engine oil to the threads of the main
bearing cap bolts.
Less than 6 mm
A23055
(k)
A23056
Author:
Date:
3330
EM-123
(l)
9
11
15
3 4
7 8
13
1 2
5 6
14
CYLINDER BLOCK
Install the 16 main bearing cap bolts. Using several steps,

uniformly tighten the bolts in the sequence as shown in
the illustration.
10
12
16
A23057
(m)
(n)
Mark the front side of the bearing cap bolts with paint.
Retighten the bearing cap bolts until 90 in the sequence
(o) Check that the painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
Painted Mark
90
Front
90
A23058
(p)
4
1
2
(q)

uniformly tighten the bolts in the sequence as shown in
the illustration.
Remove the main bearing caps.
A23059
(r)

0.018 to 0.030 mm (0.0007 to 0.0012 in.)
Maximum clearance: 0.046 mm (0.0018 in.)
If the oil clearance is greater than the maximum, replace the
bearings. If necessary, replace the crankshaft.
NOTICE:
Completely remove the Plastigage.
A23060
Author:
Date:
3331
EM-124
CYLINDER BLOCK
(s)
No. 1
No. 2
No. 3
No. 4
Number Mark
No. 1
No. 2
No. 4
Number No. 3
Mark Number MarkA23061
Item
Cylinder block main journal bore diameter (A)
If replacing a bearing, replace it with one that has the

same number. If the number of the bearing cannot be determined, select the correct bearing by adding together
the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate
bearing number. There are 5 sizes of standard bearings,
marked 1, 2, 3, 4 and 5 accordingly
Journal bearings
Cylinder
block (A)
+
Crankshaft
0 to 5
6 to 11
12 to 17
18 to 23
24 to 28
Use
Bearing
HINT:
EXAMPLE
Cylinder block 11 (A) + Crankshaft 06 (B)
= Total number 17 (Use bearing 3)
Mark
mm (in.)
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
77.000 (3.0315)
77.001 (3.0315)
77.002 (3.0316)
77.003 (3.0316)
77.004 (3.0317)
77.005 (3.0317)
77.006 (3.0317)
77.007 (3.0318)
77.008 (3.0318)
77.009 (3.0319)
77.010 (3.0319)
77.011 (3.0319)
77.012 (3.0320)
77.013 (3.0320)
77.014 (3.0320)
77.015 (3.0321)
77.016 (3.0321)
Author:
Date:
3332
EM-125
Crankshaft main journal diameter (B)
Standard bearing center wall thickness
CYLINDER BLOCK
00
01
02
03
04
05
06
07
08
09
10
11
71.999 to 72.000 (2.8346 to 2.8346)

71.998 to 71.999 (2.8346 to 2.8346)
71.997 to 71.998 (2.8345 to 2.8346)
71.996 to 71.997 (2.8345 to 2.8346)
71.995 to 71.996 (2.8344 to 2.8345)
71.994 to 71.995 (2.8344 to 2.8344)
71.993 to 71.994 (2.8343 to 2.8344)
71.992 to 71.993 (2.8343 to 2.8343)
71.991 to 71.992 (2.8343 to 2.8343)
71.990 to 71.991 (2.8343 to 2.8343)
71.989 to 71.990 (2.8342 to 2.8343)
71.988 to 71.989 (2.8342 to 2.8342)
1
2
3
4
5
2.488 to 2.491 (0.0980 to 0.0981)

2.491 to 2.494 (0.0981 to 0.0982)
2.494 to 2.497 (0.0982 to 0.0983)
2.497 to 2.500 (0.0982 to 0.0984)
2.500 to 2.503 (0.0984 to 0.0985)
Author:
Date:
3333
EM-128
CYLINDER BLOCK
EM1Y2-01
REASSEMBLY
1.
(a)
INSTALL STUD BOLT

Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A: 11 Nm (112 kgfcm, 8.1 ftlbf)
Stud bolt B: 4.5 Nm (46 kgfcm, 40 in.lbf)
Stud bolt C: 4.0 Nm (41 kgfcm, 35 in.lbf)
Front Side
Upper Side
C
42 mm
(1.65 in.)
M6
23 mm
(0.91 in.)
Lower Side
56 mm
(2.20 in.)
B
A23062
Author:
Date:
3336
EM-129
2.
(a)
CYLINDER BLOCK
INSTALL STRAIGHT PIN

Using a plastic-faced hammer, tap in the straight pin.
Standard protrusion:
Pin A: 22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B: 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin C: 8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin D: 5.5 to 6.5 mm (0.217 to 0.256 in.)
Front Side
Front Side
10 mm
(0.39 in.)
A
D
36 mm
(1.42 in.)
4 mm
(0.16 in.)
D
12 mm
Protrusion Height: 5.5 to 6.5 mm
(0.217 to 0.256 in.) (0.47 in.)
Rear Side

(0.886 to 0.925 in.)
Rear Side
B
10 mm
(0.39 in.)
4 mm
(0.16 in.)
D
22 mm
(0.87 in.)
12 mm
Protrusion Height: 5.5 to 6.5 mm (0.47 in.)
(0.217 to 0.256 in.)
Lower Side
D

(0.413 to 0.453 in.)
Upper Side
8 mm
(0.31 in.)
C
C
4 mm
(0.16 in.)
18 mm
(0.71 in.)
12 mm
(0.47 in.)
D
(0.217 to 0.256 in.)
Protrusion Height: 8.5 to 9.5 mm (0.335 to 0.374 in.)
A23063
Author:
Date:
3337
EM-130
3.
(a)
(b)
Right Side
CYLINDER BLOCK
INSTALL TIGHT PLUG

Apply adhesive around the tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent.
Using SST, install the tight plugs as shown in the illustration.
SST 09950- 60010 (09951- 00350), 09950- 70010
(09951-07150)
Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 in.)
Left Side
0.2 to 1.2 mm
(0.008 to 0.047 in.)
A23064
4.
INSTALL OIL JET
Using a screwdriver and hammer, tap in an oil jet.
26.55
A23065
5.
INSTALL OIL NOZZLE
Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
A23038
Author:
Date:
3338
EM-131
CYLINDER BLOCK
6.
INSTALL PISTON PIN HOLE SNAP RING
Using a screwdriver, install a new snap ring at one side of the
piston pin hole.
HINT:
Check that the end gap of the snap ring does not overlap the
pin hole cutout portion of the piston.
A23066
7.
(a)
INSTALL PISTON
Gradually heat the piston to about 80C (176F).
(b)
(c)
Coat the piston pin with engine oil.

Align the front marks of the piston and connecting rod,
and push in the piston pin with a thumb.
P12417
Front Mark
Front
Mark
A23067
8.
INSTALL PISTON PIN HOLE SNAP RING
Using a screwdriver, install a new snap ring on the other side
of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring does not overlap the
pin hole cutout portion of the piston.
A23066
9.
(a)
(b)
INSTALL PISTON RING SET

Install the oil ring expander and 2 side rails by hand.
Using a piston ring expander, install the 2 compression
rings.
NOTICE:
Install the compression ring No. 2 with the painted mark
facing upward.
Upward
Painted Mark
A23068
Author:
Date:
3339
EM-132
(c)
Lower side rail

No. 2
Compression
CYLINDER BLOCK
Position the piston rings so that the ring ends are as

Front Mark
Expander
Side Rail
No. 1
Compression
Upper side rail
A23069
10. INSTALL CONNECTING ROD BEARING

Align the bearing claw with the groove of the connecting rod or
connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod and prevent oil from adhering to
them.
A23070
No. 1 and No. 4
No. 2 and No. 3

Upper
Lower
22.4 mm
19.0 mm
11. INSTALL CRANKSHAFT BEARING

HINT:
Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4
mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the
No. 1 and No. 4 cylinder block journal positions with the main
bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.
2 and No. 3 positions.
(a) Clean each main journal and bearing.
A23050
(b)
Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
A23071
(c)
Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 lower bearings.
NOTICE:
HINT:
The number marked on each main bearing cap indicates the
installation position.
Mark
1, 2, 3 or 4
A23052
Author:
Date:
3340
EM-133
CYLINDER BLOCK
12.
(a)
INSTALL CRANKSHAFT
Apply engine oil to the upper bearing and install the crankshaft on the cylinder block.
(b)
Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block.
(1) Push the crankshaft toward the front (rear) side.
(2) Install the 2 upper thrust washers with the oil
grooves facing outward.
(c)
Install the 2 lower thrust washers on the No. 2 bearing cap

with the grooves facing outward.
(d)
Examine the front marks and numbers and install the

bearing caps on the cylinder block.
Apply a light coat of engine oil to the threads of the bearing cap bolts.
Temporarily install the 8 main bearing cap bolts to the inside positions.
A23072
A23073
(e)
(f)
A23054
(g)
Install the main bearing caps. Tighten the 2 bolts for each
bearing cap until the clearance between the bearing cap
and the cylinder block becomes less than 6 mm (0.23 in.).
Less than 6 mm
A23055
Author:
Date:
3341
EM-134
(h)
(i)
CYLINDER BLOCK
Using a plastic-faced hammer, lightly tap the bearing cap

to ensure a proper fit.
Apply a light coat of engine oil to the threads of the main
bearing cap bolts.
A23056
(j)

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

cap bolts in the sequence as shown in the illustration.
3
5
8
A23059
Author:
Date:
3342
EM-135
CYLINDER BLOCK
13.
(a)
Front Mark
A23074
INSTALL PISTON W/CONNECTING ROD

Apply engine oil to the cylinder walls, the pistons, and the
surfaces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:

Clean the backside of the bearing and the bearing
surface of the connecting rod cap and prevent oil
from adhering to them.

Match the numbered connecting rod cap with the connecting rod.
(d)
(e)
Check that the protrusion of the connecting rod cap is facing the correct direction.
Apply a light coat of engine oil to the threads of the connecting rod cap bolts.
Protrusion
A23023
(f)
Using SST, tighten the bolts alternately to the specified

torque.
SST 09011-38121
(g)
(h)
(i)
14.
(a)
Mark the front side of each connecting cap bolt with paint.
Retighten the cap bolts 90 as shown.
Check that the crankshaft turns smoothly.
INSTALL ENGINE REAR OIL SEAL RETAINER
Remove any old packing material (FIPG) and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.
A23024
Painted Mark
90
Front
90
A23025
Author:
Date:
3343
EM-136
CYLINDER BLOCK
(b)
Seal Packing
Seal Width: 2 to 3 mm (0.08 to 0.12 in.)

A23004
Apply a continuous bead of seal packing (diameter 2 to

3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown
in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Parts must be assembled within 3 minutes of application.
Otherwise the seal packing must be removed and reapplied.
(c) Install the oil seal retainer with the 5 bolts and 2 nuts.
Torque:
Bolt: 10 Nm (102 kgfcm, 7 ftlbf)
Nut: 9.0 Nm (92 kgfcm, 80 in.lbf)
15.
(a)
Adhesive
INSTALL WATER DRAIN COCK

Apply adhesive to 2 or 3 threads of the drain cock ends.
or equivalent
A23018
(b)
45
45
15
45
A23019
After tightening the drain cocks to the specified torque, rotate them clockwise as shown in the illustration.
NOTICE:

Do not rotate the drain cocks more than 1 complete
revolution (360) after tightening the drain cocks to
the specified torque.

Do not loosen the drain cocks after setting them correctly.
Author:
Date:
3344
EM-137
LH Bank
Engine
Rear
RH Bank
Engine
Front
16.
(a)
Upper
15
(b)
CYLINDER BLOCK
INSTALL KNOCK SENSOR

Install the 2 knock sensors with the 2 bolts within a 15
angle as shown in the illustration.
Connect the knock sensor connectors.
Upper
15
A23005
17. INSTALL WATER OUTLET PIPE NO.1

Install the water outlet pipe with the 3 bolts.
A22979
Author:
Date:
3345
EM-126
CYLINDER BLOCK
EM1Y1-01
REPLACEMENT
1.
REPLACE CONNECTING ROD SMALL END BUSH
Using SST and a press, press out the bushing.
SST 09222-30010
SST
EM6363
2.
(a)
INSTALL CONNECTING ROD SMALL END BUSH

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

SST 09222-30010
(c)
Using a pin hole grinder, hone the bushing to obtain the

standard specified clearance between the bushing and
piston pin.
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
A23043
SST
EM6363
EM6535
HINT:
Check that the piston pin fits at a normal room temperature.
Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.
P20668
Author:
Date:
3334
EM-127
CYLINDER BLOCK
3.
REPLACE ENGINE REAR OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder
block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
A22982
(2)
Using SST and a hammer, tap in a new oil seal until

its surface is flush with the rear oil seal retainer
edge.
SST 09223-78010
(3) Apply MP grease to the oil seal lip.
SST
A23003
(b)
If the rear oil seal retainer is installed to the cylinder block:

(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screwdriver tip.
Cut Position
A23080
(3)
Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-78010
(4) Apply MP grease to a new oil seal lip.
SST
A23081
Author:
Date:
3335
EM-53
CYLINDER HEAD
CYLINDER HEAD
EM1XO-01
COMPONENTS
7.5 (76, 66 in.lbf)
V-Bank Cover
Air Cleaner Hose
8.0 (82, 71 in.lbf)
Vacuum Hose
Mass Air Flow
Meter Connector
Air Cleaner
Ventilation Hose No.2
Battery Clamp
Battery
Battery Tray
Nm (kgfcm, ftlbf)
: Specified torque
A23192
Author:
Date:
3261
EM-54
CYLINDER HEAD
Radiator
Fan Shroud
Fan w/ Fluid Coupling
Fan Pulley
21 (214, 15)
Drive Belt
Nm (kgfcm, ftlbf)
: Specified torque
A23193
Author:
Date:
3262
EM-55
CYLINDER HEAD
VSV Connector
28 (286, 21)
Water By-pass Hose

x4
Intake Air Surge Tank
x2
VSV Connector
Fuel Vaper Feed Hose
Surge Tank Stay No.2
Throttle Body
Connector
21 (214, 15)
21 (214, 15)
Throttle Body Bracket

21 (214, 15)
Gasket
Oil Baffle Plate
Vane Pump
9.0 (92, 80 in.lbf)
43 (438, 32)
9.8 (100, 7)
Generator
Terminal Cap
43 (438, 32)
Generator Wire
Generator Connector
Cooler Compressor
8.0 (82, 71 in.lbf)
43 (438, 32)
8.0 (82, 71 in.lbf)

25 (255, 18)
Nm (kgfcm, ftlbf)
: Specified torque
Wire Harness Clamp Bracket
Cooler Compressor Connector
Non-reusable part
A22959
Author:
Date:
3263
EM-56
CYLINDER HEAD
40 (408, 30)
Manifold Stay
Gasket
40 (408, 30)
21 (214, 15)
Gasket
x6
RH Exhaust Manifold
RH Front Exhaust Pipe
x2
62 (630, 46)
Gasket
9.0 (92, 80 in.lbf)
43 (440, 32)
Water By-pass Joint
Spring
Ventilation Hose
Gasket
Upper Radiator Hose
O-ring
Gasket
9.0 (92, 80 in.lbf)
Ventilation Hose
Manifold Stay
40 (408, 30)
40 (408, 30)
40 (408, 30)
Gasket
48 (490, 35)
Lower Radiator Hose

x6
LH Exhaust Manifold
Gasket
21 (214, 15)
Gasket
Nm (kgfcm, ftlbf)
Non-reusable part
: Specified torque
x2
62 (630, 46)
LH Front Exhaust Pipe

A23196
Author:
Date:
3264
EM-57
CYLINDER HEAD
26 (265, 19)
Intake Manifold
x10
Oil Level Gauge
9.0 (92, 80 in.lbf)
Gasket
10 (102, 7)
Ignition Coil
Spark Plug
Water By-pass Hose No.1
Water By-pass
Hose No.2
9.0 (92, 80 in.lbf)
Camshaft Timing
Oil Control Valve
10 (102, 7)
Ignition Coil
Oil Filter Cap

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

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

Gasket
Idler Pulley No.1
Washer
39 (398, 29)
V-Ribbed Belt Tensioner
Washer
54 (551, 40)
36 (367, 27)
Nm (kgfcm, ftlbf)
: Specified torque
36 (367, 27)
Non-reusable part
A23197
Author:
Date:
3265
EM-58
CYLINDER HEAD
9.0 (92, 80 in.lbf)

9.0 (92, 80 in.lbf)
10 (102, 7)
Seal Washer
9.0 (92, 80 in.lbf)
x3
10 (102, 7)
x3
x3
x7
Seal Washer
Ventilation Valve
27 (275, 20)
x3
Cylinder Head
Cover RH
x7
9.0 (92, 80 in.lbf)

9.0 (92, 80 in.lbf)
Cylinder Head
Cover LH
VVT Sensor
Cylinder Head Cover Gasket
VVT Sensor
Gasket
Filter
62 (632, 46)
9.0 (92, 80 in.lbf)
O-ring
O-ring
Filter
Gasket
62 (632, 46)
Oil Level Gauge Guide

x2
21 (214, 15)
10 (102, 7)
x2
Oil Pan
x9
Gasket x4
x6
21 (214, 15)
37 (377, 27)
Oil Strainer
21 (214, 15)
9.0 (92, 80 in.lbf)
Oil Pan No.2

9.0 (92, 80 in.lbf)
Nm (kgfcm, ftlbf)
: Specified torque
Non-reusable part
x15
x2
10 (102, 7)
Gasket
Drain Plug
40 (408, 30)
Author:
A23198
Date:
3266
EM-59
CYLINDER HEAD
23 (235, 17)
Crankshaft Pulley
Oil Seal
x15
Timing Chain Cover
250 (2,549, 184)
19 (194, 14)
23 (235, 17)
Chain Tensioner No.2
19 (194, 14)
x9
Camshaft Timing
Sprocket
Timing Chain No.2
23 (235, 17)
x2
Camshaft Timing
Gear Assembly
Timing Chain No.2
100 (1,020, 74)
Camshaft Timing
Gear Assembly
100 (1,020, 74)
100 (1,020, 74)

100 (1,020, 74)
Camshaft Timing
Sprocket

10 (102, 7)
Chain Vibration
Damper No.2
Timing Chain
Chain Tensioner
Slipper
Idle Gear Shaft No.2
60 (612, 44)
Idle Gear No.1
O-ring
Crankshaft Timing
Sprocket
Nm (kgfcm, ftlbf)
: Specified torque
Non-reusable part
19 (194, 14)
Author:
Chain Vibration
Damper No.1
Date:
A23195
3267
EM-60
CYLINDER HEAD
9.0 (92, 80 in.lbf)

24 (245, 18)
Camshaft Bearing Cap No.1

24 (245, 18)
9.0 (92, 80 in.lbf)
Camshaft Bearing
Cap No.2
9.0 (92, 80 in.lbf)

24 (245, 18)
24 (245, 18)
9.0 (92, 80 in.lbf)
Camshaft
Camshaft
Camshaft Bearing No.1

Camshaft
Camshaft
Camshaft Bearing
Cap No.2
See page EM-89

1st 36 (367, 27)
2nd Turn 180
See page EM-89
x8
x8
x8
1st 36 (367, 27)

2nd Turn 180
30 (306, 22)
Camshaft Bearing No.2

x8
x2
Plate Washer
Cylinder Head LH
Cylinder Head RH
RH Cylinder Head Gasket
Nm (kgfcm, ftlbf)
LH Cylinder Head Gasket
: Specified torque
Non-reusable part
A23199
Author:
Date:
3268
EM-61
CYLINDER HEAD
Valve Lifter
Valve Spring Retainer Lock
Valve Spring Retainer
Inner Compression Spring

Valve Stem Oil Seal
Exhaust Valve Guide Bush
Valve Spring Seat

Intake Valve Guide Bush
Intake Valve
Exhaust Valve
Non-reusable part
A22923
Author:
Date:
3269
EM-68
CYLINDER HEAD
EM1XQ-01
DISASSEMBLY
1.
REMOVE VALVE LIFTER
HINT:
Arrange the valve lifter in the correct order.
A22924
SST
Wooden Block
A22925
2.
REMOVE VALVE
HINT:
Arrange the valves, inner compression springs, valve spring retainers and valve spring retainer locks in the correct order.
(a) Place the cylinder head on a wooden block.
(b) Using SST, compress the inner compression spring and
remove the 2 valve spring retainer locks.
SST 09202-70020 (09202-00010)
(c) Remove the valve, inner compression spring, valve
spring and valve spring retainer.
3.
REMOVE VALVE SPRING SEAL
Using compressed air and a magnetic finger, remove the valve
spring seat by blowing air.
A22926
4.
REMOVE VALVE STEM OIL SEAL
Using needle-nose pliers, remove the valve stem oil seal.
A22927
5.
(a)
CLEAN CYLENDER HEAD

Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact surface.
A22928
Author:
Date:
3276
EM-69
CYLINDER HEAD
(b)
Using a wire brush, remove all the carbon from the combustion chambers.
NOTICE:
Be careful not to scratch the combustion chambers.
A22929
(c)
Using a valve guide bushing brush and solvent, clean all

the valve guide bushes.
(d)
Using a soft brush and solvent, thoroughly clean the cylinder head.
6.
(a)
CLEAN VALVE
Using a gasket scraper, chip off any carbon from the valve
head.
Using a wire brush, thoroughly clean the valve.
A22930
A22931
(b)
EM0580
Author:
Date:
3277
EM-70
CYLINDER HEAD
EM1XR-01
INSPECTION
1.
(a)
INSPECT CYLINDER HEAD

Inspect flatness.
Using a precision straight edge and feeler gauge, measure the flatness of the contact surfaces of the cylinder
block and manifolds.
If warpage is greater than the maximum, replace the cylinder
head.
Cylinder Block Side:
Intake Manifold Side:
Exhaust Manifold Side:
A22932
(b)
Inspect cranks.
Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
A22933
Author:
Date:
3278
EM-71
CYLINDER HEAD
2.
INSPECT INTAKE MANIFOLD FOR FLATNESS

Using a precision straight edge and feeler gauge, measure the flatness of the contact surfaces of the cylinder
head and intake air surge tank.
Maximum warpage:
Intake air surge tank side: 0.8 mm (0.031 in.)
Cylinder head side: 0.2 mm (0.008 in.)
If warpage is greater than the maximum, replace the intake
manifold.
Intake Air Surge Tank Side
Cylinder Head Side
A22967
A22968
3.
INSPECT EXHAUST MANIFOLD FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
flatness of the contact surface the cylinder head.
If warpage is greater than the maximum, replace the exhaust
manifold.
HINT:
Maximum warpage of each installation surface:
0.3 mm (0.012 in.)
4.
(a)
INSPECT VALVE
Inspect valve stem diameter.
Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Exhaust
5.465 to 5.480 mm (0.2152 to 0.2158 in.)
Z00052
(b)
Inspect valve face angle.

(1) Grind the valve enough to remove pits and carbon.
(2) Check that the valve is ground to the correct valve
face angle.
Valve face angle: 44.5
44.5
Z00054
Author:
Date:
3279
EM-72
CYLINDER HEAD
(c)
Inspect valve head margin thickness.

Using vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than the minimum, replace the
valve.
EM0181
(d)
Overall
Length
Inspect overall length.

Using vernier calipers, check the overall length.
Standard overall length:
Intake
106.95 mm (4.2106 in.)
Exhaust
105.80 mm (4.1654 in.)
Minimum overall length:
EM2534
Intake
106.40 mm (4.1890 in.)
Exhaust
105.30 mm (4.1457 in.)
If the overall length is less than the minimum, replace the valve.
(e)
Inspect valve stem tip.

Check the surface of the valve stem tip for wear.
NOTICE:
Do not grind off more than the minimum length.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
EM0255
5.
(a)
(b)
CLEAN VALVE SEAT

Using a 45 carbide cutter, resurface the valve seats.
Clean the valve seats.
A22934
6.
(a)
Width
P12729
INSPECT VALVE SEAT

Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the valve seat.
NOTICE:
Do not rotate the valve.
(c) Check the valve face and seat according to the following
procedure.
(1) If prussian blue (or white lead) appears around the
entire face, the valve is centered.
Author:
Date:
3280
EM-73
CYLINDER HEAD
If not, replace the valve.

(2) If the prussian blue (or white lead) appears around
the entire valve seat, the guide and face are centered.
If not, resurface the valve seat.
(3) Check that the seat contacts the middle of the valve
face with the width below.
Standard width: 1.0 to 1.4 mm (0.039 to 0.055 in.)
45
30
7.
REPAIR VALVE SEAT
NOTICE:
Take off a cutter gradually to make the intake valve seat
smooth.
(a) If the seating is too high to the valve face, use 30 and 45
cutters to correct the seat.
1.0 to 1.4 mm
A01476
Intake Side:
(b)
Intake side:
If the seating is too low to the valve face, use 60 and 45
(c)
Exhaust side:
If the seating is too low to the valve face, use 75 and 45
(d)
Handrub the valve and valve seat with an abrasive compound.

After handrubbing, clean the valve and valve seat.
60
45
1.0 to 1.4 mm
A23191
Exhaust Side:
75
45
1.0 to 1.4 mm
A01477
(e)
A22935
Author:
Date:
3281
EM-74
CYLINDER HEAD
8.
(a)
INSPECT INNER COMPRESSION SPRING

Inspect squareness.
Using a steel square, measure the squareness of the inner compression spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than the maximum, replace the inner
compression spring.
Deviation
EM0988
(b)
Inspect free length.

Using vernier calipers, measure the free length of the inner compression spring.
Free length: 47.80 mm (1.8819 in.)
If the free length is not as specified, replace the inner compression spring.
EM0801
(c)
Inspect tension.
Using a spring tester, measure the tension of the inner
compression spring at the specified installed length.
Installed tension:
186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at
33.3 mm (1.311 in.)
If the installed tension is not as specified, replace the inner compression spring.
EM0281
9.
(a)
(b)
A22936
INSPECT VALVE GUIDE BUSH OIL CLEARANCE

valve guide bush.
Inside diameter:
5.51 to 5.53 mm (0.2169 to 0.2177 in.)
Subtract the valve stem diameter measurement (Step 8)
from the valve guide bush inside diameter measurement.
Intake
0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Maximum oil clearance:

Intake
0.08 mm (0.0031 in.)
Exhaust
0.10 mm (0.0039 in..)

valve and valve guide bush.
Author:
Date:
3282
EM-75
CYLINDER HEAD
10. INSPECT VALVE LIFTER

Using a micrometer, measure the valve lifter diameter.
Valve lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
P16860
11.
(a)
Diameter
A22942
INSPECT VALVE LIFTER OIL CLEARANCE

Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
(b) Subtract the valve lifter diameter measurement (Step 10)
from the lifter bore diameter measurement.
0.033 to 0.059 mm (0.0013 to 0.0023 in.)
valve lifter.
If necessary, replace the cylinder head.
12.
(a)
Plastigage
A22943
INSPECT CAMSHAFT OIL CLEARANCE

Clean the camshaft bearing caps, camshaft bearings and
camshaft journals.
(b) Install the camshaft bearing (See page EM-89 ).
(c) Place the camshaft on the cylinder head.
(d) Lay a strip of Plastigage across each of the camshaft journals.
(e) Install the camshaft bearing caps (See page EM-89 ).
NOTICE:
Do not turn the camshafts.
(f)
Remove the camshaft bearing caps (See page EM-62 ).
Author:
Date:
3283
EM-76
(g)
CYLINDER HEAD

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

A22944
No. 1
0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Others
0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum oil clearance (Cylinder head RH):

No. 1
(Intake)
0.07 mm (0.0028 in.)
Others
0.10 mm (0.0039 in.)
Maximum oil clearance (Cylinder head LH):

0.10 mm (0.0039 in.)
camshaft bearings and/or camshaft.
If necessary, replace the camshaft bearing caps and cylinder
head together.
Reference:
Cylinder head journal
bore diameter
40.009 to 40.017 mm (1.5752 to 1.5755 in.)
Camshaft bearing
center wall thickness
(Mark 2)
2.004 to 2.008 mm (0.0789 to 0.0791 in.)
Camshaft journal diameter
35.971 to 35.985 mm (1.4165 to 1.4167 in.)
(h)
(i)
(j)
Remove the Plastigage completely.

Remove the camshafts.
Remove the camshaft bearing.
13.
(a)
(b)
A22945
INSPECT CAMSHAFT THRUST CLEARANCE

Install the camshafts (See page EM-89 ).
Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
0.04 to 0.09 mm (0.0016 to 0.0035 in.)
If the thrust clearance is greater than the maximum, replace the
camshafts.
Author:
Date:
3284
EM-77
CYLINDER HEAD
If necessary, replace the camshaft bearing caps and cylinder

head as a set.
14.
(a)
INSPECT CAMSHAFT
Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the
center journal.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout is greater than the maximum, replace the camshaft
.
A22983
(b)
EM2011
Inspect the cam lobes.

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake: 44.168 to 44.268 mm (1.7389 to 1.7428 in.)
Exhaust: 44.580 to 44.680 mm (1.7551 to 1.7591 in.)
Minimum cam lobe height:
Intake: 44.018 mm (1.7330 in.)
Exhaust: 44.430 mm (1.7492 in.)
If the cam lobe height is less than the minimum, replace the
camshaft.
(c) Inspect the camshaft journals.
Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clearance.
15. INSPECT CAMSHAFT TIMING GEAR
(a) Fix the intake camshaft with a vise.
NOTICE:
Be careful not to damage the camshaft.
A22984
Author:
Date:
3285
EM-78
(b)
Knock Pin
(c)
CYLINDER HEAD
Align the knock pin hole in the camshaft timing gear assembly with the knock pin of the camshaft, and install the
camshaft timing gear assembly with the bolt.
Torque: 100 Nm (1,020 kgfcm, 74 ftlbf)
Confirm that the camshaft timing gear assembly is locked.
A22985
(d)
Retard Side
Paths
Advance
Side Paths
Open
Close
Close
Open
Rubber
Piece
Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with masking tape as shown in the illustration.
HINT:
One of the 2 grooves on the cam journal is for retards (upper)
and the other is for advances (lower). Each groove has 2 oil
paths. Plug one of the oil paths for each groove with rubber
pieces before wrapping the cam journal with tape.
(2) Prick a hole in the tape placed on the advance side
path. Prick a hole in the retard side path, on the opposite side to that of the advance side path, as
Masking Tape
A22986
(3)
Advance
Side Path
Retard
Side Path
Apply about 200 kPa (2.0 kgf/cm2) of air pressure

to the two broken paths (the advance side path and
the retard side path).
NOTICE:
Cover the paths with a shop rag to avoid oil splashing.
A22987
Advance
Side Path
Hold Pressure
(4)
Retard
Side Path
Decompress
A22988
Confirm that the camshaft timing gear assembly rotates in the advance direction when reducing the air
pressure applied to the retard path.
HINT:
When the lock pin is released, the camshaft timing gear rotates
in the advance direction.
(5) When the camshaft timing gear comes to the most
advanced position, release the air pressure from
the retard side path, and then release the air pressure from the advance side path.
Author:
Date:
3286
EM-79
CYLINDER HEAD
NOTICE:
The camshaft timing assembly gear occasionally shifts to
the retard side abruptly if the air pressure of the advanced
side path is released first. This often results in breakage of
the lock pin.
(e) Check for smooth revolution.
Allow the camshaft timing gear assembly to turn back and
forth at any position, except where the lock pin meets at
the most retarded angle. Check the movable range and
that there is no disturbance.
Standard: Moves smoothly in a range of about 31
NOTICE:
Be sure to perform this check by hand, instead of air pressure.
(f)
Check the lock in the most retarded position.
Confirm that the camshaft timing gear assembly is locked
at the most retarded position.
(g) Remove the set bolt and camshaft timing gear assembly.
NOTICE:
Be sure not to remove the other 3 bolts.
Set Bolt
A22989
16. INSPECT CYLINDER HEAD SET BOLT

Using a vernier caliper, measure the outside thread diameter of
the bolt.
Standard outside diameter:
10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum outside diameter:
10.7 mm (0.421 in.)
A22890
Author:
Date:
3287
EM-89
CYLINDER HEAD
EM1XU-01
INSTALLATION
1.
(a)
(b)
INSTALL CYLINDER HEAD GASKET

not to drop any oil on the contact surfaces of the cylinder
head and cylinder block.
Install the RH cylinder head gasket.
(1)
10 to 15 mm
2.5 to 3 mm
Gasket
1.25 to
1.5 mm
10 to 15 mm
Seal Packing
Apply a continuous bead of seal packing (diameter

2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder
head gasket as shown in the illustration.
NOTICE:
Install the cylinder head within 3 minutes after applying
seal packing. After installing it, the cylinder head bolts
must be tightened within 15 minutes. Otherwise the seal
packing must be removed and reapplied.
A22891
(2)
Lot No.
Place the cylinder head gasket on the cylinder block

surface with the Lot No. stamp upper side facing upward.
NOTICE:

Be careful of the installation direction.

Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.
A22892
Author:
Date:
3297
EM-90
CYLINDER HEAD
(c)
10 to 15 mm
2.5 to 3 mm
Gasket
1.25 to
1.5 mm
Install the LH cylinder head gasket.

(1) Apply a continuous bead of seal packing (diameter
2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder
head gasket as shown in the illustration.
NOTICE:
Install the cylinder head within 3 minutes after applying
seal packing. After installing it, the cylinder head bolts
10 to 15 mm
Seal Packing
A22914
(2)
Lot No.
A22915
Place the cylinder head gasket on the cylinder block

surface with the Lot No. stamp upper sied facing upward.
NOTICE:


Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.
2.
INSTALL CYLINDER HEAD
(a) Place the RH cylinder head on the cylinder head gasket.
(b) Install the 8 cylinder head bolts.
HINT:

The cylinder head bolts are tightened in 2 successive
steps (steps (3) and (5)).

If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil to the threads of the
cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.
(3)
Using several steps, tighten each bolt with a 10 mm

bi-hexagon wrench uniformly in the sequence as
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
NOTICE:
Do not drop the washers into the cylinder head.
A22888
Author:
Date:
3298
EM-91
CYLINDER HEAD
(4)
180
Engine
Front
Paint Mark
A22893
(c)
(d)
HINT:

Mark the front side of each cylinder head bolt with

paint.
(5) Retighten the cylinder head bolts by 180 as
shown.
(6) Check that the painted marks are now at 180 opposite to the engine front.
Place the LH cylinder head on the cylinder head gasket.
Install the 8 cylinder head bolts.
The cylinder head bolts are tightened in 2 successive
steps (steps (3) and (5)).
If any cylinder head bolt is broken or deformed, replace
it.
(2) Install the plate washer to the cylinder head bolt.
(3)
Using several steps, tighten each bolt with a 10 mm

bi-hexagon wrench uniformly in the sequence as
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
NOTICE:
Do not drop the washers into the cylinder head.
A22912
(4)
180
(5)
Engine
Front
(6)
Mark the front side of each cylinder head bolt with

paint.
Retighten the cylinder head bolts by 180 as
shown.
Check that the painted marks are now at 180 opposite to the engine front.
Paint Mark
A22893
(e)
1
Install the 2 cylinder head bolts.

(2) Install the 2 cylinder head bolts. Using several
steps, tighten the bolts uniformly in the sequence as
A22911
Author:
Date:
3299
EM-92
Claw
A23006
A22894
CYLINDER HEAD
3.
INSTALL CAMSHAFT BEARING NO.1
Align the bearing claw with the claw groove of the bearing cap,
and push in the camshaft bearing.
NOTICE:

Install the bearing while aligning it with the oil hole in
the bearing cap.

Clean the backside of the bearing and the bearing
surface of the bearing cap and prevent oil from adhering to them.
4.
INSTALL CAMSHAFT BEARING NO.2
Install the camshaft bearing No. 2 to the cylinder head.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the cylinder head and prevent oil from adhering to them.
5.
INSTALL CAMSHAFT
NOTICE:
As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
which receives the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
(a)
90
Set Key
Turn
A22895
Set the crankshaft position.

Using the crankshaft pulley set bolt, turn the crankshaft,
and set the crankshaft set key into the left horizontal position.
NOTICE:
Having the crankshaft at the wrong angle can cause the
piston head and valve head to come into contact with each
other when you install the camshaft, causing damage. So
always set the crankshaft at the correct angle.
(b) Apply new engine oil to the thrust portion and journal of
the camshafts.
Author:
Date:
3300
EM-93
(c)
RH Bank
CYLINDER HEAD
Install the camshaft of the RH bank.

(1) Place the 2 camshafts onto the RH cylinder head
with the cam lobes of No. 1 cylinder facing each
direction as shown in the illustration.
A22896
(2)
(3)
RH Bank
Install the 8 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads of the
bearing cap bolts.
A22897
(4)
Install the 16 bearing cap bolts. Using several

Torque:
9.0 Nm (92 kgfcm, 80 in.lbf) for 10 mm (0.39 in.) head
24 Nm (245 kgfcm, 18 ftlbf) for 12 mm (0.47 in.) head
RH Bank
14
15
13
16
11
10
9
12
5
7
8
A22898
(5)
RH Bank
Turn
Turn the camshafts clockwise with a wrench until

the camshaft knock pin comes 90 position to the
cylinder head.
Turn
90
90
A22899
(d)
LH Bank
Install the camshafts of the LH bank.

(1) Place the 2 camshafts onto the LH cylinder head
with the cam lobes of No. 2 cylinder facing as shown
A22917
Author:
Date:
3301
EM-94
(2)
(3)
LH Bank
CYLINDER HEAD

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
A22918
(4)
LH Bank
6
5
7
10
14
1 3
9 11
13 15
12
16
A22910
6.
7.
8.
Install the 16 bearing cap bolts. Using several

Torque:
INSTALL TIMING CHAIN (See page EM-44 )
INSTALL TIMING CHAIN COVER (See page EM-44 )
INSTALL OIL PAN (See page EM-44 )
9.
(a)
INSTALL EXHAUST MANIFOLD

Install the RH exhaust manifold.
(1) Set a new gasket to the RH cylinder head with the
oval shape facing forward.
NOTICE:
Oval Shape
Forward
A22906
(2)
Install the exhaust manifold with the 6 nuts. Tighten

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

(1) Set a new gasket to the LH cylinder head with the
oval shape facing backward.
NOTICE:
Forward
A22922
Author:
Date:
3302
EM-95
CYLINDER HEAD
(2)
10.
A23252
11.
12.
(a)
Mesh Part
Apply
Adhesive
13.
INSTALL OIL CONTROL VALVE FILTER

Check that no foreign objects on the mesh part of the 2
filters.
Install 2 new gaskets to each new plug.
Insert the filters to the plugs.
Apply adhesive to 2 or 3 threads of the plugs.
LOCTITE 242 or equivalent
Install the plugs to each cylinder head.
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
14.
(a)
(b)
INSTALL WATER BY-PASS JOINT

Install a new O-ring to the water outlet pipe.
Apply soapy water to the O-ring.
(c)
Install 2 new gaskets and water by-pass joint with the 2

bolts and 4 nuts.
Connect the heater hose.
Connect the engine coolant temperature sensor connector.
(b)
(c)
(d)
A23017
Install the exhaust manifold with the 6 nuts. Tighten

the nuts uniformly in several steps.
(3) Connect the A/F sensor connector.
(4) Install the manifold stay with the 3 bolts.
INSTALL RH AND LH FRONT EXHAUST PIPE
(See page EM-138 )
INSTALL VVT SENSOR (See page IG-12 )
(e)
A22904
(d)
(e)
A22883
Author:
Date:
3303
EM-96
CYLINDER HEAD
15. INSTALL INTAKE MANIFOLD

(a) Set a new gasket on each cylinder head.
NOTICE:

Align the port holes of the gasket and cylinder head.

(b) Set the intake manifold on the cylinder heads.
A22905
(c)
(d)
16.
(a)
A22882
(2)
Seal Packing
Seal Width: 2 to 3 mm
B
B
A
Nut
Install and tighten the 10 bolts uniformly in several steps.

Connect the 6 fuel injector connectors.
INSTALL CYLINDER HEAD COVER
Install the RH cylinder head cover.
(1) Remove any old packing material (FIPG) and be
careful not to drop any oil on the contact surfaces
of the cylinder head, timing chain cover and cylinder
head cover.
A23016
A
B
NutA23092
(c)
Seal Packing
Apply a continuous bead of seal packing (diameter

2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
NOTICE:
Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover
bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
(3) Install the seal washers to the bolts.
(4) Install the cylinder head cover with the 10 bolts and
2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
Bolt A, Nut: 9.0 Nm (92 kgfcm, 80 in.lbf)
Bolt B: 10 Nm (102 kgfcm, 7 ftlbf)
(b) Install a new gasket and oil filler cap housing with the 2
nuts.
A23015
Install the LH cylinder head cover.

(1) Apply a continuous bead of seal packing (diameter
2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
NOTICE:
Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover
bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
Author:
Date:
3304
EM-97
(2)
A
Nut
17.
A
B
Install the seal washers to the bolts.
(3)
B
A
CYLINDER HEAD
Install the cylinder head cover with the 10 bolts and

2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
Bolt A, Nut: 9.0 Nm (92 kgfcm, 80 in.lbf)
Bolt B: 10 Nm (102 kgfcm, 7 ftlbf)
INSTALL IGNITER
B
Nut
A22970
18.
(a)
(b)
(c)
INSTALL INTAKE AIR SURGE TANK

Install a new gasket to the intake air surge tank.
Using the socket hexagon wrench 8, install the intake air
surge tank with the 4 bolts.
Install the 2 intake air surge tank nuts.
A23091
(d)
(e)
Install the 2 surge tank stays with the 4 bolts.

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

A23089
Author:
Date:
3305
EM-98
CYLINDER HEAD
(g)
(h)
(i)
Install the 3 wire harness clamps and hose clamp.

Connect the throttle body w/ motor connector.
Connect the 2 VSV connectors.
(j)
Connect the ventilation hose.
(k)
Connect the fuel vapor feed hose.
(l)
19.
Connect the 2 water by-pass hoses.

CONNECT HEATER WATER OUTLET AND INLET
HOSE
INSTALL COOLER COMPRESSOR
(See page AC-58 )
INSTALL GENERATOR (See page CH-15 )
INSTALL VANE PUMP (See page SR-57 )
INSTALL FAN W/FLUID COUPLING
A23088
A23087
A23086
20.
21.
22.
23.
A23085
Author:
Date:
3306
EM-99
24.
(a)
(b)
(c)
CYLINDER HEAD
INSTALL DRIVE BELT

While turning the belt tensioner counterclockwise, align
with the holes. Insert a bar of 6 mm (0.24 in.) into the
holes to fix the belt tensioner.
Install the V-ribbed belt.
While turning the belt tensioner counterclockwise, remove the bar.
Turn
Holes
A22798
Water Pump
Generator
Idler No. 2
P/S Pump
(d)
Tensioner
Idler No. 2
Crankshaft
Idler No. 1
If it is hard to install the V-ribbed belt, perform the following procedure.

(1) Put the V-ribbed belt on every parts except the P/S
pump as shown in the illustration.
(2) While releasing the belt tension by turning the belt
tensioner counterclockwise, put the V-ribbed belt
on the P/S pump.
A/C Compressor
A22799
25. TIGHTEN FAN W/FLUID COUPLING

Tighten the 4 fluid coupling bolts.
26. INSTALL RADIATOR (See page CO-18 )
27. INSTALL FAN SHROUD
28. CONNECT FUEL PIPE (See page SF-1 )
A23114
29.
(a)
(b)
INSTALL AIR CLEANER

Install the air cleaner with the 2 bolts.
Tighten the 2 hose clamps.
A23210
Author:
Date:
3307
EM-100
CYLINDER HEAD
(c)
(d)
(e)
Install the 2 wire harness clamps.

Connect the mass air flow meter connector.
Connect the vacuum hose.
(f)
30.
31.
32.
Connect the ventilation hose No.2.

ADD ENGINE COOLANT
ADD ENGINE OIL
CHECK FOR LEAK
A23209
A23095
33. INSTALL V-BANK COVER

Install the V-bank cover with the 2 nuts.
A23407
Author:
Date:
3308
EM-82
CYLINDER HEAD
EM1XT-01
REASSEMBLY
1.
INSTALL RING PIN
Using a plastic-faced hammer, tap in the new ring pins until
they reach the specified protrusion height.
Specified protrusion height:
2.7 to 3.3 mm (0.106 to 0.130 in.)
Cylinder Head RH Side:
Cylinder Head LH Side:
11 mm
8 mm
Protrusion
Height
Engine
Front
Engine
Front
A22946
Author:
Date:
3290
EM-83
CYLINDER HEAD
2.
INSTALL STRAIGHT PIN
Using a plastic-faced hammer, tap in the new straight pins until
they reach the specified protrusion height.
Specified protrusion height:
A
17.5 to 19.5 mm (0.689 to 0.768 in.)
7.5 to 8.5 mm (0.295 to 0.335 in.)
7.0 to 9.0 mm (0.276 to 0.354 in.)

Upper Side:
Front Side:

Upper Side:
Front Side:
B
8 mm
5 mm
Protrusion
Height 13.8 mm
34 mm
Protrusion
Height
B and C
A
A22947
Author:
Date:
3291
EM-84
CYLINDER HEAD
3.
INSTALL STUD BOLT
Using the Torx socket wrench E5 and E7, install the stud bolts.
Torque:
4.0 Nm (41 kgfcm, 35 in.lbf) for stud bolt A, C
19.5 Nm (199 kgfcm, 14 ftlbf) for stud bolt B

Upper Side:
Rear Side:
C
A

B
Upper Side:
Rear Side:
C
A
20 mm
12 mm
33.3 mm
9 mm
A
16 mm
42 mm
13 mm
B
27 mm
9 mm
C
A22948
Author:
Date:
3292
EM-85
4.
(a)
(b)
CYLINDER HEAD
INSTALL UNION
Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
Using a deep socket wrench 12, install the unions.
Adhesive
A22949
Cylinder Head RH (Front) Side:
Cylinder Head LH (Intake Manifold) Side:
67 mm
9 mm
9 mm
Author:
30 mm
A22950
Date:
3293
EM-86
5.
(a)
(b)
Adhesive
CYLINDER HEAD
INSTALL TIGHT PLUG

Apply adhesive around the tight plugs.
Using SST, tap in the tight plugs to the specified depth.
SST 09950-60010 (09951-00250), 09950-70010
(09951-07150)
Specified depth: 1.5 mm (0.059 in.)
A22951
Cylinder Head RH (Rear) Side:
Cylinder Head LH (Rear) Side:
SST
Depth
1.5 mm
A22952
Author:
Date:
3294
EM-87
6.
(a)
CYLINDER HEAD
INSTALL STRAIGHT SCREW PLUG

Using a straight hexagon wrench 14, install a new gasket
and straight screw plug.

Upper Side:

Upper Side:
Front Side:
Front Side:
A22953
Light Brown
Gray
Intake Side:
7.
INSTALL VALVE STEM OIL SEAL
HINT:
The intake valve stem oil seal is light brown and the exhaust
valve stem oil seal is gray.
(a) Apply a light coat of engine oil to the valve guide bush.
Exhaust Side:
A22954
(b)
SST
Using SST, push in a new valve stem oil seal.

SST 09201-41020
A22955
Author:
Date:
3295
EM-88
CYLINDER HEAD
8.
INSTALL VALVE SPRING SEAT
9.
(a)
INSTALL VALVE
Apply engine oil to the valve as shown in the illustration.
(b)
(c)
Place the cylinder head on a wooden block.

Install the valve, inner compression spring and valve
spring retainer.
Using SST, compress the inner compression spring and
place the 2 valve spring retainer locks around the valve
stem.
SST 09202-70020 (09202-00010)
A22956
35 mm
(1.378 in.)
A22957
SST
(d)
Wooden Block
A22925
(e)
Using a pin punch 5, lightly tap the valve stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
A22958
10.
(a)
(b)
INSTALL VALVE LIFTER

Apply engine oil to the valve stem end and valve lifter, and
install the valve lifter to the valve stem.
Check that the valve lifter rotates smoothly by hand.
A22924
Author:
Date:
3296
EM-62
CYLINDER HEAD
EM1XP-01
REMOVAL
1.
2.
3.
PREVENT GASOLINE FROM SPILLING OUT

DRAIN ENGINE COOLANT (See page CO-2 )
DRAIN ENGINE OIL (See page LU-3 )
4.
REMOVE V-BANK COVER
Remove the 2 nuts and V-bank cover.
A23208
5.
(a)
REMOVE AIR CLEANER

Disconnect the ventilation hose No.2.
(b)
(c)
(d)
Disconnect the vacuum hose.

Disconnect the mass air flow meter connector.
Remove the 2 wire harness clamps.
(e)
(f)
6.
7.
8.
Loosen the 2 hose clamps.

Remove the 2 bolts and air cleaner
DISCONNECT FUEL PIPE (See page SF-1 )
REMOVE FAN SHROUD
REMOVE RADIATOR (See page CO-17 )
A23095
A23209
A23210
Author:
Date:
3270
EM-63
CYLINDER HEAD
9.
LOOSEN FAN W/FLUID COUPLING
Loosen the 4 nuts of the fan w/ fluid coupling.
A23114
A22797
10. REMOVE DRIVE BELT

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

Disconnect the 2 water by-pass hoses.
(b)
Disconnect the fuel vapor feed hose.
A23085
A23086
Author:
Date:
3271
EM-64
CYLINDER HEAD
(c)
Disconnect the ventilation hose.
(d)
(e)
(f)
Disconnect the 2 VSV connectors.

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

Remove the 4 bolts and 2 surge tank stays.
A23087
A23088
A23089
A23090
Author:
Date:
3272
EM-65
(j)
(k)
17.
CYLINDER HEAD
Remove the 2 nuts.

Using a socket hexagon wrench 8, remove the 4 bolts, intake air surge tank and gasket.
REMOVE IGNITER (See page IG-6 )
A23091
18.
(a)
(b)
REMOVE CYLINDER HEAD COVER

Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder
head cover RH and gasket.
Remove the 2 nuts, oil filter cap housing and gasket.
A22970
(c)
19.
(a)
Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder

head cover LH and gasket.
REMOVE INTAKE MANIFOLD
Disconnect the 6 fuel injector connectors.
A23092
(b)
20.
(a)
(b)
Remove the 10 bolts, intake manifold and 2 gaskets.

REMOVE WATER BY-PASS JOINT
Disconnect the engine coolant temperature sensor connector.
Disconnect the heater hose.
A22882
(c)
(d)
21.
Remove the 2 bolts, 4 nuts, water by-pass joint RR and

2 gaskets.
Remove the O-ring from the water outlet pipe.
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
A22883
Author:
Date:
3273
EM-66
RH Bank
LH Bank
A22969
CYLINDER HEAD
22. REMOVE OIL CONTROL VALVE FILTER

Remove the plug, filter and gasket from each cylinder head.
23. REMOVE VVT SENSOR
24. REMOVE RH AND LH FRONT EXHAUST PIPE
25. REMOVE RH AND LH EXHAUST MANIFOLD
(a) Remove the 6 bolts and 2 exhaust manifold stays.
(b) Remove the 12 nuts, RH and LH exhaust manifold and 2
gaskets.
26. REMOVE OIL PAN (See page EM-32 )
27. REMOVE TIMING CHAIN COVER (See page EM-32 )
28. REMOVE TIMING CHAIN (See page EM-32 )
29. REMOVE CAMSHAFT
NOTICE:
As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the
(a)
RH Bank
Remove the camshafts of the RH bank.

(1) Rotate the camshafts counterclockwise using the
wrench so that the cam lobes of the No. 1 cylinder
face each direction as shown in the illustration.
A22886
(2)
RH Bank
3
11
15
(3)
2
14
12
10
16
13
Using several steps, uniformly loosen and remove

the 16 bearing cap bolts in the sequence as shown
Remove the 8 bearing caps and 2 camshafts.
9
A22887
(b)
LH Bank
11
12
10
15
14
16
13
7
8
30.
Remove the camshafts of the LH bank.

(1) Using several steps, uniformly loosen and remove
the 16 bearing cap bolts in the sequence as shown
(2) Remove the 8 bearing caps and 2 camshafts.
REMOVE CAMSHAFT BEARING NO.1 AND NO.2
1
A22910
Author:
Date:
3274
EM-67
31.
(a)
LH Cylinder Head
2
CYLINDER HEAD
REMOVE CYLINDER HEAD

Using several steps, remove the 2 cylinder head bolts on
the LH cylinder head in the sequence as shown in the illustration.
A22911
RH Cylinder Head
3
5
(b)
7
Using several steps, loosen the 8 cylinder head bolts on

each cylinder head with a 10 mm bi-hexagon wrench in
the sequence as shown in the illustration. Remove the 16
cylinder head bolts and plate washers.
NOTICE:

Be careful not to drop the plate washers into the cylinder head.

Cylinder head warpage or cracking could result from
removing the bolts in the incorrect order.
LH Cylinder Head
1
2
A22977
(c)
A22978
Lift the cylinder head from the dowels on the cylinder

block, and place the 2 cylinder heads on wooden blocks
on a bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
(d) Remove the RH and LH cylinder head gaskets.
32. REMOVE CYLINDER HEAD GASKET
Author:
Date:
3275
EM-80
CYLINDER HEAD
EM1XS-01
REPLACEMENT
1.
(a)
REPLACE VALVE GUIDE BUSH

Gradually heat the cylinder head to between 80 and
100C (176 to 212F).
(b)
(c)

Using SST, tap out the valve guide bush.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
A22937
SST
Wooden Block
A22938
(d)
Using a caliper gauge, measure the bush bore diameter

of the cylinder head.
Bush bore diameter:
10.295 to 10.315 mm (0.4053 to 0.4061 in.)
If the bush bore diameter of the cylinder head is greater than
10.315 mm (0.4061 in.), machine the bush bore to dimensions
of 10.345 to 10.365 mm (0.4073 to 0.4081 in.).
Valve guide bush diameter
Diameter
A22939
(e)
STD
10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S 0.05
10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Gradually heat the cylinder head to between 80 and

100C (176 to 212F).
A22937
Author:
Date:
3288
EM-81
Protrusion
Height
SST
CYLINDER HEAD
(f)
(g)

Using SST, tap in a new valve guide bush to the specified
protrusion height.
SST 09201-10000, 09201-01055, 09950-70010
(09951-07100)
Protrusion height: 9.3 to 9.7 mm (0.366 to 0.382 in.)
(h)
Using a sharp 5.5 mm reamer, ream the valve guide bush

to obtain the standard specified clearance between the
valve guide bush and valve stem.
Wooden Block
A22940
Intake
0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
A22941
Author:
Date:
3289
EM-101
ENGINE UNIT
ENGINE UNIT
EM1XV-01
COMPONENTS
V-Bank Cover
7.5 (76, 66 in.lbf)
Hood
Air Cleaner Hose No.2
Air Cleaner Assembly

MAF Meter Connector
Heater Hose
Battery Clamp
Battery
Battery Tray
Fuel Pipe
Fuel Pipe Clamp
A23384
Author:
Date:
3309
EM-102
ENGINE UNIT
No.1 Fan Shroud
5.0 (50, 44 in.lbf)
Radiator Assembly
No.2 Fan Shroud
12 (120, 9)
Oil Cooler Pipe for

AutomaticTransmission
V-Belt
Fan Pulley
A23385
Author:
Date:
3310
EM-103
12 (122, 9)
ENGINE UNIT
34 (346, 25)
Clamp
Transmission
71 (724, 52)
Oil Cooler Pipe

2.0 Kw:
Torque
Converter
Clutch
Shift Control Cable
x6
14.5 (148, 11)

19.5 (199, 14)
37 (377, 27)
48 (490, 35)
Starter
37 (377, 27)
9.8 (100, 7)
9.8 (100, 7)
48 (490, 35)
40 (408, 30)
43 (440, 32)
Front Exhaust Pipe RH
1.6 Kw:
Starter
Flywheel Housing Side Cover

Engine Rear
Mounting Insulator
65 (660, 48)
Manifold Stay
Gasket
40 (408, 30)
72 (734, 53)
Spring
Gasket
Manifold Stay
Gasket
Front Exhaust
Pipe LH
18 (185, 13)
Crossmember
62 (630, 46)
Gasket
Exhaust Pipe Support
62 (630, 46)
Propeller Shaft
37 (377, 27)
88 (897, 65)
40 (410, 30)
Bushing
Stabilizer Bar Bracket
Stabilizer Bar
Non-reusable part
Engine Under Cover

D14136
Author:
Date:
3311
EM-104
ENGINE UNIT
Water By-pass Hose

VSV Connector
Throttle Body Motor

Connector
VSV Connector
Vane Pump Connector
Generator
43 (438, 32)
Generator Wire
43 (438, 32)
Vane Pump
Generator Connector
A/C Compressor
25 (255, 18)
A/C Compressor
Connector
A23386
Author:
Date:
3312
EM-108
ENGINE UNIT
EM1XX-01
INSTALLATION
1.
INSTALL DRIVE PLATE
HINT:

The mounting bolts are tightened in 2 progressive steps
(steps (c) and (e)).

If any of the mounting bolts is broken or deformed, replace it.
(a)
Adhesive
Apply adhesive to 2 or 3 threads of the mounting bolt end.

Adhesive:
A04869
(b)
1
Install the front spacer, drive plate and rear spacer on the
crankshaft.
(c) Install and uniformly tighten the 8 mounting bolts in several steps, in the sequence shown in the illustration.
If any of the mounting bolts do not meet the torque specification,
replace it.
8
3
4
7
6
2
A23391
(d)
(e)
(f)
Painted
Mark
90
90
2.
(a)
(b)
A23392
(c)
(d)
(e)
(f)
Mark the mounting bolt with paint.

Retighten the mounting bolts 90 in the order shown in
the illustration.
Check that the painted mark is now at a 90 angle to what
it was in step (e).
INSTALL ENGINE ASSEMBLY IN VEHICLE
Attach the engine chain hoist to the engine hangers.
Slowly lower the engine assembly into the engine
compartment.
Attach the engine mounting brackets to the frame brackets.
Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts.
Remove the engine chain hoist.
Remove the 4 bolts and 2 engine hangers.
Author:
Date:
3316
EM-109
ENGINE UNIT
3.
INSTALL PS PUMP
Install the PS pump with the 3 bolts.
A23390
4.
(a)
(b)
5.
A23389
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
6.
(a)
(b)
(c)
(d)
Connect
A09152
A23387
(e)
(f)
(g)
(h)
7.
(a)
(b)
(c)
(d)
(e)
(f)
8.
9.
10.
INSTALL A/C COMPRESSOR

Install the A/C compressor with the 3 bolts.
Connect the A/C compressor connector.
CONNECT HOSES, WIRES, CONNECTORS, CLAMPS,
GROMMET AND CABLES
Connect the generator wire and connector.
Connect the 2 heater hoses.
Connect the ground strap to the cowl panel.
Connect the fuel inlet hose and clamps.
Connect the fuel return hose and clamp.
Connect the air inlet hose to the charcoal canister.
Connect the EVAP hose to the charcoal canister.
Connect the brake booster tube.
CONNECT ENGINE WIRE TO CABIN
Push the engine wire through the cowl panel.
Install the engine wire bracket with the 2 nuts and bolt and
connect the engine wire to the bracket.
Connect the 3 connectors to the ECM.
Connect the 2 wire harness connectors (cassette connector).
Install the ECM with the 3 screws.
Install the heater to register duct.
Install the lower No.2 finish panel.
Install the glove compartment door.
INSTALL AIR CLEANER ASSEMBLY
Install the air cleaner assembly with the 2 bolts.
Connect the air cleaner case to the air cleaner hose No.1.
Connect the air cleaner case with the 2 wire clamps.
Connect the PCV hose to the air cleaner case.
Connect the MAF meter connector.
Connect the air cleaner hose No.2 to the air cleaner case.
INSTALL BATTERY
INSTALL RADIATOR ASSEMBLY (See page CO-18 )
INSTALL FRONT EXHAUST PIPES
(See page EM-139 )
Author:
Date:
3317
EM-1 10
ENGINE UNIT
11.
INSTALL AUTOMATIC TRANSMISSION

(See page AT-29 )
12. INSTALL MANUAL TRANSMISSION
(See page MT-7 )
13. FILL WITH ENGINE COOLANT (See page CO-2 )
14. FILL WITH ENGINE OIL (See page LU-3 )
15. START ENGINE AND CHECK FOR LEAKS
16. INSTALL ENGINE UNDER COVERS
18. INSTALL HOOD
19. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
20. RECHECK ENGINE COOLANT AND OIL LEVELS
Author:
Date:
3318
EM-105
ENGINE UNIT
EM1XW-01
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
(a)
(b)
(c)
(d)
(e)
A23387
(f)
11.
(a)
(b)
(c)
12.
(a)
(b)
(c)
(d)
(e)

(See page SF-1 )
REMOVE ENGINE HOOD
REMOVE ENGINE V-BANK COVER
REMOVE ENGINE UNDER COVER
REMOVE AUTOMATIC TRANSMISSION
(See page AT-25 )
REMOVE MANUAL TRANSMISSION
(See page MT-4 )
REMOVE FRONT EXHAUST PIPES
(See page EM-139 )
REMOVE RADIATOR ASSEMBLY (See page CO-17 )
REMOVE BATTERY
REMOVE AIR CLEANER ASSEMBLY

Disconnect the air cleaner hose No.2 from the air cleaner
case.
Disconnect the MAF meter connector.
Disconnect the PCV hose from the air cleaner case.
Disconnect the 2 wire clamps from the air cleaner case.
Disconnect the air cleaner case from the air cleaner hose
No.1.
Remove the 2 bolts and air cleaner assembly.
REMOVE DRIVE BELT, FAN, FLUID COUPLING AND
FAN PULLEY
Loosen the 4 nuts holding the fluid coupling to the fan
bracket.
Remove the drive belt. (See page CH-7 )
Remove the 4 nuts, fan, fluid coupling assembly and fan
pulley.
DISCONNECT ENGINE WIRE FROM CABIN
Remove the glove compartment door.
Remove the lower No.2 finish panel.
Remove the heater to register duct.
Remove the 3 screws, and disconnect the ECM from the
body bracket.
Disconnect the 3 wire harness connectors from the ECM.
Author:
Date:
3313
EM-106
(f)
(g)
13.
Disconnect
B07536
(a)
(b)
(c)
(d)
(e)
(f)
(g)
14.
(a)
(b)
ENGINE UNIT
Disconnect the engine wire from the engine wire bracket

and remove the 2 nuts, bolt and bracket.
Pull out the engine wire from the cowl panel.
DISCONNECT HOSES, WIRES, CONNECTORS,
CLAMPS, GROMMET AND CABLES
Disconnect the generator connector.
Disconnect the 2 heater hoses.
Disconnect the ground strap from the cowl panel.
Disconnect the fuel inlet hose and clamps.
Disconnect the fuel return hose and clamp.
Disconnect the air inlet hose from the charcoal canister.
Disconnect the EVAP hose from the charcoal canister.
DISCONNECT A/C COMPRESSOR FROM ENGINE

Disconnect the A/C compressor connector.
Remove the 3 bolts, and disconnect the A/C compressor
from the engine.
HINT:
Suspend the A/C compressor securely.
A23389
15. DISCONNECT PS PUMP FROM ENGINE

Remove the 3 bolts, and disconnect the PS pump from the engine.
HINT:
Suspend the PS pump securely.
A23390
16.
(a)
A22965
(b)
REMOVE ENGINE ASSEMBLY FROM VEHICLE

Install the 2 engine hangers with the 4 bolts as shown in
the illustration.
Part No. :
Engine hanger No. 1 12281-31060
Bolt 90119-08177
Attach the engine sling device and suspend the engine
using a chain block.
Author:
Date:
3314
EM-107
ENGINE UNIT
(c)
Remove the 4 bolts and 4 nuts, and separate the engine

mounting brackets from the frame brackets.
(d) Lift the engine out of the vehicle carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(e) Place the engine onto a working bench.
A22966
17. REMOVE DRIVE PLATE

Remove the 8 bolts, front spacer, drive plate and rear spacer.
A23391
Author:
Date:
3315
EM-101
ENGINE UNIT
ENGINE UNIT
EM1XV-01
COMPONENTS
V-Bank Cover
7.5 (76, 66 in.lbf)
Hood
Air Cleaner Hose No.2
Air Cleaner Assembly

MAF Meter Connector
Heater Hose
Battery Clamp
Battery
Battery Tray
Fuel Pipe
Fuel Pipe Clamp
A23384
Author:
Date:
3309
EM-102
ENGINE UNIT
No.1 Fan Shroud
5.0 (50, 44 in.lbf)
Radiator Assembly
No.2 Fan Shroud
12 (120, 9)
Oil Cooler Pipe for

AutomaticTransmission
V-Belt
Fan Pulley
A23385
Author:
Date:
3310
EM-103
12 (122, 9)
ENGINE UNIT
34 (346, 25)
Clamp
Transmission
71 (724, 52)
Oil Cooler Pipe

2.0 Kw:
Torque
Converter
Clutch
Shift Control Cable
x6
14.5 (148, 11)

19.5 (199, 14)
37 (377, 27)
48 (490, 35)
Starter
37 (377, 27)
9.8 (100, 7)
9.8 (100, 7)
48 (490, 35)
40 (408, 30)
43 (440, 32)
1.6 Kw:
Starter
Flywheel Housing Side Cover

Engine Rear
Mounting Insulator
65 (660, 48)
Manifold Stay
Gasket
40 (408, 30)
72 (734, 53)
Spring
Gasket
Manifold Stay
Gasket
Front Exhaust
Pipe LH
18 (185, 13)
Crossmember
62 (630, 46)
Gasket
62 (630, 46)
Propeller Shaft
37 (377, 27)
88 (897, 65)
40 (410, 30)
Bushing
Stabilizer Bar Bracket
Stabilizer Bar
Non-reusable part
Engine Under Cover

D14136
Author:
Date:
3311
EM-104
ENGINE UNIT
Water By-pass Hose

VSV Connector
Throttle Body Motor

Connector
VSV Connector
Vane Pump Connector
Generator
43 (438, 32)
Generator Wire
43 (438, 32)
Vane Pump
Generator Connector
A/C Compressor
25 (255, 18)
A/C Compressor
Connector
A23386
Author:
Date:
3312
EM-108
ENGINE UNIT
EM1XX-01
INSTALLATION
1.
INSTALL DRIVE PLATE
HINT:

The mounting bolts are tightened in 2 progressive steps
(steps (c) and (e)).

If any of the mounting bolts is broken or deformed, replace it.
(a)
Adhesive
Apply adhesive to 2 or 3 threads of the mounting bolt end.

Adhesive:
A04869
(b)
1
Install the front spacer, drive plate and rear spacer on the
crankshaft.
(c) Install and uniformly tighten the 8 mounting bolts in several steps, in the sequence shown in the illustration.
If any of the mounting bolts do not meet the torque specification,
replace it.
8
3
4
7
6
2
A23391
(d)
(e)
(f)
Painted
Mark
90
90
2.
(a)
(b)
A23392
(c)
(d)
(e)
(f)
Mark the mounting bolt with paint.

Retighten the mounting bolts 90 in the order shown in
the illustration.
Check that the painted mark is now at a 90 angle to what
it was in step (e).
INSTALL ENGINE ASSEMBLY IN VEHICLE
Attach the engine chain hoist to the engine hangers.
Slowly lower the engine assembly into the engine
compartment.
Attach the engine mounting brackets to the frame brackets.
Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts.
Remove the engine chain hoist.
Remove the 4 bolts and 2 engine hangers.
Author:
Date:
3316
EM-109
ENGINE UNIT
3.
INSTALL PS PUMP
Install the PS pump with the 3 bolts.
A23390
4.
(a)
(b)
5.
A23389
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
6.
(a)
(b)
(c)
(d)
Connect
A09152
A23387
(e)
(f)
(g)
(h)
7.
(a)
(b)
(c)
(d)
(e)
(f)
8.
9.
10.
INSTALL A/C COMPRESSOR

Install the A/C compressor with the 3 bolts.
Connect the A/C compressor connector.
CONNECT HOSES, WIRES, CONNECTORS, CLAMPS,
GROMMET AND CABLES
Connect the generator wire and connector.
Connect the 2 heater hoses.
Connect the ground strap to the cowl panel.
Connect the fuel inlet hose and clamps.
Connect the fuel return hose and clamp.
Connect the air inlet hose to the charcoal canister.
Connect the EVAP hose to the charcoal canister.
Connect the brake booster tube.
CONNECT ENGINE WIRE TO CABIN
Push the engine wire through the cowl panel.
Install the engine wire bracket with the 2 nuts and bolt and
connect the engine wire to the bracket.
Connect the 3 connectors to the ECM.
Connect the 2 wire harness connectors (cassette connector).
Install the ECM with the 3 screws.
Install the heater to register duct.
Install the lower No.2 finish panel.
Install the glove compartment door.
INSTALL AIR CLEANER ASSEMBLY
Install the air cleaner assembly with the 2 bolts.
Connect the air cleaner case to the air cleaner hose No.1.
Connect the air cleaner case with the 2 wire clamps.
Connect the PCV hose to the air cleaner case.
Connect the MAF meter connector.
Connect the air cleaner hose No.2 to the air cleaner case.
INSTALL BATTERY
INSTALL RADIATOR ASSEMBLY (See page CO-18 )
INSTALL FRONT EXHAUST PIPES
(See page EM-139 )
Author:
Date:
3317
EM-1 10
ENGINE UNIT
11.
INSTALL AUTOMATIC TRANSMISSION

(See page AT-29 )
12. INSTALL MANUAL TRANSMISSION
(See page MT-7 )
13. FILL WITH ENGINE COOLANT (See page CO-2 )
14. FILL WITH ENGINE OIL (See page LU-3 )
15. START ENGINE AND CHECK FOR LEAKS
16. INSTALL ENGINE UNDER COVERS
18. INSTALL HOOD
19. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
20. RECHECK ENGINE COOLANT AND OIL LEVELS
Author:
Date:
3318
EM-105
ENGINE UNIT
EM1XW-01
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
(a)
(b)
(c)
(d)
(e)
A23387
(f)
11.
(a)
(b)
(c)
12.
(a)
(b)
(c)
(d)
(e)

(See page SF-1 )
REMOVE ENGINE HOOD
REMOVE ENGINE V-BANK COVER
REMOVE ENGINE UNDER COVER
REMOVE AUTOMATIC TRANSMISSION
(See page AT-25 )
REMOVE MANUAL TRANSMISSION
(See page MT-4 )
REMOVE FRONT EXHAUST PIPES
(See page EM-139 )
REMOVE RADIATOR ASSEMBLY (See page CO-17 )
REMOVE BATTERY
REMOVE AIR CLEANER ASSEMBLY

Disconnect the air cleaner hose No.2 from the air cleaner
case.
Disconnect the MAF meter connector.
Disconnect the PCV hose from the air cleaner case.
Disconnect the 2 wire clamps from the air cleaner case.
Disconnect the air cleaner case from the air cleaner hose
No.1.
Remove the 2 bolts and air cleaner assembly.
REMOVE DRIVE BELT, FAN, FLUID COUPLING AND
FAN PULLEY
Loosen the 4 nuts holding the fluid coupling to the fan
bracket.
Remove the drive belt. (See page CH-7 )
Remove the 4 nuts, fan, fluid coupling assembly and fan
pulley.
DISCONNECT ENGINE WIRE FROM CABIN
Remove the glove compartment door.
Remove the lower No.2 finish panel.
Remove the heater to register duct.
Remove the 3 screws, and disconnect the ECM from the
body bracket.
Disconnect the 3 wire harness connectors from the ECM.
Author:
Date:
3313
EM-106
(f)
(g)
13.
Disconnect
B07536
(a)
(b)
(c)
(d)
(e)
(f)
(g)
14.
(a)
(b)
ENGINE UNIT
Disconnect the engine wire from the engine wire bracket

and remove the 2 nuts, bolt and bracket.
Pull out the engine wire from the cowl panel.
DISCONNECT HOSES, WIRES, CONNECTORS,
CLAMPS, GROMMET AND CABLES
Disconnect the generator connector.
Disconnect the 2 heater hoses.
Disconnect the ground strap from the cowl panel.
Disconnect the fuel inlet hose and clamps.
Disconnect the fuel return hose and clamp.
Disconnect the air inlet hose from the charcoal canister.
Disconnect the EVAP hose from the charcoal canister.
DISCONNECT A/C COMPRESSOR FROM ENGINE

Disconnect the A/C compressor connector.
Remove the 3 bolts, and disconnect the A/C compressor
from the engine.
HINT:
Suspend the A/C compressor securely.
A23389
15. DISCONNECT PS PUMP FROM ENGINE

Remove the 3 bolts, and disconnect the PS pump from the engine.
HINT:
Suspend the PS pump securely.
A23390
16.
(a)
A22965
(b)
REMOVE ENGINE ASSEMBLY FROM VEHICLE

Install the 2 engine hangers with the 4 bolts as shown in
the illustration.
Part No. :
Bolt 90119-08177
Attach the engine sling device and suspend the engine
using a chain block.
Author:
Date:
3314
EM-107
ENGINE UNIT
(c)
Remove the 4 bolts and 4 nuts, and separate the engine

mounting brackets from the frame brackets.
(d) Lift the engine out of the vehicle carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(e) Place the engine onto a working bench.
A22966
17. REMOVE DRIVE PLATE

Remove the 8 bolts, front spacer, drive plate and rear spacer.
A23391
Author:
Date:
3315
EM-138
EXHAUST SYSTEM
EXHAUST SYSTEM
EM1Y3-01
COMPONENTS
32 (326, 24)
Clamp
Gasket
Exhaust Tail Pipe

Heated Oxygen
Sensor (Bank 1)
48 (490, 35)
44 (450, 33)
43 (440, 32)
Gasket
Exhaust Center Pipe

48 (490, 35)
Gasket
Gasket
Spring
Heated Oxygen
Sensor (Bank 2)
62 (630, 46)
44 (450, 33)
62 (630, 46)
Gasket

Nm (kgfcm, ftlbf)
62 (630, 46)
: Specified torque
Front Exhaust Pipe LH
Non-reusable part
A23202
Author:
Date:
3346
EM-139
EXHAUST SYSTEM
EM1Y4-01
REPLACEMENT
1.
(a)
(b)
REMOVE EXHAUST TAIL PIPE

Remove the bolt and clamp.
Remove the 3 exhaust pipe supports and exhaust tail
pipe.
2.
(a)
(b)
(c)
REMOVE EXHAUST CENTER PIPE

Remove the 2 bolts and springs.
Remove the 2 bolts.
Remove the 2 exhaust pipe support and exhaust center
pipe.
Remove the gasket from the exhaust tail pipe.
REMOVE HEATED OXYGEN SENSOR
(BANK 1 OXYGEN SENSOR)
Disconnect the heated oxygen sensor.
Remove the heated oxygen sensor.
REMOVE RH FRONT EXHAUST PIPE
Remove the 2 nuts and RH front exhaust pipe.
Remove the 2 gaskets from the RH front exhaust pipe.
REMOVE HEATED OXYGEN SENSOR
Disconnect the heated oxygen sensor connector.
Remove the heated oxygen sensor.
A23249
(d)
3.
A23248
(a)
(b)
4.
(a)
(b)
5.
(a)
(b)
A23247
6.
(a)
(b)
REMOVE LH FRONT EXHAUST PIPE

Remove the 2 nuts, exhaust pipe support and LH front exhaust pipe.
Remove the 2 gaskets from the LH front exhaust pipe.
A23246
7.
(a)
(b)
(c)
8.
(a)
A23247
(b)
INSTALL RH FRONT EXHAUST PIPE

Install 2 new gaskets to the LH front exhaust pipe.
Install the LH front exhaust pipe with the 2 new nuts.
Install the exhaust pipe support.
INSTALL HEATED OXYGEN SENSOR
Install the heated oxygen sensor.
Connect the heated oxygen sensor connector.
Author:
Date:
3347
EM-140
9.
(a)
(b)
10.
(a)
A23246
(b)
EXHAUST SYSTEM
INSTALL RH FRONT EXHAUST PIPE

Install 2 new gaskets to the RH front exhaust pipe.
Install the RH front exhaust pipe with the 2 new nuts.
INSTALL HEATED OXYGEN SENSOR
(BANK2 OXYGEN SENSOR)
Install the heated oxygen sensor.
Connect the heated oxygen sensor connector.
11.
(a)
INSTALL EXHAUST CENTER PIPE

Using a vernier caliper, measure the free length of the
spring.
Minimum length: 40.5 mm (1.5945 in.)
If the free length is less than minimum, replace the spring.
(b) Install the 2 exhaust pipe supports.
Front
A23075
(c)
(d)
Install the 2 bolts.

Install the 2 bolts and springs.
A23248
12.
(a)
(b)
(c)
INSTALL EXHAUST TAIL PIPE

Install a new gasket to the exhaust center pipe.
Install the 3 exhaust pipe supports.
Install a new clamp and bolt.
30
A23250
Author:
Date:
3348
EM-25
Hand-Held Tester
IDLE SPEED
IDLE SPEED
EM1XI-01
INSPECTION
1.
(a)
CAN VIM
DLC3
D13872
When using a hand-held tester or OBD II scan tool.

Connect a hand-held tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect
the CAN VIM to the Date Link Connector 3 (DLC3).
(b) Please refer to the hand-held tester operators manual
for further details.
(c) Switch the air conditioning OFF.
(d) Race the engine at 2,500 rpm for approx. 90 seconds.
(e) Check the idle speed.
Idle speed: 650 to 750 rpm
(Transmission in neutral position)
If the idle speed is not as specified, check the air intake system.
(f)
Disconnect the hand-held tester or OBD II scan tool from
the DLC3.
2.
TAC
DLC3
SST
A23201
When not using a hand-held tester or OBD II scan

tool.
(a) Using SST, connect the tachometer probe to terminal
TAC of the DLC3.
SST 09843-18030
(b) Switch the air conditioning OFF.
(c) Race the engine at 2,500 rpm for approx. 90 seconds.
(d) Check the idle speed.
Idle speed: 650 to 750 rpm
If the idle speed is not as specified, check the air intake system.
(e) Disconnect the tachometer from the DLC3.
Author:
Date:
3233
EM-23
IGNITION TIMING
IGNITION TIMING
EM1XH-01
INSPECTION
1.
WARM UP ENGINE
Hand-Held Tester
2.
(a)
INSPECT IGNITION TIMING

(1) Connect a hand-held tester to the Controller Area
Network Vehicle Interface Module (CAN VIM). Then
connect the CAN VIM to the Date Link Connector 3
(DLC3).
(2) Please refer to the hand-held tester operators
manual for further details.
Ignition timing: 7 to 24 BTDC at idle
(Transmission in neutral)
(3) Disconnect the hand-held tester or OBD II scan tool
from the DLC3.
(b)
When not using a hand-held tester or OBD II scan tool.

(1) Remove the air cleaner cap.
(2) Connect the tester probe of a timing light to the wire
of the ignition coil connector for the No. 1 cylinder.
CAN VIM
DLC3
D13872
A22794
(3)
Using SST, connect terminals TC and CG of the

DLC3.
SST 09843-18040
TC
SST
CG
DLC3
A14755
Author:
Date:
3231
EM-24
A22795
IGNITION TIMING
(4) Using the timing light, check the ignition timing.

(5) Remove the SST from the DLC3.
(6) Check the ignition timing.
(7) Disconnect the timing light from the engine.
(8) Install the air cleaner cap.
Author:
Date:
3232
EM-23
IGNITION TIMING
IGNITION TIMING
EM1XH-01
INSPECTION
1.
WARM UP ENGINE
Hand-Held Tester
2.
(a)
INSPECT IGNITION TIMING

(1) Connect a hand-held tester to the Controller Area
Network Vehicle Interface Module (CAN VIM). Then
connect the CAN VIM to the Date Link Connector 3
(DLC3).
(2) Please refer to the hand-held tester operators
manual for further details.
(Transmission in neutral)
(3) Disconnect the hand-held tester or OBD II scan tool
from the DLC3.
(b)
When not using a hand-held tester or OBD II scan tool.

(1) Remove the air cleaner cap.
(2) Connect the tester probe of a timing light to the wire
of the ignition coil connector for the No. 1 cylinder.
CAN VIM
DLC3
D13872
A22794
(3)
Using SST, connect terminals TC and CG of the

DLC3.
SST 09843-18040
TC
SST
CG
DLC3
A14755
Author:
Date:
3231
EM-24
A22795
IGNITION TIMING
(4) Using the timing light, check the ignition timing.

(5) Remove the SST from the DLC3.
(6) Check the ignition timing.
(7) Disconnect the timing light from the engine.
(8) Install the air cleaner cap.
Author:
Date:
3232
EM-26
TIMING CHAIN
TIMING CHAIN
EM1XJ-01
COMPONENTS
7.5 (76, 66 in.lbf)
V-Bank Cover
Air Cleaner Hose
8.0 (82, 71 in.lbf)
Vacuum Hose
Mass Air Flow
Meter Connector
Air Cleaner
Battery Clamp
Battery
Battery Tray
Nm (kgfcm, ftlbf)
: Specified torque
A23192
Author:
Date:
3234
EM-27
TIMING CHAIN
Radiator
Fan Shroud
Fan Pulley
21 (214, 15)
Drive Belt
Nm (kgfcm, ftlbf)
: Specified torque
A23193
Author:
Date:
3235
EM-28
TIMING CHAIN
Oil Level Gauge
Oil Level Gauge Guide
9.0 (92, 80 in.lbf)
O-ring
Vane Pump
43 (438, 32)
9.8 (100, 7)
Generator
Terminal Cap
43 (438, 32)
Generator Wire
Generator Connector
Cooler Compressor
8.0 (82, 71 in.lbf)
43 (438, 32)
25 (255, 18)
8.0 (82, 71 in.lbf)
Cooler Compressor Connector

Nm (kgfcm, ftlbf)
: Specified torque
Non-reusable part
A22851
Author:
Date:
3236
EM-29
TIMING CHAIN

O-ring
Gasket
x5
Water Inlet
9.0 (92, 80 in.lbf)
Oil Cooler Hose
Idler Pulley No.2

Washer
V-Ribbed Belt Tensioner
Idler Pulley No.1
39 (398, 29)
Washer
54 (551, 40)
O-ring
36 (367, 27)
36 (367, 27)
21 (214, 15)
10 (102, 7)
x2
x2
Oil Pan
Gasket
21 (214, 15)
x6
x4
x9
37 (377, 27)
Oil Strainer
21 (214, 15)
9.0 (92, 80 in.lbf)
Oil Pan No.2

9.0 (92, 80 in.lbf)
x15
x2
10 (102, 7)
Gasket
Nm (kgfcm, ftlbf)
: Specified torque
Non-reusable part
Drain Plug
40 (408, 30)
A22852
Author:
Date:
3237
EM-30
TIMING CHAIN
VSV Connector
28 (286, 21)
Water By-pass Hose

Intake Air Surge Tank
x4
x2
VSV Connector
Fuel Vapor Feed Hose
Throttle Body
Connector
21 (214, 15)
21 (214, 15)
Throttle Body Bracket

21 (214, 15)
Gasket
10 (102, 7)
10 (102, 7)
9.0 (92, 80 in.lbf)
Oil Baffle Plate
9.0 (92, 80 in.lbf)
Ignition Coil
9.0 (92, 80 in.lbf)
x3
9.0 (92, 80 in.lbf)
x7
10 (102, 7)
x3
10 (102, 7)
Ignition Coil
9.0 (92, 80 in.lbf)
x3
x3
Cylinder Head
Cover RH
x7
Cylinder Head
Cover LH

Nm (kgfcm, ftlbf)
: Specified torque
Non-reusable part
A23194
Author:
Date:
3238
EM-31
TIMING CHAIN
23 (235, 17)
Crankshaft Pulley
Oil Seal
Timing Chain Cover
x15
250 (2,549, 184)
19 (194, 14)
23 (235, 17)
19 (194, 14)
x9
Camshaft Timing
Sprocket
Timing Chain No.2
23 (235, 17)
x2
Camshaft Timing
Gear Assembly
Timing Chain No.2
100 (1,020, 74)
Camshaft Timing
Gear Assembly
100 (1,020, 74)
100 (1,020, 74)

100 (1,020, 74)
Camshaft Timing
Sprocket

10 (102, 7)
Chain Vibration
Damper No.2
Timing Chain
Chain Tensioner
Slipper
60 (612, 44)
Idle Gear No.1
O-ring
Crankshaft Timing
Sprocket
Nm (kgfcm, ftlbf)
: Specified torque
Non-reusable part
19 (194, 14)
Author:
Chain Vibration
Damper No.1
Date:
A23195
3239
EM-38
TIMING CHAIN
EM1XL-01
INSPECTION
Measuring Area
0 1 2 3 4 5
15 A23207
1.
INSPECT NO.1 AND NO.2 TIMING CHAINS
Using a spring scale, pull the chain sub assembly with 147 N
(15.0 kgf, 33.1 lbf) of force and measure the length of the chain
sub assembly using a vernier caliper.
Maximum chain elongation: 146.8 mm (5.780 in.)
NOTICE:
Perform the same measurements by pulling at random in
3 or more places to obtain an average length.
If the elongation is greater than the maximum, replace the
chain.
2.
(a)
A22990
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Put the No. 1 chain on the larger gear of the camshaft timing gear assembly.
(b) Using a vernier caliper, measure the timing gear with the
chain.
Minimum gear diameter (w/ chain):
115.5 mm (4.547 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
measuring.
If the diameter is less than the minimum, replace the No. 1 chain
and camshaft timing gear assembly.
Author:
Date:
3246
EM-39
TIMING CHAIN
(c)
A22991
Put the No. 2 chain on the smaller gear of the camshaft

timing gear assembly.
(d) Using a vernier caliper, measure the timing gear with the
chain.
73.1 mm (2.878 in.)
NOTICE:
measuring.
and camshaft timing gear assembly.
3.
(a)
(b)
A22992
INSPECT CAMSHAFT TIMING SPROCKET

Put the No. 2 chain on the camshaft timing sprocket.
Using a vernier caliper, measure the camshaft timing
sprocket diameter with the chain .
73.1 mm (2.878 in.)
NOTICE:
measuring.
and the camshaft timing sprocket.
Author:
Date:
3247
EM-40
TIMING CHAIN
4.
(a)
(b)
A22993
INSPECT CRANKSHAFT TIMING SPROCKET

Put the No. 1 chain on the crankshaft timing sprocket.
Using a vernier caliper, measure the crankshaft timing
gear diameter with the chain.
61.0 mm (2.402 in.)
NOTICE:
measuring.
and crankshaft timing sprocket.
5.
(a)
(b)
A22994
INSPECT IDLE GEAR NO.1

Put the No. 1 chain on the idle gear.
Using a vernier caliper, measure the idle gear with the
chain.
61.0 mm (2.402 in.)
NOTICE:
measuring.
and idle gear.
6.
(a)
INSPECT IDLE GEAR SHAFT OIL CLEARANCE

Using a micrometer, measure the idle gear shaft diameter.
Idle gear shaft diameter:
22.987 to 23.000 mm (0.9050 to 0.9055 in.)
A22995
Author:
Date:
3248
EM-41
(b)
(c)
A22996
7.
(a)
Raise
Lock
(b)
Move
TIMING CHAIN

idle gear.
Idle gear inside diameter:
23.02 to 23.03 mm (0.9063 to 0.9067 in.)
Subtract the idle gear shaft diameter measurement from
the idle gear inside diameter measurement.
0.020 to 0.043 mm (0.0008 to 0.0017 in.)
Maximum oil clearance:
0.093 mm (0.0037 in.)
INSPECT CHAIN TENSIONER NO.1
Check that the plunger moves smoothly when the ratchet
pawl is raised with a finger.
Release the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushing with a finger.
A22997
8.
(a)
(b)
INSPECT CHAIN TENSIONER NO.2

Check that the plunger moves smoothly.
Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain tensioner No. 2.
Move
A22998
9.
INSPECT CHAIN TENSIONER SLIPPER
Measure the worn depth of the chain tensioner slipper.
If the depth is greater than the maximum, replace the chain tensioner slipper.
A23000
Author:
Date:
3249
EM-42
TIMING CHAIN
10.
INSPECT CHAIN VIBRATION DAMPER NO.1 AND

NO.2
Measure the worn depth of the chain vibration damper No. 1
and No. 2.
If the depth is greater than the maximum, replace the chain
vibration damper No. 1 or No.2.
No.1
No.2
A23001
Author:
Date:
3250
EM-44
TIMING CHAIN
EM1XN-01
INSTALLATION
90
Set Key
Turn
A22895
1.
SET CRANKSHAFT POSITION
Using the crankshaft pulley set bolt, turn the crankshaft, and set
the crankshaft set key into the left horizontal position.
NOTICE:
Having the crankshaft at the wrong angle can cause the
piston head and valve head to come into contact with each
other when you install the camshaft, causing damage. So
always set the crankshaft at the correct angle.
2.
(a)
INSTALL CHAIN TENSIONER NO.2

While pushing in the tensioner, insert a pin of 1.0 mm
(0.039 in.) into the hole to fix it.
(b)
Install the chain tensioner No. 2 with the bolt.

3.
(a)
INSTALL NO.2 TIMING CHAIN

Align the mark links (yellow) with the timing marks (1-dot
mark) of the camshaft timing gear assembly and camshaft timing sprocket as shown in the illustration.
Push
A22900
A22885
Mark Links
Timing Marks
A22901
(b)
Timing Marks
Timing Marks
Align the timing marks on the camshaft timing gear assembly and camshaft timing sprocket with the timing
marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.
NOTICE:
Do not push camshaft timing gear assembly to the camshaft forcibly when installing it.
A22902
Author:
Date:
3252
EM-45
(d)
(e)
TIMING CHAIN
Hold the hexagonal portion of the camshaft with a

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

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

Align the timing gear set key with the key groove of the
timing sprocket.
Install the timing gear onto the crankshaft with the sprocket side facing inward.
INSTALL CHAIN TENSIONER SLIPPER
A22921
Inward
(b)
6.
A23007
7.
(a)
(b)
Stopper Plate
Stopper Plate
Push
A22850
(c)
INSTALL CHAIN TENSIONER NO.1

While turning the stopper plate of the tensioner clockwise,
push in the plunger of the tensioner as shown in the illustration.
While turning the stopper plate of the tensioner counterclockwise, insert a bar of 3.5 mm (0.138 in.) into the
holes in the stopper plate and tensioner to fix the stopper
plate.
Install the chain tensioner with the 2 bolts.
Author:
Date:
3253
EM-46
RH Bank
Timing Marks
TIMING CHAIN
8.
(a)
SET NO.1 CYLINDER TO TDC/COMPRESSION

Align the timing marks of the camshaft timing gear assembly, camshaft timing sprocket and bearing caps.
(b)
Using the crankshaft pulley set bolt, turn the crankshaft

to align the crankshaft set key with the timing line of the
cylinder block.
9.
(a)
INSTALL TIMING CHAIN NO.1

Align the mark link (yellow) with the timing mark of the
crankshaft timing sprocket.
Timing Marks
LH Bank
Timing Marks
A22801
Timing Line
Set Key
A22869
Mark Link
Timing Mark
A22870
Mark Links
(b)
Align the mark links (orange) with the timing marks of the
camshaft timing gear assembly and camshaft timing
sprocket, and install the chain.
10. INSTALL CHAIN VIBRATION DAMPER NO.2
Install the 2 chain vibration damper No.2.
Timing Marks
A22871
Author:
Date:
3254
EM-47
Forward
Knock Pin
A22872
TIMING CHAIN
11.
(a)
INSTALL IDLE GEAR NO.1

Apply a light coat of engine oil to the rotating surface of
the idle gear shaft No. 1.
(b) Temporarily install the idle gear shaft No. 1 and idle gear
No. 1 with the idle gear shaft No. 2 while aligning the
knock pin of the idle gear shaft No. 1 with the knock pin
groove of the cylinder block.
NOTICE:
Be careful of the idle gear direction.
(c) Using a 10 mm hexagon wrench, tighten the idle gear
shaft No. 2.
(d) Remove the bar from the chain tensioner.
12. INSTALL TIMING CHAIN COVER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
(b)
Install a new O-ring to the LH cylinder head as shown in

the illustration.
(c)

4 mm (0.12 to 0.16 in.)) to 4 locations as shown in the illustration.
A23009
Seal
Packing
A23010
Author:
Date:
3255
EM-48
TIMING CHAIN
(d)
Seal Packing
A
B
B
Water Pump
Part
Water
Pump
Part
3 to 4 mm
Seal Packing
Seal Width 3 to 4 mm
3 to 4 mm

4 mm (0.12 to 0.16 in.)) to the timing chain cover as shown
Seal packing:
Water pump part: Part No. 08826-00100 or equivalent
Other part: Part No. 08826-00080 or equivalent
NOTICE:

Install the timing chain cover within 3 minutes after
applying seal packing. After installing it, the timing
chain cover bolts and nuts must be tightened within
15 minutes. Otherwise the seal packing must be removed and reapplied.

Do not apply seal packing to the A as shown in the
illustration.
3 to 4 mm
16.7 mm
B - B
A23011
(e)
15
Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide
the timing chain cover into place.
A23012
(f)
A
A
A
A
B
B
B
B
BB
B
Nut
B B
B
B
B
AB
B
Nut
A23186
Install the timing chain cover with the 24 bolts and 2 nuts.
Tighten the bolts and nuts uniformly in several steps.
NOTICE:

Pay attention not to wrap the chain and slipper over
the timing chain cover seal line.

Install the water pump within 15 minutes after installing the timing chain cover.
HINT:
Each bolt length is as follows:
A: 25 mm (0.98 in.)
B: 55 mm (2.17 in.)
Author:
Date:
3256
EM-49
TIMING CHAIN
13.
(a)
(b)
(c)
INSTALL WATER INLET

Install a new O-ring to the water outlet pipe.
Install a new gasket to the water pump.
Apply soapy water to the O-ring.
(d)
Install the water inlet with the 5 bolts.

Connect the 5 water by-pass hoses.
Connect the 2 radiator hoses.
Connect the 2 oil cooler hoses (w/ oil cooler).
A23120
(e)
(f)
(g)
A23121
14.
(a)
(b)
B
INSTALL OIL PAN

Install the 4 stud bolts.
not to drop any oil on the contact surfaces of the cylinder
block, rear oil seal retainer and oil pan.
16.5
13
22.5
8
Stud Bolt A
27.5
9
Stud Bolt B [mm]
A23013
(c)
Install a new O-ring to the oil pump.
A22873
Author:
Date:
3257
EM-50
B
A22874

4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration.
NOTICE:
Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be
tightened within 15 minutes. Otherwise the seal packing
must be removed and reapplied.
(e)
A
B
B
B
Nut
TIMING CHAIN
(d)
Seal Packing
Nut
A22863
Flywheel Housing
Under Cover
Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
Torque:
Bolt A, B, Nut: 21 Nm (214 kgfcm, 15 ftlbf)
Bolt C: 10 Nm (102 kgfcm, 7 ftlbf)
HINT:
A: 25 mm (0.98 in.)
B: 45 mm (1.77 in.)
C: 14 mm (0.55 in.)
(f)
Install the 4 housing bolts.
(g) Install the flywheel housing under cover.
A22862
15.
(a)
16.
(a)
INSTALL OIL STRAINER

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

to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
NOTICE:
Install the oil pan No. 2 within 3 minutes after applying seal
packing. After installing it, the oil pan No. 2 bolts and nuts
Seal Packing
A22875
Author:
Date:
3258
EM-51
(c)
TIMING CHAIN
Install the oil pan No. 2 with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
Bolt: 9.0 Nm (92 kgfcm, 80 in.lbf)
Nut: 10 Nm (102 kgfcm, 7 ftlbf)
A22859
17. INSTALL CRANKSHAFT PULLEY

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

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

Install the 2 idler pulleys with the 2 bolts.
A22878
A-1
A
B
B-1
B
B
A22856
20. INSTALL V-RIBBED BELT TENSIONER ASSY

Tighten bolts A-1 and B-1 in order first, then tighten the remaining bolts.
HINT:
A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)
21. INSTALL COOLER COMPRESSOR
(See page AC-58 )
Author:
Date:
3259
EM-52
22.
TIMING CHAIN
INSTALL GENERATOR (See page CH-15 )
23.
(a)
INSTALL VANE PUMP

Install the vane pump with the 2 bolts.
NOTICE:
Do not hit the pulley to other parts when installing the vane
pump.
(b) Connect the P/S oil pressure switch connector.
24. INSTALL WATER INLET (See page EM-89 )
A22855
O-Ring
25.
(a)
(b)
(c)
(d)
Push
A22879
(e)
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
INSTALL OIL LEVEL GAUGE GUIDE

Install a new O-ring to the oil level gauge guide.
Apply a light coat of engine oil to the O-ring.
Push in the oil level gauge guide end into the guide hole
of the oil pan.
Install the oil level gauge guide with the bolt.
Install the oil level gauge.
INSTALL CYLINDER HEAD COVER
(See page EM-89 )
(See page EM-89 )
INSTALL AIR CLEANER (See page EM-89 )
INSTALL FAN W/FLUID COUPLING
(See page EM-89 )
INSTALL DRIVE BELT (See page EM-89 )
FULLY TIGHTEN FAN W/FLUID COUPLING
INSTALL RADIATOR (See page CO-18 )
INSTALL V-BANK COVER
INSTALL BATTERY
ADD ENGINE OIL (See page LU-3 )
ADD ENGINE COOLANT (See page CO-2 )
CHECK FOR LEAKS
CHECK IGNITION TIMING (See page EM-23 )
CHECK IDLE SPEED (See page EM-25 )
Author:
Date:
3260
EM-32
TIMING CHAIN
EM1XK-01
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
(a)
(b)
(c)
A22855

DRAIN ENGINE OIL
REMOVE BATTERY
REMOVE V-BANK COVER
REMOVE RADIATOR (See page CO-17 )
LOOSEN FAN W/FLUID COUPLING
(See page EM-62 )
REMOVE DRIVE BELT (See page EM-62 )
REMOVE FAN W/FLUID COUPLING
REMOVE AIR CLEANER (See page EM-62 )
(See page EM-62 )
(See page EM-62 )
REMOVE VVT SENSOR
REMOVE OIL LEVEL GAUGE GUIDE
Remove the oil level gauge.
Remove the bolt and pull out the oil level gauge guide.
Remove the O-ring from the oil level gauge guide.
14. SEPARATE VANE PUMP

(a) Disconnect the P/S oil pressure switch connector.
(b) Remove the 2 bolts, and separate the vane pump.
NOTICE:
Do not hit the pulley to other parts when separating the
vane pump.
HINT:
The vane pump is suspended securely.
15. REMOVE GENERATOR (See page CH-7 )
16. SEPARATE COOLER COMPRESSOR
(See page AC-54 )
17. REMOVE V-RIBBED BELT TENSIONER

Remove the 5 bolts and V-ribbed belt tensioner.
18. REMOVE IDLER PULLEY NO.1 AND NO.2
A22856
Author:
Date:
3240
EM-33
TIMING CHAIN
19.
(a)
REMOVE CRANKSHAFT PULLEY

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

SST
A22857
SST
A22858
A22859
(b)
Insert the blade of SST between the oil pan and oil pan
No. 2, cut off applied sealer and remove the oil pan No.
2.
SST 09032-00100
NOTICE:

Be careful not to damage the contact surface of the oil
pan and oil pan No. 2.

Be careful not to damage the oil pan No. 2 flange.
SST
A22860
21. REMOVE OIL STRAINER

Remove the 2 nuts, oil strainer and gasket.
A22861
Author:
Date:
3241
EM-34
Flywheel Housing
Under Cover
TIMING CHAIN
22.
(a)
(b)
REMOVE OIL PAN

Remove the 4 housing bolts.
Remove the flywheel housing under cover.
(c)
Remove 17 bolts and 2 nuts.
A22862
A22863
(d)
Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence
shown.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and oil pan.
(e) Remove the O-ring from the oil pump.
Pry
LH Side
RH Side
A22864
23.
(a)
REMOVE WATER INLET

Disconnect the 2 oil cooler hoses (w/ oil cooler).
A23116
Author:
Date:
3242
EM-35
TIMING CHAIN
(b)
Disconnect the 2 radiator hoses.
(c)
Disconnect the 5 water by-pass hoses.
(d)
(e)
(f)
Remove the 5 bolts and water inlet.

Remove the O-ring from the water outlet pipe.
Remove the gasket from the water pump.
24.
(a)
REMOVE TIMING CHAIN COVER

A23117
A23118
A23119
A23186
Author:
Date:
3243
EM-36
TIMING CHAIN
(b)
Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with
a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder block and cylinder head.
(c) Remove the O-ring from the LH cylinder head.
A23187
25.
(a)
Timing Line
SET NO.1 CYLINDER TO TDC/COMPRESSION

Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of
the cylinder block.
Set Key
A22865
RH Bank
(b)
Check that the timing marks of the camshaft timing gear

assembly and camshaft timing sprocket are aligned with
the timing marks of the bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360 ) and
align the timing marks as above.
26. REMOVE CHAIN TENSIONER NO.1
NOTICE:

Never rotate the crankshaft with the chain tensioner
removed.

When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40
from the TDC first.
Timing Marks
Timing Marks
LH Bank
Timing Marks
A22866
Author:
Date:
3244
EM-37
(a)
Push
Stopper Plate
(b)
Stopper
Plate
A22807
(c)
27.
TIMING CHAIN
While turning the stopper plate of the tensioner clockwise,

push in the plunger of the chain tensioner as shown in the
illustration.
While turning the stopper plate of the tensioner counterclockwise, insert a bar of 3.5 mm (0.138 in.) into the
holes in the stopper plate and tensioner to fix the stopper
plate.
Remove the 2 bolts and chain tensioner.
REMOVE CHAIN TENSIONER SLIPPER
28. REMOVE IDLE GEAR NO.1

Using a 10 mm hexagon wrench, remove the idle gear shaft No.
2, idle gear No. 1 and idle gear shaft No. 1.
29. REMOVE CHAIN VIBRATION DAMPER NO.2
Remove the 2 chain vibration damper No.2.
30. REMOVE NO.1 TIMING CHAIN
31. REMOVE CRANKSHAFT TIMING SPROCKET
A22867
32.
(a)
REMOVE NO.2 TIMING CHAIN

While raising the chain tensioner No. 2, insert a pin of
1.0 mm (0.039 in.) into the hole to fix it.
Raise
A22884
(b)
Hold the hexagonal portion of the camshaft with a

wrench, and remove the 2 bolts, camshaft timing sprocket, camshaft timing gear assembly and timing chain No.2.
NOTICE:

Be careful not to damage the cylinder head and valve
lifter with the wrench.

Do not disassemble the camshaft timing gear assembly.
A22903
33. REMOVE CHAIN TENSIONER NO.2

Remove the bolt and chain tensioner No.2.
A22885
Author:
Date:
3245
EM-43
TIMING CHAIN
EM1XM-01
REPLACEMENT
Pry
A22976
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
REPLACE TIMING CHAIN COVER OIL SEAL
(a) If the rear timing chain cover is removed:
NOTICE:
Be careful not to damage the oil pump. Wrap the tip of the
screwdriver with tape.
(2)
Using SST and a hammer, tap in a new oil seal until

its surface is flush with the timing chain cover edge.
SST 09226-10010
(3) Apply MP grease to the oil seal lip.
SST
A23008
(b)
If the rear timing chain cover is installed:

NOTICE:
Be careful not to damage the crankshaft. Wrap the tip of the
screwdriver with tape.
A23076
(2)
Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing chain cover edge.
SST 09226-10010
(3) Apply MP grease to a new oil seal lip.
SST
A23077
Author:
Date:
3251
EM-4
VALVE CLEARANCE
VALVE CLEARANCE
EM1XG-01
INSPECTION
1.
2.
3.
4.
5.
6.
7.
(a)

REMOVE V-BANK COVER
REMOVE AIR CLEANER (See page EM-62 )
(See page EM-62 )
REMOVE IGNITION COIL
(See page EM-62 )
SET NO. 1 CYLINDER TO TDC/COMPRESSION

Turn the crankshaft pulley, and align its groove with the
timing mark 0 of the timing chain cover.
A22800
RH Bank
(b)
Check that the timing marks of the camshaft timing gears

are aligned with the timing marks of the bearing caps as
Timing Marks
Timing Marks
LH Bank
Timing Marks
A22801
Author:
Date:
3212
EM-5
3 3
RH Bank:
VALVE CLEARANCE
8.
(a)
INSPECT VALVE CLEARANCE

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

the valves indicated in the illustration.
Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)
EX
IN
1 1
Front
LH Bank:
6 6
IN
EX
2 2
A22802
5 5
RH Bank:
EX
IN
LH Bank:
3 3
Front
2 2
IN
EX
4 4
A22803
Author:
Date:
3213
EM-6
RH Bank:
1 1
VALVE CLEARANCE
(c)
Turn the crankshaft 2/3 of a revolution (240), and check

the valves indicated in the illustration.
Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.)
9.
(a)
ADJUST VALVE CLEARANCE

Set the No. 1 cylinder to the TDC/compression.
(1) Turn the crankshaft pulley, and align the notch with
the timing mark 0 of the timing chain cover.
EX
IN
5 5
LH Bank:
Front
4 4
IN
EX
6 6
A22804
A22800
RH Bank
(2)
Check that the timing marks of the camshaft timing

gears are aligned with the timing marks of the bearing caps as shown in the illustration.
Timing Marks
Timing Marks
LH Bank
Timing Marks
A22801
Author:
Date:
3214
EM-7
Paint Marks
Timing Marks
A22805
VALVE CLEARANCE
(3)
Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears.
(b) Remove the chain tensioner No. 1.
NOTICE:

Never rotate the crankshaft with the chain tensioner
removed.

When rotating the camshaft with the timing chain removed, turn the crankshaft counterclockwise 40
from the TDC first.
(1) Remove the 4 bolts, timing chain cover plate and
gasket.
A22806
(2)
Push
Stopper Plate
Stopper
Plate
A22807
While rotating the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as
(3) While rotating the stopper plate of the tensioner
downward, insert a bar of 3.5 mm (0.138 in.) into
the holes in the stopper plate and tensioner to fix the
stopper plate.
(4) Remove the 2 bolts and chain tensioner No.1.
(c) Remove the No. 2 camshaft.
NOTICE:
(1)
While raising up the chain tensioner No. 2, insert a

pin of 1.0 mm (0.039 in.) into the hole to fix it.
Raise
A22808
Author:
Date:
3215
EM-8
(2)
VALVE CLEARANCE
Hold the hexagonal portion of the No. 2 camshaft

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

wrench so that the cam lobes of the No. 1 cylinder
face upward as shown in the illustration.
(5)
Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in
the illustration.
Remove the 4 bearing caps and No. 2 camshaft.
A22810
(6)
2
5
A22811
(d)
A22812
Remove the chain tensioner No. 2.

(1) Remove the chain tensioner No. 2 bolt, and then remove the chain tensioner No. 2 and camshaft timing
sprocket.
(e) Remove the camshaft.
NOTICE:
Author:
Date:
3216
EM-9
(1)
VALVE CLEARANCE

with a wrench, and loosen the camshaft timing gear
assembly set bolt.
NOTICE:

Be careful not to damage the cylinder head and valve
lifter with the wrench.

Do not disassemble the camshaft timing gear assembly.
A22813
(2)
Slide the camshaft timing gear assembly and separate the No. 1 chain from the camshaft timing gear
sprocket.
(3)
Rotate the No. 1 camshaft counterclockwise using

a wrench so that the cam lobes of No. 1 cylinder
face upward as shown in the illustration.
(4)
the illustration.
Remove the 4 bearing caps.
Slide
A22814
A22815
(5)
6
A22816
(6)
Remove the camshaft timing gear assembly set bolt

with the No. 1 camshaft lifted up, and then remove
the No. 1 camshaft and camshaft timing gear assembly w/ No. 2 chain.
A22817
Author:
Date:
3217
EM-10
(7)
A22818
VALVE CLEARANCE
Tie the No. 1 chain with a string as shown in the illustration.
NOTICE:
Be careful not to drop anything inside the timing chain cover.
(f)
Remove the No. 4 camshaft.
NOTICE:
(1)
While pushing down the chain tensioner No. 2, insert a pin of 1.0 mm (0.039 in.) into the hole to fix
it.
(2)

with a wrench, and remove the camshaft timing
sprocket set bolt.
Push
A22819
NOTICE:
Be careful not to damage the cylinder head and valve lifter
with the wrench.
(3) Separate the camshaft timing sprocket from the No.
4 camshaft.
A22820
(4)
(5)
6
the illustration.
Remove the 4 bearing caps and No. 4 camshaft.
A22821
Author:
Date:
3218
EM-1 1
VALVE CLEARANCE
(g)
A22822
Remove the chain tensioner No. 2.

(1) Remove the chain tensioner No. 3 bolt, and then remove the chain tensioner No. 3 and camshaft timing
sprocket.
(h) Remove the No. 3 camshaft.
NOTICE:
(1)
5
(2)
6
the illustration.
Remove the 4 bearing caps.
A22823
(3)
Hold the No. 1 chain, and remove the No. 3 camshaft, camshaft timing gear assembly and No. 2
chain.
(4)
Tie the No. 1 chain with a string as shown in the illustration.
A22824
NOTICE:
Be careful not to drop anything inside the timing chain cover.
(i)
Remove the valve lifters.
A22825
Author:
Date:
3219
EM-12
(j)
A01082
VALVE CLEARANCE
Determine the size of the valve lifter to be installed according to the following formulas or charts:
(1) Using a micrometer, measure the thickness of the
removed lifter.
(2) Calculate the thickness of a new lifter so that the
valve clearance comes within the specified value.
T: Thickness of removed lifter
A: Measured valve clearance
N: Thickness of new lifter
Intake:
N = T + (A - 0.20 mm (0.008 in.))
Exhaust:
N = T + (A - 0.30 mm (0.012 in.))
(3) Select a new lifter with a thickness as close as possible to the calculated value.
HINT:
Lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260
in.).
Author:
Date:
3220
Valve Lifter Selection Chart (Intake)

Removed lifter
thickness
mm (in.)
Measured
clearance mm (in.)

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

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

Removed lifter
thickness
mm (in.)
Measured
clearance mm (in.)

-
No. Thickness No. Thickness No. Thickness
Author:
Date:
Exhaust valve clearance (Cold):

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

NOTICE:
(1)
Mark Links
(2)
Timing Marks
Align the mark link (yellow) with the timing mark

(2-dot mark) of the camshaft timing gear assembly
Apply new engine oil to the thrust portions and journals of the camshafts.
A22828
(3)
Temporarily put the No. 1 chain on the No. 2 chain

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

with the cam lobes of the No. 2 cylinder facing
downward as shown in the illustration.
(5)
(6)

Apply a light coat of engine oil to the threads of the
bearing cap bolts.
A22829
A22830
A22831
Author:
Date:
3223
EM-16
VALVE CLEARANCE
(7)
Install the 8 bearing cap bolts. Using several steps,

tighten the bolts uniformly in the sequence as
Torque:
A22832
(8)
Paint Mark
Set the paint mark of the No. 1 chain between the

timing marks of the camshaft timing gear assembly.
Timing Marks
A22833
(l)
Install the chain tensioner No. 2.

(1) While pushing in the tensioner, insert a pin of 1.0
mm (0.039 in.) into the hole to fix it.
Push
A22834
(2)
Mark Links
Timing Marks
A22835
Temporarily install the camshaft timing assembly

and chain tensioner No. 2 and align the mark links
(yellow) with the timing marks (1-dot mark and
2-dot mark) of the camshaft timing sprocket and
camshaft timing gear assembly.
(3) Tighten the chain tensioner No. 3 bolt.
(m) Install the No. 4 camshaft.
NOTICE:
Author:
Date:
3224
EM-17
(1)
(2)
VALVE CLEARANCE
Align the knock pin hole on the camshaft timing

sprocket with the knock pin of the No. 4 camshaft,
and insert the No. 4 camshaft into the camshaft timing sprocket.
Temporarily install the camshaft timing sprocket set
bolt.
A22836
(3)
(4)

A22837
(5)

Torque:
A22821
(6)
A22820

with a wrench, and tighten the camshaft timing
sprocket set bolt.
(7) Remove the pin from the chain tensioner No. 2.
(n) Install the camshaft.
NOTICE:
Author:
Date:
3225
EM-18
(1)
Mark Links
(2)
VALVE CLEARANCE
Align the mark link (yellow) with the timing mark

(1-dot mark) of the camshaft timing gear assembly
Apply new engine oil to the thrust portions and journals of the camshafts.
Timing Mark
A22838
(3)
Temporarily put the No. 1 chain on the No. 2 chain

of the camshaft timing gear assembly.
(4)
Align the knock pin hole on the camshaft timing gear

assembly with the knock pin of the No. 1 camshaft,
and insert the No. 1 camshaft into the camshaft timing gear assembly.
Temporarily install the camshaft timing gear assembly set bolt.
A22839
Knock Pin
(5)
A22840
(6)
Set the No. 1 camshaft onto the RH cylinder head

with the cam lobes of the No. 1 cylinder facing
downward as shown in the illustration.
(7)
(8)

A22841
A22842
Author:
Date:
3226
EM-19
VALVE CLEARANCE
(9)

Torque:
A22816
(10) Rotate the No. 1 camshaft clockwise using the hexagonal portion of the No. 1 camshaft so that the timing mark of the camshaft timing gear assembly is
aligned with the timing mark of the camshaft bearing cap.
Timing Marks
A22843
(11) Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear assembly.
Paint Mark
Timing Mark
A22844
(12) Hold the hexagonal portion of the No. 1 camshaft

with a wrench, and tighten the camshaft timing gear
assembly set bolt.
A22813
(o)

(1) While pushing in the tensioner, insert a pin of 1.0
mm (0.039 in.) into the hole to fix it.
Push
A22900
Author:
Date:
3227
EM-20
VALVE CLEARANCE
(2)
Mark Links
Timing Marks
A22846
Temporarily install the camshaft timing gear and

chain tensioner No. 2 and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assembly and camshaft timing
sprocket.
(3) Tighten the chain tensioner No. 2 bolt.
(p) Install the No. 2 camshaft.
NOTICE:
(1)
Set the No. 2 camshaft onto the RH cylinder head

with the cam lobes of No. 1 cylinder facing upward
(2)
(3)

A22847
A22848
(4)

Torque:
A22811
Author:
Date:
3228
EM-21
(5)
VALVE CLEARANCE
Rotate the No. 2 camshaft clockwise using a

wrench so that the knock pin of the No. 2 camshaft
is aligned with the knock pin hole of the camshaft
timing sprocket.
Knock Pin
A22849
(6)

with a wrench, and install the camshaft timing
sprocket set bolt.
(7) Remove the pin from the chain tensioner No. 2.
A22809
(q)
Stopper Plate
Stopper Plate
Push
A22850

(1) While turning the stopper plate of the tensioner
clockwise, push in the plunger of the tensioner as
(2) While turning the stopper plate of the tensioner
counterclockwise, insert a bar of 3.5 mm (0.138
in.) into the holes on the stopper plate and tensioner
to fix the stopper plate.
(3) Install the chain tensioner with the 2 bolts.
(4) Remove the bar from the chain tensioner.
(5) Install a new gasket and the timing chain cover plate
with the 4 bolts.
(6)
Turn the crankshaft pulley 2 complete revolutions

slowly, and align the notch with the timing mark 0
of the timing chain cover.
A22800
Author:
Date:
3229
EM-22
RH Bank
VALVE CLEARANCE
(7)
Timing Marks
10.
11.
12.
Timing Marks
13.
14.
15.
16.
LH Bank
Timing Marks
Check that the timing marks of the camshaft timing

gear assembly and camshaft timing sprocket are
aligned with the timing marks of the bearing caps as
INSTALL CYLINDER HEAD COVER (See page
EM-89 )
INSTALL IGNITION COIL
(See page EM-89 )
INSTALL AIR CLEANER (See page EM-89 )
ADD ENGINE COOLANT (See page CO-2 )
INSTALL V-BANK COVER
INSPECT IGNITION TIMING (See page EM-23 )
A22801
Author:
Date:
3230

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1GR-FE Engine Mechanical PDF

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EM-1

ENGINE MECHANICAL (1GR-FE)

INSERT CO/HC METER TESTING PROBE AT LEAST

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

1. Restricted air filter

Piston Ring (Expander)

Piston Ring (Side Rail)

Piston Pin Hole Snap Ring

Piston Pin Hole

Water Drain Cock

Knock Sensor Wire

See page EM-128

9.0 (92, 80 in.lbf)

Lower Crankshaft Thrust Washer

See page EM-128

Nm (kgfcm, ftlbf) : Specified torque

1st 61 (622, 45)

REMOVE WATER OUTLET PIPE NO.1

REMOVE KNOCK SENSOR

REMOVE ENGINE REAR OIL SEAL RETAINER

Lay a strip of Plastigage across the crank pin.

Using SST, tighten the bolts alternately to the specified

Measure the Plastigage at its widest point.

If replacing a bearing, replace it with one that has the

1.484 to 1.487 (0.0584 to 0.0585)

1.487 to 1.490 (0.0585 to 0.0587)

1.490 to 1.493 (0.0587 to 0.0588)

1.493 to 1.496 (0.0588 to 0.0589)

REMOVE PISTON W/CONNECTING ROD

Keep the bearings, connecting rod and cap together.

10. REMOVE PISTON PIN HOLE SNAP RING

REMOVE PISTON PIN

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

The piston and pin are a matched set.

INSPECT CRANKSHAFT THRUST CLEARANCE

Using several steps, uniformly loosen and remove the 16

Main Bearing Cap

16. REMOVE OIL NOZZLE

(2) Check twist.

INSPECT PISTON PIN OIL CLEARANCE

22.001 to 22.004 (0.8662 to 0.8663)

22.005 to 22.007 (0.8663 to 0.8664)

22.008 to 22.010 (0.8665 to 0.8665)

Using a micrometer, measure the piston pin diameter.

21.997 to 22.000 (0.8660 to 0.8661)

22.001 to 22.003 (0.8661 to 0.8663)

22.004 to 22.006 (0.8663 to 0.8664)

Using a caliper gauge, measure the inside diameter of the

22.005 to 22.008 (0.8663 to 0.8665)

22.009 to 22.011 (0.8665 to 0.8666)

22.012 to 22.014 (0.8666 to 0.8667)

Subtract the piston pin diameter measurement from the

If the oil clearance is greater than the maximum, replace

Piston Pin Hole

INSPECT PISTON RING END GAP

Using a feeler gauge, measure the end gap.

10. INSPECT CRANKSHAFT BEARING CAP SET BOLT

Using a micrometer, measure the diameter of each main

Using a micrometer, measure the diameter of each crank

No. 1 and No. 4

No. 2 and No. 3

12. INSPECT CRANKSHAFT OIL CLEARANCE

Lay a strip of Plastigage across each journal.