Part 3

OVERHAUL

61. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)

62. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the crankshaft position sensor plate with the "F" mark facing forward.

63. INSTALL TIMING GEAR COVER OIL SEAL
a. Apply a light coat of MP grease to a new oil seal lip.
b. Place the timing chain cover on wooden blocks.
c. Using SST, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09223-2201 0

NOTICE: Keep the lip off foreign materials.

64. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
a. Remove any old packing material from the contact surface.
b. Using a torx socket wrench E5, install the 3 stud bolts
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

c. Apply seal packing in the shape of bead (Diameter 3.5 mm - 4.5 mm (0.138 - 0.177 inch)) consequently as shown in the illustration.
Seal packing:
Water pump part Part No. 08826-00100 or equivalent
Other part Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.

d. Install the timing chain cover with the 12 bolts and nut.
Torque:
A 13 Nm(133 kgf-cm, 10 ft. lbs.)
B 19 Nm(189 kgf-cm, 14 ft. lbs.)

65. INSTALL CHAIN TENSIONER ASSY NO.1
a. Check an O-ring is clean, and set the hook as shown in the illustration.
b. Apply a light coat of engine oil to an O-ring.

c. Install the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
^ Be careful not twist an O-ring.
^ When installing the chain tensioner, set the hook again if the hook releases the plunger.

66. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley.
b. Using SST, install the crankshaft pulley bolt.
SST 0996-10010 (09962-01000, 0996-01000)
Torque: 138 Nm (1,407 kgf-cm, 102 ft. lbs.)

c. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.

d. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

HINT: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger springs out.

67. INSTALL WATER PUMP O-RING
a. Install a new O-ring to the timing chain cover.

68. INSTALL WATER PUMP ASSY
a. Install the water pump with the 6 bolts.
Torque:
Bolt A 9.0 Nm (92 kgf-cm, 80 inch lbs.)
Bolt B 11 Nm (112 kgf-cm, 8 ft. lbs.)

69. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the transverse engine engine mounting bracket with the 3 bolts.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)

70. INSPECT VALVE CLEARANCE
a. Set No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
2. Check that the point marks of the camshaft timing gears are in straight line on the timing chain cover surface as shown in the illustration.

HINT: If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

b. Check only the valves indicated.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
2. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
Valve clearance (Cold):
Intake 0.15 - 0.25 mm (0.0059 - 0.0098 inch)
Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 inch)

c. Turn the crankshaft 1 revolution (360°) and set No. 4 cylinder to TDC/compression.
d. Check only the valves indicated.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
2. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
Valve clearance (Cold):
Intake 0.15 - 0.25 mm (0.0059 - 0.0098 inch)
Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 inch)

71. ADJUST VALVE CLEARANCE

NOTICE: Be sure not to revolve the crankshaft without the chain tensioner.

a. Set the No. 1 cylinder to the TDC/compression.
b. Place painted marks on the chain and camshaft timing gears.

c. Remove the 2 nuts and chain tensioner.

d. Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set bolt.

NOTICE: Be careful not to damage the valve lifter.

e. Loosen the bearing cap bolts on No. 2 camshaft in the order as shown in the illustration in several passes, and remove the bearing caps.

f. Remove the camshaft timing gear as shown in the illustration.

g. Loosen the bearing cap bolts on camshaft in the order as shown in the illustration in several passes, and remove the bearing claps.

h. Remove the camshaft with holding the chain.

i. Tie the chain with a string as shown in the illustration.

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

j. Remove the valve lifters.

k. Using a micrometer, measure the thickness of the removed valve lifters.
l. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

Specified valve:
Intake A = B + (C - 0.20 mm (0.0079 inch))
Exhaust A = B - (C - 0.30 mm (0.0118 inch))
A Thickness of new lifter
B Thickness of used lifter
C Measured valve clearance

Example (Intake):
Measure intake valve clearance = 0.40 mm (0.0158 in.)
0.40 mm (0.0158 in.) - 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.)
(Measured - Specification = Excess clearance)
Used lifter measurement = 5.250 mm (0.2067 in.)
0.20 mm (0.0079 in.) + 5.250 mm (0.2067 in.) = 5.450 mm (0.2146 in.)
(Excess clearance + Used lifter = Ideal new lifter)
Closest new lifter = 5.460 mm (0.2150 in.)
Select No. 46 lifter

HINT:
^ Select a new lifter with a thickness as close as possible to the calculated values.
^ Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch).

1ZZ-FE Engine:

m. As shown in the illustration, install the chain on the camshaft timing gear, with the painted mark aligned with the timing mark on the camshaft timing gear.

n. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)

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

p. Raising the camshaft, tighten the set bolt temporarily.

q. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque:
Bearing cap No. 3 13 Nm (133 kgf-cm, 10 ft. lbs.)
Bearing cap No. 1 23 Nm (235 kgf-cm, 17 ft. lbs.)

r. Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE: Be careful not to damage the valve lifter.

s. Check the painted marks on the chain and camshaft timing gears, and then the alignment of the crankshaft pulley groove with timing mark of the timing chain cover as shown in the illustration.

t. Install chain tensioner.
1. Check an O-ring is clean, and set the hook as shown in the illustration.
2. Apply a light coat of engine oil to an O-ring.

3. Install the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
^ Be careful not twist an O-ring.
^ When installing the tensioner, set the hook again if the hook release the plunger.

4. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.

5. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

HINT: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger springs out.

72. INSTALL CYLINDER HEAD COVER GASKET
a. Install the gasket to the cylinder head cover.

73. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Remove any old packing (FIPG) material.
b. Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes after applying seal packing.
^ Do not put into engine oil 2 hours after installing.

c. Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts.
Torque:
A 11 Nm (112 kgf-cm, 8 ft. lbs.)
B 9.0 Nm (92 kgf-cm, 80 inch lbs.)

74. INSTALL SPARK PLUG
a. Using a spark plug wrench, install the spark plugs.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

75. INSTALL VENTILATION VALVE SUB-ASSY
a. Install the ventilation valve to the cylinder head cover.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

76. INSTALL OIL FILLER CAP GASKET
a. Install the gasket to the oil filler cap.

77. INSTALL OIL FILLER CAP SUB-ASSY
a. Install the oil filler cap to the cylinder head cover.