> TOYOTA ae eee MANUAL #=ENGINE =CHASSI!IS = BODY = ELECTRICAL Pe VOLUME 2FOREWORD This manual (Volume 2} contains repair procedures for the engine, chassis and body, and electrical service procedures for the 2000 CELICA. Applicable models: ZZT230, 231 series For maintenance, preparation, specifications and diagnostics service procedures, refer to VOLUME 1 (Pub. No. RM744U1). ‘The manual is divided into 21 sections with a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals for the compo- nents and systems in this vehicles. Pa Ne ‘URAOE AutoraticTrarsane Repair Manual A TAO [UDHOE, USATE Automate Tanaaste opal Manca (WG. 1850) TSS = 2000 GELIGA Elochzal Wing Diagram wos 7 Bo00 GELICA Now Car Features NOFTEGU All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. TOYOTA MOTOR CORPORATION ©2000 TOYOTA MOTOR CORPORATION All rights reserved, This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Jul. 14, 1999 01-990714-00 Fourth Printing: Mar. 14, 2000 04-000314.01CAUTION This manual does not include alll the necessary items about repair and service. This manualis made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non-specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tooi, that may cause severe injury to you or ather people around and also cause damage to your customer's vehicle. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown below. Must read this manual thoroughly. Itis especially important to have good understanding all the ‘contents written in the PRECAUTION of "IN" section. ‘The service method written in this manual is very effective to perform repair and service. When performing the operations following the procedures using this manual, be sure to use tools spe- ‘ified and recommended, If using non-specified or recommended tools and service method, be sure to confirm safety of the technicians and any possiblity of causing personal injury or damage to the customer's vehicle before starting the operation. If part replacement is necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality. {tis important to note that this manual contains various “Cautions” and "Notices” thal must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. Itis also important to understand that these “Cautions” and “Notices” are not exhaustive, because itis important to war of all the possible hazardous consequences that might result from failure to follow these instructions.NOTE: The screen toned sections below aro in VOLUME 4 (Pub. No. RM744U1). Pp SERVICE SP6 te SUPPLEMENTAL RESTRAINT SYSTEM BODY ELECTRICAL BODY AIR CONDITIONING ALPHABETICAL INDEX ENGINE MECHANICA! EMISSION CONTROL SFI COOLING LUBRICATION IGNITION STARTING CHARGING CLUTCH C56 MANUAL TRANSAXLE C60 MANUAL TRANSAXLE U240E AUTOMATIC TRANSAXLE U341E AUTOMATIC TRANSAXLE SUSPENSION AND AXLE BN BRAKE EG STEERING Bal TRS | Ea [1DENGINE MECHANICAL cOMC.. EM COMPRESSION . Ema VALVE CLEARANCE ... EN IGNITION TIMING EM-13 IDLE SPEED eM TIMING CHAIN... EMS CYLINDER HEAD EM36 ENGINE UNIT EM70 CYLINDER BLOCK . eves il] EXHALIST SYSTEM .. EMISEMA ENGINE MECHANICAL — COnIC. CO/HC INSPECTION HINT: This check is used only to dotermine whether or not the idle COVHC complies with regulations. 1. INSTALL CONDITIONS {a) Engine at normal operating temperature: (b) Air cleaner installed (¢) Air pipes and hoses of air induction system connected (@) All accessories switched OFF (@) All vacuum tines property connected (®_ SFl system wiring connectors fully plugged (a) Ignition timing check correctly {h) Transmission in neutral position (Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3, RAGE ENGINE AT 2,500 RPM FOR APPROX. 180 SE coNDs ED INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring with 3 minutes. HINT: When doing the 2 mode (idle and 2,500 rpm) test, these mea- surement order prescribed by the applicable local regulations.EM-2 ENGINE MECHANICAL — GONG {f the CO/H concentration does not comply with regulations, troubleshoot in the order given below. + Check heated oxygen sensor operation (See page. Di-49) + See the table below for possible causes, and then inspect and correct the applicable causes if neces- sary. ‘causes oneal High +. Faury ontion: stocorec ining + Fouled, shared orimeropery gapped plugs + Open or crossed igh tension cxeds 2 tncomect valve clearance J. Leaky intake and exaust ates 4. boa ylides High High rug se Fucwating HC reacing) | +PoV ses Rough ie (Peck smoke trom oxtaus) |2. Plugged PCV vane perEMS ENGINE MECHANICAL ~ COMPRESSION COMPRESSION INSPECTION HINT: IF there is tack of power, excassive 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 IGNITION COIL (See page IG-6) 3. REMOVE SPARK PLUGS 4. INSPECT CYLINDER COMPRESSION PRESSURE. (a) _ Insert a compression gauge into the spark plug hole. {b) Fully open the throttle (6) While cranking the engine, measure the compression pressure. fen | HINT: Always use a fully charged baltery to obtain engine speed of 250 rpm or more. (d)_ Ropeat steps (a) through (0) for each cylinder. NOTICE: ‘This measurement must be done in as short a time as pos- sible. Compression pressure: 1ZZ-FE 1,500 kPa (15.3 kgficm?, 218 psi) 2Z2-GE 1,400 kPa (14.3 kgticm?, 203 psi) or more Minimum pressure: 1ZZ-FE 1,000 kPa (10.2 kgtiem?, 145 psi) 2Z2-GE 1,000 kPa (10.2 kgticm?, 145 psi) Difference between each cylinder: 41ZZ-FE 100 kPa (1.0 kot/cm?, 15 psi) or less 222-GE 110 kPa (1.1 kglicm?, 16 psi) or less (2) _ If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the oylinder through the spark plug hole and repeat steps (a) through (0) for cylinders with low compression. +. If adding oil helps the compression, it is likely that the piston rings andlor cylinder bore are worn or damaged. + pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 8. REINSTALL SPARK PLUGS 6. _ INSTALL IGNITION COIL (See page IG-7)M4 ENGINE MECHANICAL _~_VALVE CLEARANCE 4ZZ-FE: VALVE CLEARANCE ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE CYLINDER HEAD COVER (See page EM-18) 2. 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. (®) Check that the point marks of the camshaft timing sprock- ets are in straight line on the timing chain cover surface as shown in the illustration. not, tum the crankshaft 1 revolution (360°) and align the marks as above. 3, INSPECT VALVE CLEARANCE (a) Check only the valves indicated. + Using a feeler gauge, measure the clearance be- tween the valve lifter and camshaft. + Record the out-of-speci valve clearance measuraments. They willbe used later to determine the required replacement adjusting shim. Valve clearance (Cold): 4ZZ-FE: Intake 0.15 - 0.25 mm (0.006 — 0.010 in.) Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.) 222-GE: Intake 0.15 — 0.25 mm (0.006 - 0.010 in.) Exhaust 0.35 - 0.45 mm (0,044 — 0.018 in.)EMS ENGINE MECHANICAL _— VALVE CLEARANCE. tb) © (e) ‘Turn the crankshaft 1 revolution (360°) and align the mark as above (See procedure in step 2). Check only the valves indicated as shown, Measure the valve clearance (See procedure in step (a)). AZZFE: ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the TDC/compression (See pro- cedure in stop 2), Place matchmarks on the timing chain and camshatt tim- ing sprockets. Remove the 2 bolts and chain tensioner. Remove the camshaft and timing sprocket assemblies (See page EM-42). (1) 19:camshaft bearing cap bolts {2) 9 camshaft bearing caps (No. 1 & No. 3) (3) Exhaust camshatt and timing sprocket assembly (4) _ Intake camshaft anc timing sprocket assembly HINT: When disconnect the timing chain from the camshaft timing ‘sprocket, holding the timing chain. Tie the timing chain with a string as shown in the illustra- tion. NOTICE: Be careful not to drop anything inside the timing chain cover. Do not allow the chain to come into contact with water ‘or dust. Remove the valve lifters.EMG ENGINE MECHANICAL — VALVE CLEARANCE (g) Determine the replacement valve lifter size according to esi ea femoved liter. + Calculate the thickness of a new filer so the valve clearance comes within the spacitied value. Toms Thickness of used lifter Measured valve clearance Thickness of new litter = T + (A—0.20 mm (0.008 in.) sr = T+ (A-0.30 mm (0.012 in.)) ‘ + Select a new lifter with a thickness as close as pos- sible to the calculated values. HINT: Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.}, from 5.080 mm (0.1992 in.) to §.740 mm (0.2260 in). 5. 2Z2-GE: ADJUST VALVE CLEARANCE (2) Remove the adjusting shim. (1) Turn the crankshait so that the cam lobe of cam- ‘shaft on the adjusting valve points upward. (2) Using SST, press down the valve. (@) Using SST, remove the adjusting shim, (4) Determine the replacement shim size according to these Formula or Charis: + Using dial indicator, measure the thickness of the removed shim, + Calculate the thickness of a new shim so the valve clearance comes within the specified value. Nu astEM? ENGINE MECHANICAL - VALVE CLEARANGE 1 Thickness of used shim .. Measured valve clearance 1» Thickness of new shim Intake: N = T+ (A~ 0.20 mm (0.008 in.)) Exhaust: N = T+ (A—0.40 mm (0.016 in.)) + Solect anew shim with a thickness as close as possible to the calculated values. 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Hold the timing chain, and place the intake camshaft and timing sprocket assembly. Align the matchmarks on the timing chain and camshaft timing sprocket. Reinstall the camshaft and timing sprocket assemblies (See page EN-65), ‘Check that the point marks of the camshaft liming sprock- ‘ts are in straight line on the timing chain cover surtace as shown in the illustration. Check that the matchmarks on the timing chain and ¢am- shaft timing sprockets. Install the chain tensioner (See page EM-25). Rocheck the valve clearance (See procedure in step 3). Check the valve timing (See page EM-28). REINSTALL CYLINDER HEAD COVER, (See page EM-25)EM-13 ENGINE MECHANICAL — IGNITION TIMING IGNITION TIMING INSPECTION 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (a) Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. (b) Please refer to the TOYOTA hand-held tester or OBDII ‘scan tool operator's for further details. 3. CONNECT TIMING LIGHT TO ENGINE 4. INSPECT IGNITION TIMING Using a timing light, check the ignition timing. Ignition timing: 1ZZ-FE: 10-18" BTDC @ Idle 2Z2-GEt 8-12" BTDC @idle (Transmission in neutral position) HINT: Alter engine rpm is kept at 1,000 — 1,300 rpm for 5 seconds, check that it returns to idle speed. 5. DISCONNECT TIMING LIGHT FROM ENGINE &. DISCONNECT TOYOTA HAND-HELD TESTER OR ‘BDI SCAN TOOLEma ENGINE MEGHAMICAL _IDLESPEED IDLE SPEED INSPECTION 1. INSTALL CONDITIONS {a) Engine at normal operating temperature {b) Aircleaner installed {c) All pipes and hoses of air induction system connected (¢) All vacuurn lines properly connected (e) SFI system wiring connectors fully plugged ()Alloperating accessories switched OFF (9) Ignition timing check correctly (h) Transmission in neutral position (Airconditioning switched OFF 2. GONNECT TOYOTA HAND-HELD TESTER OR OBDItI SCAN TOOL (@) Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. (0) Please refer to the TOYOTA hand-held tester or OBDII ‘scan tool operator's manual for further details. 3. INSPECT IDLE SPEED (a) Race the engine at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed (w/ Cooting fan OFF): 1ZZ-FE WT 700 + 50 pm I the ile speedis not as spectiod, check the IAC valve and air imake system. 4, DISCONNECT TOYOTA HAND-HELD TESTER OR OBDIISCAN TOOLENGINE MECHANICAL —_THIIG CHAN. TIMING CHAIN COMPONENTS c Upper Fron} Forder Apron Seal PS Oil Pressure SS ‘Switch Connector ‘ [sor] ° ey Pump eh ‘Upper Radiator Support “SQ Seat Generate Ye Generator Generator oe Connector 122-FE: BH Engine Mounting Insulator 3630, BH Engine Under Cover Neva (haem, fb9) | - Speciied torqueEME ENGINE MECHANICAL — TRANG CHAIN, No. 2 Cylinder Head Cover Front Crankshaft Oil Seal Crankshatt go " nena Gh Water Pump eGasket_ Camshait Timing estat | id (eae) Valve Timing Controller Assembly fA (Chain Tensioner Slipper Crankshalt Timing Sprocket Chain Vibration Dumper In Crank Angle Sensor Plate Nim tkatem, #169) | : Specified torque “@Non-réusable patEM7 ENGINE MECHANICAL — TIMING GHAI, 222-GE: BH Engine Mounting Bracket Wire Harmass Protector [48 500,36) | Driver Belt TTonsioger [x00 920,74) ERA Timing Chain Tensioner Front Crankshalt Ot Seal No.1 Ventilation Crankshaft Pufley. ney, Pipe FRE oe hain Tensioner Slipper Crankshaft Ti OH Dipstick ‘Chain Vibration Dumper aft Timing Sprocket Crank Angie Sensor Plate O-Ring ne Nim {xghom, ftibt) | : Specified toraua ‘#Non-eusabie partEM418 ENGINE MECHANICAL — TIMING CHAIN, REMOVAL 1. REMOVE UPPER FRONTFENOER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL 2, DRAIN ENGINE COOLANT 3. REMOVE RH FRONT WHEEL 4, REMOVE RH ENGINE UNDER COVER 5, REMGVE DRIVE BELT AND GENERATOR (See page CH-7) 6. DISCONNECT PS PUMP FROM ENGINE, {a) _ Disconnect the PS oil pressure switch connector. (0) Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine (See page SR-24). HINT: Put aside the pump and suspend it to the cow! with a string. 7. REMOVE RH ENGINE MOUNTING INSULATOR (a) _ Set tho jack to the engine. HINT: Place a wooden block between the jack and engine. (bh) 122-FE: Remove the 4 bolts, 2 nuts and RH engine mounting insu- lator. (©) 2z2-GE: Remove the 5bolts, 2 nuts and RH engine mounting insu- lator. 8 1ZZ-FE: REMOVE CYLINDER HEAD COVER (@) Remove the 4 bolts and No. 2 cylinder head cover. (b) Remove the 4 ignition coils (See page IG-6). (c) Disconnect the 2 PCV hoses from the cylinder head.EM19 ENGINE MECHANICAL — TIMING CHAIN (4) Remove the 9 bolts, 2 seal washers, 2 nuts, cylinderhead cover and gasket 9. 2Z2-GE: REMOVE CYLINDER HEAD COVER (a) Remove the 4 bolts and No. 2 cylinder head cover, (b) Remove the ignition coils (See page IG-6). (c) Disconnect the 2 PCV hoses from the eylinder head cov- er. (d) Remove the 2 nuts, bolt and disconnect the No. 3 ventila- tion hose from the No. ventiation pipe (e) Remove the No. 1 ventilation pipe and gasket, (f) Remove the 9 bolts, wire harness protector, cylinder head ‘cover and gasket. (g) Remove the O-ring from the cylinder head cover. 10. SET NO. 1 CYLINDER TO TDC/COMPRESSION (2) Tur the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover. (b) Check that the point marks of the camshatt timing sprock- cts are in straight line on the timing chain cover surface as shown in the illustration, H not, turn the crankshaft 1 revolution (360°) and align the marks as above,EM-20 ENGINE MECHANICAL — TING CHANL 11. REMOVE CRANKSHAFT PULLEY (a) Using SST and 2 nuts (width: 10 mm (0.25 in.)}, remove the pulley bolt SST 09213-70010, 09330-00021 {b) Remove the crankshaft pulley. HINT: Itnecessary, remove the pulley with SST. SST 09950-50012 (09951-05010, 09952-05010, 09953-05020, 09954-05020} 12, DISCONNECT CRANKSHAFT POSITION SENSOR FROM TIMING CHAIN COVER Remove the 2 bolts and crankshaft position sensor. 13, REMOVE DRIVE BELT TENSIONER, Remove the bolt, nut and drive belt tensioner. 14. REMOVE RH ENGINE MOUNTING BRACKET (a) 1ZZ-FE: Remove the 3 bolts and mounting bracket. (b) 222-GE Remove the 4 bolts and mounting bracket. 45. REMOVE CHAIN TENSIONER Remove the 2 nuts and chain tensioner. 16. REMOVE WATER PUMP (See page CO-5) 47, 12Z-FE: REMOVE TIMING CHAIN COVER (a) Remove the 11 bolts and nut. (b) Using atorx wrench socket (E8), remove the stud bolt. (©) Remove the timing chain cover by prying the portions be- tween the oylinder head and oylinder block with a screw- driver, NOTICE: Be carefut not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.eM21 ENGINE MECHANICAL TRANG CHAIN, 48. 222-GE: REMOVE TIMING CHAIN COVER (a) Remove the 12 bolts. (0) Using a torx wrench socket (E8), remove the stud bol. {c)_ Remove the timing chain cover and 2 gaskets. 49, REMOVE CRANK ANGLE SENSOR PLATE 20. REMOVE CHAIN TENSIONER SLIPPER, Remove the boll and slipper. 21. REMOVE TIMING CHAIN AND CRANKSHAFT TIMING ‘SPROCKET It the crankshaft timing sprocket cannot be removed by hand, use 2 screwdrivers. NOTICE: Position shop rags as shown to prevent damage. 22, REMOVE CHAIN VIBRATION DAMPER: Remove the 2 bolts and damper. 23. REMOVE VALVE TIMING CONTROL ASSEMBLY AND CAMSHAFT TIMING SPROCKET Hold the hexagonal head wrench portion of the camshaft with ‘awrench, and remove the bolt, valve timing contoller assembly and timing sprocket. NOTICE: + Becareful not to damage the cylinder head and valve lifter with the wrench. + Do not disassemble the valve timing controller as- sembly.eM-22 ENGINE MECHANICAL TIMING CHAN 7 INSPECTION 1. INSPECT TIMING CHAIN AND TIMING SPROCKETS (a) Using a vernier calipers, measure the length of 16 links with the chain dully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) lr the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places se- lected at random. (©) Wrap the chain around the timing sprocket. (©) Using a vernier calipers, measure the timing sprocket di- ameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measur- ing. Minimum sprocket diameter (w/ Chain): Camshaft 97.3 mm (3.831 in.) Crankshaft 51.6 mm (2.031 in.) I the diameter is less than minimum, replace the chain and sprockets. 2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA- TION DAMPER Measure the chain tensioner slipper and vibration damper wears. ‘Maximum wear: 1.0 mm (0.039 in.) Ifthe wear is greater than maximum, replace the slipper andor damper.EM-23 ENGINE MECHANICAL TIMING GHAI @) (b) INSPECT CHAIN TENSIONER ‘Chack that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet paw and does not move when pushed with your finger. INSPECT Olt. JET (See page LU-11)EM24 ENGINE MECHANICAL — TIMING CHAIN REPLACEMENT HINT: ‘There are 2 methods (A and B) to replace the oll seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL (@) If timing chain cover is removed from cylinder block. (1) Using a screwdriver and a hammer, tap out the oil seal. 2) Using SST and a hammer, tap in a new cil seal until its surface is flush with the timing chain cover edge. SST 09309-37010 (3) Apply MP grease to the oil seal lp. {b) timing chain cover is instaliod to the cylinder block (1) Using a knite, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screw- driver tip, (3) Using SST and a hammer, tap in the oll seal until its surface is flush with the timing chain cover edge. SST 09309-37010M25 ENGINE MECHANICAL — TING. CHAIN INSTALLATION 1, INSTALL VALVE TIMING CONTROLLER ASSEMBLY AND CAMSHAFT TIMING SPROCKET {a} Apply engine cit in the range from the tip of the intake ‘camshaft to 16 mm from that tip. (b) Align the timing mark on the value timing controller as- sembly with the knock pin, and install the value timing controller assembly to the cam shaft. NOTICE: Do not push valve timing controller assembly to the cam- shatt forcibly when Installing it. (©) Align the knock pin hole in the cam shaft timing sprocket with the knock pin of the cam shaft, and exhaust the sprocket to the cam shaft. (@) Temporarily install the timing sprocket bolt. (e) Hold the hexagon wrench head portion of the camshaft vith @ wrench, and tighten the timing sprocket bolt Torque: 1ZZ-FE 45 N-m (460 kgf-com, 33 telbf) 2Z2-GE 54 N-m (554 kaf-cm, 40 ft-bf) 2, SETNO. 1 CYLINDER TO TDC/COMPRESSION, (a) Tur the hexagonal wrench head portion of the cam- shafts, and align the point marks of the camshaft timing sprockets Using a crankshaft pulley bolt, Turn the crankshaft and set the set key on the crankshaft upward.ENGINE MECHANICAL — TIMING CHAIN row 3, _ INSTALL CHAIN VIBRATION DAMPER Install the damper with the 2 botts. Torque: 1ZZ-FE 11 Nem (113 kgf-em, 8 fib) 2ZZ-GE 20.5 N.m (209 kaf-om, 15 ftlbf) 4. INSTALL TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET {@) Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on the crankshatt timing sprocket. HINT: Ht necessary, install the sprocket with SST. SST 09223-22010 (b) 1ZZ-FE: Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on the camshaft timing sprockets. (9) 222-GE: Install the timing chain on the camshaft timing sprockets with the orange color links aligned with the timing marks. ‘on the camshaft timing sprockets.EM-27 ENGINE MECHANICAL —._ TIMING CHAIN {d) Check that the tension between the intake camshaft tim- ing sprocket and crankshatt timing sprocket. 5. _ INSTALL CHAIN TENSIONER SLIPPER (@) Install the slipper with the bott. ‘Torque: 4ZZ-FE 18.5 N:m (189 kgf-cm, 14 ftlbf) 2ZZ~GE 20.5 Nem (209 kgf-cm, 15 fbf) (©) Check that the stipper moves is caught on the cylinder head stopper. NOTICE: DO not turn the crankshatt. 6 INSTALL CRANK ANGLE SENSOR PLATE Install the plate with the "F* mark facing forward.EM-28 ENGINE MECHANICAL — TIMING CHAIN, 7. AZZFE: INSTALL TIMING CHAIN COVER AND WATER PUMP (a) Remove any old packing {FIPG) materiat and be careful rot to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. + Using a razor blade and a gasket scraper, remove ail the old packing (FIPG) material from the gasket surfaces and sealing grooves. + Thoroughly clean all components to remove all the loose material. + Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the timing chain cover as shown in the illustration, Seal packi Part No. 08826 — 00100 or equivaient + Install a nozzle that has been cut to a 4.5 mm (0.16 = 0.20 in.) opening. HINT: ‘Avoid applying an excessive amount to the surface. + Parts must be assembled within 3 minules of ap- plication. Otherwise the material must be removed and reapplied + Immediately remove nozzle from the tube and rein- stall cap, (c) Apply seal packing to 2 locations as shown in the illustra- tion. Seal packing: Part No. 08826 — 00080 or equivalent + Install a nozzle that has been cut to @ 1.5 mm (0.46 —0.20 in.) opening. HINT: ‘Avoid applying an excessive amount to tho surface. + Parts must be assembled within 3 minutes of ap- lication. Otherwise the material must be removed and reapplied. + Immediately remove nozzle from the tube and rein- statl cap.EM-29 ENGINE MECHAMCAL — TIMING CHAIN (@) Install the timing chain cover, O-ting and water pump with the 17 bolts and nut. Uniformly tighten the bolts and nut in several passes. Torque: 10 mm head: 9.Num (92 kgf.cm, 80 In. Ibf) for C 13 Nem (133 kg-om, 10 thibf} for A ‘11m (113 kgt-om, 8 ftibf) for others 12mm head: 18.5 N.m (189 kgticm, 14 ftibf) NOTICE: + Pay attention not to wrap the chain and stipper over the chain cover seal line. + After instalfing the chain cover, must install the mounting bracket and water pump within 15 minutes. HINT: Each bolt length in indicated in the itustration, A 45mm (1.77 in) B 35mm (1.38 in.) © 30mm (1.18 in) D_26 mm (0.98 in) (2) Using a torx wench socket (E8), install the stud bolt Torque: 9.3 N-m (95 kgf-cm, 82 in.tbf)Seal Width 4—5 mm 8, 222-GE: INSTALL TIMING CHAIN COVER AND WATER PUMP {a) Remove any old packing (FIPG) material and be careful ‘not to drop any cil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. + Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. + Thoroughly clean all components to remove all the loose material. + Using a non-residue solvent, clean both seating ‘surfaces. (®) Apply seal packing to the timing chain cover as shown in the illustration. ‘Seal packing: Part No, 08826-00100 or equivalent + Install a nozzle that has beon cut to a 1.5 mm open- ing. HINT: Avoid appiying an excessive amount to the surface. + Parts must be assembled within 3 minutes of ap- lication. Otherwise the material must be removed and reapplied. + Immediately remove nozzle from the tube and rein- stall cap. (©) _ Instat the 2 gasket to the timing chain cover as shown in the illustration. (@) Apply seai packing to 4 locations as shown in the ilustra- tion. Seal packing: Part No, 08826-00080 or equivalent + Install anozzie that has been cutto.a 4-5 mm (0.16 = 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. + Parts must be assembied within 3 minutes of ap- plication. Otherwise the material must be removed and reapplied. + Immediately remove nozzle from the tube and rein- stall cap.EMst ENGINE MECHANICAL —_TNING GHAI (e) _ Install the timing chain cover, O-ring and water pump with the 19 bolts. Uniformly tighten the bolts in several passes. Torque: Nm (214 kgt-om, 15 fbf) 1 Nem (113 kgtom, 8 ftlbf) }.0 Nam (92 kgf-cm, 80 In-bf) + Pay attention not to wrap the chain and slipper over the chain cover seal line. + After install the chain cover, must install the mount- ing bracket and water pump within 15 minutes. (Using a torx wrench socket (E8), install the stud bolt Torque: 9.3 N-m (95 kaf-cm, 82 in. bf) 9 1ZZ-FE: INSTALL RH ENGINE MOUNTING BRACKET (2) Apply seal packing to threads of the mounting bolt. Seal packing: Part No. 08826 — 00080 or equivalent HINT: 0 not apply seal packing to 2 or 3 threads of the bolt end. (©) Install the mounting bracket with the 3 bolts. 47 Nem (479 kgt-cm, 35 ftlbf) INSTALL RH ENGINE MOUNTING BRACKET Install the mounting bracket with the 4 bolts. Torque: 49 N.m (500 kgf.cm, 36 ft.Ibf) 11. INSTALL DRIVE BELT TENSIONER (@) Check the appearance before installing the drive belt ton- sioner. Itin case of having the oil leakage, crack, and etc,, replace the drive belt tensioner, (b) Install the drive bolt tensioner. Torque: Bolt 12Z-FE 69 Nem (704 kgf-cm, 81 ft-lbf) 2Z2—GE 100 N-m (1,020 kgf-cm, 74 ft-Ibf) Nut 29 Nem (296 kgf-om, 24 ft-lb) (©) Hook the tool on the hexagonal portion of the drive belt tensioner bracket and operate drive belt tensioner 3 times. with full stroke. HINT: Take 3 seconds or more for 1 full strokeEM-a2 ENGINE MECHANICAL TANG CHAT 12. 13. @ ©) © 14, fa) (bo) ©) INSTALL CRANKSHAFT POSITION SENSOR Torque: 9.0 N-m (92 kgf-cm, 80 In-Ibf) INSTALL CRANKSHAFT PULLEY Clean the crankshaft pulley inside. ‘Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST and 2 nuts (width: 10 mm (0.25 in), install the pulley bolt. SST 09213-70010, 09330-00021 Torque: 1ZZ-FE 136 Nem (1,409 kgf-cm, 102 ftlbf) 2ZZ-GE 120 Nem (1,200 kgf-cm, 87 ftbf) INSTALL CHAIN TENSIONER: Check the chain tensioner. (See page EM—18) Release the ratchet pawl, fully push in the plunger and ap- ply the hook to the pin so that the plunger cannot spring out Insert the O-ring with your hand until it reaches to the chamfering position and install nut temporally. Then, by tightening the nut, insert the chain tensioner to the instal lation position. Inthe case that the hook is released while pushing in, ap- ply the hook again and push the tensioner in. Pay attention not to catch the O-ring as It is built in the chain tensioner previously. Tighten the 2 nuts. Torque: 9.0 N-m (92 kgf-om, 80 In-Ibf)EM-93 ENGINE MECHANICAL TIMING CHAIN 15, SET CHAIN TENSION (2) Tum the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. (b) _Tusn the crankshaft clockwise, and check that the slipper is pushed by the plunger. HINT: if the plunger does not spring out, pross the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out. 16. CHECK VALVE TIMING (a) Tumthe crankshaft pulley, and align its groove with timing mark “0° of the timing chain cover. NOTICE: Always turn the crankshaft clockwise. {b) Check that the point marks ofthe camshaft timing sprock- els are in straight line on the timing chain cover surface as shown in the illustration, If not, turn the crankshaft + revolution (360°) and align the marks as above. 47. 1Z2-FE: INSTALL CYLINDER HEAD COVER (a) Remove any old packing (FIPG) material. (®) Apply seal packing to 2 locations as shown in the illustra- tion. ‘Seat packing: Part No. 08826 — 00080 or equivalentENGINE MECHANICAL —_TMING CHAIN (©) _ Install the gasket to the cylinder head cover. HINT: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied (@)__ Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown, Torque: ‘wio washer 11 Nem (113 kgt.om, 8 fbf) w! washer 9.0 N-m (92 kgf-em, 80 In-Abt) (0) Connect the 2 PCV hoses to the cylinder head cover. (Install the ignition coil (See page IC-7), 18 22Z-GE: INSTALL CYLINDER HEAD COVER (a) _ Remove any old packing (FIPG) materia HINT: When FIPG on the head cover gasket side cannot be eiimi- nated completely, replace the gasket. (©) Apply seal packing to 2 locations as shown in the ilustra- tion. Seal packing: Parl No. 08826-00080 or equivalent (©) _ Install the gasket to the cylinder head cover. HINT: Part must be assembled within 3 minutes of application. Other- wise the material must be remove and reapplied. (d) Install a new O-ring to the cylinder head cover.EM.35 ENGINE MECHANICAL —_ TIMING CHAIN _ @ (b) ©) 23. 25. 26. Install the cylinder head cover and wire hamess protector with the9 bolts. Uniformly tighten the bolts, in the several passes, in the sequence shown. Torque: 10 Nem (100 kgf-om, 7 fttbh, ‘Connect the 2 PCV hoses to the cylinder head cover. Install a new gasket and No. 1 ventilation pipe with 2 nuts and bolt. Torque: Nut 10.N-m (100 kgf-cm, 7 fbf) Bolt 25 N-m (255 kgtcm, 18 tttbf) ‘Connect the No. 3 ventilation hose to the No. 1 ventilation pipe. Install the ignition coit (See page IG-7). INSTALL RH ENGINE MOUNTING INSULATOR AZZ-FE: tnstall the FH engine mounting insulator with the 4 bolts, and 2 nuts. Torque: 52 N-m (530 kgt-om, 38 ft-lb?) 222-GE: Install the RH engine mounting insulator with the 5 bolts and 2 nuts. Torque: 52 N-m (530 kgf.cm, 38 ftlbf) INSTALL PS PUMP Install the PS pump with the 2 through bolts and nuts. Torque: 36 N.m (370 kgf-om, 27 ft-bf) Install the PS pump pulley with the pulley nut. Connect the PS oil pressure switch connector. INSTALL GENERATOR AND DRIVE BELT (See page CH-17) INSTALL RH ENGINE UNDER COVER INSTALL RH FRONT WHEEL FILL WITH ENGINE COOLANT (See page CO-2) INSTALL FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL START ENGINE AND CHECK FOR COOLANT LEAKSEMA36 = Gruner nen CYLINDER HEAD COMPONENTS _ ‘Upper Front Fender Apron Seal Drive Bett Gonwrtor yy NEON a. aor Wire oS ‘Generator —S" ‘Connector (520330, 38) } 122FE: RH Engine Mounting, oes We 22Z-GE: ‘| RH Engine Mounting Insulator 1. cosy tf cuir ——@ Ni egtem, FBI] : Specitied torque nu @ Non-rousabieENGINEMECHANICAL -GYLINDERHEAD 1Z2-FE: ‘No. 2 Gylinder Head Cover ‘Upper Heated Insulator xb <<" - < on am’ cena Brake Booster ‘Tarattle BedyHEAD No. 2 Cylinder Head Cover z Wire Hamess Protector ignition Coil (w! Igniter} t t 9 PITT cu ECT Sensor ibe Risembiy Camehal Poston Sensor we KN S #O-FIND injector Connsctor b ‘Acoolerator Control 9 _@ Cable Bracket ue 1AG Valve Connector ‘Generator Bracket le Body Nem (kgtom, ttibf) | : Specified torque In @Non-reusable pat 0 Intake Manifold InsulatorEmo 122-FE: Cylinder Head Cover aS LQ % Gasket [7305370] valve Liter No. 3) ie ‘Camshaft same t al © Beara Can 2 Keone © sui 101 Cant ong Cap 3, Into Camshat eer Exhaust cant $< OP ote Camshaft Timing — ee Spring Seat ml Engine coon”) Valve Valve Guide| Mounting —— Bushing aT} Heater: ee = ia 2nd “Turn 90° 1 Cylinder ~ aA lao wn | sag | 1 ting | - f Chain SS. PF ehain | i Nearer | Chain Tensioner | | Stipper 1 el ‘Timing Chain Cover e Crank Angle Sensor Plate ‘Chain Vibration Damper Grankshatt Postion Sensor {Na RGF | Specs txque 1v @Nlor-reusabie part ‘eneENGINE MECHANICAL CYLINDER HEAD _ Chain Tonsioner TO, BATRA (Reta om Tate, TBA) ] : Spocitied torque N-@Non-reusable pant ylinder Head Cover: soreomnacuanooe Pal Exhaust Camshat Camshaft Timing Sprocket came ® =o Intake Camshaft No.2 Camshal ty i eeay Bearna Cap Ree 3 Canehatt Bearing Cap ist 2nd Turn 480" [Seopace ews | Tensioner, Slipper Crank Angle Sensor Plate ‘Chain Vibration Damper Crankshaft Position SensorEM4t [ENGINE MECHANICAL — GYUNDER HEAD Tein (kgrom, fbf) “FNlon-reusable Valve Rocker Arm eS il Pressure Switch Oil Control Valve Housing | [3:0(02;80in. ta) &— Keeper © — spring Rerainer Valve Spring @— Spring Seat ‘Oi Control Valve for WWT 5500, 22), ‘Valve ‘#Gasket : Specified torqueMaz ENGINE MECHANICAL CYLINDER HEAD REMOVAL 2. REMOVE BATTERY REMOVE ECU BOX (See page EM-74) DRAIN ENGINE COOLANT DISCONNECT ENGINE COOLANT RESERVOIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT ACCELERATOR CABLE REMOVE DRIVE BELT AND ALTERNATOR (See page CH-7) REMOVE EXHAUST PIPE (See page EM-74) 1Z2-FE: REMOVE EXHAUST MANIFOLD Remove the 3 bolts and exhaust manifolé stay. Remove the 6 bolts and upper heat insulator. Remove the 5 nuts, exhaust manifold and gasket Remove the 3 bolts and lower heat insulator.EMa3 ___ENGINE MECHANICAL. CYLINDER HEAD 10. f@) ©) ©) @ n. 12. 13. 14, 15. 16. @) 0) ©) ® ©) 222-GE: REMOVE EXHAUST MANIFOLD Remove the 4 bolts and exhaust manitold stay. Remove the 5 bolts and upper heat insulator. Remove the 3 bolts, 2 nuts, exhaust manifold and gasket. Remove the 4 bolls and lower heat insulator. REMOVE IGNITION COIL (See page IG-6) REMOVE SPARK PLUG (See page IG-1) REMOVE PCV HOSES REMOVE THROTTLE BODY (See page SF-36) REMOVE INJECTOR (See page SF-21) 41Z2-FE: DISCONNECT ENGINE WIRE FROM CYLINDER HEAD Disconnect the ECT sensor connector. Disconnect the camshatt position sensor connector. Disconnect the oil control valve for WT connector. Disconnect the 2 ground wires. Disconnact the 2 clamps and engine wire protector from the intake manifold. 22Z-GE: DISCONNECT ENGINE WIRE FROM CYLINDER HEAD Disconnect the ECT sensor connector. Disconnect the camshatt position sensor connector. Disconnect the oll control valve for VVT connectors. Disconnect the oll control valve for VTL connectors. Disconnect the oil pressure switch connector. Disconnect the 2 ground wires. Remove the 2 bolts, and disconnect the engine wire. Remove the intake manifold No. 2 insulator. 1ZZ-FE: REMOVE INTAKE MANIFOLD Disconnect the EVAP hose for ORVR. Disconnect the brake booster vacuum hose. Remove the 4 bolts, 2 nuts, intake manifold, 2 wire har- ness stays and gasket,EMAaa EF 19, 222-GE: REMOVE INTAKE MANIFOLD (@) Disconnect the EVAP hose for ORVR. (b) Disconnect the brake booster vacuum hose. ()_ Remove the bolt and disconnect the No. 1 ventilation pipe and oil dipstick and guide, (@) Remove the 2 bolts, nut and stay. (e) Remove the 4 bolts, 2 nuts, intake manifold and gasket. (Remove the intake manifold insulator. 20. REMOVE CAMSHAFT POSITION SENSOR 21. REMOVE ECT SENSOR 22, REMOVE PCV VALVE AND GROMMET 23. REMOVE Olt FILLER CAP 24, REMOVE CAMSHAFT TIMING SPROCKETS. (See page 1G-9) 25. 122-FE: REMOVE CAMSHAFT Uniformly ioosen and remove the 19 bearing cap bolts, in sever- al passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts. 26, 222-GE: REMOVE CAMSHAFT Uniformly loosen and remove the 20 bearing cap bolts, in sever- al passes, in the sequence shown, and remove the 9 bearing ‘caps intake and exhaust camshaft.M45 ENGINE MECHANICAL — CYLNDERHEAD 27. REMOVE CYLINDER HEAD (@) Disconnect the upper radiator hoses from the water hose ‘union. (b) Disconnect the heater water hose from the water hose union. (©) Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts, and plate washers. NoTICE: Head warpage or cracking could result from removing bolts in an incorrect order. (@)_ Remove the bolt holding the water bypass pipe to the cyl- inder head. {e) _Liftthe eylinder from the dowels on the oylinder block and replace the oylinder head on wooden blocks on a bench. HINT: Ifthe cylinder head is dtficult to lift off, pry botween the oylinder head and cylinder block with a sorewdriver. NoTIC! Be careful not to damage the contact surfaces of the cylin- der head and cylinder block.ENGINE MECHANICAL = CYLINDER HEAD. ‘See DISASSEMBLY 1. REMOVE OIL CONTROL VALVE for VT Remove the bolt and cam timing oil control valve. 2. REMOVE OIL CONTROL VALVE FILTER Remove the bolt, gasket and oll control valve fiter. 3 222-GE: REMOVE OIL CONTROL VALVE HOUSING {@) Remove the bolt and oil control valve for VVTL. () Using SST, remove the oil pressure switch, SST 09816-30010 (¢) Remove the 3 bolts, 2 nuts, oil contral valve housing and gasket. (8) Remove the oil control vaive fiter. 4, 22Z-GE: REMOVE VALVE ROCKER ARM (a) Remove the 2 bolts, rocker No. 1 and No. 2 shatts. (b)__ Remove the 8 valve rocker arm. HINT: ‘Arrange the rocker arms in the correct order. 5, _ REMOVE VALVE LIFTERS HINT: Arrange the valve lifters in the correct order. 6, REMOVE VALVES (a) _ Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00020) (b) Remove the spring retainer. (©) Remove the valve spring. (6) Remove the valve. {e) Using needle—-nose pliers, remove the oil seal.EMAT ENGINE MECHANICAL = GYLINDER HEAD (f) Using compressed air and magnetic finger, remove the spring seat by blowing air. HINT: Arrange the valves, valve springs, spring seats, and spring re- tainers in the correct order.ENGINE MECHANICAL —_ OYLINDER MEAD iNSPECTION 1. CLEAN TOP SURFACES OF PISTONS AND CYL- INDER BLOCK {a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the car- ton from the piston surface. {e) Using a gasket scraper, remove ali the gasket material from the cylinder block surface. {c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. 2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact sur- face. 3. CLEAN COMBUSTION CHAMBERS: Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder black contact sur- face. 4. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the cylinder head.EMaa ENGINE MECHANICAL — CYLINDER HEAD Exhaust Manifold Side 5. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings, 6. INSPECT FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for war- page. Maximum warpage: 0.06 mm (0.0020 in.) warpage is greater than maximum, replace the cylinder head. 7, INSPECT FOR CRACKS Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surlace for cracks. Hf cracked, reptace the cylinder head. 8 CLEAN VALVES (a) Using @ gasket scraper, chip off any carbon from the valve head. (b) Using a wire brush, thoroughly clean the valve,E ® [i v A ENGINE MECHANICAL — _GYLNOER HEAD LamoeSrmmee zene} i ae 9. INSPECT VALVE STEMS AND GUIDE BUSHINGS {a) Using acaliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter 1ZZ-FE 5.510 — 5.530 mm (0.2169 ~ 0.2177 in.) 2Z2-GE 5.500 - 5.518 mm (0.2165 ~ 0.2172 in.) {b) Using @ micrometer, measure the diameter of the valve stem. Valve stem diameter: 4ZZ-FE Intake 5.470 — 5.485 nom (0.2154 — 0.2159 In.) Exhaust 5.465 ~ 5.480 mm (0.2152 - 0.2457 in.) 222-GE Intake 5.460 — 5.475 mm (0.21496 - 0.21555 in.) Exhaust 5.445 — 5.470 mm (0.21437 — 0.21535 in.) (6) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oif clearance: 1Z2-FE Intake 0.025 — 0.060 mm (0.0010 — 0.0024 in.) Exhaust 0.030 — 0.065 mm (0.0012 ~ 0.0026 in.) 222-GE Intake 0,025 — 0.058 mm (0.00098 — 0.00228 in.) Exhaust 0.030 — 0.063 mm (0.00118 — 0.00248 in.) ‘Maximum oil clearance: 1ZZ-FE Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) 2Z2-GE 0.10 mm (0.0039 in.) Inthe clearance is greater than maximum, replace the valve and guide bushing, 10. INSPECT VALVES (a) _ Check the vaive is ground to the correct valve face angle. Valve face angle: 44.5° (©) Check that the surface of the valve for wear. It the valve face is wom, replace the valve.EMS1 MECHANICAL CYLINDER HEAD ‘Overall Length Se (©) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.7 mm (0.028 in.) Ifthe margia thickness is less than minimum, replace the valve. {@) Check the valve overail length. Standard overall length: 1ZZ-FE Intake 88.65 mm (3.4902 in.) Exhaust 88,69 mm (3.4917 in.) 2ZZ-GE Intake 111.3 mm (4.382 in) Exhaust 111.7 mm (4.398 in.) Minimum overall length: 422-FE Intake 88.35 mm (3.4783 in.) Exhaust 68.39 mm (3.4799 in.) 222-GE Intake 110.9 mm (4.366 In.) Exhaust 111.3 mm (4.382 in.) It the overall length is less than minimum, replace the valve. (e) Check the surface of the vaive stem tip for wear. Htthe valve stem tip is worn, replace the valve. 11, INSPECT AND CLEAN VALVE SEATS (@) Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats {b) After resurfacing the valve seat 45°, measure the residu- ary width of the valve seat 45°. Minimum residuary length: Intake 3.3 mm (0.130 in.) Exhaust 3.2 mm (0.126 in) Itthe valve seat 45° residuary width less than minimum, replace the cylinder head, (©) Chock the valve seating position. Apply a light coat of prussian biue (or white lead) to the valve face. Lightly press the valve against the seat, Donot rotate valve. (@) Check the vaive face and seat for the following: + If blue appears 360° around the face, the valve is concentric, If not, replace the valve.ENGINE MECHANICAL — CYLINDER HEAD. + If blue appears 360" around the valve seat, the guide and face are concentric. f not, resurface the seat. + Check that the seat contact is in the middle of the valve face with the following width: 1.0 — 1.4 mm (0.039 — 0.085 in.) \f not, correct the valve seats as follows: (1) _ Ifthe seating is too high on the valve face, use 30° and 45° cutters to correct the seat. (2) _ Ifthe seating is too tow on the vaive face, use 75° and 45° cutters to correct the seat. Hand-tap the valve and valve seat with an abrasive com- pound. After hand-iapping, clean the vaive and valve seat. 12, INSPECT VALVE SPRINGS (@) Using a stee! square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than maximum, replace the valve spring.EM.53 ENGINE MECHANICAL —_ CYLINDER HEAD a, i i? {0) Using vernier calipers, measure the free length of the valve spring. Free length: 1ZZ-FE 45.90 mm (1.8070 in.) 222-GE Intake 46.4 mm (1.830 in.) Exhaust 46.5 mm (1.831 in.) (©) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 1Z2-FE 189.6 - 154.4 N (14.2~ 15.8 kgf, 31.3 - 34.8 Ibf) at 33.6 mm {1.323 in.) 222-GE Intake 220.2 - 243.8 N (22.5 — 24.7 kgf, 49.6 — 55.5 Ibt) at 38.5 mm (1.516 in.) Exhaust 208.2 ~ 229.8 N (21.2- 23.4 kgf, 47.6 — 52.6 Ibf) at 38.5 mm (1.516 in.) Maximum working tension: ZZ-FE 244.9 — 276.1 N (25.5 — 28.1 kgf, 56.2 - 61.9 Ibf) ‘at 24.6 mm (0.969 in.) 22Z-GE Intake 1533 — 589 N (54.4 — 60.1 kgf, 119.9 ~ 132.5 Ibf) at 27.3 mm (1.075 in.) Exhaust 495.5 ~ 548.5 N (50.5 ~ 55.9 kgf, 111.3 123.2 Ibf) at 28.5 mm (1.122 in.) It the installed tension is not as specified, replace the valve spring 13, INSPECT CAMSHAFT FOR RUNOUT (@) Place the camshaft on V-blocks. (©) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) Ifthe circte runout is greater than maximum, replace the cam- shaft,ENGINE MECHANICAL = CYLINDER HEAD. 14, INSPECT CAM LOBES Using a micrometer, measure the cam lobe height, ‘Standard cam lobe helght: 1ZZ-FE: Intake 44.333 — 44.433 mm (1.7454 — 1.7493 in.) Exhaust 43.761 — 43.861 mm (1.7229 - 1.7268 in.) 222-GE: INTAKE No. 1 40.607 — 40.707 mm (1.59586 - 1.59979 in.) No. 2 38.769 — 38.869 mm (1.52362 — 1.52755 in.) 222-GE: EXHAUST No. 1 40.019 — 40.119 mm (1.57275 — 1.57668 In.) No. 2 38.863 ~ 38.963 mm (1.52732 — 1.53125 in.) Minimum cam lobe height: 1ZZ-FE: Intake 44.18 mm (1.7394 in.) Exhaust 43.61 mm (1.7169 in.) 222-GE: Intake No.1 40.45 mm (1.5925 in.) No.2 36.61 mm (1.5201 In.) Exhaust No.1 39.86 mm (1.5693) No.2 38.71 mm (1.5240) Ifthe cam lobe height is less than minimum, replace the cam- shaft. 15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. 12Z-FE: No.1 Journal diameter: 34.449 — 34.465 mm (1.3563 - 1.3569 in.) Others journal diameter: 22,949 — 22.965 mm (0.9035 - 0.9041 in.) 222-GE: No.1 journal diameter: 34.449 — 34.465 mm (1.95626 — 1.35689 in.) ‘Other journal diamet 27.949 — 27.965 mm (1.10035 — 1.10096 in.) tthe journal diameter is not as specified, check the oil clear- ance.EM-55 ENGINE MECHANICAL —_GYLINDER HEAD 16. INSPECT CAMSHAFT JOURNAL CLEARANCE (a) Clean the bearing caps and camshaft journals. (b) Place the camshafts on the cylinder head. (c}_ Layastrip of Plastigage across each of the camshaft jour- nal. (@) Install the bearing caps (See page EM-65). Torque: 122-FE: No.1 23 Nem (235 kgf-cm, 17 ftlbf) No.3 13 N-m (133 kgt-om, 10 fttbh) 2Z2-GE: 18.5 Nem (189 kgt-cm, 14 ftlbf) NOTICE: Do not turn the camshaft. (@} Remove the bearing caps. ‘Measure the plastigage at its widest point. 1ZZ-FE: Standard oll clearance: 0.035 — 0.072 mm (0.0014 — 0.0028 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) 2Z2-GE: ‘Standard oil clearance: No. 1 journal 0.035 - 0.076 mm (0.00138 — 0.00299 in.) ‘Other journal 0.035 — 0.072 mm (0.00438 — 0.00283 in.) Maximum oll clearance: 0.10 mm (0.039 in.) IFthe oil clearance is greater than maximum, replace the cam- shaft, It necessary, replace the bearing caps and cylinder head asa set. (a) Completely semove the Plastigage. {h) Flemove the camshafts.EM56 ENGINE MECHANICAL — CYLINDER HEAD . INSPECT CAMSHAFT THRUST CLEARANCE Install the camshatts. (See page EM-65) Using a diat indicator, measure the thrust clearance while moving the camshaft back and forth. 1ZZ-FE: ‘Standard thrust clearance: 0.040 - 0.095 mm (0.0016 — Maximum thrust clearance: 0.11 mm (0.0043 in.) 222-GE: Standard thrust clearance: 0.04 — 0.14 mm (0.0016 - 0.0055 in.) Maximum thrust clearance: 0.15 mm (0.0059 in.) if the thrust clearance is greater than maximum, replace the camshaft If necessary, replace the bearing caps and cylinder head as a set. (c) Remove the camshafts. .0037 in.) 48, INSPECT VALVE TIMING CONTROLLER ASSEMBLY (a) Apply vinyl tape to all the ports except the one indicated by the arrow in the illustration. NOTICE: Do not apply tape in the range from the tip of the camshaft to 18 mm from that tip. (0) _ install the valve timing controller assembly. Torque: 47 N.m (480 kgf-cm, 36 ftlbf) ssa] NOTICE: Do not push vatve timing controller assembly to the cam- shaft forcibly when installing it. (©) Check that the valve timing controller assembly will not turn. (d) Wind tape around the tip of the air gun and apply air of ‘approx. 100 kPa (1 kgticrn®, 14 psi) to the port of the cam- shaft NOTICE: ‘When the oll splashes, wipe it off with a shop rag and the Sikes. HINT: Perform this in order to release the lock pin for the maximum delay angle locking.EMs7 ENGINE MECHANICAL —_ CYLNDER HEAD (e) Under the condition of (d) turn the valve timing controller assembly fo the advance angel side (the arrow marked direction in the illustration) with your hand. Standard: Must turn HINT: Depending on the air pressure, the vaive timing controller as- sembly will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there ‘may be the case that the lock pin could be hardly released. (Except the position where the lock pin meets at the maxt- mum delay angle, let the valve timing controller assembly turn baok and forth and check the movable range and that there Is no disturbance. ‘Standard: Movable smoothly in the range about 30° (g) Turn the valve timing controller assembly with your hand and lock it at the maximum delay angel position. 19, 1ZZ-FE: INSPECT VALVE LIFTERS AND LIFTER BORES (@) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31,000 ~ 31.025 mm (1.2205 — 1.2218 in.) {b) Using a micrometer, measure the lifer diameter. Lifter diameter: 30.966 — 30.976 mm (1.2191 - 1.2195 in.) (6) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 - 0.059 mm (0.0009 — 0.0023 in.) ‘Maximum oil clearance: 0.079 mm (0.0031 in.) {f the oll clearance is greater than maximum, replace the fier. f necessary, replace the cylinder head.ENGINE MECHANICAL ~ CYLINDER HEAD. 20. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. ‘Maximum warpage: 0.10 mm (0.0039 In.) i warpage is greater than maximum, replace the manifold. 21, INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If warpage is greater than maximum, replace the manifold. 22, INSPECT CYLINDER HEAD BOLTS Standard outside diameter: 9.0 - 9.2 mm (0.354 — 0.362 in.) Minimum outside diameter: 9.0 mm (0.354 in.) {the outer diameter is less than minimum, replace the boll.EN-5o ENGINE MECHANICAL — CYLINDER HEAD 80 ~ 100" sss PUPP Both intake and exhaust saiGomseone | pers CEES | ust “aaa a8 eosacs REPLACEMENT REPLACE VALVE GUIDE BUSHINGS {a) Gradually heat the cylinder head to 110 ~ 130 "G (230 — 286 °F). (b) Using SST and a hammer, tap out the guide bushing. SST 09201~01055, 09950-70010 (09851-07100) (©) Using a caliper gauge, measure the bushing bore diame- ter of the oylinder head. (@) 1ZZ-Fe: Select the new guide bushing (STD or OYS 0.05). Ifthe bushing bore diameter of the cylinder head is greater than 10.308 mm (0.4057 in.), machine the bushing bore to the fol- lowing dimension: 10.335 10.356 mm (0.4068 - 0.4077 in.) Ifthe bushing bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. (@) 12Z-FE: Gradually heat the cylinder head to 0 - 100 °C (176 ~ 212 °F).EM-60 ENGINE MECHANICAL = _GYLINOER HEAD. Both intake and exhaust Bushingborediameter | aysring size 10.488 - 10.506 (0.4129 — 0.4136) Use STD 10528” 10.556 (0.4149 - 0.4156) Use O/S 0.05 ) 222-GE: Select the new guide bushing (STD or O/S 0.05}. If the bushing bore diameter of the cylinder heads greater than 10.506 mm (0.4136 in.}, machine the bushing bore to the fol- Jowing dimension: 10.538 — 10.556 mm (0.4149 — 0.4156 in.) Ifthe bushing bore diameter of the cylinder head is greater than 10.556 mm (0.4158 in.), replace the cylinder head. (9) 222-GE: Gradually heat the cylinder head to #10~ 130 °C (230- 266 *F). {h) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201-07055, 09950-70010 (09951-07100) Protrusion height: 4Z2-FE 8.7 — 9.1 mm (0.342 - 0.358 in.) 222-GE 15.3 - 15.7 mm (0.602 ~ 0.618 in.) (i) Using a sharp 5.5 mm reamer, ream the guide bushing to. obtain the standard specified clearance (See page EM-48) between the guide bushing and valvé stem.EM6t ENGINE MECHANICAL —_ CYLINDER HEAD 15 mm Fo" Radiator Hose (A) For Heater Hose (B) 20mm 9mm For Water Bypass Hose ott) REASSEMBLY HINT. + Thoroughly clean all parts to be assembled + Before installing the parts, apply fresh engine oilto all sid ing and rotating surfaces. + Replace oil seals with new ones. 1. _ INSTALL WATER HOSE UNIONS HINT: When using @ new cylinder head, water hose unions must be installed. (a) Mark the standard position away from the edge, onto the water hose union. {b) Apply adhesive to the water hose union hole of the cylin- der head. Adhesive: Part No.08833-00070, THREE BOND 1324 or equiva- tenteM-62 ENGINE MECHANICAL — GYLINDER HEAD a Tae: (©) Using a press, press in a new water hose union until these is protruding from the cylinder head. 8 Standard protrusion: A29 mm (1.14 in.) A B 66.5 mm (2.618 in.) Rye © 24. mm (0.96 in.) 1D 69.8 mm (2.630 In.) NOTICE: Avoid pressing a new water hose union in too far by mea- suring the amount of protrusion white pressing. 2. INSTALL VALVES (@) Using SST, push in a new oil seal SST 09201-41020 veme ggg awe) ae a Mark The intake valve oil seal is light brown and the exhaust vaive oil seal is gray. + PZL-GE: The intake valve oil seal is black and the exhaust valve oit seal is green. NoTICE: “ 1ZZ-FE: 1Z2-FE: Pay much attention assembling the oi} seal for intake and e Light Brown Gray exhaust. Assembling the wrong one may cause a failure. 222-GE: 222-GE: Black GreenEM-63 ENGINE MECHANICAL — CYLINDER HEAD Exhaust Side sit Intake Sido por (b) Install the valve (1}, spring (2), valve spring (3), and spring rotainer (4). (©) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00020) (@) Using a plastic—taced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 3. INSTALL VALVE LIFTERS (a) _ Install the valve lifter. (©) Check that the vaive lifter rotates smoothly by hand. 4, 22Z-GE: INSTALL VALVE ROCKER ARM (a) Set the 8 valve rocker arms. (b) _ Install the rocker No. 1 and No. 2 shatt with the 2 bolts. Torque: 7.5 Nem (76 kgf-cm, 66 in.-Ibf) HINT: + Position the sft of the locker shaft in the direction shown in the illustration. Align the tocker shaft end with the cylinder head end. 5. 222-GE: INSTALL OIL CONTROL VALVE HOUSING (a) _ Install the oil control vaive fiter. (©) _ Install the gasket and oil control vaive housing with the 3 bolts and 2 nuts, Torque: 9.0 Nim (92 kgt-cm, 80 In-Ibf)ENGINE MECHANICAL — CYLINDER HEAD ee (©) Apply adhesive to2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (a) _ Using SST, instaii the oil pressure switch. SST 09816-0010 Torque: 13 N-m (130 kgf-cm, 9 ttlbf) (@) Install the oll control valve for VVTL with the bo. 6. INSTALL CONTROL VALVE for VT Install the oll control valve for VVT with the bolt 7. INSTALL OIL CONTROL VALVE FILTER Instail the oil control valve filter and new gasket with the bolt. Torque: 29 N-m (300 kgf.cm, 22 fib)EM-85 ENGINE MECHANICAL CYLINDER HEAD INSTALLATION HINT: + Thoroughly clean all parts to be assembled. + Before installing the parts, apply fresh engine oil to all slid- ing and rotating surfaces. + Replace all gaskets and oil seals with new ones. 4. PLAGE CYLINDER HEAD ON CYLINDER BLOCK (a) Place a new cylinder head gaskot on the cylinder block surface with the Lod No. stamp upward, NOTICE: Be careful of the Installation direction. (b) Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head. 2. _ INSTALL CYLINDER HEAD BOLTS HINT. + The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)) + If-any cylinder head bolt is broken or deformed, replace it (@) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. (0) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown, Torqu 12Z-FE: 49 N-m (500 kgf-cm, 36 ftlbf) 222-GE: 35 Nom (375 kgt-cm, 26 ft.lbf) It any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bot. (©) Mark the front of the cylinder head bolt with paint, (d) 1Z2-FE: Retighten the oylinder head bolts 90° in the numerical or- der shown. (e) 2ZZ-GE: Retighten the cylinder head bolts 180° in the numerical order shown. () 1ZZ-FE: Check that the paint markis not at a 90° angle tothe front.M66 ENGINE MECHAWCAL —_CYUNDER HEAD 88 (@ 2zz-Ge: Check that the paint mark is not at a 180° angle to the front (bh) _ Install the bolt holding the water bypass pipe to the eylin- Be der head. Torque: 9.0 Nem (92 kgf-cm, 80 in.-Ibf) (@ Connect the upper radiator hose to the water hose unions. (Connect the heater hose to the water hose unions. 3. INSTALL CAMSHAFTS: (a) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration. (©) _ Install the boaring caps in their proper locations. HINT: + Ze: No.3 camshatt bearing cap has a number and front mark. + 222-GE: No. 2, No.3 camshaft bearing cap has a number and front mark, (©) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (6) 1ZZ-FE: Install and uniformly tighten the 19 bearing cap bolts. Ater tightening the No. 1 camshaft bearing cap, tighten then in several passes, in the sequence shown, Torque: No. 123 Nom (235 kgf.cm, 17 ftlbt) No. 313 Nem (133 kgf-cm, 10 ft-lbf) arateEM67 ENGINE MECHANICAL CYLINDER HEAD te) 10. fa) {b) (o) n. fa) tb) fe) @) we) cu) 222-GE: {Install and uniformly tighten the 20 bearing cap botts. Ater tightening the No. 1 camshaft bearing cap, tighten then in several passes, in the sequence shown. Torque: 18.5 Nem (189 kgf-cm, 14 ft.lbt) CHECK AND ADJUST VALVE CLEARANCE (See page EM-4) INSTALL CAMSHAFT TIMING SPROCKETS AND VALVE TIMING CONTROLLER ASSEMBLY (See page EM-25) INSTALL OIL FILTER CAP INSTALL GROMMET AND PCV VALVE INSTALL ECT SENSOR (See page SF-63) INSTALL CAMSHAFT POSITION SENSOR (See page 16-10) 12Z-FE: INSTALL INTAKE MANIFOLD Install a new gasket, the intake manifald with the 4 bolts and 2 nuts. Torque: 18.5 Nom (189 kgf.cm, 14 fbf) Conneet the brake booster vacuum hose. ‘Connect the EVAP hose for ORVR. 222-GE: INSTALL INTAKE MANIFOLD Install the intake manifold insulator to the cylinder block. Install a new gasket, the intake manifold with the 4 bolts and 2 nuts, Torque: A: 27 Nem (275 kgtiom, 20 ft.lbf) B: 46 Nem (469 kgf-om, 34 ftlbf) Install the stay with the 2 bolts and nut. Torque: 24 Nm (245 kgf-em, 18 ftibf) Install the cil dipstick and guide with tho bolt. Torque: 25 N-m (255 kgf-cm, 18 ft:lbf) Connect the brake booster vacuum hose. Connect the EVAP hose for ORVR.Em6a ENGINE MECHANICAL —_ CYLINDER MEAD a 12 a) (o) {e} (a) @) 13. (a) (b) © (d) @ 0 (9) ) 14. 15. 16. W 18, 19. (a) {b) © ® 12Z-FE: CONNECT ENGINE WIRE TO CYLINDER HEAD Connect the 2 clamps of engine wire to the intake man- fold. Connect the 2 ground cables. Connect the oil control valve for VWT connector. Connect the camshaft position sensor connector. Connect the ECT sensor connector. 222-GE: CONNECT ENGINE WIRE TO CYLINDER HEAD Install the intake manifold insulator No. 2. ‘Connect the 2 ground cables. Connect the oil pressure switch connector. Connect the oil control valve for WT connector. Connect the oil control valve for WTL connector. Connect the camshaft position sensor connector. Connect the ECT sensor connector. Install the accelerator cable bracket with the 2 bolts. INSTALL INJECTORS (See page SF-24) INSTALL THROTTLE BODY (See page SF-39) INSTAL PCV HOSES INSTALL SPARK PLUGS (See page IG-1) INSTALL IGNITION COIL (See page IG-7) 12ZZ-FE: INSTALL EXHAUST MANIFOLD {install the lower heat insulator with the 3 bolts. Torque: 12 N.m (123 kgt-cm, 9 ftbf) Install a new gasket, and the exhaust manifold with the nuts. Uniformly tighten the nuts in several passes. Torque: 37 N.m (377 kgt-cm, 27 ftbf) Install the upper heat insulator with the 6 bolts. Torque: 12 N.m (123 kgt-om, 9 ftIbf) Install the exhaust manifold stay with the 3 bolts. Torque: 49 N-ms (500 kgt-cm, 37 fbf)ENGINE MECHANICAL —_CYLINDEA HEAD, 20. fa) fe) {o) (a) 2. 22. 222-GE: INSTALL EXHAUST MANIFOLD Install the fower heat insulator with the 4 bolts. Torque: 20 N.m (204 kgt.cm, 15 fulbf) Jnstall the exhaust manifold with the 3 bolts and 2 nuts. Torque: 50 N.m (810 kgt.cm, 37 ftlbf) {install the upper heat insulator with the 5 bolts. Torque: 20 N.m (204 kgf.cm, 15 ftlbt) Install the exhaust manifold stay withe 4 bolts. Torque: 60 N-m (510 kgf-cm, 37 ft-Ibf) INSTALL EXHAUST PIPE (See page EM-80) INSTALL GENERATOR AND DRIVE BELT (See page CH-17) CONNECT ACCELERATOR CABLE INSTALL AIR CLEANER ASSEMBLY INSTALL ECM BOX (See page EM-80) INSTALL BATTERY FILL WITH ENGINE COOLANT (See page CO-2) START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE COOLANT LEVEL AND OIL LEV- ELEM-70 ENGINE UNIT COMPONENTS INE MECHANICAL — ENGINE Upper Front Fender Apron Seal (Suasinw 1 ECM Box Cover \ SY ccmsoe & 1 03) Cruise Control Accumulator . SV for EVAP RH Engine Under ‘Air Cleanar Cap Oe SCL Be» Fitter ‘ { Li Engine Under Air Cleaner Case Gover Lm afer, RAB] : Specities torqueEMa71 ENGINE MECHANICAL —_ ENGINE UNIT ore Bet bps pump NC Compressor BS ‘Generator Engine Coolant Reservoir Condenser ¢ Gondoreae we cover & \ center brace Hood Lock EP se , 7 GA nine , Upper Support < Pater Assembly es euenpor ver a + Specified torque aEM 72 ENGINE MECHANICAL —_ ENGINE WUT ae Stabilizer Bar Bracket ‘Stabilizer Bar Rear Engine Mounting Insulator oat Ergin Mening Be sees c a Pa [aesa.a7 oe RH Drive Shaft snap Ring FF Y Snap Ring LH Drive Shait *Gasket Nim (kghom, tibi) ] : Specified torque hy Norreusable paiENGINE MECHANICAL — ENGINE UNIT. Uppor Front Fender Apron Seal 122-FE. No. 2 Cylinder Head Cover 222-68: No. 2 Cylinder Head AZZ-FE: Upper Heated insulator 227-GE: 1ZZ-FE: Upper Hoatod Insulator Exhaust Manifold AZZ-FE: Lower Heated Insulator ZZ: 1Z2-FE: RH Engine Mounting East a Insulator ¥ ue L at 222-GE: Transmission AH Engine Mounting Tenaripsion MT. ‘Transmission Control Cable Insulator ’EM-74 ENGINE MECHANICAL —_ENGINE UN nen REMOVAL . REMOVE BATTERY AND TRAY REMOVE HOOD REMOVE ENGINE UNDER COVERS DRAIN ENGINE COOLANT DRAIN ENGINE OIL, DRAIN TRANSAXLE OIL REMOVE BUMPER COVER AND HEAD LIGHT Nope eS |. REMOVE AIR CLEANER CAP (a) _ Disconnect the MAF meter connector. (b) Disconnect the VSV for EVAP. (©) Disconnect the 2 hoses. (d) Disconnect the 3 clamps, and disconnect the air cleaner cap from the air cleaner case. (e) Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body. . REMOVE AIR CLEANER CASE (a) Remove the air fitter. {) Disconnect the hose from the VSV for Canister Closed VALVE (GVC). (©) Disconnect the hose from the intake air control valve. {d) Remove the 2 bolts, and disconnect the air cleaner case. (@) Disconnect the 2 hoses from the air cleaner case. 10. REMOVE ECM BOX {@) Remove the 2 bolts and ECM cover. (©) Disconnect the 4 connectors from the ECM. (c) Disconnect the 2 connectors from the ECM box. (d)_ Remove the ECM from the ECM box. (@) Disconnect the clamp from the ECM box. (Disconnect the 2 engine wires from the ECM box. (g) Remove the 3 bolts and ECM box. (h) Remove the 2 nuts, bolt and ECM box stay.M75 ENGINE MECHANICAL —_ ENGINE UN 41. DISCONNECT ENGINE WIRE FROM ENGINE ‘COMPARTMENT RELAY BOX (a) Remove the relay box upper cover. {b) Disconnect the 3 connectors. (c) Disconnect tha 7 claws and J/B from the relay box. (d) Disconnect the 3 connectors. {e) Disconnect the engine wire from the relay box. 12. w/ Crulse Control System: DISCONNECT CRUISE CONTROL ACTUATOR (a) Disconnect the actuator connector. (©) Remove the 3 bolts and disconnect the actuator from the body. 13. REMOVE RADIATOR ASSEMBLY (See page CO-17) 14. REMOVE DRIVE BELT AND GENERATOR (See page CH-7) 18. wi AIC: DISCONNECT A/C COMPRESSOR (a) Disconnect the A/C compressor connector. {b) Remove the 3 bolts, and cisconnect the A/C compressor from the engine. HINT: Suspend the A/C compressor securely. 16. DISCONNECT TUBE AND HOSE (@) Disconnect the fue! tube from the fuel pipe on vehicle side. (©) Disconnect the 2 heater hoses from the engine side. (©) Disconnect the brake booster vacuum hose.EM76 ENGINE MECHANICAL = ENGINE UNIT 17. @ () 18. 19, 20, a. (a) tb} © (a) (0) © Ma DISCONNECT CLUTCH RELEASE CYLINDER Remove the 3 bolts, and disconnect the brackets from the transaxle. Remove the 2 bolts, and disconnect the release cylinder ‘from the transaxle. DISCONNECT TRANSAXLE CONTROL CABLE (S) DISCONNECT 2 GROUND CABLES REMOVE DRIVE SHAFT (See page SA-20) REMOVE EXHAUST PIPE Disconnect the 2 heated oxygen sensor. Remove the 4 bolts and springs. Disconnect the 2 O-rings, and remove the exhaust pipe and 2 gaskets. 12Z-FE: REMOVE EXHAUST MANIFOLD Remove the 6 bolts and upper heat insulator. Remove the 3 bolts and exhaust manifold stay. Remove the 5 nuts, exhaust manifold and gasket. 222-GE: REMOVE EXHAUST MANIFOLD Remove the 5 bolts and upper heat insulator. Remove the 4 bolts and exhaust manitoid stay. Remove the 2 nuts, 3 bolts, exhaust manifold and gasket,eM77 ENGINE MECHANICAL —_ ENGINE UNIT 24, DISCONNECT PS PUMP (a) Disconnect the PS oil pressure switch connector. (b) Remove the 2 nuts and through bolts, and disconnect the PS pump from the ongine (See page SR-24). HINT: Put aside the pump and suspend it lo the cowl with a string. 25. REMOVE STABILIZER BAR BRACKET (See page SA-51) 26. DISCONNECT PS GEAR Remove the 4 bolts, and disconnect the PS gear from the sus- pension member. HINT: ‘Suspend the PS gear securaly. 27. REMOVE SUSPENSION MEMBER Remove the 9 bolts, 3 nuts and suspension member. 28, ATTACH ENGINE SLIDING DEVICE TO ENGINE HANGER: () Remove the 4 bolts and No. 2 cylinder head cover. (b} Disconnect the PCV hoses from the cylinder head cover.EM-78 ENGINE MECHANICAL — ENGINE UNIT () @ (a) ®) 30. @ tb) (co) Install the 2 engine hangers in the correct direction. Engine hanger part No.: 1ZZ-FE Front: 12281-22021 Rear: 12281-15040 or 12261-15050 Bolt: 91512-B1016 22Z-GE Front: 12261-88600 Rear: 12282-88600 Bolt: 91512-61020 ‘Torque: 38 N-m (388 kgf-em, 28 ft-lbf) Attach the engine sting device to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. REMOVE REAR ENGINE MOUNTING Remove the through bolt and rear engine mounting insu- lator. Remove the 3 bolis and rear engine mounting bracket. REMOVE ENGINE AND TRANSAXLE ASSEMBLY Remove the LH engine mounting through bolt and nut. 12Z-FE: Remove the 4 bolls, 2 nuts and RH engine mounting insu- lator. 222-GE: Remove the 5 botts, 2 nuts and RH engine mounting insu- lator.EM-79 ENGINE MECHANICAL, (6) Lower the engine out of vehicle slowly and carefutly, and raise the vehicle. HINT: Make sure the engine is clear of all wiring, hoses and cables. (e) Place the engine and transaxle assembly onto the stand, 31, SEPARATE ENGINE AND TRANSAXLE (C56 MT: See page MX-4) (C60 MIT: See page MX—4) (U240E A/T: See page AX-31) (U341E A/T: See page AX-31)ENGINE MECHANICAL = ENGINE UNIT a INSTALLATION 1 @) (b) ©) @) A @ ) ASSEMBLY ENGINE AND TRANSAXLE (C86 MIT: See page MX-8) (C60 MIT: See page MX-2) (U2d0E A/T: See page AX-35) (U341E AMT: See page AX-35) INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN. VEHICLE ‘Attach the engine sling device to the engine hangers. Slowly lower the vehicle, and raise the engine into the en- gine compartment. Koop the engine level, and align RH and LH mountings with the body bracket. 12Z-FE: install the RH engine mounting insulator with the 4 bolts and 2 nuts. Torque: 52 N.m (530 kgt-cm, 38 ftbf) 222-GE: Install the RH engine mounting insulator with the 5 bolts and 2 nuts. Torque: 52 N-m (530 kgf-cm, 38 ftlbf) {Install the LH engine mounting through bolt and nut. ‘Torque: 80 N-m (816 kgf-cm, 59 ftlbf) REMOVE ENGINE SLING DEVICE INSTALL REAR ENGINE MOUNTING Install the rear engine mounting bracket with the 3 bolts. Torque: 64 Nom (653 kgf-cm, 47 fbf) “Temporarily install the rear engine mounting insulator with the through bok.ENGINE MECHANICAL —_ €1 5. INSTALL SUSPENSION MEMBER (2) _ Install the suspension member with the 9 bolts and 9 nuts. Torque: ‘A52 Nom (530 kaficm, 32 fbf) B 82 N-m (630 kgf-cm, 32 ft.Ibf) C157 Nem (1,600 kgf-cm, 116 ttlbf) D157 N.m (1,600 kgt-om, 116 ft:tbf) E39 Nem (400 kgh-om, 29 fbf) Nut 52 Nom (530 kaf-cm, 32 fbf) (b) Tighten the rear engine mounting through bot. Torque: 87 N-m (887 kgf-cm, 64 ft.Ibf) 6 CONNECT PS GEAR Install the PS gear with the 4 bots. Torque: 45 N-m (460 kgf-em, 33 ft.lbf) 7. INSTALL STABILIZER BAR BRACKET (See page SA-53) 8. CONNECT PS PUMP (a) _ Install the PS pump with the 2 through bolts and nuts (See page SR22) Torque: 36 N-m (370 kgf-cm, 27 ttbf) {b) Connest the PS oil pressure switch connector. 9. 122-FE: INSTALL EXHAUST MANIFOLD {a) Install the gasket and exhaust manifold with the 5 nuts. Torque: 37 Nem (377 kgf-cm, 27 ftbf) {b) Install the exhaust manifold stay with the 8 boits. Torque: 49 Nem (500 kgt-cm, 37ft-Ibt) {c) Install the upper heat insulator with the 6 bolts. Torque: 12 Nem (123 kgf-cm, 9 ftibf) 10. 222-GE: INSTALL EXHAUST MANIFOLD (a) Install the gasket and exhaust manifold with the 2 nuts and 3 bolts Torque: 50 N-m (510 kgt-cm, 37 ft-bf) (b) Install the exhaust manifold stay with the 4 boks. Torque: 50 N-m (510 kgf-cm, 37 ftlbf) (¢) Install the upper heat insulator with the 5 bots. Torque: 20 N-m (204 kgt-om, 15 fbf)ENGINE MECHANICAL = ENGINE UNIT nt. (a) ) ©) (@ (b) © w. (@) tb) 18. INSTALL EXHAUST PIPE Install the 2 gaskets and exhaust pipe. ‘Connect the 2 O-rings. Install the 4 springs and bolts. Torque: 43 N-m (440 kat-om, 32 ftbf) Connect the 2 heated oxygen sensor. INSTALL DRIVE SHAFT (See page SA~32) CONNECT 2 GROUND CABLES: CONNECT TRANSAXLE CONTROL CABLE (8) MT: CONNECT CLUTCH RELEASE CYLINDER Install the release cylinder with the 2 bolts. Torque: 12 N-m (120 kgf.cm, 9 felbf) Install the brackets with the 3 bolts. Torque: Bolt A 12 N.m (120 kaf-cm, 9 fttbf) Bolt B 4.9 Nin (50 kgl-cm, 43 in.-tbt) CONNECT TUBE AND HOSE Connect the brake booster vacuum hose. Connect the 2 heater hoses to the engine side, Connect the fual tube to the fuel pipe on vehicle side. wi AC: INSTALL A/C COMPRESSOR Install the A/C compressor with the 3 bolts. Torque: 25 N-m (255 kgf-cm, 18 Flb/) Connect the A/C compressor connector. INSTALL GENERATOR AND DRIVE BELT (See page CH-17) INSTALL RADIATOR ASSEMBLY (See page CO-23)EM6a ENGINE MECHANICAL ENGINE UNIT 20. w/ Cruise Control System: INSTALL CRUISE CONTROL ACTUATOR. (a) _ Install the actuator with the 3 boits. () Connect the actuator connector. 21. CONNECT ENGINE WIRE TO ENGINE COMPART- MENT RELAY BOX (a) _ Install the engine wire to the relay box. {b) Connect the 3 connectors, (©) Connect the W/B to the relay box. (@ Connect the 3 connectors. (©) Install the relay box upper cover. 22. INSTALL ECM BOX (@) Install the ECM box stay with the 2 nuts and bolt. Torque: Nut 12 Nem (120 kgf-cm, 9 ftibf) Bolt 18 N-m (185 kgfom, 13 ttbf) (0) Instal the ECM box with the 3 bolts. Torque: 6.9 Nm (70 kgf-cm, 61 in.-bf) {e) Connect the 2 engine wire to the ECM box. (8) Corinect the clamp to the ECM box. (2) _ Install the ECM to the ECM box. (Connect the 2 connectors to the ECM box. (g) Connect the 4 connectors to the ECM (h) Install the ECM cover with the 2 bolts. Torque: 6.9 N-m (70 kgf.cm, 61 In-Ibt)ENGINE MECHANICAL ENGINE UNITE sane 23, INSTALL AIR CLEANER CASE (a) Connect the 2 hoses to the air oleaner case. {b) Install the air cleaner case with the 2 batts. ‘Torque: 5.0 N-m (51 kat-om, 44 in.Jbf) (0) Connect the hose to the intake air control valve, {@) Connect the hose to the VSV for canister closed valve (eve). {e) Install the air iter 24, INSTALL AIR CLEANER CAP (@) Install the air cleaner hose to the throttle body with the hose clamp. (b) Connect the air cleaner cap to the air cleaner case with the 3 ciamps. {) Connect the 2 hoses. (d) Connect the VSV for EVAP. {e) Connect the MAF meter connector. INSTALL HEADLIGHT AND BUMPER COVER: INSTALL BATTERY AND TRAY FILL WITH TRANSAXLE OIL, FILL WITH ENGINE OIL FILL WITH ENGINE COOLANT (See page CO-2) START ENGINE AND CHECK FOR LEADS PERFORM ENGINE ADJUSTMENT CHECK FRONT WHEEL ALIGNMENT INSTALL ENGINE UNDER COVERS INSTALL ENGINE HOOD ROAD TEST VEHICLE Check tor abnormal noises, shock slippage, correct shift points and smooth operation. 36. RECHECK ENGINE COOLANT AND OIL LEVELS BESRESBRSRSENGINE MECHANICAL — CYLINDER BLOCK CYLINDER BLOCK COMPONENTS EM-85 1ZZ-FE: Nim (kgfem, fHbH) | : Specitod torque n, @Non-reusable part Water Bypass Pipe ll Guide and Oil DipstickEN-86 ENGINE MECHANICAL CYLINDER BLOCK Water Bypass Pipe Engine Coolant Deain Union Rem (egtom, Tibi) } : Specified torque ‘¢ Non-reusable part S57, 78m) ‘Knock Sensor ~~~~-@lgps, No. 3 Ventilation Hose Water Inlet edEM87 ENGINE MECHANICAL — GYLINDER BLOCK. Tare: No.1 Compression eo ey i 2 4 Connecting Red Bushing No.2 Compression Ring” @==S_ (Ring (Expando) ED Connecting Rod Connecting Rod Bearing 4 Snap Ring" Cylinder Block oie “ ‘Crankshaft Thrust Washer Uper th Boning ee Crankshaft Thrust Washer y Crankshaft ee ae rato mL _ ts = peoERT] Ae Ce ) — # cater —_ Nemikgem, trib) | : Spectiied torque x “@Nor-feusable part portEM88 ENGINE MECHANICAL CYLINDER BLOCK 22Z-GE: No. 1 Compression ae =) No. 2 Compression Oil Ring ‘(Side Pal it Ring (Expander) — Piston ‘#Snap Ring ey“ iston Pin Upper Main Beating Oil Pan Battle Nemfkghem, Ribi) ] :Specited torque # Gasket “Snap Ring Rp ie} io Crankshaft Thrust Washer 7% g DD | © ¢ Connecting Rod Bushing Connecting Rod ‘Connecting Rod Bearing Connecting Rod Cap EDR Sg— oil Nozzle g@— Ol Fier Union N_@Non-rousable partEM-89 ENGINE MECHANICAL — CYLINDER ELOGK DISASSEMBLY 1 MT REMOVE FLYWHEEL 2 at REMOVE DRIVE PLATE 3, _ INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 4, REMOVE TIMING CHAIN AND SPROCKETS (See page EM-18) 5. REMOVE ENGINE WIRE 6. REMOVE CYLINDER HEAD (See page EM-42) 7 1Z2-FE: REMOVE OIL DIPSTICK AND GUIDE {a) Remove the boit and oil dipstick and guide. (©) Remove the O-ring from the dipstick. 8, REMOVE WATER BYPASS PIPE Remove the 2 nuts, bolts and water bypass pipe. 9, REMOVE THERMOSTAT (See page CO-) 40. REMOVE KNOCK SENSOR +1. REMOVE ENGINE COOLANT DRAIN UNION 12. REMOVE OIL PUMP (See page LU-9) 13. 222-GE: REMOVE VENTILATION CASE (2) Remove the 3 nuts, ventilation case and gasket. (b) Remove the clip and No. 3 ventilation hose.ENGINE MECHANICAL — CYLINDER BLOCK ee roves + ss 14. REMOVE OIL FILTER (See page LU-3) 45. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remave the oil filter union. 16. REMOVE OIL PAN fa) 1ZZ-FE: Remove the 14 bolts and 2 nuts. (o) 222-GE: Remove the 12 bolts and 4 nuts. (©) _ Insert the blade of SST between the bearing cap sub-as- sembly and oil pan, and cut off applied sealer and remove the oil pan. SST 09032-00100 NOTICE: + Be careful not te the damage the oil pan contact sur- face of the bearing cap sub-assembly. + Be careful not to damage the oil pan flange. 17. 1ZZ-FE: REMOVE OIL STRAINER Remove the 2 nuts, bolt, oil strainer and gasket. 18, 2Z2-GE: REMOVE OIL STRAINER AND OIL PAN BAFFLE {a) Remove the 2 nuts, bolt, oll strainer and gasket (b) Remove the 4 bolts, 2 nuts and cil pan battle.EM-91 ENGINE MECHANICAL — CYLINDER SLOgK 19. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while mov- ing the connecting rod back and forth. Standard thrust clearance: 0.160 ~ 0.342 mm (0.0063 - 0.0135 in.) Maximum thrust clearance: 0.342 mm (0.0135 in.) if the thrust clearance is greater than maximum, replace the connecting rod assembly(s). f necessary, replace the crank- shalt Connecting rod thickness: 19.788 - 19.840 mm (0.7791 - 0.7811 in.) 20, REMOVE CONNECTING ROD GAPS AND CHECK OIL. CLEARANCE (@) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts. (6) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the ‘connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. (d) Clean the crank pin and bearing. (©) _ Check the crank pin and bearing for pitting and scratches. |Fthe crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.L_=_ CYLINDER BLOCK ee () Lay a strip of Plastigage the crank pin. (g) _ Install the connecting rod cap with the 2 bolts (See page EM-106). ist: 1ZZ-FE: 20 Nem (204 kgt-cm, 15 ftbf) 2Z2-GE: 30 N-m (306 kgf.cm, 22 ftbf) 2nd: Turn extra 90° NOTICE: Do not turn the crankshaft. (h) Remove the 2 bolts, connecting rod cap and lower bear- ing. (See procedure (b) and (c) above) (i) Measure the Plastigage at its widest point. ‘Standard oll clearance: 1ZZ-E: 0.028 — 0.060 mm (0.0011 - 0.0024 in.) (2ZZ-GE: 0.028 — 0.052 mm (0.0011 — 0.0020 in.) Maximum oil clearance; 0.08 mm (0.0031 in.) Iv the oil clearance is greater than maximum, replace the bear- ings. If necessary, grind or replace the crankshaft.EM-o3 ENGINE MECHANICAL — CYLINDER 8LO0K Mark 1,20r3, HINT: Ireplacing a bearing, replace it with one having the same num- ber as marked on the connecting rod. There are 3 sizes of star- dard bearings, marked "1", 2" and "3" accordingly. Reference Standard bearing center wall thickness 1ZZ-FE: Mark om nd * 1.486 ~1 490 (6.0585 ~ 0.0567) = 1490 9.494 (0.0587 — 0.0588) Ea 5 494~ 1 496 (0.0588 0.0880) 22Z-GE: Mane a) Ey 1.482 ~ 1486 (0.0569 — 0.0585) = 1.486 — 1490 010565 00587) = 113901496 (0.0587 0.0580) Completely remove the Plastigage. 21. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES (@) Using a ridge reamer, remove all the carbon from the top of the cylinder. (b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: + Keep the bearings, connecting rod and cap together. + Arrange the piston and connecting rod assemblies in the correct order. 22. REMOVE BEARING CAP SUB-ASSEMBLY AND CRANKSHAFT REAR OIL SEAL, AND CHECK OIL CLEARANCE (a) 222-GE: Remove the 4 screw plugs from the bearing cap sub-as- sembly. (®) Remove the 10 hexagon head bearing cap sub-assem- bly botts. (©) Uniformly loosen and remove the 10 bearing cap sub-as- ‘sembly bolts, in several passes, in the sequence shown.JE MECHANICAL —_ CYLINDER BL: (6) _ Using a screwdriver, remove the bearing cap sub-essem- biy by prying the portions between the cylinder block and bearing cap sub-assembly. Remove the 5 lower main bearings. NOTICE: Be careful not to damage the contact surfaces of the cylin- der block and bearing cap sub-assembly. HINT: Keep the lower bearing and bearing cap subassembly togeth- er. (©) Remove the crankshatt rear cil seal ( _Liftout the crankshaft. HINT: Keep the upper bearings together with the oylinder block. (g) Clean each main journal and bearing. (h) Check each main journal and bearing for pitting and scratches. Ifthe journal or bearing is damaged, replace the bearings. Iinecessary, replace the crankshaft. (Place the crankshaft on the cylinder block. () Lay astrip of Plastigage across each journal. {K) _ Install the bearing cap sub-assembly (See page EM-106). NOTICE: Bo not turn the crankshaft. () Remove the bearing cap sub-assembly (See procedures {@) to (e) above). (m) Measure the Plastigage at its widest point. Standard oil clearance: ZZ-FE: 0.015 — 0.032 mm (0.0006 - 0.0013 In.) 222-GE: 0.016 — 0.032 mm (0.0006 — 0.0013 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) Ifthe oil clearance is greater then maximum, replace the bear- ings. necessary, replace the crankshaft.ENGINE MECHANICAL — GYLINDERBLOGK. () 12Z-FE: {fusing a standard bearing, replace it with one having the ‘same number. If he number of the bearing cannot be de- termined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crank- shaft, then selecting the bearing with the same number as the total. Thete are 4 sizes of standard bearings, marked "1", °2°, °3" and "4" accordingly. EM95 Total number =: Number mark Cylinder block (A) + 0-2) 3-5 | 6-8 | e-1 Crankshaft (8) Use bearing vv [| = fe | « fo) EXAMPLE: Cylinder block "4" (A} + Crankshaft 3" (8) = Total number 7 (Use bearing 3") 2ZZ-GE: It using standard bearing, replace it with one having the ‘same number. f the number of the bearing cannot be de- termined, reter to the following table to select bearing. ‘Standard bearings selection chart Cylinder block ‘Crank shalt number mark Number mark. a i 2 3 z 5 ° 1 1 1 2 2 2 4 1 1 2 2 2 ‘3 2 1 2 2 2 3 3 3 2 2 2 3 3 3 « 2 3 3 3 4 4 5 3 3 3 4 4 4 6 3 3 4 4 4 6 XAMPLE: Cylinder block “4”, Crank shaft “3”, Use bearing "3"EMA96 ENGINE MECHANICAL — CYLINDER BLOCK tem Reference rm in) ‘Gyincer bck main journal bore diameter (A) ‘52.000 ~ 52068 (2 047220478) 162.003 - 52.005 (20473-20474) 52.005 ~52.007(20474~2.0475), ‘52007 ~62010 (20475-20478) ‘52010 ~82.012 20476-20477) 52.012~s2014 20677-20478) 52014-52016 (20478 2.0479) Grankshan main ourat kara {8) aladsanielE “47,998 ~ 49000 (1.9897 1.8898) ‘AT S96 - 47588 (1 8808~ 1.8897) 47.904 -47.$96 (1.8095 - 1.8096) 47892 ~47.996{13804~ 1.8695) 47 990 ~ 47.292 (1.8889~ 1.8898) 47 980~ 47990 {1.8882 1.8099) gags ZF, Standard bearing conter wat tiokress 1.989 1.898 (00785 0.0766), 1.996 1.599 (00788-00787) 1.999 -2.602 (20787 0.0788), 2002-2006 (0.0768—0.0780) an 2a2-GE ‘Standard bearing canter wal thickness 7.8891 982 (20783—0.07EA) 1.992 1.805 (0.0784 0.0785} 1.985~ 1.908 (0.0785 - 0.0787; 1.998 -2.001 (00787-0.0788} = 2.001 —2.04 (0.0788 -0.9788) {p) Completely remove the Plastigage. 23, CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a sorewdriver. Standard thrust clearance: 0.04 — 0.24 mm (0.0016 ~ 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. ‘Thrust washer thickness: 2.430 — 2.480 mm (0.0957 — 0.0976 in.) 24, REMOVE CRANKSHAFT (@) Lift out the crankshaft. (b) Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. HINT: Arrange the main bearings and thrust washers in the correct or- der.