Part 4

PARTIAL ENGINE ASSEMBLY (2AZ-FE)
OVERHAUL





91. ADJUST VALVE CLEARANCE
a. Set the No. 1 cylinder to the TDC/compression.
b. Place paint marks on the chain and camshaft timing gears.





c. Remove the 2 nuts, chain tensioner and gasket.

NOTICE: Do not turn the crankshaft without the chain tensioner.





d. Remove the No. 2 camshaft.
1. While holding the camshaft with a wrench, loosen the camshaft timing gear set bolt.

NOTICE: Be careful not to damage the valve lifter.





2. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
3. Remove the 5 bearing caps.





4. While holding the No. 2 camshaft by hand, remove the camshaft timing gear set bolt.
5. Remove the camshaft timing gear from the No. 2 camshaft with the timing chain wrapped.
6. Remove the camshaft timing gear from the timing chain.





e. Remove the camshaft.
1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
2. Remove the 5 bearing caps.
3. Remove the camshaft and camshaft timing gear while holding the timing chain by hand.





f. Tie the timing chain with a string as shown in the illustration.

NOTICE: Be careful not to drop anything inside the timing chain cover.

g. Remove the valve lifters.








h. Using a micrometer, measure the thickness of the removed valve lifters.





i. Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.
Valve clearance:
Intake A = B + (C - 0.24 mm (0.0095 inch))
Exhaust A = B + (C - 0.35 mm (0.0138 inch))

HINT:
- Select a new lifter with a thickness as close to the calculated values as possible.
- Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch).
- Refer to New Lifter Thickness table on the next 2 pages.





Valve Lifter Selection Chart (Intake)





Valve Lifter Selection Chart (Exhaust)

j. Install the camshaft
1. Apply a light coat of engine oil to the journal portion of the camshaft.





2. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration.





3. 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.
4. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
5. Using several steps, uniformly tighten the 10 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
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3
k. Install the No. 2 camshaft.
1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.





2. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing gear.





3. While holding the No. 2 camshaft by hand, temporally tighten the camshaft timing gear set bolt.





4. 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.
5. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
6. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque:
29.5 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 2
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3





7. While holding the camshaft with a wrench, tighten the camshaft timing gear set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE: Be careful not to damage the valve lifter.





l. Check that the paint marks on the chain and camshaft timing gears are aligned. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.





m. Install the chain tensioner.
1. 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.





2. 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.





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





4. Turn the crankshaft clockwise, then check that the plunger is extended.
92. INSTALL CYLINDER HEAD COVER GASKET
a. Install the gasket onto the cylinder head cover.
93. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove any old packing material from the contact surface





b. Apply seal packing to the 2 locations shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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





c. Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
11 Nm (112 kgf-cm, 8 ft. lbs.) for bolt A
14 Nm (143 kgf-cm, 10 ft. lbs.) for bolt B
11 Nm (112 kgf-cm, 8 ft. lbs.) for nut
94. INSTALL VENTILATION VALVE SUB-ASSEMBLY
a. Apply adhesive to the threads of the ventilation valve.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
95. INSTALL OIL FILLER CAP GASKET
96. INSTALL OIL FILLER CAP SUB-ASSEMBLY
97. INSTALL SPARK PLUG
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)