Part 3

PARTIAL ENGINE ASSEMBLY (2AZ-FE)
OVERHAUL
67. INSTALL CAMSHAFT BEARING NO.2
a. Clean the contact surfaces of the bearing and the cylinder head.





b. Install the camshaft bearing No. 2 onto the cylinder head.

NOTICE: Do not apply engine oil to the bearing and its contact surface.

68. INSTALL CAMSHAFT BEARING NO.1
a. Clean the contact surfaces of the bearing and the bearing cap No. 1.





b. Align the bearing claw with the claw groove of bearing cap No. 1, and push in the bearing.

NOTICE: Do not apply engine oil to the bearing and its contact surface.

69. INSTALL CAMSHAFTS
a. Apply a light coat of engine oil to the journal portion of the camshaft.





b. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.





c. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
d. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.





e. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.
Torque:
29.5 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 1 and No. 2
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3

NOTICE:
- Tighten the bolts after deciding the position in the thrust direction of the camshaft by the bearing cap No. 1 and No. 2.
- Install the camshaft with its timing mark of the camshaft timing gear on the top.





70. INSTALL OIL PUMP ASSEMBLY
a. Install a new gasket and oil pump with the 3 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





71. INSTALL NO.2 CHAIN SUB-ASSEMBLY
a. Set the crankshaft key in the left horizontal position.
b. Turn the cutout of the drive shaft to the top.





c. Align the yellow mark links with the timing marks of the each gear as shown in the illustration.
d. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped.
e. Temporarily tighten the oil pump drive shaft gear with the nut.





f. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)





g. Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
h. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then tighten the nut.
Torque: 29.5 Nm (301 kgf-cm, 22 ft. lbs.)





i. Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
72. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
73. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





74. INSTALL CHAIN SUB-ASSEMBLY
a. Set the No. 1 cylinder to TDC/compression.
1. Turn the camshafts with a wrench on the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.





2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.





b. Install the chain onto the crankshaft timing gear with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear.





c. Using SST, tap in the crankshaft timing gear.
SST 09309-37010





d. Align the gold or yellow mark links with each timing mark located on the camshaft timing gears, then install the chain.
75. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





76. INSTALL TIMING CHAIN GUIDE
a. Install the timing chain guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





77. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the sensor plate with the "F" mark facing forward.
78. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE 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 in the new oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010
79. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.





b. Apply a continuous bead of seal packing (Diameter 2.0 mm (0.079 inch)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent

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

c. Apply a continuous bead of seal packing as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent





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





d. Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt A
25 Nm (255 kgf-cm, 18 ft. lbs.) for bolt B
55 Nm (561 kgf-cm, 41 ft. lbs.) for bolt C
43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt D
11 Nm (112 kgf-cm, 8 ft. lbs.) for nut





HINT: Bolt length





80. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
a. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position.





b. Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: When installing the chain tensioner, set the hook again if the hook releases the plunger.





81. INSTALL CRANKSHAFT PULLEY
a. Using SST, fix the pulley and tighten the bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 180 Nm (1,835 kgf-cm, 133 ft. lbs.)





b. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.





c. Turn the crankshaft clockwise, then check that the plunger is extended.
82. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.





b. Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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

c. Install the oil pan to the cylinder block.





d. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
83. INSTALL OIL PAN DRAIN PLUG
a. Place a new gasket on the oil pan drain plug, then install it onto the oil pan.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
84. INSTALL WATER PUMP ASSEMBLY
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and water pump.





b. Apply a continuous bead of seal packing (Diameter 2.2 to 2.5 mm (0.087 to 0.098 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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





c. Install the water pump with the 4 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: Tighten the outside bolt and nut with the clamp.





85. INSTALL WATER PUMP PULLEY
a. Using SST, install the water pump pulley with the 4 bolts.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)

NOTICE: Be careful that the O-ring is not cracked or jammed when installing.





86. INSTALL CRANKSHAFT POSITION SENSOR
a. Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.
b. Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: Be careful that the O-ring is not cracked or jammed when installing.





c. Confirm that the wire harness of the sensor is placed as shown in the illustration.





87. INSTALL CAMSHAFT POSITION SENSOR
a. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
b. Install the camshaft position sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: Be careful that the O-ring is not cracked or jammed when installing.

88. INSTALL OIL FILTER UNION
a. Using a socket hexagon wrench 12, install the oil filter union.
Torque: 29.5 Nm (301 kgf-cm, 22 ft. lbs.)
89. INSTALL OIL FILTER SUB-ASSEMBLY
a. Check and clean the oil filter installation surface.
b. Apply clean engine oil to the gasket of a new oil filter.
c. Lightly screw the oil filter into place, then tighten it until the gasket comes into contact with the seat.





d. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)





90. INSPECT VALVE CLEARANCE
a. Set the No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley until its groove and the timing mark "O" of the timing chain cover are aligned.
2. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.





b. Check only the valves indicated.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.19 to 0.29 mm (0.0075 to 0.0114 inch) for intake
0.30 to 0.40 mm (0.0118 to 0.0158 inch) for exhaust
2. Record any out of specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
c. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression.





d. Check only the valves indicated.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.19 to 0.29 mm (0.0075 to 0.0114 inch) for intake
0.30 to 0.40 mm (0.0118 to 0.0158 inch) for exhaust
2. Record any out of specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.