Part 4
PARTIAL ENGINE ASSY (1NZ-FXE)
OVERHAUL
61. ADJUST VALVE CLEARANCE
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".
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.
3. Put the paint marks on the timing chain plates which align with timing marks of the camshaft timing gear.
b. Using 8 mm socket hexagon wrench, remove the service hole screw plug.
c. Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner upward.
HINT: Lifting up the stopper plate of the chain tensioner unlocks the plunger.
d. Keeping the stopper plate of the chain tensioner lifted, slightly rotate the hexagonal lobe of the camshaft No. 2 to the right with an adjustable wrench so the plunger of the chain tensioner is pushed.
HINT: When the camshaft No. 2 is slightly rotated to the right, the plunger is pushed.
e. Keeping the adjustable wrench installed, remove the screwdriver with the plunger pushed.
NOTICE: Do not move the adjustable wrench.
HINT: Removing the screwdriver lifts down the stopper plate and locks the plunger.
f. Insert a 3.0 mm (0.118 inch) diameter bar into the hole of the stopper plate with the stopper plate of the chain tensioner lifted down and locked.
HINT: If a 3.0 mm (0.118 inch) diameter bar cannot be inserted into the hole of the stopper plate, rotate the camshaft No. 2 slightly to the left and right. Then a 3.0 mm (0.118 inch) diameter bar can be inserted easily.
g. Secure the 3.0 mm (0.118 inch) diameter tear with tape.
h. Hold the hexagonal lobe of the camshaft No. 2 with the adjustable wrench.
i. Using SST, loosen the bolt.
SST 09023-38400
j. Remove the camshaft bearing caps No. 1 and No. 2 in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts keeping the camshaft No. 2 level.
k. Remove the bolt when the camshaft No. 2 is lifted slightly, then remove the camshaft No. 2 and camshaft timing gear.
l. Remove the camshaft bearing caps No. 2 in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts keeping the camshaft level.
m. Hold the timing chain by hand, then remove the camshaft.
n. Tie the timing chain with a string or wire.
NOTICE: Prevent foreign object from getting into the engine compartment with a shop rag.
o. Using a micrometer, measure the thickness of the removed valve lifter.
p. Calculate the thickness of the valve lifter so that the valve clearance comes within the specified value.
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.008 inch))
Exhaust A = B + (C - 0.30 mm (0.012 inch))
q. Select a new lifter with a thickness as close to the calculated values as possible.
HINT:
^ The lifters 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)
^ Refer to the New Lifter Thickness table on the next 2 pages.
Valve Lifter Selection Chart (Intake)
Valve Lifter Selection Chart (Exhaust)
r. Install the selected valve lifter.
s. Apply engine oil to the cam and cylinder head journal.
t. Hold the chain as illustrated, then install the camshaft and camshaft timing gear assembly so that the pain mark of the chain and the timing mark of the camshaft timing gear assembly are aligned.
u. 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.
v. Hold the chain as illustrated, then install the camshaft No. 2 and camshaft timing gear so that the pain mark of the chain and the timing mark of the camshaft timing gear are aligned.
w. Align the knock pin of the camshaft No. 2 with the pin groove of the camshaft timing gear.
x. Temporarily tighten the camshaft timing chain with the bolt.
y. Check the front marks and numbers on the bearing caps No. 1 and No. 2, then tighten the bolts uniformly in several steps in the sequence shown in the illustration.
Torque:
23 Nm (235 kgf-cm, 17 ft. lbs.) for Bearing Cap No. 1
13 Nm (130 kgf-cm, 9.6 ft. lbs.) for Bearing Cap No. 2
NOTICE: Tighten the bolts uniformly keeping the camshaft level.
z. Hold the hexagonal lobe of the camshaft No. 2 with the adjustable wrench.
aa. Using SST, tighten the bolt.
SST 09023-38400
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
ab. Remove the 3.0 mm (0.118 inch) diameter bar from the chain tensioner.
ac. Turn the crankshaft damper clockwise, then align its timing mark notch with the timing mark "0".
ad. Check that the timing marks are located as illustrated.
ae. Apply adhesive to 2 or 3 threads of the service hole screw plug bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324, or equivalent
NOTICE: Remove any oil from the bolts and bolt holes.
af. Using an 8 mm socket hexagon wrench, install the service hole screw plug.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
62. INSTALL FUEL INJECTOR ASSY
a. Install a new O-ring to the fuel injector.
b. Apply gasoline to the O-ring.
c. While turning the fuel injector clockwise and counterclockwise, push it to the fuel delivery pipe.
NOTICE:
^ Do not twist the O-ring.
^ After installing the fuel injector, check that it turns smoothly. If not, replace the O-ring with a new one and reinstall the fuel injector.
63. INSTALL FUEL DELIVERY PIPE SUB-ASSY
a. Install the 4 new insulators to the cylinder head.
b. Install the 2 delivery pipe spacers to the cylinder head.
c. Install the delivery pipe together with the injectors using the 3 bolts.
Torque:
19 Nm (194 kgf-cm, 14 ft. lbs.) for Bolt A
9.0 Nm (92 kgf-cm, 80 inch lbs.) for Bolt B
NOTICE:
^ Do not drop the fuel injectors.
^ After installing the delivery pipe, check that it is installed securely by turning the fuel injectors.
64. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Install the cylinder head gasket to the cylinder head cover.
b. Apply seal packing to the 2 locations as shown in the illustration, then install the cylinder head cover.
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.
c. Temporarily tighten the 9 bolts and 2 nuts on the cylinder head cover.
d. Using several steps, tighten the bolts and nuts with the specified torque in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.)
65. INSTALL VENTILATION VALVE SUB-ASSY
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
66. INSTALL OIL FILLER CAP GASKET
a. Install the oil filler cap gasket to the oil filler cap.
67. INSTALL OIL FILLER CAP SUB-ASSY
68. INSTALL WATER PUMP PULLEY
a. Temporarily install the water pump pulley with the 3 bolts.
b. Using SST, secure the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
c. Tighten the 3 bolts with the specified torque.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
69. INSTALL CRANK POSITION SENSOR
a. Apply a light coat of engine oil to the O-ring.
NOTICE: If the O-ring is damaged, replace the crank position sensor.
b. Install the crank position sensor with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
70. INSTALL THERMOSTAT
a. Install a new gasket to the thermostat.
b. Install the thermostat with the jiggle valve facing upward.
HINT: The jiggle valve may be set within 10° at either side as illustrated.
c. Install the water inlet with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
71. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
a. Apply a light coat of engine oil to the O-ring.
b. Install the camshaft timing oil control valve assembly with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
72. INSTALL CAM POSITION SENSOR
a. Apply a light coat of engine oil to the O-ring.
NOTICE: If the O-ring is damaged, replace the camshaft position sensor.
b. Install the camshaft position sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
73. INSTALL SPARK PLUG
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)