Toyota Camry

 XV30 (2002–2006) Service Manual

Engine mechanical
Partial engine assy (2AZ−FE)(From July, 2003)

REPLACEMENT

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

2.  REMOVE FRONT WHEELS

3. REMOVE ENGINE UNDER COVER LH

4. REMOVE ENGINE UNDER COVER RH

5. REMOVE FRONT FENDER APRON SEAL RH

6. DRAIN ENGINE OIL

7. DRAIN ENGINE COOLANT

8. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T)

1. Using a 10 mm hexagon wrench, remove the drain plug and gasket. Drain automatic transaxle fluid.

2.  Install a new gasket and the drain plug.

   Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

9. DRAIN MANUAL TRANSAXLE OIL (M/T)

a. Install a new gasket and the drain plug after draining transaxle oil.

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

10. REMOVE BATTERY

11. REMOVE AIR CLEANER ASSY

12. REMOVE ENGINE COVER SUB−ASSY No.1

13. DISCONNECT RADIATOR HOSE INLET

14. DISCONNECT RADIATOR HOSE OUTLET

15. DISCONNECT OIL COOLER OUTLET HOSE No.2 (A/T)

16. DISCONNECT OIL COOLER OUTLET HOSE No.3 (A/T)

17. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET

a. Remove the 3 bolts and the engine moving control rod w/ bracket.

18. REMOVE ENGINE MOUNTING STAY No.2 RH

19. REMOVE ENGINE MOUNTING BRACKET No.2 RH

20. REMOVE FAN AND GENERATOR V BELT

21. DISCONNECT OIL RESERVOIR TO PUMP HOSE No.1

22. DISCONNECT RETURN TUBE SUB−ASSY

23. DISCONNECT UNION TO CONNECTOR TUBE HOSE

24. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T)

25. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T)

26. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T)

27. REMOVE CLUTCH RELEASE CYLINDER ASSY (M/T)

1. Remove the bolt and flexible hose.

2. Remove the 2 bolts and clutch release cylinder.

28. DISCONNECT HEATER INLET WATER HOSE

29. DISCONNECT HEATER OUTLET WATER HOSE

30. DISCONNECT FUEL TUBE SUB−ASSY

31. DISCONNECT ENGINE WIRE

1. Disconnect the engine wire from the ECM and J/B.

2. Disconnect the engine wire from the engine room J/B.

1. Remove the nut fixing the wire harness.

2. Using a screwdriver, unlock the engine room J/B.

Disconnect the engine wire by pulling it upward.

3. Disconnect the connectors.

c. Pull out the engine wire.

4.  Disconnect the B terminal of the generator.

5. Remove the body ground.

6. Remove the starter connector.

32. DISCONNECT ENGINE WIRE No.2

a. Remove the nut and disconnect terminal 30 of the starter.

 Disconnect engine wire No.2

33. REMOVE GENERATOR ASSY

34. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

HINT: Hang up the hoses instead of detaching.

35. REMOVE EXHAUST PIPE ASSY FRONT

36. REMOVE FRONT STABILIZER LINK ASSY LH

1. Using a 6 mm socket hexagon wrench, fix the stud bolt.

2. Remove the nut and disconnect the stabilizer link.

37. REMOVE FRONT STABILIZER LINK ASSY RH

HINT: Use the same procedures described for the LH side.

38. REMOVE FRONT AXLE HUB LH NUT

a. Using SST and a hammer, strike the lock nut covering to remove it.

SST 09930−00010

NOTICE:

• Set the drive shaft’s groove so that it faces up. Then use the SST and hammer.

• Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged.

• Do not sharpen the tip of the SST.

b. Using a 30 mm socket wrench, remove the lock nut.

 Remove front axle hub LH nut

39. REMOVE FRONT AXLE HUB RH NUT

HINT: Use the same procedures described for the LH side.

40. REMOVE SPEED FRONT LH (W/ ABS)

a. Remove the bolt and disconnect the speed from the steering knuckle.

NOTICE: Keep the speed tip and connection free from foreign matter.

41. REMOVE SPEED FRONT RH (W/ ABS)

HINT: Use the same procedures described for the LH side.

42. DISCONNECT TIE ROD ASSY LH

1. Remove the cotter pin and castle nut.

2. Using SST, disconnect the tie rod end from the steering knuckle.

   SST 09628−62011

NOTICE: Be careful not to damage the cover of the ball joint.

Remove speed front RH (W/ abs)

43. DISCONNECT TIE ROD ASSY RH

HINT: Use the same procedures described for the LH side.

44. DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER No.1 LH

1. Remove the bolt and 2 nuts, as shown in the illustration.

2. Using a plastic hammer, disconnect the drive shaft from the axle hub.

 Disconnect front suspension arm sub-assy lower No.1 LH

45. DISCONNECT FRONT SUSPENSION ARM SUB−ASSY LOWER No.1 RH

HINT: Use the same procedures described for the LH side.

46. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT

a. Fix the crankshaft and remove the 6 setting bolts.

47. REMOVE STEERING INTERMEDIATE SHAFT ASSY

a. Loosen the sliding yoke bolt.

2. Place matchmarks on the intermediate shaft and control valve shaft.

3. Remove the bolt and the steering intermediate shaft.

d. To prevent the steering wheel from rotating, fix the wheel with the seat belt.

NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged.

48. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

1. Set the engine lifter.

2.  Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.

3. Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.

4. Carefully remove the engine assembly from the vehicle.

e. Install the 2 engine hangers as shown in the illustration.

Parts No.:

Torque: 38 N·m (387 kgf·cm, 28 ft lbf)

f. Using a chain block and an engine sling device, hang the engine assembly.

49. REMOVE VANE PUMP ASSY

1. Disconnect the PS oil pressure switch connector.

2. Remove the 2 bolts and vane pump from the engine.

 Remove vane pump assy

50. REMOVE FRONT FRAME ASSY

a. A/T: Remove the nut installing the engine mounting insulator LH.

b. M/T: Remove the bolt installing the engine mounting insulator LH.

c. Remove the nut installing the engine mounting insulator RH.

d. Remove the bolt installing the engine mounting insulator FR.

e. M/T: Remove the bolt installing the engine lateral control rod.

f. Raise the engine assembly and separate the front frame.

51. REMOVE FRONT DRIVE SHAFT ASSY LH

52. REMOVE FRONT DRIVE SHAFT ASSY RH

53. REMOVE STARTER ASSY

54. SEPARATE AUTOMATIC TRANSAXLE ASSY (A/T)

55. SEPARATE MANUAL TRANSAXLE ASSY (M/T)

56. REMOVE DRIVE PLATE & RING GEAR SUB−ASSY

    (A/T)

a. TMC made: Using SST, fix the crankshaft.

SST 09213−54015 (91651−60855), 09330−00021

b. TMMK made: Using SST, fix the crankshaft.

SST 09960−10010 (09962−01000, 09963−01000)

c. Remove the 8 bolts, rear spacer, drive plate and front spacer.

57. REMOVE CLUTCH COVER ASSY (M/T)

58. REMOVE CLUTCH DISC ASSY (M/T)

59. REMOVE FLYWHEEL SUB−ASSY (M/T)

a. Using SST, fix the crankshaft.

SST 09213−54015 (91651−60855), 09330−00021

b. Remove the 8 bolts, rear spacer and flywheel.

60. INSTALL ENGINE STAND

61. REMOVE INTAKE MANIFOLD

a. Remove the 5 bolts, 2 nuts, intake manifold and gasket.

62. INSPECT INTAKE MANIFOLD

a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

Maximum warpage: 0.20 mm (0.0079 in.)

If the warpage is greater than maximum, replace the manifold.

 Inspect intake manifold

63. REMOVE INTAKE MANIFOLD RUNNER VALVE ASSY (PZEV only)

64. REMOVE VENTILATION HOSE

65. REMOVE VENTILATION HOSE No.2

66. REMOVE ENGINE WIRE

67. REMOVE INTAKE MANIFOLD INSULATOR No.1

68. REMOVE OIL LEVEL GAGE SUB−ASSY

69. REMOVE OIL LEVEL GAGE GUIDE

70. REMOVE MANIFOLD CONVERTER INSULATOR No.1

71. REMOVE EXHAUST MANIFOLD CONVERTER SUB−ASSY

a. Remove the 3 bolts, 2 nuts, and the No. 1 and No. 2 exhaust manifold stays.

b. Remove the 5 nuts, exhaust manifold converter and gasket.

72. INSPECT CONVERTER SUB−ASSY, EXHAUST MANIFOLD

a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

Maximum warpage: 0.70 mm (0.0276 in.)

If the warpage is greater than the maximum, replace the manifold.

 Inspect converter sub-assy, exhaust manifold

73. REMOVE WATER INLET

74. REMOVE THERMOSTAT

75. REMOVE IGNITION COIL ASSY

76. REMOVE V−RIBBED BELT TENSIONER ASSY

a. Remove the bolt, nut and belt tensioner.

Remove V-ribbed belt tensioner assy

77. REMOVE DRIVE SHAFT BEARING BRACKET

78. REMOVE ENGINE MOUNTING BRACKET RH

79. REMOVE FUEL DELIVERY PIPE W/INJECTOR

80. REMOVE WATER BY−PASS PIPE No.1

81. REMOVE ENGINE OIL PRESSURE SWITCH ASSY

a. Remove the oil pressure switch.

 Remove engine oil pressure switch assy

82. REMOVE KNOCK

1. Disconnect the connector.

2.  Remove the nut and .

83. REMOVE ENGINE COOLANT TEMPERATURE

84. REPLACE PARTIAL ENGINE ASSY

85. INSTALL ENGINE COOLANT TEMPERATURE

1. Install a new gasket to the .

2. Install the .

   Torque: 20 N·m (204 kgf·cm, 15 ft·lbf)

86. INSTALL KNOCK

a. Install the with the nut, as shown in the illustration.

Torque: 20 N·m (204 kgf·cm, 15 ft·lbf)

Install knock

87. INSTALL ENGINE OIL PRESSURE SWITCH ASSY

1. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil.

   Adhesive: Part No. 08833−00080 THREE BOND 1344 or equivalent

2. Install the oil pressure switch.

   Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)

88. INSTALL WATER BY−PASS PIPE No.1

a. Install a new gasket and the by−pass pipe with the bolt and 2 nuts.

Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)

89. INSTALL FUEL DELIVERY PIPE W/INJECTOR

90. INSTALL ENGINE MOUNTING BRACKET RH Torque: 54 N·m (551 kgf·cm, 40 ft·lbf)

91. INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N·m (653 kgf·cm, 47 ft·lbf)

92. INSTALL V−RIBBED BELT TENSIONER ASSY

a. Install the belt tensioner with the bolt and the nut.

Torque: 59.5 N·m (607 kgf·cm, 44 ft·lbf)

Install v-ribbed belt tensioner assy

93.  INSTALL IGNITION COIL ASSY Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)

94. INSTALL THERMOSTAT

95. INSTALL WATER INLET Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)

96. INSTALL EXHAUST MANIFOLD CONVERTER SUB−ASSY

a. Install a new gasket and the exhaust manifold converter.

Uniformly tighten the 5 nuts in the sequence shown in the illustration.

Torque: 37 N·m (378 kgf·cm, 27 ft·lbf)

b. Install the No. 1 and No. 2 exhaust manifold stays with the 3 bolts and 2 nuts.

Torque: 44 N·m (449 kgf·cm, 32 ft·lbf)

97. INSTALL MANIFOLD CONVERTER INSULATOR No.1 Torque: 12 N·m (122 kgf·cm, 9 ft·lbf)

98. INSTALL OIL LEVEL GAGE GUIDE

1. Apply a light coat of engine oil to the O−ring and install it to the guide.

2. Install the oil level gage and guide with the bolt.

   Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)

99. INSTALL INTAKE MANIFOLD RUNNER VALVE ASSY (PZEV only)

100. INSTALL INTAKE MANIFOLD

a. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.

Torque: 30 N·m (306 kgf·cm, 22 ft·lbf)

101. INSTALL DRIVE PLATE & RING GEAR SUB−ASSY (A/T)

a. TMC made: Using SST, fix the crankshaft.

SST 09213−54015 (91651−60855), 09330−00021

b. TMMK made: Using SST, fix the crankshaft.

SST 09960−10010 (09962−01000, 09963−01000)

3. Clean the bolt and the bolt hole.

4. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833−00070, THREE BOND or equivalent.

5. Install the front spacer, drive plate and rear spacer with 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration.

   Torque: 98 N·m (1,000 kgf·cm, 72 ft·lbf)

102. INSTALL FLYWHEEL SUB−ASSY

a. Using SST, fix the crankshaft.

SST 09213−54015 (91651−60855), 09330−00021

1. Clean the bolt and the bolt hole.

2. Apply adhesive to 2 or 3 threads of the bolt end.

   Adhesive: Part No. 08833−00070, THREE BOND or equivalent.

3. Install the flywheel. Uniformly tighten the 8 bolts in the sequence shown in the illustration.

   Torque: 130 N·m (1,330 kgf·cm, 96 ft·lbf)

103. INSTALL CLUTCH DISC ASSY (M/T)

104. INSTALL CLUTCH COVER ASSY (M/T)

105. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T)

106. INSTALL MANUAL TRANSAXLE ASSY (M/T)

107. INSTALL STARTER ASSY Torque: 39 N·m (398 kgf·cm, 29 ft·lbf)

108. INSTALL FRONT DRIVE SHAFT ASSY RH

109. INSTALL FRONT DRIVE SHAFT ASSY LH

110. INSTALL FRONT FRAME ASSY

a. A/T: Install the engine mounting insulator LH with the nut.

Torque: 95 N·m (969 kgf·cm, 70 ft·lbf)

b. M/T: Install the engine mounting insulator LH with the bolt.

Torque: 143 N·m (1,459 kgf·cm, 105 ft·lbf)

c. Install the engine mounting insulator RH with the nut.

Torque: 95 N·m (969 kgf·cm, 70 ft·lbf)

d. Install the engine mounting insulator FR with the bolt.

Torque: 87 N·m (888 kgf·cm, 64 ft·lbf)

e. M/T: Install the engine lateral control rod with the bolt.

Torque: 89 N·m (910 kgf·cm, 66 ft·lbf)

111. INSTALL VANE PUMP ASSY

1. Install the vane pump to the engine with the 2 bolts.

2. Connect the PS oil pressure switch connector.

   Torque: 43 N·m (439 kgf·cm, 32 ft·lbf)

 Install vane pump assy

112. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

1. Set the engine assembly with transaxle on the engine lifter.

2. Install the engine assembly to the vehicle.

3. Install the frame side plate LH and RH with the 4 bolts and 2 nuts.

   Torque:
   85 N·m (867 kgf·cm, 63 ft·lbf) for bolt A 32 N·m (326 kgf·cm, 24 ft·lbf) for bolt B and nut

d. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

Torque:
85 N·m (867 kgf·cm, 63 ft·lbf) for bolt C 32 N·m (326 kgf·cm, 24 ft·lbf) for bolt D and nut

113. INSTALL STEERING INTERMEDIATE SHAFT ASSY

a. Align the matchmarks on the intermediate shaft and control valve shaft.

Torque: 35 N·m (357 kgf·cm, 26 ft·lbf)

b. Tighten the bolt.

Torque: 35 N·m (357 kgf·cm, 26 ft·lbf)

114. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (A/T)

a. Fix the crankshaft, and install the 6 setting bolts.

Torque: 41 N·m (418 kgf·cm, 30 ft·lbf)

Install drive plate & torque converter clutch setting bolt (A/T)

115. INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER No.1 LH

1. Install the drive shaft to the steering knuckle.

2.  Install the suspension lower arm with the bolt and the 2 nuts. Torque: 75 N·m (765 kgf·cm, 55 ft·lbf)

 
Install front suspension arm sub-assy lower No.1 LH

116. INSTALL FRONT SUSPENSION ARM SUB−ASSY LOWER No.1 RH

HINT: Use the same procedures described for the LH side.

117. INSTALL TIE ROD ASSY LH

a. Connect the tie rod end to the steering knuckle and install a new castle nut.

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

NOTICE:

• Prevent any lubricant from contacting the thread and the taper portions.

• fter tightening the castle nut, tighten it to the additional direction within 60 to put into a cotter pin.

b. Insert a new cotter pin.

118. INSTALL TIE ROD ASSY RH

HINT: Use the same procedures described for the LH side.

119. INSTALL SPEED FRONT LH (W/ABS) Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

120. INSTALL SPEED FRONT RH (W/ABS) Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

121. INSTALL FRONT AXLE HUB LH NUT

1. Using a 30 mm socket wrench, install a new hub nut.

   Torque: 294 N·m (3,000 kgf·cm, 217 ft·lbf)

2. Using a chisel and hammer, tapped the front axle hub LH nut.

Install front axle hub LH nut

122. INSTALL FRONT AXLE HUB RH NUT

HINT: Use the same procedures described for the LH side.

123. INSTALL FRONT STABILIZER LINK ASSY LH

a. Using a 5 mm socket hexagon wrench, fix the stud bolt and install the nut.

Torque: 74 N·m (755 kgf·cm, 55 ft·lbf)

124. INSTALL FRONT STABILIZER LINK ASSY RH

HINT: Use the same procedures described for the LH side.

125. INSTALL EXHAUST PIPE ASSY FRONT

126. CONNECT FUEL TUBE SUB−ASSY

127. INSTALL RETURN TUBE SUB−ASSY

128. INSTALL OIL RESERVOIR TO PUMP HOSE No.1

129. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

130. INSTALL GENERATOR ASSY

131. INSTALL FAN AND GENERATOR V BELT

132. CONNECT ENGINE WIRE No.2

133. CONNECT ENGINE WIRE

134. INSTALL ENGINE MOUNTING BRACKET No.2 RH Torque: 52 N·m (531 kgf·cm, 38 ft·lbf)

135. INSTALL ENGINE MOUNTING STAY No.2 RH Torque: 64 N·m (653 kgf·cm, 47 ft·lbf)

136. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET

a. Install the engine mounting control rod with the 3 bolts.

Torque: 64 N·m (653 kgf·cm, 47 ft·lbf)

Install engine moving control rod W/bracket

137. INSTALL AIR CLEANER ASSY Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf)

138. ADD AUTOMATIC TRANSAXLE FLUID (A/T)

139. ADD MANUAL TRANSAXLE OIL (M/T)

140. ADD ENGINE OIL

141. ADD ENGINE COOLANT

142. ADD POWER STEERING FLUID

143. BLEED POWER STEERING FLUID

144. CHECK FOR OIL LEAKS

145. CHECK FOR ENGINE COOLANT LEAKS

146. CHECK FOR FUEL LEAKS

147. INSTALL FRONT WHEEL

148. ADJUST FRONT WHEEL ALIGNMENT

149. INSPECT CHECK IDLE SPEED AND IGNITION TIMING

150. INSPECT CO/HC

151. CHECK ABS SPEED SIGNAL (W/ ABS)

OVERHAUL

1. REMOVE OIL FILTER SUB−ASSY

a. Using SST, remove the oil filter.

SST 09228−06501

Remove oil filter sub-assy

2. REMOVE OIL FILTER UNION

a. Using a 12 mm hexagon wrench, remove the union.

3. REMOVE OIL FILLER CAP SUB−ASSY

4. REMOVE VENTILATION VALVE SUB−ASSY

5. REMOVE SPARK PLUG

6. REMOVE CYLINDER HEAD COVER SUB−ASSY

a. Remove the 8 bolts, 2 nuts, and cylinder head cover.

Remove cylinder head cover sub-assy

7. REMOVE CYLINDER HEAD COVER GASKET

8. REMOVE CRANKSHAFT POSITION

9.  REMOVE CRANKSHAFT PULLEY

1. Turn the crankshaft pulley and align its groove with timing mark 0 of the timing chain cover.

2. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap, as shown in the illustration.

c. TMC made: Remove the crankshaft pulley.

1. Using SST, fix the pulley and loosen the bolt.

SST 09213−54015 (91651−60855), 09330−00021

2. Using SST, remove the bolt and pulley.

SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021)

d TMMK made: Remove the crankshaft pulley.

1. Using SST, fix the crankshaft pulley and loosen a pulley set bolt.

SST 09960−10010 (09962−01000, 09963−01000)

2. Using SST, remove the crankshaft pulley.

SST 09950−40011 (09951−04010, 09952−04010, 09953−04030, 09954−04010, 09955−04041, 09957−04010, 91111−51014)

10. REMOVE CHAIN TENSIONER ASSY No.1

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

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

Remove chain tensioner assy No.1

11. REMOVE WATER PUMP PULLEY

a. Using SST, remove the water pump pulley.

SST 09960−10010 (09962−01000, 09963−00700)

Remove water pump pulley

12. REMOVE WATER PUMP ASSY

a. Remove the 4 bolts, 2 nuts, bracket and water pump.

Remove water pump assy

13. REMOVE OIL PAN DRAIN PLUG

14. REMOVE OIL PAN SUB−ASSY

a. Remove the 12 bolts and 2 nuts.

b. Insert the blade of SST between the crankcase and oil pan. Cut off applied sealer and remove the oil pan.

SST 09032−00100

NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan.

15. REMOVE TIMING CHAIN OR BELT COVER SUB−ASSY

1. Remove the 14 bolts and 2 nuts.

2. Remove the timing chain cover by prying between the timing 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.

Remove timing chain or belt cover sub-assy

16. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

a. Using a screwdriver and a hammer, remove the oil seal.

Remove timing gear case or timing chain case oil seal

17. REMOVE CRANKSHAFT POSITION PLATE No.1

18. REMOVE TIMING CHAIN GUIDE

19. REMOVE CHAIN TENSIONER SLIPPER

20. REMOVE CHAIN VIBRATION DAMPER No.1

21. REMOVE CHAIN SUB−ASSY

22. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

23. REMOVE No.2 CHAIN SUB−ASSY

a) Turn the crankshaft counterclockwise by 90 , and align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.

b. Put a bar (ϕ 4 mm) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position.

Remove the nut.

3. Remove the bolt, chain tensioner plate and spring.

4.  Remove the oil pump drive sprocket, oil pump driven sprocket and chain.

24. REMOVE OIL PUMP ASSY

a. Remove the 3 bolts, oil pump and gasket.

25. REMOVE No.2 CAMSHAFT

1. Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration.

   Then remove the 5 bearings.

2.  Remove the camshaft.

Remove No.2 Camshaft

26. REMOVE CAMSHAFT

1. Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration.

   Then remove the 5 bearings.

2. Remove the camshaft.

Remove camshaft

27. REMOVE CAMSHAFT BEARING No.1

28. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

a. Fix the camshaft with a vise and remove the camshaft timing sprocket.

NOTICE: Be careful not to damage the camshaft.

Remove camshaft timing gear or sprocket

29. REMOVE CAMSHAFT TIMING GEAR ASSY

1. Fix the camshaft with a vise, and make sure that the camshaft timing gear does not move.

2. Cover all the oil ports with vinyl tape except the advanced angle side, as shown in the illustration.

c. Using an air gun, apply about 150 kPA (1.5 kgf/cm, 21 psi) of air pressure to the port on the advanced angle side.

CAUTION: Some oil spraying will occur. Contain the spray with a shop rag.

HINT: This operation releases the lock pin for the extreme retarded angle lock.

d. Under the condition above, check that the camshaft timing gear can be turned by hand to the advanced angle side (counterclockwise), the direction of the arrow in the illustration.

Standard: Must turn

HINT: The camshaft timing gear will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock−pin may be difficult to release.

e. Remove the fringe bolt from the camshaft timing gear.

NOTICE:

• Be sure not to remove the other 4 bolts.

• If planning to reuse the camshaft timing gear, release the straight pin lock first, and then install the gear.

30.  REMOVE CAMSHAFT BEARING No.2

31. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY

32. REMOVE CYLINDER HEAD SUB−ASSY

a. Using a 10 mm bi−hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

• Be careful not to drop washers into the cylinder head.

• Head warpage or cracking could

33. REMOVE CYLINDER HEAD GASKET

34. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB−ASSY

35. REMOVE OIL CONTROL VALVE FILTER

a. Using a 6 mm socket hexagon wrench, remove the plug and filter.

36.  REMOVE W/HEAD TAPER SCREW PLUG No.1

37. INSPECT BALANCESHAFT THRUST CLEARANCE

a. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.

Specified thrust clearance: 0.050 to 0.090 mm (0.0020 to 0.0035 in.)

If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.

 Inspect balanceshaft thrust clearance

38. INSPECT BALANCESHAFT OIL CLEARANCE

a. Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

NOTICE: Be careful not to damage the contact surfaces of the balance shaft housing and crankcase.

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

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

HINT: Keep the upper bearing with the crankcase.

3. Clean each bearing and journal.

4.  Check each bearing and journal for pitting and scratches.

If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.

e. Place the No. 1 and No. 2 balance shafts on the crankcase.

6.  Lay a strip of Plastigage across each journal, and install the balance shaft housing.

7. Apply light coat of engine oil on the threads and under the heads of the balance shaft housing bolts.

h. Uniformly tighten the 8 bolts in the sequence shown in the illustration.

Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)

HINT: The balance shaft housing bolts are tightened in 2 progressive steps.

9. Mark the front side of each balance shaft housing bolt head with paint.

10. Retighten the bolts by 90 as shown in the illustration.

11. Check that the paint marks are now at a 90 angle to the front.

l. Remove the balance shaft housing, and measure the Plastigage at its widest point.

Specified oil clearance: 0.004 to 0.031 mm (0.0002 to 0.0012 in.)

m. Completely remove the plastigage after the inspection.

If the clearance is greater than the maximum, replace the bearing.

If necessary, replace the balance shaft.

HINT: If replacing a bearing, replace it with one that has the same number as the stiffening crankcase. There are 3 sizes of standard bearings: 1, 2 and 3.

Balance shaft housing journal bore diameter:

 

Balance shaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Standard bearing center wall thickness:

n. Completely remove the Plastigage after the inspection.

39. REMOVE BALANCESHAFT

40.  REMOVE BALANCESHAFT BEARING No. 1

41. REMOVE ENGINE REAR OIL SEAL

1. Using a knife, cut off the oil seal lip.

2. Using a screwdriver with its tip taped, pry out the oil seal.

NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400−grit sandpaper.

Remove engine rear oil seal

42. REMOVE STIFFENING CRANKCASE ASSY

1. Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

2. Using a screwdriver, remove the crankcase by prying the portions between the crankcase and cylinder block.

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

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

Remove stiffening crankcase assy

43. INSPECT OIL PUMP DRIVE SPROCKET

1. Wrap the chain around the drive sprocket.

2. Using a vernier caliper, measure the drive sprocket diameter with the chain.

NOTICE:

The vernier caliper must contact the chain rollers for the measurement.

Minimum sprocket diameter (w/ chain): 48.2 mm (1.898 in.)

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

Inspect oil pump drive sprocket

44. INSPECT OIL PUMP DRIVEN SPROCKET

1. Wrap the chain around the driven sprocket.

2. Using a vernier caliper, measure the driven sprocket diameter with the chain.

NOTICE: The vernier caliper must contact the chain rollers for the measurement.

Minimum sprocket diameter (w/ chain): 48.2 mm (1.898 in.)

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

Inspect oil pump driven sprocket

45. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET

1. Wrap the chain around the timing sprocket.

2. Using a vernier caliper, measure the timing sprocket diameter with the chain.

NOTICE: The vernier caliper must contact the chain rollers for the measurement.

Minimum sprocket diameter (w/ chain): 51.6 mm (2.031 in.)

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

Inspect crankshaft timing gear or sprocket

46. INSPECT CHAIN TENSIONER SLIPPER

a. Measure the tensioner slipper wear.

Maximum wear: 1.0 mm (0.039 in.)

If the wear is greater than the maximum, replace the tensioner slipper.

 Inspect chain tensioner slipper

47. INSPECT CHAIN VIBRATION DAMPER No.1

a. Measure the vibration damper wear.

Maximum wear: 1.0 mm (0.039 in.)

If the wear is greater than the maximum, replace the vibration damper.

Inspect chain vibration damper No.1

48. INSPECT CYLINDER HEAD SET BOLT

a. Using a vernier caliper, measure the length of the head bolts from the seat to the end.

Specified bolt length: 161.3 to 164.2 mm (6.350 to 6.465 in.)

If the length is greater than the maximum, replace the bolt.

Inspect cylinder head set bolt

49. INSPECT CHAIN TENSIONER ASSY No.1

1. Check that the plunger moves smoothly when the ratchet pawl is raised.

2. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with finger.

Inspect chain tensioner assy No.1

50. INSPECT CHAIN SUB−ASSY

a. Using a vernier caliper, measure the length of 15 links with the chain fully stretched.

Maximum chain elongation: 115.4 mm (4.543 in.)

If the elongation is greater than the maximum, replace the chain.

NOTICE: Make the same measurements pulling at 3 or more places selected at random. Average the measurements.

Inspect chain sub-assy

51. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET

1. Wrap the chain around the timing sprocket.

2. Using a vernier caliper, measure the timing sprocket diameter with the chain.

   Minimum sprocket diameter (w/chain): 97.3 mm (3.831 in.)

NOTICE: The vernier caliper must contact the chain rollers for the measurement.

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

Inspect camshaft timing gear or sprocket

52. INSPECT CAMSHAFT

a. Check the camshaft for runout.

1. Place the camshaft on V−blocks.

2. Using a dial indicator, measure the circle runout at the center journal.

   Maximum circle runout: 0.03 mm (0.0012 in.)

If the circle runout is greater than the maximum, replace the camshaft.

b. Using a micrometer, measure the cam lobe height.

Specified cam lobe height: 46.599 to 46.809 mm (1.8346 to 1.8429 in.)

If the cam lobe height is less than the minimum, replace the camshaft.

c. Using a micrometer, measure the journal diameter.

No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.)

If the journal diameter is not as specified, check the oil clearance.

53. INSPECT No.2 CAMSHAFT

a. Check the camshaft for runout.

1. Place the camshaft on V−blocks.

Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout: 0.03 mm (0.0012 in.)

If the circle runout is greater than the maximum, replace the camshaft.

b. Using a micrometer, measure the cam lobe height.

Specified cam lobe height: 45.599 to 46.809 mm (1.8346 to 1.8429 in.)

If the cam lobe height is less than the minimum, replace the camshaft.

c. Using a micrometer, measure the journal diameter.

No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.)

If the journal diameter is not as specified, check the oil clearance.

54. INSTALL BALANCESHAFT BEARING No.1

1. Install the bearings in the crankcase and balance shaft housing.

2. Apply a light coat of engine oil on the bearings.

55. INSTALL BALANCESHAFT No. 1 AND No. 2

1. Rotate the driven gear No. 1 of balance shaft No. 1 for the rotating direction until it hits the stopper.

2. Confirm that the matchmarks on driven gear No. 1 and No. 2 are matched.

3. Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration.

4. Place the No. 1 and No. 2 balance shafts on the crank case.

5. Apply a light coat of engine oil under the heads of the balance shaft housing bolts.

f. Uniformly tighten the 8 bolts in the sequence shown in the illustration.

Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)

HINT: The balance shaft housing bolts are tightened in 2 progressive steps.

7. Mark the front side of each balance shaft housing bolt head with paint.

8. Retighten the bolts by 90 as shown in the illustration.

9. Check that the painted marks are now at a 90 angle to the front.

56. INSTALL STIFFENING CRANKCASE ASSY

a. Apply seal packing in a continuous bead (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to the places shown in the illustration.

Seal packing: Part No. 08826−00080 or equivalent

NOTICE:

• Remove any oil from the contact surface.

• Install the crankcase within 3 minutes after applying seal packing.

• Do not start the engine for at least 2 hours after installing.

b. Place a new O−ring on the cylinder block, as shown in the illustration.

c. With the No. 1 crank pin of the crankshaft placed at 6 o’clock, install the No. 1 and No. 2 balanceshaft and the adjusting hole as shown in the illustration.

d. Uniformly tighten the 11 bolts in the sequence shown in the illustration.

Torque: 33 N·m (332 kgf·cm, 24 ft·lbf

e. Confirm that the timing marks of the balanceshafts are matched when the key groove is placed at 6 o’clock, as shown in the illustration.

57. INSTALL ENGINE REAR OIL SEAL

a. Apply MP grease to a new oil seal lip.

NOTICE: Keep the lip off the foreign materials.

b. Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.

SST 09223−15030, 09950−70010 (09951−07100)

NOTICE: Wipe off extra grease on the crankshaft.

Install engine rear oil seal

58. INSTALL W/HEAD TAPER SCREW PLUG No.1

a. Apply adhesive to the threads of the plug and install it.

Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)

Install W/head taper screw plug No.1

59. INSTALL OIL CONTROL VALVE FILTER

1. Check that no foreign substance is on the mesh part of the filter.

2. Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.

   Torque: 30 N·m (306 kgf·cm, 22 ft·lbf)

Install oil control valve filter

60. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB−ASSY

a. Install the water drain cock within the range shown in the illustration.

Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)

Install cylinder block water drain cock sub-assy

61. INSTALL CYLINDER HEAD GASKET

a. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:

• Remove any oil from contact surface.

• Be careful of the installation direction.

• To avoid damage to the gasket, place the cylinder head on the gasket carefully.

 Install cylinder head gasket

62. INSTALL CYLINDER HEAD SUB−ASSY

HINT: The cylinder head bolts are tightened in 2 progressive steps.

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

2. Install the 10 bolts and plate washers to the cylinder head.

NOTICE: Do not drop the washers into the cylinder head.

c. Using a 10 mm bi−hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.

Torque: 79 N·m (806 kgf·cm, 58 ft·lbf)

4. Mark the front side of each cylinder head bolt with paint.

5. Retighten the cylinder head bolts by 90 in the sequence shown in the illustration.

6. Check that the painted marks are now at a 90 angle to the front.

63. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)

64. INSTALL CAMSHAFT BEARING No.2

65. INSTALL CAMSHAFT TIMING GEAR ASSY

1. Put the camshaft timing gear and the camshaft together with the straight pin and key groove.

2. Turn the camshaft timing gear (as shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin enters the groove.

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

3. Check that there is no clearance between the gear’s fringe and the camshaft.

4. Tighten the fringe bolt with the camshaft timing gear fixed.

   Torque: 54 N·m (551 kgf·cm, 40 ft·lbf)

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