1gr-Fe MT
1gr-Fe MT
1gr-Fe MT
NEW FEATURES
J1GR-FE ENGINE
1. General
D The 1GR-FE engine is a 4.0-liter, 24-valve DOHC V6 engine. In this engine, a Dual Variable Valve
Timing-intelligent (Dual VVT-i) system, in which the VVT-i system has also been added to the exhaust
side, and the roller rocker arm are used to minimize friction, offering excellent engine performance, fuel
economy and clean emissions.
D The 1GR-FE engine is compatible with gasoline/ethanol mixed fuel which contains up to 20% ethanol
(E20). Unleaded gasoline with an octane rating of 87 (research octane number 91) or higher can be used
on this engine.
D For detailed comparisons to the ’09 FJ Cruiser, see Major Difference (See page 8).
147EG01TE
147EG02TE
6 – NEW FEATURES
244_ 236_
71_
60_ 60_
54_
Intake VVT-i
Intake VVT-i 31_ Operation Range
25_
Operation Range 10_
BDC Exhaust VVT-i BDC
’10 FJ Cruiser Operation Range ’09 FJ Cruiser 147EG03S
(HP) kW
280
200
260
N⋅m (ft⋅lbf) 240 180
400 300 220 160
300 200 200
Torque 140
200 180
100
100 160 120 Output
0 0 140 100
120
80
100
80 60
60 40
40
20
20
0 0
2. Major Difference
System Outline
D Oil delivery pipes are used for the cylinder head cover.
D The cylinder head structure has been changed; the camshaft housing is
now separate from the cylinder head.
D The shapes of the cylinder head intake ports and the locations of the fuel
Engine Proper injectors have been optimized.
D The surface treatment of the cylinder block liner has been changed.
D A cylinder block water jacket spacer has been added.
D The shape of the piston has been changed.
D A 5 balance weight crankshaft is used.
D A Dual Variable Valve Timing-intelligent (Dual VVT-i) system, in
which the VVT-i system has also been added to the exhaust side, is used.
Valve Mechanism D A roller rocker arm is used.
D A hydraulic lash adjuster is used.
D Cam lobes with indented R profiles are used.
D Oil passages for the VVT-i controller (exhaust) and the hydraulic lash
Lubrication System adjuster have been added.
D An oil filter with a replaceable element is used.
D The shape and installation location of the air cleaner have been changed.
D A filter paper type air cleaner element is used.
D The throttle valve diameter has been increased.
D The shape of the intake air chamber has been optimized.
Intake and Exhaust System D The Acoustic Control Induction System (ACIS) has been discontinued.
D The shape of the exhaust manifold has been changed.
D The volume and cell density of the three-way catalytic converter have
been optimized.
D The material of the tail exhaust pipe has been changed.
Fuel System The fuel system is made compatible with E20 fuel.
Ignition System Iridium-tipped spark plugs are used.
Charging System A generator pulley with a one-way clutch is used.
Starting System The starter has been changed to one with a 1.4 kW rating output.
D A Dual VVT-i system is used.
D A fuel pump control that can regulate the fuel pump speed to one of
Engine Control System
Low, Middle or High is used.
D A power steering oil pressure sensor is used.
– NEW FEATURES 9
’10 FJ ’09 FJ
Item (1) (2) (3) (4) (5)
Cruiser Cruiser
Upright intake ports are used. f f f f
A taper squish shape is used for the combustion
f f f f
chamber.
A steel laminate type cylinder head gasket is used. f f f
Engine
A cylinder block made of aluminum alloy is used. f f f
Proper
Cylinder block water jacket spacers are used. f f —
The skirt portion of the piston has a resin coating
f f f f f
applied to reduce friction.
A No. 1 oil pan made of aluminum alloy is used. f f f f
A Dual Variable Valve Timing-intelligent (Dual
f f f —
VVT-i) system is used.
A VVT-i system is used. f f — f
Valve Hydraulic lash adjusters are used. f f f f f —
Mechanism
Roller rocker arms are used. f f f —
Shim-less type valve lifters are used. f f — f
Timing chains and chain tensioners are used. f f f f f
Lubrication
An oil filter with a replaceable element is used. f f —
System
Cooling Toyota genuine Super Long Life Coolant (SLLC)
f f f
System is used.
’10 FJ ’09 FJ
Item (1) (2) (3) (4) (5)
Cruiser Cruiser
Magnetic Resistance Element (MRE) type VVT
f f f
sensors are used.
Engine The Electronic Throttle Control System-intelligent
f f f f
Control (ETCS-i) is used.
System An Acoustic Control Induction System (ACIS) is
f f — f
used.
An evaporative emission control system is used. f f f
– NEW FEATURES 11
4. Engine Proper
Cylinder Head
D The cylinder head structure has been simplified by separating the camshaft housing (cam journal portion)
from the cylinder head.
D By fitting the fuel injector so that its nozzle end juts into the intake port, the intake port cross sectional
area has become smooth, enhancing the efficiency of air intake. Furthermore, the distance between the
injector nozzle end and intake valve has been shortened and as a result, the amount of fuel that adheres
to the intake port will be reduced, increasing the fuel economy as well as reducing the exhaust emissions.
Camshaft Housing
Fuel Injector
Cylinder Head
’10 FJ Cruiser ’09 FJ Cruiser
147EG06TE 238EG07
12 – NEW FEATURES
Cylinder Block
1) Liner
The shape of the cross-hatching of the liner surface has been optimized to improve oil retention
performance, resulting in reduced friction.
Liner
Cylinder Block
Enlarged View of
Cross-hatching
147EG07TE
Cylinder Block
Water Jacket Spacer
Water Jacket
A Cylinder Block
A Water Jacket
Spacer
Piston
D The piston shape has been optimized for high-compression ratio.
D In order to reduce weight, cast holes have been provided on the bottom of the piston head near the pin
bosses as shown in the illustration below.
D The outer surface of the No. 2 compression ring has been plated with chrome in order to be compatible
with gasoline/ethanol mixed fuel.
Weight Reduction
147EG09TE
’10 FJ Cruiser ’09 FJ Cruiser
Crankshaft
The 5 balance weight crankshaft is used for weight reduction, and the installation location of the balance
weight has been optimized to reduce vibration and noise.
Front
5 Balance Weights
’10 FJ Cruiser
Front
9 Balance Weights
’09 FJ Cruiser 147EG10TE
14 – NEW FEATURES
5. Valve Mechanism
General
D A Dual Variable Valve Timing-intelligent (Dual VVT-i) system, in which the VVT-i system has also been
added to the exhaust side, is used. As a result, the valve timing has been optimized, achieving lower fuel
consumption, higher engine performance and lower exhaust emissions.
D The ’10 FJ Cruiser 1GR-FE engine uses the roller rocker arms with built-in needle bearings. This reduces
the friction that occurs between the cams and the roller rocker arms that push the valves down, thus
improving fuel economy.
D Hydraulic lash adjusters, which maintain a constant zero valve clearance through the use of oil pressure
and spring force, are used.
VVT-i Controller
(Exhaust)
Valve Lifter
Hydraulic Lash
Adjuster
Camshaft
D A VVT-i controller has been added at the front end of the exhaust camshafts to vary the timing of the
exhaust valves.
D Oil passages are provided on the intake and exhaust camshafts in order to supply engine oil to the VVT-i
system.
D Together with the use of the roller rocker arms, the cam profile has been modified. This results in
increased valve lift when the valve begins to open and as it finishes closing, helping to achieve enhanced
output performance.
No. 1 Camshaft
VVT-i Controller (Intake)
(Exhaust)
Indented R Portion
of Cam (Profile)
Cam with Indented R
No. 3 Camshaft
(Intake)
No. 4 Camshaft
VVT-i Controller (Exhaust)
(Intake)
Timing Rotor for VVT
Sensor (Exhaust)
VVT-i Controller
147EG20TE
(Exhaust)
16 – NEW FEATURES
Cam
Plunger
Roller Rocker
Arm
Oil
Oil Passage Passage
Check Ball
Service Tip
Valve clearance adjustment is not necessary because hydraulic lash adjusters are used.
– NEW FEATURES 17
6. Lubrication System
General
D Oil passages for the camshaft timing oil control valve (exhaust) and the VVT-i controller (exhaust) have
been added with the use of the VVT-i system on the exhaust side.
D With the use of the hydraulic lash adjuster and the roller rocker arm, oil passages have been added and
an oil delivery pipe is used.
D An oil filter with a replaceable element is used.
Hydraulic
Lash
Adjuster
Oil
Pump
Oil Filter
VVT-i Controller
(Exhaust)
Oil Filter
’10 FJ Cruiser ’09 FJ Cruiser
147EG13TE
18 – NEW FEATURES
Oil
Camshaft Cylinder Camshaft Cylinder
Filter Timing Head Timing Head
Oil Cover Crankshaft Oil Cover
Relief Control Oil Journals Control Oil
Valve Valve Delivery Valve Delivery
(Intake) Pipe (Intake) Pipe
Camshaft Camshaft
Timing Timing
Oil Crankshaft Primary Oil
Control Pins Chain Control
Valve Tensioner Valve
(Exhaust) (Exhaust)
Oil Pan
147EG14S
" Specification A
Oil Filter
D The oil filter element uses a high-performance filter paper to improve filtration performance. It is also
combustible for environmental protection.
D A plastic oil filter cap assembly is used for weight reduction.
D This oil filter has a structure which can allow the draining of the oil remaining in the oil filter. This
prevents oil from spattering when replacing the oil filter element and allows the technician to work
without touching hot oil.
O-ring
Drain Pipe
Service Tip
D The oil in the oil filter can be drained by removing the oil filter drain plug and inserting the drain
pipe supplied with the oil filter element into the oil filter. For details, refer to the 2010 FJ
CRUISER Repair Manual (Pub. No. RM1470U).
D The engine oil maintenance interval for a model that has an oil filter with a replaceable oil filter
element is the same as that for a conventional model.
20 – NEW FEATURES
7. Cooling System
The cooling system of the ’10 FJ Cruiser is basically the same as in the ’09 FJ Cruiser.
Model
TOYOTA Genuine Super
Engine Coolant Type Long Life Coolant (SLLC) z
[liters or the equivalent*
(US qts, Imp. qts)] M/T 9.4 (9.9, 8.3) z
Capacity
A/T 9.8 (10.4, 8.6) z
*: Similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant
with long-life hybrid organic acid technology (Coolant with long-life hybrid organic acid technology is
a combination of low phosphates and organic acids).
– NEW FEATURES 21
General
D The shape and installation location of the air cleaner have been changed to improve the output power.
D The throttle valve diameter has been increased from 65 mm (2.6 in.) to 70 mm (2.8 in.) to improve the
output power.
D The shape of the intake air chamber has been optimized to reduce pressure loss.
D The Acoustic Control Induction System (ACIS) has been discontinued to make the intake system more
simple and light-weighted.
D The shapes of the exhaust manifolds have been changed to optimize the exhaust gas flow and reduce
pressure loss.
D The volume and cell density of the three-way catalytic converter which is located at the front exhaust
pipe have been optimized.
D The material of the tail exhaust pipe has been changed to improve the rust resistance.
Air Cleaner
Throttle Body
Tail Exhaust Pipe
Center Exhaust Pipe
Exhaust Manifold
147EG17TE
22 – NEW FEATURES
Air Cleaner
D The shape and installation location of the air cleaner have been changed to make the intake passage
shorter and straight, thus reducing pressure loss and improving the output power.
D The air cleaner element has been changed from the full-fabric type for the ’09 FJ Cruiser to a filter paper
type to reduce pressure loss.
Air Cleaner
Air Cleaner
Front Front
Intake Air Chamber Intake Air Chamber
9. Fuel System
D The fuel pressure has been increased from 284 kPa (2.9 kgf/cm2, 41 psi) to 324 kPa (3.3 kgf/cm2, 47 psi)
to be compatible with alcohol fuel.
D The pulsation damper and pressure regulator are surface-treated to be compatible with alcohol fuel,
resulting in improving the corrosion resistance.
Pressure Regulator
Fuel Tank
147EG21TE
24 – NEW FEATURES
Iridium Tip
Platinum Tip
147EG22S
" Specification A
Generator Pulley
Shaft One-way Clutch 147EG23TE
– NEW FEATURES 25
" Specification A
Length Length
147EG24TE
General
The ’10 and ’09 FJ Cruiser 1GR-FE engine control systems have the following differences:
’10 FJ ’09 FJ
System Outline
Cruiser Cruiser
SFI
An L-type SFI system detects the intake air volume with a
(Sequential Multiport f f
hot-wire type mass air flow meter.
Fuel Injection)
D This ECM determines the optimal ignition timing in
ESA accordance with the signals received from the sensors
(Electronic Spark and sends (IGT) ignition signal to the igniter. f f
Advance) D The ECM corrects ignition timing in response to engine
knocking.
ETCS-i
Optimally controls the opening angle of the throttle valve
(Electronic Throttle
in accordance with the accelerator pedal input and the f f
Control
engine and vehicle conditions.
System-intelligent)
Dual VVT-i
Controls the intake and exhaust camshafts to optimal valve
(Variable Valve f —
timing in accordance with the engine operating conditions.
Timing-intelligent)
Controls the intake camshaft to optimal valve timing in
VVT-i — f
accordance with the engine operating conditions.
ACIS The intake air passages are switched based on engine speed
(Acoustic Control and throttle valve opening angle to provide high — f
Induction System) performance in all engine speed ranges.
Based on signals from the ECM, the fuel pump control
f —
ECU controls the fuel pump to 3 stages.
The ECM controls fuel pump speed by switching the circuit
Fuel Pump Control — f
to the fuel pump resistor.
The fuel pump is stopped when the SRS airbag is deployed
f f
in a frontal, side, or rear side collision.
Air Fuel Ratio Sensor Maintains the temperature of the air fuel ratio sensors or
and Oxygen Sensor heated oxygen sensors at an appropriate level to increase the f f
Heater Control detection accuracy of the exhaust gas oxygen concentration.
D The ECM controls the purge flow of evaporative
emission (HC) in the canister in accordance with engine
conditions.
Evaporative
D Approximately 5 hours after the ignition switch has been
Emission f f
turned off, the ECM operates the pump module to detect
Control
any evaporative emission leakage occurring between the
fuel tank and the charcoal canister. The ECM can detect
leaks by monitoring for changes in the fuel tank pressure.
By turning the air conditioning compressor on or off in
Air Conditioning
accordance with the engine condition, driveability is f f
Cut-off Control
maintained.
When the ECM detects a malfunction, the ECM records the
Diagnosis f f
malfunction and memorizes information related to the fault.
When the ECM detects a malfunction, the ECM stops or
Fail-safe controls the engine according to the data already stored in f f
the memory.
– NEW FEATURES 27
Construction
The configuration of the engine control system is as shown in the following chart.
VG
MASS AIR FLOW METER SFI
THA #10
INTAKE AIR TEMP. SENSOR NO. 1 INJECTOR
#20
NO. 2 INJECTOR
#30
NO. 3 INJECTOR
CRANKSHAFT POSITION NE #40
NO. 4 INJECTOR
SENSOR #50
NO. 5 INJECTOR
#60
NO. 6 INJECTOR
ENGINE COOLANT THW
TEMP. SENSOR
ESA
IGT1 to
IGT6
VPA IGNITION COIL
ACCELERATOR PEDAL
WITH IGNITER
POSITION SENSOR VPA2 IGF1
SPARK PLUGS
VTA1
THROTTLE POSITION SENSOR
VTA2
ETCS-i
KNK1
KNOCK SENSORS M THROTTLE CONTROL
KNK2 MOTOR
VV1
VVT SENSORS (INTAKE) ECM
VV2 VVT-i (INTAKE)
L4
L4 POSITION SWITCH*1 VVT-i (EXHAUST)
(Continued)
147EG25S
28 – NEW FEATURES
Electronic Controlled
Transmission Solenoid Valve*
Fuel Pump
Control ECU
A/C Amplifier
Accelerator Pedal Position Sensor
DLC3
Battery Power Steering Oil Pressure Sensor
Electric Load Switch (Taillight Relay)
CAN
Stop Light Switch
Fuel Pump
ECM
Leak
Detection
Pump
Vent Purge VSV
Valve
Intake Air
Temp. Sensor Throttle Control Motor
Canister
Pressure Canister
Sensor
147EG27S
VVT Sensor
(Bank 2, Exhaust)
VVT Sensor Camshaft Timing
(Bank 1, Intake) Oil Control Valve
(Bank 2, Exhaust)
VVT Sensor
(Bank 2, Intake)
Injector
Crankshaft Position Sensor Knock Sensor 2
147EG29TE
– NEW FEATURES 31
1) General
The 1GR-FE engine control system has the following main components:
’10 FJ ’09 FJ
Components Outline Quantity Function
Cruiser Cruiser
The ECM optimally controls the
32-bit CPU SFI, ESA, and ISC to suit the
ECM (Supplier / 1 operating conditions of the engine f f
DENSO) in accordance with the signals
provided by the sensors.
This sensor has a built-in hot-wire
Mass Air Flow
Hot-wire Type 1 to directly detect the intake air f f
Meter
mass and flow rate.
Intake Air This sensor detects the intake air
Thermistor
Temperature 1 temperature by means of an f f
Type
Sensor internal thermistor.
Pick-up Coil This sensor detects the engine
Crankshaft
Type (Rotor 1 speed and performs the cylinder f f
Position Sensor
Teeth/36-2) identification.
2
VVT Sensors MRE Type This sensor performs the cylinder
(1 Each f f
(Intake) (Rotor Teeth/3) identification.
Bank)
2
VVT Sensors MRE Type This sensor performs the cylinder
(1 Each f —
(Exhaust) (Rotor Teeth/3) identification.
Bank)
This sensor detects the amount of
Accelerator Pedal No-contact
1 pedal effort applied to the f f
Position Sensor Type
accelerator pedal.
Throttle No-contact This sensor detects the throttle
1 f f
Position Sensor Type valve opening angle.
This sensor detects an occurrence
Built-in
2 of the engine knocking indirectly
Piezoelectric
Knock Sensors (1 Each from the vibration of the cylinder f f
Type
Bank) block caused by the occurrence of
(Flat Type)
engine knocking.
This sensor detects the oxygen
Heated Oxygen
2 concentration in the exhaust
Sensors Heated Type
(1 Each emission by measuring the f f
(Bank 1, Sensor 2) (Cup Type)
Bank) electromotive force which is
(Bank 2, Sensor 2)
generated in the sensor itself.
As with the oxygen sensor, this
Air Fuel sensor detects the oxygen
2
Ratio Sensors Heated Type concentration in the exhaust
(1 Each f f
(Bank 1, Sensor 1) (Planar Type) emission. However, it detects the
Bank)
(Bank 2, Sensor 1) oxygen concentration in the
exhaust emission linearly.
Engine Coolant This sensor detects the engine
Thermistor
Temperature 1 coolant temperature by means of f f
Type
Sensor an internal thermistor.
(Continued)
32 – NEW FEATURES
’10 FJ ’09 FJ
Components Outline Quantity Function
Cruiser Cruiser
Power Steering
Piezoresistance This sensor detects the oil
Oil Pressure 1 f —
Type pressure of the power steering.
Sensor
This fuel injector contains an
electro-magnetically operated
Injectors 12-hole Type 6 f f
nozzle to inject fuel into the intake
port.
The camshaft timing oil control
valve changes the valve timing by
Camshaft Timing Electro- 4
switching the oil passage that acts
Oil Control magnetic (2 Each f f
on the VVT-i controller in
Valves Coil Type Bank)
accordance with the signals
received from the ECM.
– NEW FEATURES 33
147EG30TE
Timing Rotor
Piezoresistance
Voltage
Ratio
Oil Pressure
Pressure (MPa)
1) General
D The Dual VVT-i system is designed to control the intake and exhaust camshafts within a range of 40_
and 35_ respectively (of Crankshaft Angle) to provide valve timing that is optimally suited to the
engine condition. This improves torque in all the speed ranges as well as increasing fuel economy, and
reducing exhaust emissions.
147EG32TE
ECM
Crankshaft Position Sensor
BDC 147EG34S
to Advance to Retard
Side (EX) Side (IN)
Eliminating overlap
Ensured engine
At Light Load EX IN to reduce blow back
stability
to the intake side.
147EG35S
to Advance to Retard
Side (IN) Side (EX) D Better fuel
Increasing overlap economy
increases internal
At Medium Load EX IN D Improved
EGR, reducing
emission
pumping loss.
control
147EG36S
3) Construction
a. VVT-i Controller
D The VVT-i controller consists of an outer housing that is driven by the timing chain sprocket, and
a vane sub-assembly that is coupled to each camshaft.
D The intake side uses a VVT-i controller with 3 vanes, and the exhaust side has used one with 4 vanes.
D When the engine stops, the VVT-i controller (intake) is locked at the most retarded angle by its lock
pin, and the VVT-i controller (exhaust) is locked at the most advanced angle. This ensures excellent
engine startability.
D The oil pressure sent from the advance or retard side passages of the intake and exhaust camshafts
causes rotation of the VVT-i controller vane sub-assembly relative to the timing chain sprocket, to
vary the valve timing continuously.
D An advance assist spring is provided on the VVT-i controller (exhaust). This helps to apply torque
in the advanced angle direction so that the vane lock pin securely engages with the housing when
the engine stops.
Outer Housing
Intake Camshaft
In Operation At a Stop
Lock Pin 147EG41TE
Lock Pin
Outer Housing
Exhaust Camshaft
Vane Sub-assembly
Advance Assist Spring 147EG42TE
– NEW FEATURES 37
Sleeve
*: The advance and retard sides of the intake side oil control valve are reverse of the exhaust side.
38 – NEW FEATURES
4) Operation
a. Advance
When the camshaft timing oil control valve is positioned as illustrated below by the advance signals
from the ECM, the resultant oil pressure is applied to the timing advance side vane chamber to rotate
the camshaft in the timing advance direction.
ECM
Oil Pressure
Rotation Direction IN Drain
147EG43TE
ECM
b. Retard
When the camshaft timing oil control valve is positioned as illustrated below by the retard signals from
the ECM, the resultant oil pressure is applied to the timing retard side vane chamber to rotate the
camshaft in the timing retard direction.
ECM
Oil Pressure
Vane Sub-assembly Drain IN
147EG45TE
Rotation Direction
Camshaft Timing Oil
Control Valve (Exhaust)
ECM
Oil Pressure
IN Drain
Vane Sub-assembly
147EG46TE
c. Hold
After reaching the target timing, the engine valve timing is maintained by keeping the camshaft timing
oil control valve in the neutral position unless the engine operating conditions change. This maintains
the engine valve timing at the desired target position by preventing the engine oil from running out of
the oil control valve.
40 – NEW FEATURES
Fuel Pump
Operation Request
FPC FPC
Fuel Pump
Duty Signal
Diagnosis Signal
DI DI
04E0EG24C
12.3 ms
8.2 ms
+B Middle
GND 04E0EG26C
4.1 ms
+B Low
GND
04E0EG27C
GND Stop
04E0EG28C
CH-1
CHARGING (1GR-FE) - CHARGING SYSTEM
ON-VEHICLE INSPECTION
CAUTION:
Check that the battery cables are connected to the
correct terminals.
Disconnect the battery cables when the battery is giv-
en a quick charge.
Do not perform tests with a high voltage insulation re-
sistance tester.
Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell (Maintenance-
Free Battery).
If under the lower level, replace the battery (or add distilled wa-
ter if possible) and check the charging system.
(b) Check the electrolyte quantity of each cell (Except Main-
tenance-Free Battery).
If under the lower level, add distilled water.
2. CHECK BATTERY SPECIFIC GRAVITY
(Except Maintenance-Free Battery)
(a) Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
HINT:
If the specific gravity is less than specification, charge the bat-
tery.
A01259
GENERATOR
CH0N6-01
COMPONENTS
V-Bank Cover
Battery Clamp
Battery Tray
Battery Tray
Engine Under Cover
x5
Drive Belt
43 (438, 32)
Generator Wire
Generator Connector
A/C Compressor
A/C Compressor
Connector
Generator
Bearing Cover
Generator
Drive End Frame Bearing
2.6 (27, 23 in.⋅lbf)
x4 Washer
Generator
Generator Pulley Rotor Bearing
Retainer Plate
x4
B17633
(d) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one-half turn.
(e) Remove the generator from SST (C).
Turn
B17634
SST (A) (f) Turn SST (B), and remove SST (A) and (B).
(g) Remove the pulley nut and pulley.
SST (B)
Hold
Turn
B17635
B17636
B17637
B17638
B17639
Hold
B17640
B17641
Ohmmeter
INSPECTION
1. INSPECT ROTOR
(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Continuity Standard resistance: 2.3 to 2.7 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.
B12264
B12265
B17642
2. INSPECT BRUSHES
Using vernier caliper, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Length Minimum exposed length: 4.5 mm (0.177 in.)
If the exposed length is less than the minimum, replace the
brushes and the brush holder assembly.
3. INSPECT BEARING
Check the bearing is not rough or worn.
B16374 If necessary, replace the bearing (See page CH-1 1).
INSTALLATION
1. INSTALL GENERATOR
(a) Install the generator with the 2 bolts.
Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf)
B17626
(b) Install the wire harness clamp bracket with the 2 bolts.
Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
B17625
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSY
(a) Place the drive end frame on the rotor.
(b) Install the rotor and washer.
B17641
B17651
B17637
B17636
B17633
(e) Tighten the pulley nut by turning SST (A) in the direction
shown in the illustration.
Torque: 111 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf)
(f) Remove the generator from SST (C).
Turn
B17657
SST (A)
(g) Turn SST (B), and remove SST (A), (B).
(h) Turn the pulley, and check that the pulley moves smooth-
ly.
SST (B)
Hold
Turn
B17635
REMOVAL
1. REMOVE V-BANK COVER
2. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
3. REMOVE FAN AND GENERATOR V BELT
(See page EM-62 )
4. REMOVE BATTERY
5. REMOVE GENERATOR
(a) Disconnect the wire harness.
(1) Remove the bolt and wire harness stay.
(2) Disconnect the connector from the generator.
(3) Remove the terminal cap and nut.
(4) Disconnect the wire harness from the terminal B.
B17624
(b) Remove the 2 bolts and wire harness clamp bracket from
the generator assy.
B17625
B17626
REPLACEMENT
1. INSPECT GENERATOR ROTOR BEARING
(a) Check the bearing is not rough or worn.
If necessary, replace the bearing.
B17643
B17644
Pulley B17645
B17646
B17647
B17648
SST
B17649
B17650
COOLANT
CO1D4-01
INSPECTION
HINT:
Check the coolant level when the engine is cold.
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines at normal temperature
(20°C(68°F)).
If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based
non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology
up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the coolant.
(c) Reinstall the radiator cap.
REPLACEMENT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot as fluid
and steam can be blown out under pressure.
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
COMPONENTS
5.0 (50, 44 in.·lbf)
Radiator Assembly
No.2 Fan Shroud
12 (120, 9)
21 (214, 15)
INSTALLATION
1. INSTALL NO.1 FAN SHROUD
Install the No.1 fan shroud with the 4 bolts.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)
RADIATOR CO1DD-01
ON-VEHICLE CLEANING
INSPECT FINS FOR BLOCKAGE
If fins are clogged, wash them with water or a steam cleaner and
dry with compressed air.
NOTICE:
If the distance between the steam cleaner and the
B14807
core is too close, there is a possibility of damaging
the fin, so keep the following injection distance.
Injection Pressure Injection Distance
2,942 to 4,903 kpa
300 mm (11.811 in)
(30 to 50 kg/cm2, 427 to711 psi)
ON-VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT RADIATOR RESERVOIR HOSE FROM
RADIATOR
4. DISCONNECT UPPER RADIATOR HOSE FROM RA-
DIATOR
5. DISCONNECT LOWER RADIATOR HOSE FROM RA-
DIATOR
6. DISCONNECT A/T OIL COOLER HOSES FROM RA-
DIATOR
7. REMOVE NO.2 FAN SHROUD
Remove the 2 clips and No.2 fan shroud.
B07219
INSPECTION
INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the thermostat.
A23110
(a) Immerse the thermostat in the water, then heat the water
gradually.
(b) Check the valve opening temperature of the thermostat.
Valve opening temperature:
80 to 84C (176 to 183F)
If the valve opening temperature is not as specified, replace the
thermostat.
A23111
Valve Lift
A23112
INSTALLATION
1. INSTALL WATER INLET W/THERMOSTAT
(a) Install a new gasket to the water inlet w/ thermostat.
(b) Install the water inlet w/ thermostat with the 3 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
2. CONNECT RADIATOR OUTLET, NO.2 HOSE CLAMP
OR CLIP
3. ADD ENGINE COOLANT (See page CO-2 )
A23122
4. CHECK FOR ENGINE COOLANT LEAKS
5. INSTALL V-BANK COVER
Install the V-bank cover with the 2 nuts.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)
THERMOSTAT CO1DA-01
REMOVAL
HINT:
If the thermostat was not installed, cooling efficiency would be
harmed. If the engine should tend to overheat, do not remove
the thermostat.
1. DRAIN ENGINE COOLANT (See page CO-2 )
2. REMOVE V-BANK COVER
3. DISCONNECT RADIATOR OUTLET, NO.2 HOSE
CLAMP OR CLIP
A23122
WATER PUMP
CO1D6-01
COMPONENTS
V-Bank Cover
Vacuum Hose
Battery Clamp
Battery
Battery Tray
x5
Radiator Assembly
No.1 Fan Shroud
12 (120, 9)
21 (214, 15)
O-ring
Water By-pass
Hose No.1
O-ring
Water Inlet
Gasket
Water Pump
Washer
54 (551, 40)
36 (367, 27)
A23109
INSTALLATION
1. INSTALL WATER PUMP
(a) Install a new gasket and the water pump with the 17 bolts.
Torque:
9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head
23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for 12 mm (0.47 in.) head
2. INSTALL V-RIBBED BELT TENSIONER ASSY
(See page EM-44 )
A22973
3. INSTALL COOLER COMPRESSOR
(See page EM-108 )
4. INSTALL GENERATOR (See page CH-15 )
5. INSTALL IDLER PULLEY
(a) Install the 2 idler pulleys with the 2 bolts.
Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf)
A23120
A23121
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE V-BANK COVER
A23116
A23117
A23118
A23119
A22878
A22973
CO/HC EM0KQ-10
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f) SFI system wiring connectors fully plugged
(g) Correct ignition timing
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
COMPRESSION EM06C-06
INSPECTION
HINT:
If there is a lack of power, excessive 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 SPARK PLUGS
(a) Remove the V-bank cover.
(b) Remove the air cleaner.
(c) Remove the intake air surge tank (See page EM-62 ).
(d) Remove the 6 ignition coils.
(e) Remove the 6 spark plugs.
(f) Disconnect the 6 injector connectors.
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain an engine speed
of 250 rpm or more.
A22796 (d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in the shortest possible
time.
Compression pressure:
1.3 MPa (13.3 kgf/cm2, 189 psi) or more
Minimum pressure: 1.0 MPa (10.2 kgf/cm2, 145 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm2, 15 psi) or less
(e) If the cylinder compression pressure in 1 or more cylin-
ders is low, pour a small amount of engine oil into the cylin-
der through the spark plug hole and repeat steps (a)
through (c) for cylinders with low compression pressure.
If adding oil improves the compression pressure, it
is likely that the piston rings and/or cylinder bore are
worn or damaged.
If compression pressure stays low, a valve may be
sticking, seating may be improper, or there may be
a leak past the gasket.
4. REINSTALL SPARK PLUGS
(a) Connect the 6 injector connectors.
(b) Install the 6 spark plugs.
Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)
(c) Install the 6 ignition coils.
(d) Install the intake air surge tank (See page EM-89 ).
(e) Install the air cleaner.
(f) Install the V-bank cover.
CYLINDER BLOCK
EM1XY-01
COMPONENTS
Knock Sensor
Connecting Rod 20 (204, 15)
Bearing
Connecting Rod
Cap 20 (204, 15)
Knock Sensor
Water Drain Cock
25 (255, 18) Knock Sensor Wire
Engine Rear Oil
Seal Retainer 10 (102, 7)
See page EM-128 Oil Seal
1st 25 (250, 18)
2nd Turn 90
x5
x2
Crankshaft
DISASSEMBLY
1. REMOVE WATER OUTLET PIPE NO.1
(a) Separate the knock sensor wire.
(b) Remove the 3 bolts and water outlet pipe.
A22979
A22980
A22981
A23022
(f) Check that the protrusion of the connecting rod cap is fac-
ing the correct direction.
(g) Apply a light coat of engine oil to the threads of the con-
necting rod cap bolts.
Protrusion
A23023
A23024
Painted Mark (i) Mark the front side of each connecting cap bolt with paint.
90 (j) Retighten the cap bolts 90 as shown in the illustration.
NOTICE:
Front 90 Do not turn the crankshaft.
(k) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
A23025
A23026
Number Mark (m) If replacing a bearing, replace it with one that has the
Number Mark
same number marked on the connecting rod. There are
4 sizes of standard bearings, marked ”1 ”, ”2”, ”3” and ”4”
accordingly.
HINT:
Standard bearing center wall thickness
Mark mm (in.)
”1” 1.484 to 1.487 (0.0584 to 0.0585)
A23027 ”2” 1.487 to 1.490 (0.0585 to 0.0587)
”3” 1.490 to 1.493 (0.0587 to 0.0588)
”4” 1.493 to 1.496 (0.0588 to 0.0589)
A23029
A23030
A23031
A23032
A23034
A23035
(c) Using a screwdriver, pry out the main bearing caps. Re-
move the 4 main bearing caps and lower bearings.
NOTICE:
Pull up the main bearing cap while turning it little by
little to the right and the left.
A23036
Cylinder
Block
A23037
A23038
INSPECTION
1. INSPECT CYLINDER BLOCK FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
flatness of the surface that is in contact with the cylinder head
gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than the maximum, replace the cylinder
block.
A23039
Thrust Direction
Front
Axial Direction
A 10 mm
A23040
3. INSPECT PISTON
Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 27.7 mm (1.091 in.) from the
piston head.
Piston diameter:
93.910 to 93.940 mm (3.6972 to 3.6984 in.)
27.7 mm
(1.091 in.)
A23041
Z00065
Front Mark
Connecting Rod
Bushing Inside
Diameter Mark
A23042
A23044
110 mm
A23045
A23046
A23046
A23047
A23048
A23049
(b) Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
A23051
(c) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 bottom bearings.
NOTICE:
Do not apply engine oil to the bearing or its contact surface.
HINT:
A number marked on each main bearing cap indicates the
Mark
installation position.
1, 2, 3, or 4
(d) Place the crankshaft on the cylinder block.
A23052
A23053
(f) Examine the front marks and numbers and install the
bearing caps on the cylinder block.
(g) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(h) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
A23054
(i) Install the main bearing caps. Tighten the 2 bolts for each
bearing cap until the clearance between the bearing cap
and the cylinder block becomes less than 6 mm (0.23 in.).
Less than 6 mm
A23055
A23056
(l) Install the 16 main bearing cap bolts. Using several steps,
uniformly tighten the bolts in the sequence as shown in
13 the illustration.
9 5 6
11 1 2 Torque: 61 N⋅m (622 kgf⋅cm, 45 ft⋅lbf)
3 4 14
10
15 7 8 12
16
A23057
Painted Mark
(m) Mark the front side of the bearing cap bolts with paint.
90 (n) Retighten the bearing cap bolts until 90 in the sequence
as shown in the illustration.
Front
90
(o) Check that the painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
A23058
(p) Install the 8 main bearing cap bolts. Using several steps,
4
1 uniformly tighten the bolts in the sequence as shown in
2 the illustration.
7
3 Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
6
5
(q) Remove the main bearing caps.
A23059
HINT:
No. 1 EXAMPLE
No. 2 Cylinder block ”11” (A) + Crankshaft ”06” (B)
No. 4 = Total number 17 (Use bearing ”3”)
Number No. 3
Mark Number MarkA23061
Standard bearing center wall thickness ”1” 2.488 to 2.491 (0.0980 to 0.0981)
”2” 2.491 to 2.494 (0.0981 to 0.0982)
”3” 2.494 to 2.497 (0.0982 to 0.0983)
”4” 2.497 to 2.500 (0.0982 to 0.0984)
”5” 2.500 to 2.503 (0.0984 to 0.0985)
REASSEMBLY
1. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A: 11 N⋅m (112 kgf⋅cm, 8.1 ft⋅lbf)
Stud bolt B: 4.5 N⋅m (46 kgf⋅cm, 40 in.⋅lbf)
Stud bolt C: 4.0 N⋅m (41 kgf⋅cm, 35 in.⋅lbf)
42 mm C
(1.65 in.)
A 23 mm
A (0.91 in.)
M6
Lower Side
56 mm
(2.20 in.)
B B
A23062
10 mm
(0.39 in.)
A 4 mm
(0.16 in.)
D
36 mm D
(1.42 in.)
Protrusion Height: 5.5 to 6.5 mm 12 mm
Protrusion Height: 22.5 to 23.5 mm
(0.886 to 0.925 in.) Rear Side (0.217 to 0.256 in.) (0.47 in.)
Rear Side
B
10 mm
(0.39 in.) 4 mm
(0.16 in.)
22 mm D
B (0.87 in.)
12 mm
Protrusion Height: 10.5 to 11.5 mm Protrusion Height: 5.5 to 6.5 mm (0.47 in.)
(0.217 to 0.256 in.)
(0.413 to 0.453 in.) Lower Side
D
Upper Side
8 mm 4 mm
(0.31 in.) (0.16 in.)
18 mm
C C (0.71 in.)
C C 12 mm
D (0.47 in.)
Protrusion Height: 5.5 to 6.5 mm
(0.217 to 0.256 in.)
Protrusion Height: 8.5 to 9.5 mm (0.335 to 0.374 in.) A23063
0.2 to 1.2 mm
(0.008 to 0.047 in.)
A23064
26.55
A23065
A23038
A23066
7. INSTALL PISTON
(a) Gradually heat the piston to about 80C (176F).
P12417
Front
Mark
A23067
A23066
A23068
No. 2 Lower side rail (c) Position the piston rings so that the ring ends are as
Compression shown in the illustration.
Front Mark
No. 1
Compression
Upper side rail A23069
A23070
(b) Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Do not apply engine oil to the bearing or its contact surface.
A23071
(c) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 lower bearings.
NOTICE:
Do not apply engine oil to the bearing or its contact surface.
HINT:
The number marked on each main bearing cap indicates the
Mark
1, 2, 3 or 4 installation position.
A23052
(b) Install the 2 upper thrust washers to the No. 2 journal posi-
tion of the cylinder block.
(1) Push the crankshaft toward the front (rear) side.
(2) Install the 2 upper thrust washers with the oil
grooves facing outward.
A23072
(c) Install the 2 lower thrust washers on the No. 2 bearing cap
with the grooves facing outward.
A23073
(d) Examine the front marks and numbers and install the
bearing caps on the cylinder block.
(e) Apply a light coat of engine oil to the threads of the bear-
ing cap bolts.
(f) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
A23054
(g) Install the main bearing caps. Tighten the 2 bolts for each
bearing cap until the clearance between the bearing cap
and the cylinder block becomes less than 6 mm (0.23 in.).
Less than 6 mm
A23055
A23056
(j) Install the 16 main bearing cap bolts. Using several steps,
uniformly tighten the bolts in the sequence shown in the
13 illustration.
9 5 6
Torque: 61 N⋅m (622 kgf⋅cm, 45 ft⋅lbf)
1 2 14
11
3 4
10
15 7 8 12
16
A23057
Painted Mark (k) Mark the front side of the bearing cap bolts with paint.
90 (l) Retighten the bearing cap bolts 90 in the sequence as
shown in the illustration.
Front (m) Check that the painted mark is now at a 90 angle to the
90
front.
(n) Check that the crankshaft turns smoothly.
A23058
A23059
(d) Check that the protrusion of the connecting rod cap is fac-
ing the correct direction.
(e) Apply a light coat of engine oil to the threads of the con-
necting rod cap bolts.
Protrusion
A23023
A23024
Painted Mark (g) Mark the front side of each connecting cap bolt with paint.
90 (h) Retighten the cap bolts 90 as shown.
(i) Check that the crankshaft turns smoothly.
Front 90 14. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing material (FIPG) and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.
A23025
A23018
(b) After tightening the drain cocks to the specified torque, ro-
tate them clockwise as shown in the illustration.
Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
NOTICE:
Do not rotate the drain cocks more than 1 complete
45 15
revolution (360) after tightening the drain cocks to
the specified torque.
Do not loosen the drain cocks after setting them cor-
45 45
A23019 rectly.
RH Bank Upper
Engine
Front 15
A23005
A22979
REPLACEMENT
1. REPLACE CONNECTING ROD SMALL END BUSH
SST
Using SST and a press, press out the bushing.
SST 09222-30010
EM6363
A23043
EM6363
(c) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance between the bushing and
piston pin.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
HINT:
Check that the piston pin fits at a normal room temperature.
Coat the piston pin with engine oil, and push it into the connect-
EM6535 ing rod with a thumb.
P20668
A22982
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223-78010
(3) Apply MP grease to the oil seal lip.
SST
A23003
(b) If the rear oil seal retainer is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
Cut Position NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
A23080
(3) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-78010
(4) Apply MP grease to a new oil seal lip.
SST
A23081
CYLINDER HEAD
EM1XO-01
COMPONENTS
V-Bank Cover
Vacuum Hose
Mass Air Flow
Meter Connector
Battery Clamp
Battery
Battery Tray
Radiator
Fan Shroud
Fan Pulley
21 (214, 15)
Drive Belt
VSV Connector
28 (286, 21)
Water By-pass Hose
x4 Intake Air Surge Tank
x2
VSV Connector
Fuel Vaper Feed Hose
21 (214, 15)
21 (214, 15)
Throttle Body Bracket
Ventilation Hose No.1
21 (214, 15)
Surge Tank Stay No.1
Gasket
Oil Baffle Plate
Vane Pump
43 (438, 32)
9.8 (100, 7)
Terminal Cap
Generator
43 (438, 32)
Generator Wire
Generator Connector
Cooler Compressor
8.0 (82, 71 in.·lbf)
43 (438, 32)
40 (408, 30)
21 (214, 15)
Gasket
x6
9.0 (92, 80 in.·lbf)
RH Exhaust Manifold 43 (440, 32)
RH Front Exhaust Pipe Gasket Water By-pass Joint
x2 Spring
62 (630, 46) Ventilation Hose
Gasket
Gasket
Ventilation Hose
Manifold Stay
40 (408, 30)
40 (408, 30)
40 (408, 30)
Gasket
21 (214, 15)
Gasket
x2
N·m (kgf·cm, ft·lbf) : Specified torque
62 (630, 46) LH Front Exhaust Pipe
Non-reusable part A23196
26 (265, 19)
Intake Manifold
x10 9.0 (92, 80 in.·lbf)
Oil Level Gauge
Gasket
10 (102, 7)
Gasket
9.0 (92, 80 in.·lbf)
36 (367, 27)
10 (102, 7)
x3
Cylinder Head
x7
Cover RH
9.0 (92, 80 in.·lbf)
9.0 (92, 80 in.·lbf)
Cylinder Head
Cover LH
VVT Sensor
Gasket
Filter
62 (632, 46)
x2
21 (214, 15) 10 (102, 7)
x2
Oil Pan
x9 x6 Gasket x4
21 (214, 15)
37 (377, 27)
Oil Strainer
21 (214, 15)
9.0 (92, 80 in.·lbf)
Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
Drain Plug
Non-reusable part 40 (408, 30) A23198
23 (235, 17)
Crankshaft Pulley
Oil Seal x15
250 (2,549, 184) Timing Chain Cover
19 (194, 14)
Camshaft Timing
Gear Assembly 100 (1,020, 74)
100 (1,020, 74) Camshaft Timing
100 (1,020, 74)
Sprocket
10 (102, 7)
Chain Vibration
Damper No.2
Timing Chain
Chain Tensioner
Slipper
Crankshaft Timing
Sprocket
N·m (kgf·cm, ft·lbf) : Specified torque Chain Vibration
19 (194, 14) Damper No.1
Non-reusable part A23195
24 (245, 18)
Camshaft
Camshaft Camshaft Bearing Cap No.1
Camshaft Bearing No.1
Camshaft Bearing
Camshaft Bearing Cap No.2 Cap No.2
Camshaft
Camshaft
Camshaft Bearing Cap No.1 See page EM-89
Cylinder Head LH
Cylinder Head RH
Valve Lifter
Intake Valve
Exhaust Valve
DISASSEMBLY
1. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifter in the correct order.
A22924
2. REMOVE VALVE
SST HINT:
Arrange the valves, inner compression springs, valve spring re-
tainers and valve spring retainer locks in the correct order.
(a) Place the cylinder head on a wooden block.
(b) Using SST, compress the inner compression spring and
remove the 2 valve spring retainer locks.
SST 09202-70020 (09202-00010)
Wooden Block
A22925 (c) Remove the valve, inner compression spring, valve
spring and valve spring retainer.
3. REMOVE VALVE SPRING SEAL
Using compressed air and a magnetic finger, remove the valve
spring seat by blowing air.
A22926
A22927
A22928
(b) Using a wire brush, remove all the carbon from the com-
bustion chambers.
NOTICE:
Be careful not to scratch the combustion chambers.
A22929
(c) Using a valve guide bushing brush and solvent, clean all
the valve guide bushes.
A22930
(d) Using a soft brush and solvent, thoroughly clean the cylin-
der head.
A22931
6. CLEAN VALVE
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.
EM0580
INSPECTION
1. INSPECT CYLINDER HEAD
(a) Inspect flatness.
Using a precision straight edge and feeler gauge, mea-
sure the flatness of the contact surfaces of the cylinder
block and manifolds.
Maximum warpage: 0.10 mm (0.0039 in.)
Cylinder Block Side:
If warpage is greater than the maximum, replace the cylinder
head.
A22932
A22933
A22967
4. INSPECT VALVE
(a) Inspect valve stem diameter.
Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Exhaust 5.465 to 5.480 mm (0.2152 to 0.2158 in.)
Z00052
44.5
Z00054
EM0181
EM0255
A22934
1.0 to 1.4 mm
A01476
1.0 to 1.4 mm
A23191
1.0 to 1.4 mm
A01477
(d) Handrub the valve and valve seat with an abrasive com-
pound.
(e) After handrubbing, clean the valve and valve seat.
A22935
EM0988
EM0801
P16860
A22984
(b) Align the knock pin hole in the camshaft timing gear as-
Knock Pin sembly with the knock pin of the camshaft, and install the
camshaft timing gear assembly with the bolt.
Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf)
(c) Confirm that the camshaft timing gear assembly is locked.
A22985
Open Close
Close Open
Rubber
Piece Masking Tape
A22986
A22987
NOTICE:
The camshaft timing assembly gear occasionally shifts to
the retard side abruptly if the air pressure of the advanced
side path is released first. This often results in breakage of
the lock pin.
(e) Check for smooth revolution.
Allow the camshaft timing gear assembly to turn back and
forth at any position, except where the lock pin meets at
the most retarded angle. Check the movable range and
that there is no disturbance.
Standard: Moves smoothly in a range of about 31
NOTICE:
Be sure to perform this check by hand, instead of air pres-
sure.
(f) Check the lock in the most retarded position.
Confirm that the camshaft timing gear assembly is locked
at the most retarded position.
(g) Remove the set bolt and camshaft timing gear assembly.
NOTICE:
Be sure not to remove the other 3 bolts.
Set Bolt
A22989
A22890
INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Remove any old packing material (FIPG) and be careful
not to drop any oil on the contact surfaces of the cylinder
head and cylinder block.
(b) Install the RH cylinder head gasket.
10 to 15 mm
Seal Packing A22891
A22892
10 to 15 mm
(4) Mark the front side of each cylinder head bolt with
180 paint.
(5) Retighten the cylinder head bolts by 180 as
shown.
Engine (6) Check that the painted marks are now at 180 op-
Front
posite to the engine front.
(c) Place the LH cylinder head on the cylinder head gasket.
Paint Mark (d) Install the 8 cylinder head bolts.
A22893 HINT:
The cylinder head bolts are tightened in 2 successive
steps (steps (3) and (5)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil to the threads of the
cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.
(4) Mark the front side of each cylinder head bolt with
180 paint.
(5) Retighten the cylinder head bolts by 180 as
shown.
Engine (6) Check that the painted marks are now at 180 op-
Front
posite to the engine front.
Paint Mark
A22893
A22911
RH Bank
(c) Install the camshaft of the RH bank.
(1) Place the 2 camshafts onto the RH cylinder head
with the cam lobes of No. 1 cylinder facing each
direction as shown in the illustration.
A22896
A22897
16 12 4 8
A22898
90
90
A22899
LH Bank
(d) Install the camshafts of the LH bank.
(1) Place the 2 camshafts onto the LH cylinder head
with the cam lobes of No. 2 cylinder facing as shown
in the illustration.
A22917
A22918
LH Bank
(4) Install the 16 bearing cap bolts. Using several
steps, tighten the bolts uniformly in the sequence as
6
2 10 14 shown in the illustration.
Torque:
5 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head
1 3 9 11 13 15
7 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head
6. INSTALL TIMING CHAIN (See page EM-44 )
4 12 16 7. INSTALL TIMING CHAIN COVER (See page EM-44 )
8
A22910 8. INSTALL OIL PAN (See page EM-44 )
Forward
A22906
A23251
Forward
A22922
A22904
(c) Install 2 new gaskets and water by-pass joint with the 2
bolts and 4 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(d) Connect the heater hose.
(e) Connect the engine coolant temperature sensor connec-
tor.
A22883
A22905
B (3) Install the cylinder head cover with the 10 bolts and
B B
B 2 nuts. Tighten the bolts and nuts uniformly in sever-
al steps.
Torque:
Bolt A, Nut: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
B Bolt B: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
A 17. INSTALL IGNITER
A A B
Nut B Nut A22970
A23091
A23090
A23089
A23088
A23087
A23086
Turn
Holes
A22798
A23114
A23210
A23209
A23095
A23407
REASSEMBLY
1. INSTALL RING PIN
Using a plastic-faced hammer, tap in the new ring pins until
they reach the specified protrusion height.
Specified protrusion height:
2.7 to 3.3 mm (0.106 to 0.130 in.)
11 mm
Protrusion
8 mm Height
Engine Engine
Front Front
A22946
Front Side:
B
Intake Manifold Side:
B
Intake Manifold Side:
8 mm
5 mm
Protrusion
34 mm Height 13.8 mm Protrusion
Height
C
B and C
A
A22947
Upper Side:
Rear Side:
Upper Side:
Rear Side:
C
A
33.3 mm 42 mm 27 mm
9 mm 13 mm 9 mm
B A B C
A22948
4. INSTALL UNION
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
(b) Using a deep socket wrench 12, install the unions.
Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf)
Adhesive
A22949
A B
67 mm
9 mm 9 mm
30 mm
A B A22950
A22951
SST
Depth
1.5 mm
A22952
A22953
SST
(b) Using SST, push in a new valve stem oil seal.
SST 09201-41020
A22955
A22956
9. INSTALL VALVE
(a) Apply engine oil to the valve as shown in the illustration.
35 mm
(1.378 in.)
A22957
(e) Using a pin punch 5, lightly tap the valve stem tip to en-
sure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
A22958
A22924
REMOVAL
1. PREVENT GASOLINE FROM SPILLING OUT
2. DRAIN ENGINE COOLANT (See page CO-2 )
3. DRAIN ENGINE OIL (See page LU-3 )
A23208
A23095
A23209
A23210
A23114
A23085
A23086
A23087
A23088
A23089
A23090
A23091
A22970
A23092
A22882
A22883
A22886
1 5 13 9
A22887
9 13 5 1
A22910
A22911
RH Cylinder Head (b) Using several steps, loosen the 8 cylinder head bolts on
3 5 7 2 each cylinder head with a 10 mm bi-hexagon wrench in
the sequence as shown in the illustration. Remove the 16
cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop the plate washers into the cylin-
der head.
1 8 6 4 Cylinder head warpage or cracking could result from
removing the bolts in the incorrect order.
LH Cylinder Head
1 8 6 4
3 5 7 2
A22977
(c) Lift the cylinder head from the dowels on the cylinder
block, and place the 2 cylinder heads on wooden blocks
on a bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
A22978 head and cylinder block with a screwdriver.
(d) Remove the RH and LH cylinder head gaskets.
32. REMOVE CYLINDER HEAD GASKET
REPLACEMENT
1. REPLACE VALVE GUIDE BUSH
(a) Gradually heat the cylinder head to between 80 and
100C (176 to 212F).
A22937
Wooden Block
A22938
A22937
A22940
(h) Using a sharp 5.5 mm reamer, ream the valve guide bush
to obtain the standard specified clearance between the
valve guide bush and valve stem.
Standard oil clearance:
Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
A22941
ENGINE UNIT
EM1XV-01
COMPONENTS
Hood
Battery
Battery Tray
Radiator Assembly
No.2 Fan Shroud
12 (120, 9)
71 (724, 52)
Propeller Shaft
37 (377, 27)
88 (897, 65)
40 (410, 30)
Bushing
Stabilizer Bar Bracket
Stabilizer Bar
Generator
43 (438, 32)
Generator Wire
43 (438, 32) Vane Pump
Generator Connector
A/C Compressor
A/C Compressor
Connector
N·m (kgf·cm, ft·lbf) : Specified torque
A23386
INSTALLATION
1. INSTALL DRIVE PLATE
HINT:
The mounting bolts are tightened in 2 progressive steps
(steps (c) and (e)).
If any of the mounting bolts is broken or deformed, re-
place it.
A04869
(b) Install the front spacer, drive plate and rear spacer on the
crankshaft.
1 (c) Install and uniformly tighten the 8 mounting bolts in sever-
5
8 al steps, in the sequence shown in the illustration.
3 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
4
If any of the mounting bolts do not meet the torque specification,
7 replace it.
6 2
A23391
3. INSTALL PS PUMP
Install the PS pump with the 3 bolts.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
A23390
(b) Install the engine wire bracket with the 2 nuts and bolt and
connect the engine wire to the bracket.
(c) Connect the 3 connectors to the ECM.
(d) Connect the 2 wire harness connectors (cassette con-
Connect nector).
(e) Install the ECM with the 3 screws.
(f) Install the heater to register duct.
(g) Install the lower No.2 finish panel.
A09152 (h) Install the glove compartment door.
REMOVAL
1. PREVENT GASOLINE FROM SPILLING OUT
(See page SF-1 )
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE V-BANK COVER
4. REMOVE ENGINE UNDER COVER
5. REMOVE AUTOMATIC TRANSMISSION
(See page AT-25 )
6. REMOVE MANUAL TRANSMISSION
(See page MT-4 )
7. REMOVE FRONT EXHAUST PIPES
(See page EM-139 )
8. REMOVE RADIATOR ASSEMBLY (See page CO-17 )
9. REMOVE BATTERY
(f) Disconnect the engine wire from the engine wire bracket
and remove the 2 nuts, bolt and bracket.
(g) Pull out the engine wire from the cowl panel.
13. DISCONNECT HOSES, WIRES, CONNECTORS,
CLAMPS, GROMMET AND CABLES
Disconnect
(a) Disconnect the generator connector.
(b) Disconnect the 2 heater hoses.
(c) Disconnect the ground strap from the cowl panel.
B07536 (d) Disconnect the fuel inlet hose and clamps.
(e) Disconnect the fuel return hose and clamp.
(f) Disconnect the air inlet hose from the charcoal canister.
(g) Disconnect the EVAP hose from the charcoal canister.
A23389
A23390
(c) Remove the 4 bolts and 4 nuts, and separate the engine
mounting brackets from the frame brackets.
(d) Lift the engine out of the vehicle carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(e) Place the engine onto a working bench.
A22966
A23391
ENGINE UNIT
EM1XV-01
COMPONENTS
Hood
Battery
Battery Tray
Radiator Assembly
No.2 Fan Shroud
12 (120, 9)
71 (724, 52)
Propeller Shaft
37 (377, 27)
88 (897, 65)
40 (410, 30)
Bushing
Stabilizer Bar Bracket
Stabilizer Bar
Generator
43 (438, 32)
Generator Wire
43 (438, 32) Vane Pump
Generator Connector
A/C Compressor
A/C Compressor
Connector
N·m (kgf·cm, ft·lbf) : Specified torque
A23386
INSTALLATION
1. INSTALL DRIVE PLATE
HINT:
The mounting bolts are tightened in 2 progressive steps
(steps (c) and (e)).
If any of the mounting bolts is broken or deformed, re-
place it.
A04869
(b) Install the front spacer, drive plate and rear spacer on the
crankshaft.
1 (c) Install and uniformly tighten the 8 mounting bolts in sever-
5
8 al steps, in the sequence shown in the illustration.
3 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
4
If any of the mounting bolts do not meet the torque specification,
7 replace it.
6 2
A23391
3. INSTALL PS PUMP
Install the PS pump with the 3 bolts.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
A23390
(b) Install the engine wire bracket with the 2 nuts and bolt and
connect the engine wire to the bracket.
(c) Connect the 3 connectors to the ECM.
(d) Connect the 2 wire harness connectors (cassette con-
Connect nector).
(e) Install the ECM with the 3 screws.
(f) Install the heater to register duct.
(g) Install the lower No.2 finish panel.
A09152 (h) Install the glove compartment door.
REMOVAL
1. PREVENT GASOLINE FROM SPILLING OUT
(See page SF-1 )
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE V-BANK COVER
4. REMOVE ENGINE UNDER COVER
5. REMOVE AUTOMATIC TRANSMISSION
(See page AT-25 )
6. REMOVE MANUAL TRANSMISSION
(See page MT-4 )
7. REMOVE FRONT EXHAUST PIPES
(See page EM-139 )
8. REMOVE RADIATOR ASSEMBLY (See page CO-17 )
9. REMOVE BATTERY
(f) Disconnect the engine wire from the engine wire bracket
and remove the 2 nuts, bolt and bracket.
(g) Pull out the engine wire from the cowl panel.
13. DISCONNECT HOSES, WIRES, CONNECTORS,
CLAMPS, GROMMET AND CABLES
Disconnect
(a) Disconnect the generator connector.
(b) Disconnect the 2 heater hoses.
(c) Disconnect the ground strap from the cowl panel.
B07536 (d) Disconnect the fuel inlet hose and clamps.
(e) Disconnect the fuel return hose and clamp.
(f) Disconnect the air inlet hose from the charcoal canister.
(g) Disconnect the EVAP hose from the charcoal canister.
A23389
A23390
(c) Remove the 4 bolts and 4 nuts, and separate the engine
mounting brackets from the frame brackets.
(d) Lift the engine out of the vehicle carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(e) Place the engine onto a working bench.
A22966
A23391
EXHAUST SYSTEM
EM1Y3-01
COMPONENTS
Exhaust Pipe Support
32 (326, 24)
Clamp
Gasket
Exhaust Center Pipe
48 (490, 35)
Gasket
Gasket Spring
Front Exhaust Pipe RH
Heated Oxygen
62 (630, 46) Sensor (Bank 2)
44 (450, 33)
62 (630, 46)
Gasket
62 (630, 46)
REPLACEMENT
1. REMOVE EXHAUST TAIL PIPE
(a) Remove the bolt and clamp.
(b) Remove the 3 exhaust pipe supports and exhaust tail
pipe.
A23249
A23247
A23246
A23075
A23248
A23250
INSPECTION
1. When using a hand-held tester or OBD II scan tool.
(a) Connect a hand-held tester to the Controller Area Net-
work Vehicle Interface Module (CAN VIM). Then connect
the CAN VIM to the Date Link Connector 3 (DLC3).
CAN VIM
(b) Please refer to the hand-held tester operator’s manual
DLC3
D13872
for further details.
(c) Switch the air conditioning OFF.
(d) Race the engine at 2,500 rpm for approx. 90 seconds.
(e) Check the idle speed.
Idle speed: 650 to 750 rpm
(Transmission in neutral position)
If the idle speed is not as specified, check the air intake system.
(f) Disconnect the hand-held tester or OBD II scan tool from
the DLC3.
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
A22794
SST
CG
DLC3 A14755
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
A22794
SST
CG
DLC3 A14755
TIMING CHAIN
EM1XJ-01
COMPONENTS
V-Bank Cover
Vacuum Hose
Mass Air Flow
Meter Connector
Battery Clamp
Battery
Battery Tray
Radiator
Fan Shroud
Fan Pulley
21 (214, 15)
Drive Belt
Vane Pump
43 (438, 32)
9.8 (100, 7)
Terminal Cap
Generator
43 (438, 32)
Generator Wire
Generator Connector
Cooler Compressor
8.0 (82, 71 in.·lbf)
43 (438, 32)
O-ring
Gasket
x5
9.0 (92, 80 in.·lbf) Water Inlet
39 (398, 29)
Washer
54 (551, 40)
36 (367, 27)
Gasket
28 (286, 21)
VSV Connector
Water By-pass Hose
x2
VSV Connector
Cylinder Head
Cover LH
23 (235, 17)
Crankshaft Pulley
Oil Seal x15
Timing Chain Cover
250 (2,549, 184)
19 (194, 14)
Camshaft Timing
Gear Assembly 100 (1,020, 74)
100 (1,020, 74) Camshaft Timing
100 (1,020, 74)
Sprocket
10 (102, 7)
Chain Vibration
Damper No.2
Timing Chain
Chain Tensioner
Slipper
Crankshaft Timing
Sprocket
N·m (kgf·cm, ft·lbf) : Specified torque Chain Vibration
19 (194, 14) Damper No.1
Non-reusable part A23195
INSPECTION
1. INSPECT NO.1 AND NO.2 TIMING CHAINS
Using a spring scale, pull the chain sub assembly with 147 N
(15.0 kgf, 33.1 lbf) of force and measure the length of the chain
sub assembly using a vernier caliper.
Measuring Area Maximum chain elongation: 146.8 mm (5.780 in.)
NOTICE:
Perform the same measurements by pulling at random in
0 1 2 3 4 5 15 A23207
3 or more places to obtain an average length.
If the elongation is greater than the maximum, replace the
chain.
(c) Put the No. 2 chain on the smaller gear of the camshaft
timing gear assembly.
(d) Using a vernier caliper, measure the timing gear with the
chain.
Minimum gear diameter (w/ chain):
73.1 mm (2.878 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
A22991 measuring.
If the diameter is less than the minimum, replace the No. 2 chain
and camshaft timing gear assembly.
A22995
A22997
A22998
A23000
No.2
A23001
INSTALLATION
90
1. SET CRANKSHAFT POSITION
Using the crankshaft pulley set bolt, turn the crankshaft, and set
the crankshaft set key into the left horizontal position.
NOTICE:
Set Key Having the crankshaft at the wrong angle can cause the
piston head and valve head to come into contact with each
Turn other when you install the camshaft, causing damage. So
A22895
always set the crankshaft at the correct angle.
Push
A22900
A22885
Timing Marks
A22901
Timing Marks (b) Align the timing marks on the camshaft timing gear as-
sembly and camshaft timing sprocket with the timing
marks on the bearing caps, and install the camshaft tim-
ing gears with the chain to the RH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.
NOTICE:
Do not push camshaft timing gear assembly to the cam-
shaft forcibly when installing it.
Timing Marks
A22902
A22903
A22921
A23007
Timing Marks
LH Bank
(b) Using the crankshaft pulley set bolt, turn the crankshaft
Timing Line to align the crankshaft set key with the timing line of the
cylinder block.
Set Key
A22869
Mark Link
(b) Align the mark links (orange) with the timing marks of the
Mark Links
camshaft timing gear assembly and camshaft timing
sprocket, and install the chain.
10. INSTALL CHAIN VIBRATION DAMPER NO.2
Install the 2 chain vibration damper No.2.
Timing Marks
A22871
A23009
Seal
Packing
A23010
3 to 4 mm
3 to 4 mm
16.7 mm
B - B
A23011
(e) Align the key way of the oil pump drive rotor with the rect-
15 angular portion of the crankshaft timing gear, and slide
the timing chain cover into place.
A23012
A A (f) Install the timing chain cover with the 24 bolts and 2 nuts.
A
Tighten the bolts and nuts uniformly in several steps.
B Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf)
A A A NOTICE:
A B A
B B
B Pay attention not to wrap the chain and slipper over
B
B the timing chain cover seal line.
B
AB Install the water pump within 15 minutes after instal-
BB B B B
B Nut
ling the timing chain cover.
Nut A23186 HINT:
Each bolt length is as follows:
A: 25 mm (0.98 in.)
B: 55 mm (2.17 in.)
A23120
A23121
13 16.5
22.5 27.5
8 9
Stud Bolt A Stud Bolt B [mm]
A23013
A22873
A A B B (e) Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
A Torque:
A B Bolt A, B, Nut: 21 N⋅m (214 kgf⋅cm, 15 ft·lbf)
A A C
Bolt C: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
B C
HINT:
B Each bolt length is as follows:
A: 25 mm (0.98 in.)
Nut B B Nut B B A22863 B: 45 mm (1.77 in.)
C: 14 mm (0.55 in.)
(f) Install the 4 housing bolts.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)
(g) Install the flywheel housing under cover.
Flywheel Housing
Under Cover
A22862
A22861
(c) Install the oil pan No. 2 with the 15 bolts and 2 nuts. Tight-
en the bolts and nuts uniformly in several steps.
Torque:
Bolt: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
Nut: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
A22859
A22876
”DOUBLE”
A22877
A22878
REMOVAL
1. DRAIN ENGINE COOLANT (See page CO-2 )
2. DRAIN ENGINE OIL
3. REMOVE BATTERY
4. REMOVE V-BANK COVER
5. REMOVE RADIATOR (See page CO-17 )
6. LOOSEN FAN W/FLUID COUPLING
(See page EM-62 )
7. REMOVE DRIVE BELT (See page EM-62 )
8. REMOVE FAN W/FLUID COUPLING
9. REMOVE AIR CLEANER (See page EM-62 )
10. REMOVE INTAKE AIR SURGE TANK
(See page EM-62 )
11. REMOVE CYLINDER HEAD COVER
(See page EM-62 )
12. REMOVE VVT SENSOR
13. REMOVE OIL LEVEL GAUGE GUIDE
(a) Remove the oil level gauge.
(b) Remove the bolt and pull out the oil level gauge guide.
(c) Remove the O-ring from the oil level gauge guide.
A22856
SST
A22857
(b) Using the pulley set bolt and SST, remove the crankshaft
pulley.
SST
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05031)
A22858
A22859
(b) Insert the blade of SST between the oil pan and oil pan
No. 2, cut off applied sealer and remove the oil pan No.
2.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of the oil
pan and oil pan No. 2.
Be careful not to damage the oil pan No. 2 flange.
SST
A22860
A22861
A22862
A22863
RH Side
A22864
A23116
A23117
A23118
A23119
A23186
(b) Remove the timing chain cover by prying between the tim-
ing chain cover and cylinder head or cylinder block with
a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder block and cylinder head.
(c) Remove the O-ring from the LH cylinder head.
A23187
Set Key
A22865
RH Bank Timing Marks (b) Check that the timing marks of the camshaft timing gear
assembly and camshaft timing sprocket are aligned with
the timing marks of the bearing caps as shown in the il-
lustration.
If not, turn the crankshaft 1 complete revolution (360 ) and
align the timing marks as above.
26. REMOVE CHAIN TENSIONER NO.1
NOTICE:
Never rotate the crankshaft with the chain tensioner
Timing Marks removed.
LH Bank
When rotating the camshaft with the timing chain re-
moved, rotate the crankshaft counterclockwise 40
from the TDC first.
A22867
Raise
A22884
A22885
REPLACEMENT
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
REPLACE TIMING CHAIN COVER OIL SEAL
(a) If the rear timing chain cover is removed:
Pry (1) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the oil pump. Wrap the tip of the
A22976
screwdriver with tape.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09226-10010
(3) Apply MP grease to the oil seal lip.
SST
A23008
A23076
(2) Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing chain cover edge.
SST 09226-10010
(3) Apply MP grease to a new oil seal lip.
SST
A23077
INSPECTION
1. DRAIN ENGINE COOLANT (See page CO-2 )
2. REMOVE V-BANK COVER
3. REMOVE AIR CLEANER (See page EM-62 )
4. REMOVE INTAKE AIR SURGE TANK
(See page EM-62 )
5. REMOVE IGNITION COIL
6. REMOVE CYLINDER HEAD COVER
(See page EM-62 )
A22800
RH Bank Timing Marks (b) Check that the timing marks of the camshaft timing gears
are aligned with the timing marks of the bearing caps as
shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360 ) and
align the timing marks as above.
Timing Marks
LH Bank
IN
EX
2 2
A22802
IN
EX
4 4
A22803
IN
EX
6 6
A22804
A22800
RH Bank Timing Marks (2) Check that the timing marks of the camshaft timing
gears are aligned with the timing marks of the bear-
ing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360 ) and
align the timing marks as above.
Timing Marks
LH Bank
A22806
Raise
A22808
A22810
2 4 8 6
1 3 7 5
A22811
Slide
A22814
A22815
2 4 8 6
A22816
A22817
(7) Tie the No. 1 chain with a string as shown in the il-
lustration.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(f) Remove the No. 4 camshaft.
NOTICE:
As the thrust clearance of the camshaft is small, the cam-
A22818 shaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
which receives the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
A22819
5 7 3 1
A22821
8 4 2
6
A22823
(3) Hold the No. 1 chain, and remove the No. 3 cam-
shaft, camshaft timing gear assembly and No. 2
chain.
A22824
(4) Tie the No. 1 chain with a string as shown in the il-
lustration.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(i) Remove the valve lifters.
A22825
Removed lifter
thickness
mm (in.)
Measured
clearance mm (in.)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter is installed, and the
measured clearance is 0.400 mm (0.0158 in.).
Replace the 5.250 mm (0.2067 in.) shim with a new
No. 46 lifter.
EM-13
3221
A22826
EM-14
Valve Lifter Selection Chart (Exhaust)
Removed lifter
thickness
mm (in.)
Measured
clearance mm (in.)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter is installed, and the
measured clearance is 0.480 mm (0.0189 in.).
Replace the 5.340 mm (0.2102 in.) shim with a new
No. 48 lifter.
A22827
3222
EM-15
ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE
Mark Links (1) Align the mark link (yellow) with the timing mark
(2-dot mark) of the camshaft timing gear assembly
as shown in the illustration.
(2) Apply new engine oil to the thrust portions and jour-
nals of the camshafts.
Timing Marks
A22828
A22829
A22830
A22831
A22832
(8) Set the paint mark of the No. 1 chain between the
Paint Mark timing marks of the camshaft timing gear assembly.
Timing Marks
A22833
Push
A22834
A22836
A22837
4 2 6 8
A22821
Mark Links (1) Align the mark link (yellow) with the timing mark
(1-dot mark) of the camshaft timing gear assembly
as shown in the illustration.
(2) Apply new engine oil to the thrust portions and jour-
nals of the camshafts.
Timing Mark
A22838
A22839
(4) Align the knock pin hole on the camshaft timing gear
Knock Pin
assembly with the knock pin of the No. 1 camshaft,
and insert the No. 1 camshaft into the camshaft tim-
ing gear assembly.
(5) Temporarily install the camshaft timing gear assem-
bly set bolt.
A22840
A22841
A22842
A22816
A22843
(11) Align the paint mark of the No. 1 chain with the tim-
Paint Mark
ing mark of the camshaft timing gear assembly.
Timing Mark
A22844
A22813
Push
A22900
Mark Links (2) Temporarily install the camshaft timing gear and
chain tensioner No. 2 and align the mark links (yel-
low) with the timing marks (1-dot mark) of the cam-
shaft timing gear assembly and camshaft timing
sprocket.
(3) Tighten the chain tensioner No. 2 bolt.
Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)
(p) Install the No. 2 camshaft.
Timing Marks A22846 NOTICE:
As the thrust clearance of the camshaft is small, the cam-
shaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
which receives the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
A22847
A22848
8 6 2 4
A22811
Knock Pin
A22849
A22809
A22800
RH Bank Timing Marks (7) Check that the timing marks of the camshaft timing
gear assembly and camshaft timing sprocket are
aligned with the timing marks of the bearing caps as
shown in the illustration.
10. INSTALL CYLINDER HEAD COVER (See page
EM-89 )
11. INSTALL IGNITION COIL
12. INSTALL INTAKE AIR SURGE TANK
(See page EM-89 )
Timing Marks 13. INSTALL AIR CLEANER (See page EM-89 )
LH Bank
14. ADD ENGINE COOLANT (See page CO-2 )
15. INSTALL V-BANK COVER
16. INSPECT IGNITION TIMING (See page EM-23 )