Disassembly

DISASSEMBLY OF CYLINDER BLOCK

7M-GE

7M-GTE

REMOVAL OF CYLINDER HEAD
1. REMOVE ALTERNATOR
(a) Disconnect the No.3 PCV hose.
(b) Remove the drive belt.
(c) Remove the alternator and adjusting bar.

2. (7M-GTE)
REMOVE PS RESERVOIR TANK
Remove the two bolts, nut and reservoir tank with bracket.
3. (7M-GTE)
REMOVE CAM POSITION SENSOR
4. REMOVE AIR INTAKE CHAMBER WITH CONNECTOR
(a) Remove the PCV pipe.
(b) Disconnect the following connectors: (7M-GE)
Cold start injector connector
- Throttle position sensor connector
- ISC valve connector
(c) Disconnect the following hoses:
- BVSV hose from throttle body
- EGR hoses from throttle body
- Vacuum lines from intake chamber
- Pressure regulator hose
- PS air hose
- (7M-GTE)
VSV hoses (for FPU)
- (7M-GE)
Diaphragm hose
- (7M-GTE)
Auxiliary air pipe hose from vacuum line
- No.1 water by-pass hose from ISC valve
- (7M-GE)
No.3 water by-pass hose from throttle body
- (7M-GTE)
No.3 water by-pass hose from water by-pass pipe

(d) Remove the EGR pipe mounting bolts.
(e) Remove the manifold stay mounting bolts.

(f) (7M-GE)
Remove the throttle body brackets.

(g) (7M-GTE) Remove the ISC pipe

(h) (7M-GTE)
Remove the air intake connector mounting bolts.

(I) (7M-GE)
Remove the air intake connector bracket mounting bolts.
(j) Remove the cold start injector tube.
(k) Remove the EGR vacuum modulator from the bracket.
(I) Disconnect the engine wire from the clamps of intake chamber.
(m) Remove the two nuts, five bolts, vacuum lines and intake chamber with connector and gasket.
(n) (7M-GTE)
Disconnect the cold start injector connector.
5. (7M-GTE)
REMOVE IGNITION COIL WITH BRACKET
6. REMOVE ENGINE WIRE
(a) Disconnect the following connectors and wire:
- Oxygen sensor connector
- Oil pressure sender gauge connector
- Water temp. sensor connector
- Water temp. sender gauge connector
- Cold start injector time switch connector
- (7M-GE)
Distributor connector
- Injector connectors
- Two VSV connectors
- Knock sensor connector(s)
- Ground strap from intake manifold
- Check connector
- (7M-GTE)
Solenoid resistor connector
- (7M-GE)
Ignition coil connector
(7M-GTE)
Igniter connectors
- Noise filter connector
- Main relay connector
- Starter connector (terminal 50)
- Transmission connectors
(b) Remove the engine wire from the four clamps.

7. REMOVE NO.1 FUEL PIPE
(a) Remove the union bolt (7M-GE) or pulsation damper (7M-GTE) and two gaskets from the delivery pipe.
(b) Remove the union bolt and two gaskets from the fuel support.
(c) Remove the clamp bolt and No.1 fuel pipe with VSV.

8. REMOVE NO.2 FUEL PIPE
(a) Disconnect the fuel hose from the fuel support.
(b) Remove the bolt, union bolt, No.2 fuel pipe and gaskets.

9. (7M-GTE)
REMOVE AUXILIARY AIR PIPE
10. (7M-GE)
REMOVE HIGH-TENSION CORDS AND DISTRIBUTOR
11. (7M-GE)
REMOVE OIL DIPSTICK
12. (7M-GTE)
REMOVE TURBOCHARGER

13. REMOVE EXHAUST MANIFOLD
(a) (7M-GTE)
Remove the five nuts and heat insulators.

(b) (7M-GTE) Remove the three bolts and exhaust manifold stay.

14. REMOVE WATER OUTLET HOUSING
(a) (7M-GE)
Remove the union bolts, union with No.4 water bypass hose and gaskets.
(b) Disconnect the No.6 water by-pass hose from the water by-pass pipe.

15. REMOVE CYLINDER HEAD COVERS
(a) Remove the accelerator link.
(b) Remove the heater hose clamp.
(c) Remove the No.1 and No.2 cylinder head covers.

(d) Using SST, remove the No.3 cylinder head cover. SST 09923-00010
16. REMOVE SPARK PLUGS
17. REMOVE TIMING BELT AND CAMSHAFT TIMING PULLEYS

18. REMOVE FAN AND ALTERNATOR DRIVE BELT
19. REMOVE PS BELT

20. REMOVE NO.3 TIMING BELT COVER
Remove the five bolts, nut and No.3 timing belt cover with the gasket.

21. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with the "0" mark on the No.1 timing belt cover.

(b) Check that the matchmarks on the camshaft timing pulleys and No.2 timing belt cover are aligned. If not, turn the crankshaft pulley one complete revolution.

22. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS

NOTICE: If reusing the timing belt, draw a direction arrow on the belt (in direction of engine revolution).

(a) Loosen the idler pulley bolt and shift it left as far as it will go with a screwdriver and wrench.
(b) Temporarily tighten the set bolt and then relieve the timing belt tension.
(c) Remove the belt from the camshaft timing pulleys.

NOTICE:
- Support the belt so the meshing of the crankshaft timing pulley and timing belt does not shift.
- Be careful not to drop anything inside the timing belt cover.
- Do not allow the belt to come into contact with oil, water and dust.

23. REMOVE CAMSHAFT TIMING PULLEYS
Using SST to hold the pulley, remove the pulley bolt, timing pulley and match pin. SST 09278-54012

HINT: Place the matchmarks on the camshaft timing pulley where the straight pin is inserted.

NOTICE: Do not make use of the timing belt tension when removing and installing the pulley bolts.

24. REMOVE CYLINDER HEAD
(a) Using SST, remove the head bolts gradually in three passes and in the numerical order shown. SST 0904338100

NOTICE: Head warpage or cracking could result from removing bolts in incorrect order.

(b) Lift the cylinder head from the dowels on the cylinder block. As the cylinder head is lifted, separate the No.5 water by-pass hose from the union.
(c) Place the head on wooden blocks on a bench. If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block projection.

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

1. REMOVE FLYWHEEL OR DRIVE PLATE AND REAR END PLATE
2. INSTALL ENGINE STAND FOR DISASSEMBLY
3. REMOVE TIMING BELT Timing Components
4. REMOVE CYLINDER HEAD

5. REMOVE WATER BY-PASS PIPE AND HOSES
(a) Remove the two nuts from the timing belt case.
(b) Remove the three bolts from the cylinder block and the water by-pass pipe and hose with gasket.
6. REMOVE GROUND STRAP FROM CYLINDER BLOCK
7. (7M-GE)
REMOVE VACUUM CONTROL VALVE SET

8. REMOVE FUEL RETURN PIPE SUPPORT
Remove the two nuts, fuel pipe support and insulator.
9. REMOVE ENGINE MOUNTING BRACKETS
10. (7M-GE)
REMOVE OIL FILTER
(7M-GTE)
REMOVE OIL FILTER BRACKET
11. (7M-GE)
REMOVE OIL HOLE COVER PLATE

12. REMOVE PS PUMP BRACKET
13. REMOVE OIL PAN Oil Pan

14. REMOVE TIMING BELT CASE WITH WATER PUMP
Remove the seven bolts and three nuts, and remove the timing belt case and gaskets.

15. REMOVE REAR OIL SEAL RETAINER
Remove the five bolts, and remove rear oil seal retainer and gasket.

16. REMOVE OIL PUMP DRIVE SHAFT
(a) Remove the bolt and oil pump drive shaft.
(b) While turning oil pump drive shaft, slowly pull out so as not to damage the bearing.

17. REMOVE OIL PUMP
(a) Loosen the union nut.
(b) Remove the two bolts, and remove the oil pump.

18. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial gauge, measure the thrust clearance.
Standard clearance: 0.160 - 0.296 mm (0.0063 - 0.0017 in.)
Maximum clearance: 0.3 mm (0.012 in.)
If clearance is greater than maximum, replace the connecting rod and/or crankshaft.

19. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE
(a) Using a punch or numbering stamp, mark the connecting rod and cap to ensure correct reassembly.
(b) Remove the rod cap nuts.

(c) Using a plastic-faced hammer, tap the rod bolts lightly and lift off the rod cap.

HINT: Keep the lower bearing inserted with the cap.

(d) Clean the bearings and crankshaft pins.
(e) Inspect each bearing for pitting and radial scratches. If bearings are damaged, replace the bearings.

(f) Lay a strip of Plastigage across the crankshaft pin.

(g) Align the rod and cap marks and fit on the cap. Torque the rod cap nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

NOTICE: Do not turn the crankshaft.

(h) Remove the rod cap.
(i) Measure the Plastigage at its widest point.
Standard clearance: 0.030 - 0.048 mm (0.0012 - 0.0019 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
1987-88 Model
Standard clearance: 0.021 - 0.053 mm (0.0008 - 0.0021 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
1989-92 Model
If the clearance is greater than maximum, replace the bearings and/or grind the crank pins.
Undersized bearing: U/S 0.25
(j) Clean any Plastigage from the bearing and crankshaft pin.

HINT: If using a standard size bearing, replace with one having the same number. If the number of the bearing cannot be determined, select a bearing from the table below according to the numbers imprinted on the connecting rod cap and crankshaft. There are five sizes of standard bearings, marked "1", "2", "3,', "4" and "5" accordingly.

20. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES

(a) Remove all the carbon from the top of the cylinder.

(b) Cover the rod bolts with a short piece of hose to protect the crank pin from damage.
(c) Push the piston and connecting rod assembly out through the top of the cylinder block.

HINT: Keep the bearings inserted with the connecting rod and cap. Arrange the piston and connecting rod assemblies in correct order.

21. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial gauge, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard clearance: 0.05-0.25 mm (0.0020 - 0.0098 in.)
Maximum clearance: 0.30 mm (0.0118 in.)
If the clearance is greater than maximum, replace the thrust washers as a set and/or crankshaft.

HINT: Thrust washer thickness:
STD 2.925 - 2.975 mm (0.1152 - 0.1171 in.)
0versize 0.125 2.988 - 3.038 mm (0.1176 - 0.1196 in.)

22. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE

(a) Uniformly loosen and remove the main bearing cap bolts in several passes, in the sequence shown.

(b) Using the removed bearing cap bolts, wiggle the bearing cap back and forth, and remove it with the lower bearing and thrust washers (No.4 journal only).

HINT: Keep the lower bearing inserted with the cap. Arrange the caps and lower thrust washers in correct order.
(c) Lift off the crankshaft.

HINT: Keep the upper bearings and upper thrust washers (for the No.4 journal only) inserted in the cylinder block

(d) Clean the journals and bearings.
(e) Check the journals and bearings for pitting and scratches.
If the journal or a bearing is damaged, grind or replace the crankshaft and replace the bearings.

(f) Install the upper main bearing on the cylinder block and crankshaft.
(g) Lay a strip of Plastigage across the main journals.

(h) Install the main bearing caps. Torque the cap bolts.
Torque: 102 N.m (1,040 kgf.cm, 75 ft.lbf)

NOTICE: Do not turn crankshaft.

(i) Remove the main bearing caps.
(j) Measure the Plastigage at its widest point.
Standard clearance: 0.030 - 0.055 mm (0.0012 - 0.0022 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
1987-89 Model
Standard clearance: 0.030 - 0.048 mm (0.0012 - 0.0019 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
1989-92 Model
If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.
Undersized bearing: Undersize 0.25

HINT: If using a standard size bearing, replace with one having the same number. If the number of the bearing cannot be determined, select a bearing from the table below according to the numbers imprinted on the cylinder block and crankshaft. There are five sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

(Reference)

23. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust washers from the cylinder block.
(c) Clean out the scraps of Plastigage from bearing and journals.

HINT: Arrange the caps, bearings and thrust washers in correct order. The pilot bearing in the crankshaft rear end is permanently lubricated and requires no cleaning or lubrication.

24. (7M-GTE) REMOVE OIL NOZZLES