Part 2

CHAIN SUB-ASSEMBLY (2AZ-FE)
REPLACEMENT
35. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





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





37. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the sensor plate with the "F" mark facing forward.
38. 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
39. 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





e. Using a Torx socket E10, install the stud bolt for the V-ribbed belt tensioner.
Torque: 21.5 Nm (219 kgf-cm, 16 ft. lbs.)





40. 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.





41. 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.





d. Connect the wire harness protector clamp.
e. Install the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
42. 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 into 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.)





e. Place a transmission jack underneath the engine, then put a wooden block on the jack.
f. Remove the chain block and sling device.
g. Remove the engine hanger No. 1 and No. 2.
43. INSTALL CRANKSHAFT POSITION SENSOR





44. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the V-ribbed belt tensioner with the bolt and nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft. lbs.)

NOTICE: Do not lift the engine more than necessary.

45. 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





d. Install the engine wire with the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
e. Connect the clamp of the engine wire.





f. Connect the 2 ventilation hoses to the cylinder head cover.
46. INSTALL IGNITION COIL ASSEMBLY





47. INSTALL ENGINE MOUNTING INSULATOR RH
a. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





b. Install the engine mounting insulator FR with the bolt and nut.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





c. Connect the 2 clamps of the engine wire.
d. Install the wire harness protector with the bolt.





e. Install the oil reservoir bracket No. 1 with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





f. Install the return tube with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





g. Install the vane pump oil reservoir onto the oil reservoir bracket No. 1.





h. Install the radiator reserve tank with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
48. INSTALL VANE PUMP ASSEMBLY
SST 09249-63010
49. INSTALL GENERATOR ASSEMBLY
50. INSTALL FAN AND GENERATOR V-BELT
SST 09249-63010
51. INSTALL EXHAUST PIPE ASSEMBLY FRONT
52. ADD ENGINE OIL
53. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
54. CHECK FOR ENGINE OIL LEAKAGE
55. CHECK FOR EXHAUST GAS LEAKAGE





56. INSTALL ENGINE COVER SUB-ASSEMBLY NO.1
a. Install the engine cover No. 1 with the 2 nuts.
Torque: 7.0 Nm (70 kgf-cm, 62 inch lbs.)
57. INSTALL FRONT FENDER APRON SEAL RH
58. INSTALL ENGINE UNDER COVER LH
59. INSTALL ENGINE UNDER COVER RH
60. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
61. INSTALL HOOD SUB-ASSEMBLY