Part 3

PARTIAL ENGINE ASSY (1NZ-FXE)
OVERHAUL





41. INSPECT CYLINDER HEAD SET BOLT





a. Using vernier calipers, measure the length of the head bolts from the seating to the end.
Standard bolt length: 142.8 to 144.2 mm (5.622 to 5.677 inch)
Maximum bolt length: 147.1 mm (5.791 inch)
If the length is greater than maximum, replace the head bolt.
42. INSTALL OIL PAN SUB-ASSY
a. Using a Torx socket wrench E5, install the 4 stud bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)





b. Apply a continuous bead of seal packing (Diameter 2.0 to 3.0 mm (0.079 to 0.118 inch)) to the oil pan as illustrated.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes after applying seal packing.
^ Do not expose the seal packing to engine oil within 2 hours of installation.





c. Install 2 new O-rings to the cylinder block, then install the oil pan.

NOTICE:
^ Clean the contact surface of the new O-rings.
^ Be careful that the O-rings are not jammed when installing the oil pan.





d. Using several steps, temporarily tighten the 13 bolts in the sequence shown in the illustration, then tighten the bolts with the specified torque.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)

HINT: The bolt length is as follows.
Bolt A 46 mm (1.81 inch)
Bolt B 85 mm (3.35 inch)
Bolt C 140.7 mm (5.54 inch)





43. INSTALL ENGINE REAR OIL SEAL
a. Apply a light coat of multipurpose grease No. 2 to the lip of a new oil seal.

NOTICE: Keep the lip free of foreign objects.

b. Using SST, uniformly tap in the oil seal until its surface is flush with the cylinder block edge.
SST 09223-56010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Wipe off extra grease on the crankshaft.





44. INSTALL OIL STRAINER SUB-ASSY
a. Install a new gasket, then install the oil strainer with the bolt and 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8.1 ft. lbs.)
45. INSTALL OIL PAN SUB-ASSY NO.2





a. Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 inch)) to the oil pan as illustrated.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes after applying seal packing.
^ Do not expose the seal packing to engine oil within 2 hours of installation.





b. Install the oil pan No. 2 with the 9 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
c. Install a new gasket and oil pan drain plug.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)





46. INSTALL OIL FILTER UNION
a. Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





47. INSTALL OIL FILTER SUB-ASSY
a. Clean the oil filter installation surface of the engine.
b. Apply a light coat of engine oil to the O-ring of a new oil filter.
c. Install the O-ring by hand until it contacts the seat.
d. Using SST, tighten it by an additional 3/4 turn.
SST 09228-06501





48. INSTALL CYLINDER HEAD GASKET
a. Place a new head gasket on the cylinder block with the Lot No. facing upward.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installation direction.
^ Do not damage the cylinder head gasket when installing.

49. INSTALL CYLINDER HEAD SUB-ASSY

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

a. Install the cylinder head to the cylinder block.

NOTICE: Do not damage the cylinder head gasket at the bottom of the cylinder head.

b. Apply a light coat of engine oil to the threads and seating of the cylinder head bolts.





c. Using several steps, temporarily install the cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration, then tighten the bolts with the specified torque.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





d. Mark the front of the cylinder head bolts with paint.
e. Retighten the bolts by additional 90° in the same sequence as step (c), then retighten them by one more additional 90°.
f. Check that each paint mark is now at the 180° angle to the front.





50. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Put the camshaft timing gear assembly and camshaft together with the straight pin off the groove as illustrated.
b. Turn the camshaft timing gear assembly in the direction shown (to the left) while pushing it lightly into the camshaft. Push further at the position where the pin fits into the groove.

NOTICE: Do not turn the camshaft timing gear to the retard direction (to the right).

c. Check that there is no clearance between the camshaft timing gear assembly and fringe.
d. Tighten the bolt with the camshaft timing gear fixed.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

NOTICE: If the camshaft timing gear is locked at the most retarded position, unlock the lock pin inside the timing gear, then tighten the bolts.

e. Check that the camshaft timing gear moves to the retard direction (to the right) and it is locked at the most retarded position. 51. INSTALL CAMSHAFT





a. Turn the crankshaft by 40° counterclockwise from the TDC/compression.





b. Apply engine oil to the cam and cylinder head journal.
c. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
d. Check the front marks and numbers on the bearing cap No. 2, then tighten the bolts uniformly in several steps in the sequence shown in the illustration.
Torque: 13 Nm (130 kgf-cm, 9.6 ft. lbs.)

NOTICE: Tighten the bolts uniformly keeping the camshaft level.





52. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Clamp the hexagonal lobe of the camshaft in a vise (using an aluminum protector).
b. Align the knock pin of the camshaft No. 2 and the pin groove of the camshaft timing gear, then install the camshaft timing gear with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

NOTICE: Do not damage the camshaft.





53. INSTALL NO.2 CAMSHAFT
a. Apply engine oil to the cam and cylinder head journal.
b. Place the camshaft No. 2 on the cylinder head with the timing mark on the camshaft timing gear facing upward.
c. Check the front marks and numbers on the bearing cap No. 2, then tighten the bolts uniformly in several steps in the sequence shown in the illustration.
Torque: 13 Nm (130 kgf-cm, 9.6 ft. lbs.)

NOTICE: Tighten the bolts uniformly keeping the camshaft level.

d. Install the camshaft bearing cap No. 1.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
54. INSTALL CHAIN SUB-ASSY





a. Check that the timing marks are located as illustrated.





b. Install the chain so the timing mark and the mark plate of the chain are aligned.

HINT:
^ The camshaft side Orange
^ The crankshaft side Yellow





c. To prevent misalignment of the mark plate and timing mark, tie the chain around the crankshaft timing sprocket with a string.

HINT: Tie the chain to prevent misalignment of the timing marks.





d. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





e. Remove the string, then install the chain tensioner stopper.
f. Install the chain tensioner.





1. Lift up the stopper plate, then unlock the plunger.
2. Push in the plunger to the end with the plunger unlocked.





3. Lift down the stopper plate with the plunger pushed to the end, then lock the plunger.





4. Insert a 3.0 mm (0.118 inch) diameter bar into the hole of the stopper plate with the plunger locked.

HINT: If the stopper plate is not completely lifted down and a 3.0 mm (0.118 inch) diameter bar cannot be inserted, unlock and pull out the plunger slightly. The stopper plate will be completely lifted down and a 3.0 mm (0.118 inch) diameter bar can be inserted easily.





5. Install the chain tensioner with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
6. Remove the 3.0 mm (0.118 inch) diameter bar from the chain tensioner.





55. INSTALL OIL PUMP SEAL
a. Using SST, uniformly tap in a new oil seal until its surface is flush with the oil pump edge.
SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100)

NOTICE: Be careful not to tap the oil seal at an angle.

b. Apply a light coat of multipurpose grease No. 2 to the lip of the new oil seal.

NOTICE: Keep the lip free of foreign objects.





56. INSTALL OIL PUMP ASSY
a. Install 2 new O-rings to the 2 locations as shown in the illustration.
b. Apply seal packing to the engine body and oil pump as shown in the illustration below.
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, and tighten the bolts within 15 minutes after applying seal packing.
^ Do not expose the seal packing to engine oil within 2 hours of installation.





c. Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft, then slide the oil pump assembly into place.





d. Install the oil pump assembly with the 15 bolts and nut as illustrated.
Torque:
32 Nm (326 kgf-cm, 24 ft. lbs.) for Bolt A
11 Nm (112 kgf-cm, 8.1 ft. lbs.) for Bolt B
11 Nm (112 kgf-cm, 8.1 ft. lbs.) for Bolt C
24 Nm (245 kgf-cm, 18 ft. lbs.) for Nut D
24 Nm (245 kgf-cm, 18 ft. lbs.) for Bolt E

NOTICE:
^ Be careful that the chain does not contact the seal packing when installing the oil pump assembly.
^ Install the engine mounting bracket RH and water pump assembly within 15 minutes after installing the oil pump assembly.

HINT: The bolt length is as follows.
Bolt A 30 mm (1.18 inch)
Bolt B 35 mm (1.38 inch)
Bolt C 20 mm (0.79 inch)
Bolt E 20 and 14 mm (0.79 and 0.55 inch) double ended bolt

57. INSTALL CRANKSHAFT DAMPER SUB-ASSY





a. Install the crankshaft straight pin to the crankshaft.
b. Align the hole of the crankshaft damper with the straight pin, then install the crankshaft damper.





c. Using SST, hold the crankshaft damper and tighten the crankshaft bolt.
SST 09213-58013 (91111-50845), 09330-00021
Torque: 128 Nm (1305 kgf-cm, 95 ft. lbs.)

NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.





58. INSTALL WATER PUMP ASSY
a. Install a new gasket, then install the water pump assembly with the 3 bolts and 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8.1 ft. lbs.)





59. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 55 Nm (561 kgf-cm, 41 ft. lbs.)
60. INSPECT VALVE CLEARANCE

NOTICE: Inspect and adjust the valve clearance when the engine is cold.





a. Set the No. 1 cylinder to the TDC/compression.
1. Turn the crankshaft damper clockwise, then align its timing mark notch with the timing mark "0" of the chain cover.
2. Check that the timing marks of the camshaft timing gear are located as illustrated.

HINT: If not, turn the crankshaft to align the marks.





b. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.17 to 0.23 mm (0.007 to 0.009 inch)
Exhaust 0.27 to 0.33 mm (0.011 to 0.013 inch)

HINT: If the clearance is not as specified, record the out-of-specification measurement, then adjust the valve clearance.

c. Turn the crankshaft clockwise by 1 complete revolution (360°) and set the No. 4 cylinder to the TDC/compression.





d. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.17 to 0.23 mm (0.007 to 0.009 inch)
Exhaust 0.27 to 0.33 mm (0.011 to 0.013 inch)

HINT: If the clearance is not as specified, record the out-of-specification measurement, then adjust the valve clearance.