Part 2

PARTIAL ENGINE ASSEMBLY (2AZ-FE)
OVERHAUL
34. REMOVE CYLINDER HEAD GASKET
35. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY





36. REMOVE OIL CONTROL VALVE FILTER
a. Using a socket hexagon wrench 6, remove the plug and gasket.
b. Remove the oil control valve filter.





37. REMOVE W/HEAD TAPER SCREW PLUG NO.1
a. Remove the plug from the cylinder block.





38. INSPECT BALANCE SHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 inch)
Maximum thrust clearance: 0.09 mm (0.0035 inch)
- If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings.
- If necessary, replace the balance shaft.





39. CHECK BALANCE SHAFT OIL CLEARANCE
a. Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.
b. Remove the balance shaft housing from the crankcase.

HINT: Keep the lower bearing and balance shaft housing together.

c. Lift out the No. 1 and No. 2 balance shafts.

HINT: Keep the upper bearing with the crankcase.

d. Clean each bearing and journal.
e. Check each bearing and journal for pitting and scratches.
- If a bearing or journal is damaged, replace the bearings.
- If necessary, replace the balance shaft.
f. Place the No. 1 and No. 2 balance shafts onto the crank case.





g. Lay a strip of Plastigage across each journal.
h. Install the balance shaft housing.
i. Apply a light coat of engine oil on the threads and under the heads of the bolts.





j. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 21.6 Nm (220 kgf-cm, 16 ft. lbs.)





k. Mark the front of the bolts with paint.
l. Retighten the bolts 90° as shown in the illustration.
m. Check that the painted mark is now at a 90° angle to the front.
n. Remove the balance shaft housing from the crankcase.





o. Measure the Plastigage at its widest point.
Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 inch)
Maximum oil clearance: 0.049 mm (0.0019 inch)

NOTICE: Remove the Plastigage completely after the measurement.

- If the oil clearance is greater than maximum, replace the bearing.
- If necessary, replace the balance shaft.





HINT: If replacing a bearing, select a new one with the same number.





Balance shaft housing journal bore diameter:

Balance shaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 inch)





Standard bearing center wall thickness:

40. REMOVE BALANCE SHAFT
41. REMOVE BALANCE SHAFT BEARING NO.1





42. REMOVE ENGINE REAR OIL SEAL
a. Using a knife, cut off the oil seal lip.
b. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.

NOTICE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400 grit sandpaper.





43. REMOVE STIFFENING CRANKCASE ASSEMBLY
a. Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
b. Remove the crankcase by prying the portions between the crankcase and cylinder block.

NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block.

c. Remove the O-ring from the cylinder block.





44. INSPECT CHAIN TENSIONER ASSEMBLY NO.1
a. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
b. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.





45. INSPECT CHAIN SUB-ASSEMBLY
a. Using vernier calipers, measure the length of the 16 links with the chain fully stretched.
Maximum chain elongation: 122.6 mm (4.827 inch)
If the chain elongation is greater than maximum, replace the chain.

HINT: Take the same measurements by pulling at 3 or more places selected at random.





46. INSPECT CHAIN TENSIONER SLIPPER
a. Using vernier calipers, measure the tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the tensioner slipper.





47. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Using vernier calipers, measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the vibration damper.





48. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing gear.
b. Using vernier calipers, measure the timing gear diameter with the chain.
Minimum gear diameter (w/ chain): 51.6 mm (2.031 inch)

NOTICE: Vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than minimum, replace the chain and timing gear.





49. INSPECT OIL PUMP DRIVE GEAR
a. Wrap the chain around the drive gear.
b. Using vernier calipers, measure the drive gear diameter with the chain.
Minimum gear diameter (w/ chain): 48.2 mm (1.898 inch)

NOTICE: Vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than minimum, replace the chain and drive gear.





50. INSPECT OIL PUMP DRIVE SHAFT GEAR
a. Wrap the chain around the drive shaft gear.
b. Using vernier calipers, measure the drive shaft gear diameter with the chain.
Minimum gear diameter (w/ chain): 48.2 mm (1.898 inch)

NOTICE: Vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than minimum, replace the chain and drive shaft gear.





51. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing gear.
b. Using vernier calipers, measure the timing gear diameter with the chain.
Minimum gear diameter (w/ chain): 97.3 mm (3.831 inch)

NOTICE: Vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than minimum, replace the chain and timing gear.





52. INSPECT CAMSHAFT
a. Check the camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the camshaft.





b. Inspect the cam lobes.
1. Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 46.495 to 46.595 mm (1.8305 to 1.8345 inch)
Minimum cam lobe height: 46.385 mm (1.8262 inch)
If the cam lobe height is less than minimum, replace the camshaft.





c. Inspect the camshaft journals.
1. Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 inch)
Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 inch)
If the journal diameter is not as specified, check the oil clearance.





53. INSPECT NO.2 CAMSHAFT
a. Check the camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the camshaft.





b. Inspect the cam lobes.
1. Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 45.983 to 46.083 mm (1.8104 to 1.8143 inch)
Minimum cam lobe height: 45.873 mm (1.8060 inch)
If the cam lobe height is less than minimum, replace the cam shaft.





c. Inspect the camshaft journals.
1. Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 inch)
Other journal diameters: 22.959 to 22.975 mm (0.9039 to 0.9045 inch)
If the journal diameter is not as specified, check the oil clearance.





54. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of the head bolts from the seat to the end.
Standard bolt length: 161.3 to 162.7 mm (6.350 to 6.406 inch)
Maximum bolt length: 164.2 mm (6.465 inch)
If the bolt length is greater than maximum, replace the bolt.
55. INSTALL BALANCE SHAFT BEARING NO.1
a. Install the bearings onto the crankcase and balance shaft housing.
b. Apply a light coat of engine oil to the bearings.





56. INSTALL BALANCE SHAFT
a. Rotate the driven gear No. 1 of balance shaft No. 1 in the rotating direction until it hits the stopper.
b. Confirm that the matchmarks on driven gear No. 1 and No. 2 are aligned.





c. Align the matchmarks of the No. 1 and No. 2 balance shafts as shown in the illustration.
d. Place the No. 1 and No. 2 balance shafts onto the crank case.
e. Apply a light coat of engine oil to the threads and under the heads of the bolts.





f. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 21.6 Nm (224 kgf-cm, 16 ft. lbs.)





g. Mark the front of the bolts with paint.
h. Retighten the bolts 90° as shown in the illustration.
i. Check that the painted mark is now at a 90° angle to the front.
57. INSTALL STIFFENING CRANKCASE ASSEMBLY
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase.





b. Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes of applying seal packing.
- Do not put in engine oil for at least 2 hours after installing the crankcase.





c. Place a new O-ring on the cylinder block as shown in the illustration.





d. With the No. 1 crank pin of the crankshaft placed at 6 o'clock, install the No. 1 and No. 2 balance shaft and the adjusting hole as shown in the illustration.





e. Temporarily install the crank case with the 11 bolts.

HINT: Bolt length:
112 mm (4.41 inch) for A of 12 mm head
35 mm (1.38 inch) for B of 12 mm head

f. Uniformly tighten the bolts.
Torque: 32.5 Nm (331 kgf-cm, 24 ft. lbs.)





g. Confirm that the timing marks of the balance shafts are aligned when the key groove is placed at 6 o'clock position, as shown in the illustration.
58. INSTALL ENGINE REAR OIL SEAL
a. Apply multipurpose grease to a new oil seal lip.

NOTICE: Keep the lip free of foreign objects.





b. Using SST and a hammer, tap the oil seal in until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE: Wipe any extra grease off the crankshaft.





59. INSTALL W/HEAD TAPER SCREW PLUG NO.1
a. Apply adhesive to 2 or 3 threads of the plug, and install it.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

NOTICE:
- Install the plug within 3 minutes of applying adhesive.
- Do not put in coolant for at least an hour after installing the plug.





60. INSTALL OIL CONTROL VALVE FILTER
a. Check that there is no foreign objects on the mesh part of the oil control valve filter.
b. Using a socket hexagon wrench 6, install a new gasket and the oil control valve filter with the plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
61. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the drain cock.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. After tightening the drain cock to the specified torque, turn the drain cock clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

NOTICE:
- Install the drain cock within 3 minutes of applying adhesive.
- Do not put in coolant for at least an hour after installing the drain cock.
- Do not turn the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque.
- Do not loosen the drain cock after setting it correctly.





62. INSTALL CYLINDER HEAD GASKET
a. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
- Remove any oil from contact surface.
- Be careful of the installation direction.
- Place the cylinder head gently in order to avoid damaging the gasket with the bottom part of the head.

63. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





b. Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 78.5 Nm (800 kgf-cm, 58 ft. lbs.)





c. Mark the front of the cylinder head bolts with paint.
d. Retighten the cylinder head bolts 90° in the same sequence as step (c).
e. Check that the painted mark is now at a 90° angle to the front.
64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.
b. Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





65. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
a. Put the camshaft timing gear and camshaft together with the straight pin off the key groove.
b. Turn the camshaft timing gear in the left as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

c. Check that there is no clearance between the gear fringe and camshaft.
d. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
e. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.





66. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Clamp the camshaft in a vise, then install the camshaft timing gear with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE: Be careful not to damage the No. 2 camshaft.