Manual de Taller Toyota Celica 1.8 st

1997 Toyota Celica ST Liftback L4-1762cc 1.8L DOHC MFI Copyright © 2007, ALLDATA 9.50 Page 1

Engine: Service and RepairRemoval




1. Remove battery and tray.2. Remove engine hood and under covers.3. Drain engine coolant, engine oil and transaxle oil.4. Remove air cleaner.

(a) Disconnect the connector, cables and hose:(1) Intake Air Temperature (IAT) sensor connector.(2) Accelerator cable from clamp on air cleaner hose.(3) Cruise control actuator cable from clamp on air cleaner hose.(4) Vacuum hose (from port P of throttle body) from air cleaner hose.

(b) Disconnect the 4 clamps, and disconnect the air cleaner cap from the air cleaner case. (c) Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body.(d) Remove the air cleaner cap and air cleaner hose assembly.(e) Remove the air filter.

(f) Disconnect the 2 engine wires from the clamps on the air cleaner case.(g) Remove the 3 bolts and air cleaner case.


5. Disconnect accelerator cable from throttle body and cable bracket.6. Disconnect cruise control actuator cable from clamps.7. Remove radiator assembly. Refer to Cooling System.8. Disconnect connector, wire, cable, strap and hoses.

Disconnect the connector, wire, cable, strap and hoses:

(1) Manifold Absolute Pressure (MAP) sensor vacuum hose from gas filter on intake manifold.(2) Power Steering (PS) air hose from intake manifold.(3) PS air hose from air pipe.(4) Brake booster vacuum hose from intake manifold.

(5) Data Link Connector (DLC)1 from bracket.(6) Engine wire protector from bracket.

(7) Ground cable from body.(8) Ground strap from body.


(9) 2 heater hoses from water inlet housing.

(10) Fuel inlet hose from fuel filter.(11) Fuel return hose from return pipe.(12) Evaporative Emission (EVAP) hose from charcoal canister.

9. Disconnect engine wire from engine compartment relay box.(a) Remove the 2 relay box covers.(b) Disconnect the 2 connectors.

10. Disconnect engine wire from cabin.(a) Remove these parts:

^ Scuff plate.^ Cowl side trim.^ Lower instrument panel finish panel.

(b) Take out the front side of the floor carpet.

(c) Disconnect the wire and connectors: (1) Engine wire from clamp on Engine Control Module (ECM) bracket.(2) 3 ECM connectors.(3) Circuit opening relay connector.(4) 3 connectors from the connectors on bracket.(5) A/C amplifier connector.

(d) Disconnect the connector, wire and clamp: (1) MAP sensor connector.(2) MAP sensor wire from clamp on bracket.(3) Engine wire clamp from the bracket.


(e) Remove the 2 nuts holding the engine wire retainer to the cowl panel.(f) Pull out the engine wire from the cabin.

11. Remove front exhaust pipe.(a) Disconnect the oxygen sensor connector (bank 1 sensor 1).(b) Remove the 2 bolts holding the front exhaust pipe to the exhaust pipe support bracket.(c) Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the Three-Way Catalytic Converter (TWC).(d) Remove the 3 nuts holding the front exhaust pipe to the exhaust manifold.(e) Remove the front exhaust pipe and 2 gaskets.

12. Remove drive shafts.

13. Remove generator drive belt. (a) Loosen the pivot bolt, adjusting lock bolt and adjusting bolt. (b) Remove the drive belt.

14. Disconnect A/C compressor from engine.

(a) Loosen the pulley nut and adjusting bolt. (b) Remove the drive belt.(c) Disconnect the A/C compressor connector.

(d) Remove the 4 bolts, and disconnect the A/C compressor from the engine.

NOTE: Suspend the A/C compressor securely.

15. Disconnect PS pump from engine.


(a) Loosen the pivot bolt and adjusting bolt. (b) Remove the drive belt.

(c) Remove the 4 bolts, and disconnect the PS pump from the engine.

NOTE: Suspend the PS pump securely.

16. Disconnect relay box for A/C. Remove the 2 bolts, and disconnect the relay box from the body.

17. M/T only: Disconnect clutch release cylinder from transaxle. (a) Remove the bolt, and disconnect the bracket from the transaxle.(b) Remove the 2 bolts, and disconnect the release cylinder from the transaxle.


18. Disconnect transaxle control cable(s) from transaxle.

19. A/T only: Disconnect transaxle control cable from engine mounting center member Remove the 2 bolts and clamp, and disconnect the control cable from the center member.

20. Remove exhaust pipe support bracket. Remove the 2 bolts, nut and support bracket.

21. Remove engine mounting center member.(a) Remove the 2 dust covers from the rear side of the center member.(b) Disconnect the A/C pipe from the bracket.(c) Remove the bolt and nut holding the front engine-mounting bracket to the mounting insulator.(d) Remove the bolt holding the rear engine mounting bracket to the mounting insulator.(e) Remove the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member.(f) Remove the 2 bolts and rear engine mounting bracket.


(g) Remove the 2 bolts holding the center member to the body, and remove the center member and rear engine mounting insulator.22. Remove engine and transaxle assembly from vehicle.

(a) Install an engine hanger No. 1 in the correct direction.Part No.:

Engine hanger No. 1: 12281 - 15050Bolt: 90119 - 10062

Torque: 27 Nm (20 ft. lbs.)(b) Attach the engine chain hoist to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

(c) Remove the 2 bolts and nut, and disconnect the LH engine mounting bracket from the mounting insulator.(d) Remove the through bolt and LH engine mounting insulator.

(e) Disconnect the ground strap connector.(f) Remove the bolt and 2 nuts, and disconnect the RH engine mounting bracket from the mounting insulator.


(g) Lift the engine out of the vehicle slowly and carefully.

NOTE: Make sure the engine is clear of all wiring, hoses and cables.

(h) Place the engine and transaxle assembly onto the stand.


Engine: Service and RepairInstallation

1. Install engine and transaxle assembly in vehicle.(a) Attach the engine chain hoist to the engine hangers.

(b) Slowly lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH body mounting.(c) Keep the engine level, and align RH and LH mountings with the body mountings.(d) Attach the RH engine mounting bracket to the mounting insulator, and temporarily install the 3 nuts.(e) Temporarily install the LH engine mounting insulator to the body with the through bolt.(f) Attach the LH engine mounting bracket to the mounting insulator, and install the 2 bolts and nut.

Torque: 64 Nm (47 ft. lbs.)(g) Tighten the through bolt holding the LH engine mounting insulator to the body.

Torque: 73 Nm (54 ft. lbs.)(h) Tighten the 3 nuts holding the RH engine mounting bracket to the mounting insulator.

Torque:12 mm head: 28 Nm (21 ft. lbs.)14 mm head: 52 Nm (38 ft. lbs.)

(i) Connect the ground strap connector.(j) Remove the engine chain hoist from the engine.(k) Remove the bolt and engine hanger No. 1.

2. Install engine mounting center member.(a) Attach the center member together with the rear engine mounting insulator to the front suspension member.(b) Temporarily install the 2 bolts holding the center member to the body.(c) Install the rear engine mounting bracket with the 2 bolts.

Torque: 78 Nm (58 ft. lbs.)(d) Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member.(e) Temporarily install the bolt holding the rear engine mounting bracket to the mounting insulator.(f) Temporarily install the bolt and nut holding the front engine mounting bracket to the mounting insulator.(g) Tighten the 2 bolts holding the center member to the body.

Torque: 35 Nm (26 ft. lbs.)(h) Tighten the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member.

Torque: 80 Nm (59 ft. lbs.) (i) Tighten the bolt holding the rear engine mounting bracket to the mounting insulator.

Torque: 88 Nm (65 ft. lbs.)(j) Tighten the bolt and nut holding the front engine mounting bracket to the mounting insulator.


Torque: 88 Nm (65 ft. lbs.)(k) Install the A/C pipe to the bracket.(i) Install the 2 dust covers to the center member.

3. Install exhaust pipe support bracket. Torque: 19 Nm (14 ft. lbs.)

4. Connect transaxle control cable(s) to transaxle.5. A/T only: Install transaxle control cable to engine mounting center member.6. Install transaxle control cable(s) to transaxle.7. M/T only: Install clutch release cylinder.

Torque: 12 Nm (9 ft. lbs.)8. Install relay box for A/C.9. Install Power Steering (PS) pump.

(a) Install the PS pump with the 4 bolts. Torque:

12 mm head: 19 Nm (14 ft. lbs.)14 mm head: 39 Nm (29 ft. lbs.)

(b) Install the adjusting bracket with the 2 bolts. Torque: 39 Nm (29 ft. lbs.)

(c) Temporarily install the lock bolt and drive belt.(d) Adjust the drive belt.

10. Install A/C compressor.

(a) Install the A/C compressor with the 4 bolts. Torque: 25 Nm (18 ft. lbs.)

(b) Connect the A/C compressor connector. (c) Install the drive belt with the adjusting bolt.(d) Tighten the idler pulley lock nut.

Torque: 39 Nm (29 ft. lbs.)11. Install generator drive belt. Refer to Starting and Charging. 12. Install drive shafts.

13. Install front exhaust pipe.(a) Place 2 new gaskets to the front and rear of the front exhaust pipe.(b) Temporarily install the 2 bolts and 2 new nuts holding the front exhaust pipe to the Three-Way Catalytic Converter (TWC).(c) Temporarily install 3 new nuts holding the front exhaust pipe to the exhaust manifold.(d) Temporarily install the 2 bolts holding the front exhaust pipe to the exhaust pipe support bracket.(e) Tighten the 3 nuts holding the front exhaust pipe to the exhaust manifold.

Torque: 62 Nm (46 ft. lbs.)


(f) Tighten the 2 bolts and 2 nuts holding the front exhaust pipe to the TWC.Torque: 43 Nm (32 ft. lbs.)

(g) Tighten install the 2 bolts holding the front exhaust pipe to the exhaust pipe support bracket. Torque: 19 Nm (14 ft. lbs.)

(h) Connect the oxygen sensor connector (bank 1 sensor 1).14. Connect engine wire to cabin.

(a) Push in the engine wire through the cowl panel.

(b) Install the engine wire retainer with the 2 nuts.(c) Connect the connector, wire and clamp:

(1) Manifold Absolute Pressure (MAP) sensor connector.(2) MAP sensor wire from clamp on bracket.(3) Engine wire clamp from the bracket.

(d) Connect the wire and connectors: (1) Engine wire from clamp on Engine Control Module (ECM) bracket.(2) 3 ECM connectors.(3) Circuit opening relay connector.(4) 3 connectors to connectors on bracket.(5) A/C amplifier connector.

(e) Install the floor carpet.(f) Install these parts:

^ Lower instrument panel finish panel.^ Cowl side trim.^ Scuff plate.

15. Connect engine wire to engine compartment relay box.16. Connect connector, wire, cable, strap and hoses.

Connect the connector, wire, cable, strap and hoses:

(1) MAP sensor vacuum hose to gas filter on intake manifold.(2) PS air hose to intake manifold.(3) PS air hose to air pipe.(4) Brake booster vacuum hose to intake manifold.


(5) Data Link Connector (DLC)1 to bracket.(6) Engine wire protector to bracket.

(7) Ground cable to body.(8) Ground strap to body.

(9) 2 heater hoses to water inlet housing.

(10) Fuel inlet hose to fuel filter.Connect the inlet hose with 2 new gaskets and the union bolt.Torque: 30 Nm (22 ft. lbs.)

(11) Fuel return hose to return pipe.(12) Evaporative Emission (EVAP) hose to charcoal canister.

17. Install radiator. Refer to Cooling System. 18. Install accelerator cable to throttle body, cable bracket and clamps.19. Install cruise control actuator cable to clamps.20. Install air cleaner.21. Fill with engine coolant and engine oil.22. Install battery and tray.23. Start engine and check for leaks.24. Perform engine adjustment.25. Install engine under covers and hood.26. Road test vehicle.

Check for abnormal noises, shock slippage, correct shift points and smooth operation.27. Recheck engine coolant and oil levels.


Compression Check: Testing and InspectionNOTE: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

1. Warm up and stop engine.Allow the engine to warm up to normal operating temperature.

2. Disconnect distributor connector.3. Disconnect high-tension cords from spark plugs.4. Remove spark plugs.5. Check cylinder compression pressure.

(a) Insert a compression gauge into the spark plug hole.(b) Fully open the throttle.(c) While cranking the engine, measure the compression pressure.

NOTE: Always use a fully charged battery to obtain engine revolutions of 250 rpm or more.

(d) Repeat steps (a) through (c) for each cylinder.

CAUTION: This measurement must be done in as short a time as possible.

Compression pressure: 1,320 kPa (191 psi) or more. Minimum pressure: 981 kPa (142 psi) Difference between each cylinder: 98 kPa (14 psi) or less.

(e) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plughole and repeat steps (a) through (c) for cylinders with low compression.^ If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.^ If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.

6. Reinstall spark plugs.Torque: 18 Nm (13 ft. lbs.)

7. Reconnect high-tension cords to spark plugs.8. Reconnect distributor connector.


Camshaft: Testing and InspectionINSPECT CAMSHAFTS AND BEARINGS

A. Inspect camshaft for runout.(a) Place the camshaft on V-blocks.(b) Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout: 0.04 mm (0.0016 inch)If the circle runout is greater than maximum, replace the camshaft.

B. Inspect cam lobes.Using a micrometer, measure the cam lobe height.Standard cam lobe height:

Intake: 42.610 - 42.710 mm (1.6776 - 1.6815 inch)Exhaust: 41.960 - 42.060 mm (1.6520 - 1.6560 inch)

Minimum cam lobe height:Intake: 42.20 mm (1.6614 inch)Exhaust; 41.55 mm (1.6358 inch)

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

C. Inspect camshaft journals.Using a micrometer, measure the journal diameter.Journal diameter:

Exhaust No. 1: 24.949 - 24.965 mm (0.9822 - 0.9829 inch)Others: 22.949 - 22.965 mm (0.9035 - 0.9041 inch)

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

D. Inspect camshaft bearings.


Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.

E. Inspect camshaft gear spring.Using a vernier caliper, measure the free distance between the spring ends.Free distance: 17.0 - 17.6 mm (0.669 - 0.693 inch)If the free distance is not as specified, replace the gear spring.

F. Inspect camshaft journal oil clearance.(a) Clean the bearing caps and camshaft journals.(b) Place the camshafts on the cylinder head.

(c) Lay a strip of Plastigage across each of the camshaft journals.

(d) Install the bearing caps.

CAUTION: Do not turn the camshaft.

(e) Remove the bearing caps.

(f) Measure the Plastigage at its widest point.Standard oil clearance: 0.035 - 0.072 mm (0.0014 - 0.0028 inch)Maximum oil clearance: 0.10 mm (0.0039 inch)If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.

(h) Completely remove the Plastigage.G. Inspect camshaft thrust clearance.

(a) Install the camshaft.


(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.Standard thrust clearance:


Maximum thrust clearance: 0.11 mm (0.0043 inch)If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as aset.

H. Inspect camshaft gear backlash.(a) Install the camshafts without installing the exhaust cam sub-gear.

(b) Using a dial indicator, measure the backlash.Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 inch)Maximum backlash: 0.30 mm (0.0188 inch)If the backlash is greater then maximum, replace the camshafts.


Camshaft: Service and RepairRemoval



1. Remove RH engine under cover.2. Drain engine coolant.

3. Disconnect these cables:


(1) Accelerator cable.(2) A/T: Throttle cable.(3) w/ Cruise control system: Cruise control actuator cable.

4. Remove air cleaner hose and cap.5. Remove distributor. Refer to Powertrain Management.

6. Loosen water pump pulley bolts.Stretch the belt tight and loosen the 4 water pump pulley bolts.

7. Remove generator and drive belt. Refer to Starting and Charging.8. w/ A/C: Remove A/C drive belt and idler pulley. 9. Remove Power Steering (PS) pump adjusting bracket and drive belt.

10. Remove water pump pulley.11. Remove front exhaust pipe. Refer to Exhaust System.

12. Remove exhaust manifold.(a) Remove the 5 bolts and upper heat insulator.(b) Remove the 3 bolts and exhaust manifold stay.(c) Remove the 5 nuts, exhaust manifold and gasket.(d) Remove the 3 bolts and lower heat insulator from the exhaust manifold.

13. Remove water outlet.(a) Disconnect the radiator upper hose from the water outlet.

(b) Remove the 2 bolts and water outlet.14. Remove water inlet and inlet housing assembly.

(a) Disconnect these connectors:^ Engine Coolant Temperature (ECT) sensor connector.^ ECT switch connector.^ Idle Air Control (IAC) valve connector.


(b) Disconnect these hoses:(1) Radiator outlet hose.(2) Water bypass hoses.(3) Heater water hoses.(4) 2 Evaporative Emission (EVAP) Thermal Vacuum Valve (TVV) vacuum hoses.

(c) Remove the bolt, 2 nuts, the water inlet and inlet housing assembly.15. Disconnect ground strap connector.

16. Disconnect hoses.Disconnect these hoses from the intake chamber:(1) Manifold Absolute Pressure (MAP) sensor vacuum hose from gas filters on intake manifold.(2) PS air hose from intake manifold.(3) PS air hose from air pipe.(4) Brake booster vacuum hose from intake manifold.

17. Remove Exhaust Gas Recirculation (EGR) vacuum modulator and Vacuum Switching Valve (VSV).18. Remove intake manifold stay.19. Remove air pipe.20. Remove throttle body. Refer to Powertrain Management.21. Remove air intake chamber cover. Refer to Powertrain Management.22. Remove delivery pipe and injectors. Refer to Powertrain Management.23. Disconnect engine wire.

(a) Disconnect these connectors:^ w/ A/C: A/C compressor connector. ^ Oil pressure switch connector.^ Crankshaft position sensor connector.^ Injector connector.


(b) Remove the 2 bolts and engine wire cover, and disconnect the engine wire from the cylinder head cover.(c) Disconnect the clamp from the wire harness bracket.

(d) Remove the bolt and 2 nuts, and disconnect the engine wire.

24. Remove intake manifold.Remove the 7 bolts, 4 nuts, ground strap, intake manifold and 2 gaskets.

25. Remove RH engine mounting insulator.26. Remove cylinder head cover.

Remove the 4 cap nuts, seal washers, head cover and gasket.27. Remove semi-circular plug.28. Remove spark plugs.29. Remove timing belt cover and timing belt.

30. Remove camshaft timing pulley.

31. Remove generator bracket. Remove the 3 bolts and bracket.

32. Remove oil dipstick guide and dipstick.(a) Disconnect the crankshaft position sensor connector from the dipstick guide.


(b) Remove the mounting bolt and pull out the dipstick guide and gauge.(c) Remove the O-ring from the dipstick guide.

33. Remove water inlet No. 2.Remove the 2 nuts and water inlet from the water inlet hose.

34. Remove camshafts.

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft isnot kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. Toavoid this, these steps should be carried out.

A. Remove intake camshaft.

(a) Set the exhaust camshaft so the knock pin is slightly above the top of the cylinder head.

NOTE: The above angle allows the No. 1 and No. 3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

(b) Remove the 2 bolts and front bearing cap.


(c) Secure the intake camshaft sub-gear to the main gear with a service bolt.Recommended service bolt:

Thread diameter: 6 mmThread pitch: 1.0 mmBolt length: 16 - 20 mm (0.63 - 0.79 inch)

NOTE: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the aboveoperation.

(d) Uniformly loosen and remove the 8 bearing cap bolts in several passes in the sequence shown.(e) Remove the 4 bearing caps and camshaft.

NOTE: If the camshaft is not lifted out straight and level, reinstall the No. 2 bearing cap with the 2 bolts. Then alternately loosenand remove the bearing cap bolts with the camshaft gear pulled up.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

B. Remove exhaust camshaft.

(a) Set the exhaust camshaft so the knock pin is located slightly counterclockwise from the vertical axis of the camshaft.

NOTE: The above angle allows the No. 1 and No. 3 cylinder cam lobes of exhaust camshaft to push their valve lifters evenly.


(b) Remove the 2 bolts; front bearing cap and oil seal.

CAUTION: The front bearing cap is difficult to remove, do not use a hammer and chisel as this may damage the bearing cap.

(c) Uniformly loosen and remove the 8 bearing cap bolts in several passes in the sequence shown.(d) Remove the 4 bearing caps and camshaft.

NOTE: If the camshaft is not being lifted out straight and level, reinstall the No. 3 bearing cap with the 2 bolts.

Then alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.



Camshaft: Service and RepairDisassemblyDISASSEMBLE INTAKE CAMSHAFT

1. Mount the hexagonal wrench head portion of the camshaft in a vise.

CAUTION: Be careful not to damage the camshaft.

2. Insert service bolts (A) and (B) into the service holes of the camshaft sub-gear. 3. Using a screwdriver, turn the sub-gear clockwise, and remove service bolt (C).


4. Using snap ring pliers, remove the snap ring.

5. Remove the following parts: (1) Wave washer. (2) Camshaft sub-gear.(3) Camshaft gear spring.


Camshaft: Service and RepairAssemblyASSEMBLE INTAKE CAMSHAFT

1. Mount the hexagon wrench head portion of the cam shaft in a vise.


2. Install these parts:(1) Camshaft gear spring.(2) Camshaft sub-gear.(3) Wave washer.

NOTE: Align the pins on the gears with the spring ends.

3. Using snap ring pliers, install the snap ring.

4. Insert service bolts (A) and (B) into the service hole of the camshaft sub-gear.5. Using a screwdriver, align the holes of the camshaft drive gear and sub-gear by turning camshaft sub-gear clockwise, and install a service

bolt (C).


6. Remove service bolts (A) and (B).


Camshaft: Service and RepairInstallation

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft isnot kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. Toavoid this, the following steps should be carried out.

A. Install exhaust camshaft.(a) Apply Multipurpose (MP) grease to the thrust portion of the camshaft.

(b) Place the exhaust camshaft so that the knock pin is located slightly counterclockwise from the vertical axis of the camshaft.

NOTE: The above angle allows the No. 1 and No. 3 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.

(c) Remove any old packing Formed In Place Gasket (FIPG) material.

(d) Apply seal packing to the cylinder head as shown in the illustration.Seal packing: Part No. 08826 - 00080 or equivalent.

(e) Install the 5 bearing caps in their proper locations.(f) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(g) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.Torque: 13 Nm (9 ft. lbs.)

(h) Apply MP grease to a new oil seal lip.


(i) Using SST Crankshaft Front Oil Seal Replacer # 09223 - 46011 or equivalent, tap in the oil seal.

NOTE: ^ Do not install the oil seal with the lip facing the wrong direction. ^ Insert the oil seal into the deepest part of the cylinder head.

B. Install intake camshaft.

(a) Set the intake camshaft so that the knock pin is slightly above the top of the cylinder head.(b) Apply MP grease to the thrust portion of the camshaft.

(c) Engage the intake camshaft gear to the exhaust camshaft gear by matching the assembly installation marks on each gear.

CAUTION: There are also timing marks (for Top Dead Center (TDC)) on each gear as shown in the illustration. Do not use thesemarks.

(d) Roll down the intake camshaft onto the bearing journals while engaging gears with each other.





(h) Remove the service bolt (C).

(i) Install the No. 1 bearing cap with the arrow mark facing forward.

CAUTION: If the No. 1 bearing cap does not fit properly, push the camshaft gear backwards by prying apart the cylinder head andcamshaft gear with a screwdriver.

(j) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.(k) Install and alternately tighten the 2 bolts in several passes.


(l) Turn the exhaust camshaft clockwise, and set it with the knock pin facing upward.

(m) Check that the timing marks of the camshaft gears are aligned.


NOTE: The assembly installation marks are on the upside.


Lifter: Testing and InspectionINSPECT VALVE LIFTERS AND LIFTER BORES

1. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.Lifter bore diameter: 31.000 - 31.025 mm (1.2205 - 1.2215 inch)

2. Using a micrometer, measure the lifter diameter.Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 inch)

3. Subtract the lifter diameter measurement from the lifter bore diameter measurement.Standard oil clearance: 0.024 - 0.059 mm (0.0009 - 0.0023 inch)Maximum oil clearance: 0.07 mm (0.0028 inch)If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.


Cylinder Block Assembly: Testing and Inspection1. Clean cylinder block.

A. Remove gasket material.Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

B. Clean cylinder block.Using a soft brush and solvent, thoroughly clean the cylinder block.

2. Inspect top surface of cylinder block for flatness.Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for warpage.Maximum warpage: 0.05 mm (0.0020 inch)If warpage is greater than maximum, replace the cylinder block.

3. Inspect cylinder for vertical scratches.Visually check the cylinder for vertical scratches.If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

4. Inspect cylinder bore diameter.

NOTE: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of thecylinder block.


Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.Standard diameter:

STDMark "1": 81.000 - 81.010 mm (3.1890 - 3.1894 inch)Mark "2": 81.010 - 81.020 mm (3.1894 - 3.1898 inch)Mark "3": 81.020 - 81.030 mm (3.1898 - 3.1902 inch)

Maximum diameter:STD: 81.23 mm (3.1982 inch)O/S 0.50: 81.73 mm (3.2177 inch)

If the diameter is greater than maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

5. Remove cylinder ridge.If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.


Cylinder Block Assembly: Service and Repair

Preparation For Disassembly

1. M/T: Remove flywheel.2. A/T: Remove drive plate.


3. Remove rear end plate.Remove the 2 bolts and end plate.

4. Install engine to engine stand for disassembly.5. Remove timing belt and pulleys.6. Remove cylinder head.

7. Remove generator bracket.Remove the 3 bolts and generator bracket.

8. Remove RH engine mounting bracket.Remove the 3 bolts and mounting bracket.

9. Remove water pump. Refer to Cooling System.10. Remove oil filter.11. Remove engine coolant drain plug.12. Remove oil pressure switch.

13. Remove knock sensor.Using Special Service Tool (SST) Oil Pressure Switch Socket # 09816 - 30010 or equivalent, remove the knock sensor.

14. Remove oil pan and oil pump.

Disassembly


1. Remove rear oil seal retainer.Remove the 6 bolts, retainer and gasket.


2. Check connecting rod thrust clearance.Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.Standard thrust clearance: 0.15 - 0.25 mm (0.0059 - 0.0098 inch)Maximum thrust clearance: 0.30 mm (0.0118 inch)If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

3. Remove connecting rod caps and check oil clearance.

(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.(b) Remove the 2 connecting rod cap nuts.

(c) Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap rightand left.

NOTE: Keep the lower bearing inserted with the connecting rod cap.

(d) Clean the crank pin and bearing.(e) Check the crank pin and bearing for pitting and scratches.

If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

(f) Lay a strip of Plastigage across the crank pin.(g) Install the connecting rod cap with the 2 bolts.

CAUTION: Do not turn the crankshaft.

(h) Remove the 2 bolts, connecting rod cap and lower bearing (See procedure (b) and (c) above).


(i) Measure the Plastigage at its widest point.Standard oil clearance:

STD: 0.020 - 0.048 mm (0.0008 - 0.0019 inch)U/S 0.25: 0.019 - 0.058 mm (0.0007 - 0.0022 inch)

Maximum oil clearance: 0.08 mm (0.0031 inch)If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.

NOTE: If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes ofstandard bearings, marked "1", "2" and "3" accordingly.

Standard sized bearing center wall thickness:Mark "1": 1.486 - 1.490 mm (0.0585 - 0.0587 inch)Mark "2": 1.490 - 1.494 mm (0.0587 - 0.0588 inch)Mark "3": 1.494 - 1.498 mm (0.0588 - 0.0590 inch)

(j) Completely remove the Plastigage.4. Remove piston and connecting rod assemblies.

(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

NOTE: ^ Keep the bearings, connecting rod and cap together.^ Arrange the piston and connecting rod assemblies in the correct order.

5. Check crankshaft thrust clearance.Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.


Standard thrust clearance: 0.015 - 0.220 mm (0.0006 - 0.0087 inch)Maximum thrust clearance: 0.30 mm (0.0118 inch)If the thrust clearance is greater than maximum, replace the thrust washer as a set.Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 inch)

6. Remove main bearing caps and check oil clearance.

(a) Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown.

(b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearingsand lower thrust washers (No. 3 main bearing cap only).

NOTE: ^ Keep the lower bearing and main bearing cap together.^ Arrange the main bearing caps and lower thrust washers in the correct order.

(c) Lift out the crankshaft.

NOTE: Keep the upper bearing and upper thrust washers together with the cylinder block.

(d) Clean each main journal and bearing.(e) Check each main journal and bearing for pitting and scratches.

If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.(f) Place the crankshaft on the cylinder block.

(g) Lay a strip of Plastigage across each journal.(h) Install the main bearing caps.

CAUTION: Do not turn the crankshaft.

(i) Remove the main bearing caps.(See procedure (a) and (b) above).


(j) Measure the Plastigage at its widest point.Standard clearance:

STD: 0.015 - 0.033 mm (0.0006 - 0.0013 inch)U/S 0.25: 0.016 - 0.056 mm (0.0006 - 0.0022 inch)

Maximum clearance: 0.08 mm (O.0031 inch)

NOTE: If replacing the cylinder block subassembly, the bearing standard clearance will be: 0.015 - 0.045 mm (0.0006 - 0.0018 inch)

If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.

NOTE: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined,select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing withthe same number as the total. There are 5 sizes of standard bearings, marked "1","2","3","4" and "5" accordingly.

Cylinder block main journal bore diameter:Mark 1: 52.025 - 52.031 mm (2.0482 2.0485 inch)Mark 2: 52.031 - 52.037 mm (2.0485 2.0487 inch)Mark 3: 52.037 - 52.043 mm (2.0487 2.0489 inch)

Crankshaft journal diameter:Mark 0: 47.994 - 48.000 mm (1.8895 - 1.8898 inch)Mark 1: 47.988 - 47.994 mm (1.8893 - 1.8895 inch)Mark 2: 47.982 - 47.988 mm (1.8891 - 1.8893 inch)

Standard sized bearing center wall thickness:Mark 1: 2.002 - 2.005 mm (0.0788 - 0.0789 inch)


Mark 2: 2.005 - 2.008 mm (0.0789 - 0.0791 inch)Mark 3: 2.008 - 2.011 mm (0.0791 - 0.0792 inch)Mark 4: 2.011 - 2.014 mm (0.0792 - 0.0793 inch)Mark 5: 2.014 - 2.017 mm (0.0793 - 0.0794 inch)

(k) Completely remove the Plastigage.7. Remove crankshaft.

(a) Lift out the crankshaft.(b) Remove the 5 upper bearings and 2 upper thrust washers from the cylinder block.

NOTE: Arrange the main bearing caps, bearings and thrust washers in the correct order.

Cleaning1. Clean cylinder block.

A. Remove gasket material.Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

B. Clean cylinder block.Using a soft brush and solvent, thoroughly clean the cylinder block.

AssemblyNOTE:

^ Thoroughly clean all parts to be assembled.^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.^ Replace all gaskets, O-rings and oil seals with new parts.

1. Install main bearings.

NOTE: Upper bearings have an oil groove and oil holes; lower bearings do not.


(a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

NOTE: A number is marked on each main bearing cap to indicate the installation position.

2. Install upper thrust washers.Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

3. Place crankshaft on cylinder block.4. Install main bearing caps and lower thrust washers.

(a) Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.

(b) Install the 5 main bearing caps in their proper locations.

NOTE: Each bearing cap has a number and front mark.


(c) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.

(d) Install and uniformly tighten the 10 bolts of the main bearing cap in several passes, in the sequence shown.Torque: 60 Nm (44 ft. lbs.)

(e) Check that the crankshaft turns smoothly.

(f) Check the crankshaft thrust clearance.^ Using a dial indicator, measures the thrust clearance while prying the crankshaft back and forth: with a screwdriver.

Standard thrust clearance: 0.015 - 0.220 mm (0.0006 - 0.0087 inch)Maximum thrust clearance: 0.30 mm (0.0118 inch)If the thrust clearance is greater than maximum, replace the thrust washers as a set.

5. Install piston and connecting rod assembles.

Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark ofthe piston facing forward.

6. Install connecting rod caps.A. Place connecting rod cap on connecting rod.

(a) Match the numbered connecting rod cap with the connecting rod.

(b) Install the connecting rod cap with the front mark facing forward.B. Install connecting rod cap nuts.

NOTE: ^ The cap nuts are tightened in 2 progressive steps (steps (b) and (d)).^ If any one of the connecting rod bolts are broken or deformed, replace it.


(a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.

(b) Install and alternately tighten the bolts of the connecting rod cap in several passes.Torque: 25 Nm (18 ft. lbs.)If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolt.

(c) Mark the front of the connecting rod cap bolt with paint.

(d) Tighten the connecting rod cap bolts by an additional 90° as shown.(e) Check that the painted mark is now at a 90° angle to the front.(f) Check that the crankshaft turns smoothly.

(g) Check connecting rod thrust clearance.Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.Standard thrust clearance: 0.15 - 0.25 mm (0.0059 - 0.0098 inch)Maximum thrust clearance: 0.30 mm (0.0118 inch)If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

7. Install rear oil seal retainer.Install a new gasket and the retainer with the 6 bolts.Torque: 9.3 Nm (82 inch lbs.)

Cylinder BoringNOTE:

^ Bore all the 4 cylinders for the oversized piston outside diameter.^ Replace all the piston rings with ones to match the oversized pistons.


1. Keep oversized pistons.Oversized piston diameter:O/S 0.50: 81.405 - 81.435 mm (3.2049 - 3.2061 inch)

2. Calculate amount to bore cylinders.

(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 24.5 mm (0.965 inch) from the pistonhead.

(b) Calculate the amount of each cylinder is to be rebored as follows:Size to be rebored = P + C - H

P = Piston diameter.C = Piston oil clearance: 0.085 - 0.105 mm (0.0031 - 0.0041 inch)H = Allowance for honing: 0.020 mm (0.0008 inch) or less

3. Bore and hone cylinder to calculated dimensions.Maximum honing: 0.02 mm (0.0008 inch)

CAUTION: Excess honing will destroy the finished roundness.

After Assembly1. Install oil pan and oil pump.

2. Install knock sensor.Using Special Service Tool (SST) Oil Pressure Switch Socket # 09816 - 30010 or equivalent, install the knock sensor.Torque: 37 Nm (27 ft. lbs.)

3. Install oil pressure switch.4. Install engine coolant drain plug.5. Install oil filter.6. Install water pump. Refer to Cooling System.7. Install RH engine mounting bracket.

Torque: 51 Nm (38 ft. lbs.)8. Install generator bracket.

Torque: 26 Nm (20 ft. lbs.)9. Install cylinder head.

10. Install timing belt and pulleys.11. Disconnect engine from engine stand.12. Install rear end plate.

Torque: 5.6 Nm (48 inch lbs.)14. M/T: Install flywheel.


(a) Apply adhesive to 2 or 3 threads of the mounting bold end. Adhesive: Part No. 08833 - 00070, Adhesive 1324, THREE BOND 1324 or equivalent.

(b) Install the flywheel on the crankshaft.

Flywheel Tightening Sequence

(c) Install and uniformly tighten the 6 mounting bolts, in several passes, in the sequence shown. Torque: 78 Nm (58 ft. lbs.)

A/T Drive Plate Tightening Sequence

15. A/T: Install drive plate.(See procedure in step 14).Torque: 64 Nm (47 ft. lbs.)


Connecting Rod Bearing: Service and Repair

1. Align the bearing claw with the groove of the connecting rod or connecting cap.2. Install the bearings in the connecting rod and connecting rod cap.


Connecting Rod: Service and RepairDisassembly

DISCONNECT CONNECTING ROD FROM PISTON 1. Using Special Service Tool (SST) Piston Pin Remover & Replacer # 09221 - 25026 (Body # 09221 - 00020, Spring # 09221 - 00030,

Bushing "E" # 09221 - 00181, Guide "K" # 09221 - 00190, Guide "L" # 09221 - 00200) or equivalents, press out the piston pin from the piston.

2. Remove the connecting rod.

NOTE: ^ The piston and pin are a matched set.^ Arrange the pistons, pins, rings, connecting rods and bearings in correct order.


Connecting Rod: Service and RepairAssemblyASSEMBLE PISTON AND CONNECTING ROD

1. Coat the piston pin and piston pin holes with engine oil.

2. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

3. Using Special Service Tool (SST) Piston Pin Remover & Replacer # 09221 - 25026 (Body # 09221 - 00020, Spring # 09221 - 00030,Bushing "E" # 09221 - 00181, Guide "K" # 09221 - 00190, Guide "L" # 09221 - 00200) or equivalents, press in the piston pin.


Piston: Service and RepairDisassembly

DISCONNECT CONNECTING ROD FROM PISTONUsing Special Service Tool (SST) Piston Pin Remover & Replacer # 09221 - 25026 (Body # 09221 - 00020, Spring # 09221 - 00030,Bushing "E" # 09221 - 00181, Guide "K" # 09221 - 00190, Guide "L" # 09221 - 00200) or equivalents, press out the piston pin from thepiston.Remove the connecting rod.

NOTE:^ The piston and pin are a matched set.^ Arrange the pistons, pins, rings, connecting rods and bearings in correct order.


Piston: Service and RepairCleaning

1. Using a gasket scraper, remove the carbon from the piston top.

2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.

3. Using solvent and a brush, thoroughly clean the piston.

CAUTION: Do not use a wire brush.


Piston: Service and RepairAssemblyASSEMBLE PISTON AND CONNECTING ROD

1. Coat the piston pin and piston pin holes with engine oil.

2. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

3. Using Special Service Tool (SST) Piston Pin Remover & Replacer # 09221 - 25026 (Body # 09221 - 00020, Spring # 09221 - 00030,Bushing "E" # 09221 - 00181, Guide "K" # 09221 - 00190, Guide "L" # 09221 - 00200) or equivalents, press in the piston pin.


Piston Ring: Service and RepairRemoval

1. Using a piston ring expander, remove the 2 compression rings.2. Remove the 2 side rails and oil ring expander by hand.

NOTE: Arrange the piston rings in correct order only.


Piston Ring: Service and RepairInstallation

1. Install the oil ring expander and 2 side rails by hand.

2. Using a piston ring expander; install the 2 compression rings with the code mark facing upward (No. 2 compression ring only).Code mark (No. 2 compression ring only): 2R or T

3. Position the piston rings so that the ring ends are as shown.

CAUTION: Do not align the ring ends.


Cylinder Head Assembly: Testing and Inspection1. Clean top surfaces of pistons and cylinder block.

(a) Turn the crankshaft, and bring each piston to Top Dead Center (TDC). Using a gasket scraper, remove all the carbon from the piston topsurface.

(b) Using a gasket scraper, remove all the gasket material from the cylinder block surface.(c) Using compressed air, blow carbon and oil from the bolt holes.

WARNING: Protect your eyes when using high-pressure compressed air.

2. Clean cylinder head.

A. Remove gasket material.Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

CAUTION: Be careful not to scratch the cylinder block contact surface.

B. Clean combustion chambers.Using a wire brush, remove all the carbon from the. combustion chamber.



C. Clean valve guide bushings.Using a valve guide bushing brush and solvent, clean all the guide bushings.

D. Clean cylinder head Using a soft brush and solvent, thoroughly clean the cylinder head.3. Inspect cylinder head.

A. Inspect for flatness.Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage.Maximum warpage:

Cylinder block side: 0.05 mm (0.0020 inch)Manifold side: 0.10 mm (0.0039 inch)

If warpage is greater than maximum, replace the cylinder head.

B. Inspect for cracks.Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.If cracked, replace the cylinder head.


4. Clean valves.(a) Using a gasket scraper, chip off any carbon from the valve head.(b) Using a wire brush, thoroughly clean the valve.

5. Inspect valve stems and guide bushings.

(a) Using a caliper gauge, measure the inside diameter of the guide bushing.Bushing inside diameter: 6.010 - 6.030 mm (0.2366 - 0.2374 inch)

(b) Using a micrometer, measure the diameter of the valve stem.Valve stem diameter:


(c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.Standard oil clearance:


Maximum oil clearance:Intake: 0.08 mm (0.0031 inch)Exhaust: 0.10 mm (0.0039 inch)

If the clearance is greater than maximum, replace the valve and guide bushing.6. If necessary, replace valve guide bushings.

(a) Gradually heat the cylinder head to 80 - 100° C (176 - 212° F).

(b) Using Special Service Tool (SST) Valve Guide Bushing Remover & Replacer Set # 09201 - 10000 (Valve Guide Bushing Remover &Replacer 6 # 09201 - 01060), Handle Set # 09950 - 70010 (Handle 150 # 09951 - 07150) or equivalents and a hammer, tap out the guidebushing.


(c) Using a caliper gauge, measure the bushing bore diameter of the cylinder head.

(d) Select a new guide bushing (STD or O/S 0.05).If the bushing bore diameter of the cylinder head is greater than 11.027 mm (0.4341 inch), machine the bushing bore to the followingdimension: 11.050 - 11.077 mm (0.4350 - 0.4361 inch)If the bushing bore diameter of the cylinder head is greater than 11.077 mm (0.4361 inch), replace the cylinder head.

(e) Gradually heat the cylinder head to 80 - 100° C (176 - 212° F).

(f) Using SST Valve Guide Bushing Remover & Replacer Set # 09201 - 10000 (Valve Guide Bushing Remover & Replacer 6 # 09201 -01060), Handle Set # 09950 - 70010 (Handle 150 # 09951 - 07150) or equivalents and a hammer, tap in a new guide bushing until thereis 12.7 - 13.1 mm (0.500 - 0.516 inch) protruding from the cylinder head.

(g) Using a sharp 6 mm reamer, ream the guide bushing to obtain the standard specified clearance (See step 5 above) between the guidebushing and valve stem.

7. Inspect and grind valves.(a) Grind the valve enough to remove pits and carbon.

(b) Check that the valve is ground to the correct valve face angle.Valve face angle: 44.5°


(c) Check the valve head margin thickness.Standard margin thickness: 0.8 - 1.2 mm (0.031 - O.047 inch)Minimum margin thickness: 0.5 mm (0.020 inch)If the margin thickness is less than minimum, replace the valve.

(d) Check the valve overall length.Standard overall length:

Intake: 87.45 mm (3.4429 inch)Exhaust: 87.84 mm (3.4583 inch)

Minimum overall length:Intake: 86.95 mm (3.4232 inch)Exhaust: 87.34 mm (3.4386 inch)

If the overall length is less than minimum, replace the valve.

(e) Check the surface of the valve stem tip for wear.If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

CAUTION: Do not grind off more than the minimum length.

8. Inspect and clean valve seats.

(a) Using a 45° carbide cutter, resurface the valve seats.Remove only enough metal to clean the seats.


(b) Check the valve seating position.Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve.

(c) Check the valve face and seat for the following:^ If blue appears 360° around the face, the valve is concentric. If not, replace the valve.^ If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.^ Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 inch)If not, correct the valve seats as follows:

(1) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

(2) If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

(d) Hand-lap the valve and valve seat with an abrasive compound.(e) After hand-lapping, clean the valve and valve seat.

9. Inspect valve springs.

(a) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 inch)If the deviation is greater than maximum, replace the valve spring.


(b) Using a vernier caliper, measure the free length of the valve spring.Free length: 38.57 mm (1.5185 inch)If the free length is not as specified, replace the valve spring.

(c) Using a spring tester, measure the tension of the valve spring at the specified installed length.Installed tension: 166 N (37.3 lbs) at 31.7 mm (1.248 inch)If the installed tension is not as specified, replace the valve spring.

10. Inspect camshafts and bearings.

A. Inspect camshaft for runout.(a) Place the camshaft on V-blocks.(b) Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout: 0.04 mm (0.0016 inch)If the circle runout is greater than maximum, replace the camshaft.

B. Inspect cam lobes.Using a micrometer, measure the cam lobe height.Standard cam lobe height:


Minimum cam lobe height:Intake: 42.20 mm (1.6614 inch)Exhaust; 41.55 mm (1.6358 inch)

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


C. Inspect camshaft journals.Using a micrometer, measure the journal diameter.Journal diameter:

Exhaust No. 1: 24.949 - 24.965 mm (0.9822 - 0.9829 inch)Others: 22.949 - 22.965 mm (0.9035 - 0.9041 inch)

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

D. Inspect camshaft bearings.Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.

E. Inspect camshaft gear spring.Using a vernier caliper, measure the free distance between the spring ends.Free distance: 17.0 - 17.6 mm (0.669 - 0.693 inch)If the free distance is not as specified, replace the gear spring.

F. Inspect camshaft journal oil clearance.(a) Clean the bearing caps and camshaft journals.(b) Place the camshafts on the cylinder head.

(c) Lay a strip of Plastigage across each of the camshaft journals.


(d) Install the bearing caps.

CAUTION: Do not turn the camshaft.

(e) Remove the bearing caps.

(f) Measure the Plastigage at its widest point.Standard oil clearance: 0.035 - 0.072 mm (0.0014 - 0.0028 inch)Maximum oil clearance: 0.10 mm (0.0039 inch)If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.

(g) Completely remove the Plastigage.G. Inspect camshaft thrust clearance.

(a) Install the camshaft.

(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.Standard thrust clearance:


Maximum thrust clearance: 0.11 mm (0.0043 inch)If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as aset.

H. Inspect camshaft gear backlash.(a) Install the camshafts without installing the exhaust cam sub-gear.

(b) Using a dial indicator, measure the backlash.Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 inch)Maximum backlash: 0.30 mm (0.0188 inch)If the backlash is greater then maximum, replace the camshafts.


11. Inspect valve lifters and lifter bores.

(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.Lifter bore diameter: 31.000 - 31.025 mm (1.2205 - 1.2215 inch)

(b) Using a micrometer, measure the lifter diameter.Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 inch)

(c) Subtract the lifter diameter measurement from the lifter bore diameter measurement.Standard oil clearance: 0.024 - 0.059 mm (0.0009 - 0.0023 inch)Maximum oil clearance: 0.07 mm (0.0028 inch)If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.

12. Inspect intake and exhaust manifolds.

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

Intake manifold: 0.20 mm (0.0079 inch)Exhaust manifold: 0.30 mm (0.0118 inch)

If warpage is greater than maximum, replace the manifold.

13. If necessary, replace spark plug tube gaskets.(a) Using a screwdriver, pry out the tube gasket.


(b) Using SST Replacer Set "B" # 09550 - 10012 (No. 2 Replacer Handle # 09552 - 10010, Differential Drive Pinion Front BearingRemover # 09556 - 10010) or equivalents and a hammer, tap in a new tube gasket until its surface is flush with the upper edge of thecylinder head cover.

(c) Apply a light coat of Multipurpose (MP) grease to the gasket lip.


Cylinder Head Assembly: Service and RepairCylinder Head Removal



1. Remove RH engine under cover.2. Drain engine coolant.

3. Disconnect these cables:


(1) Accelerator cable.(2) A/T: Throttle cable.(3) w/ Cruise control system: Cruise control actuator cable.

4. Remove air cleaner hose and cap.5. Remove distributor. Refer to Powertrain Management.

6. Loosen water pump pulley bolts.Stretch the belt tight and loosen the 4 water pump pulley bolts.

7. Remove generator and drive belt. Refer to Starting and Charging.8. w/ A/C: Remove A/C drive belt and idler pulley. 9. Remove Power Steering (PS) pump adjusting bracket and drive belt.

10. Remove water pump pulley.11. Remove front exhaust pipe. Refer to Exhaust System.

12. Remove exhaust manifold.(a) Remove the 5 bolts and upper heat insulator.(b) Remove the 3 bolts and exhaust manifold stay.(c) Remove the 5 nuts, exhaust manifold and gasket.(d) Remove the 3 bolts and lower heat insulator from the exhaust manifold.

13. Remove water outlet.(a) Disconnect the radiator upper hose from the water outlet.

(b) Remove the 2 bolts and water outlet.14. Remove water inlet and inlet housing assembly.

(a) Disconnect these connectors:^ Engine Coolant Temperature (ECT) sensor connector.^ ECT switch connector.^ Idle Air Control (IAC) valve connector.


(b) Disconnect these hoses:(1) Radiator outlet hose.(2) Water bypass hoses.(3) Heater water hoses.(4) 2 Evaporative Emission (EVAP) Thermal Vacuum Valve (TVV) vacuum hoses.

(c) Remove the bolt, 2 nuts, the water inlet and inlet housing assembly.15. Disconnect ground strap connector.

16. Disconnect hoses.Disconnect these hoses from the intake chamber:(1) Manifold Absolute Pressure (MAP) sensor vacuum hose from gas filters on intake manifold.(2) PS air hose from intake manifold.(3) PS air hose from air pipe.(4) Brake booster vacuum hose from intake manifold.

17. Remove Exhaust Gas Recirculation (EGR) vacuum modulator and Vacuum Switching Valve (VSV).18. Remove intake manifold stay.19. Remove air pipe.20. Remove throttle body. Refer to Powertrain Management.21. Remove air intake chamber cover. Refer to Powertrain Management.22. Remove delivery pipe and injectors. Refer to Powertrain Management.23. Disconnect engine wire.

(a) Disconnect these connectors:^ w/ A/C: A/C compressor connector. ^ Oil pressure switch connector.^ Crankshaft position sensor connector.^ Injector connector.


(b) Remove the 2 bolts and engine wire cover, and disconnect the engine wire from the cylinder head cover.(c) Disconnect the clamp from the wire harness bracket.

(d) Remove the bolt and 2 nuts, and disconnect the engine wire.

24. Remove intake manifold.Remove the 7 bolts, 4 nuts, ground strap, intake manifold and 2 gaskets.

25. Remove RH engine mounting insulator.26. Remove cylinder head cover.

Remove the 4 cap nuts, seal washers, head cover and gasket.27. Remove semi-circular plug.28. Remove spark plugs.29. Remove timing belt cover and timing belt.

30. Remove camshaft timing pulley.

31. Remove generator bracket. Remove the 3 bolts and bracket.

32. Remove oil dipstick guide and dipstick.(a) Disconnect the crankshaft position sensor connector from the dipstick guide.


(b) Remove the mounting bolt and pull out the dipstick guide and gauge.(c) Remove the O-ring from the dipstick guide.

33. Remove water inlet No. 2.Remove the 2 nuts and water inlet from the water inlet hose.

34. Remove camshafts.

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft isnot kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. Toavoid this, these steps should be carried out.


(a) Set the exhaust camshaft so the knock pin is slightly above the top of the cylinder head.


(b) Remove the 2 bolts and front bearing cap.


(c) Secure the intake camshaft sub-gear to the main gear with a service bolt.Recommended service bolt:

Thread diameter: 6 mmThread pitch: 1.0 mmBolt length: 16 - 20 mm (0.63 - 0.79 inch)

NOTE: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the aboveoperation.

(d) Uniformly loosen and remove the 8 bearing cap bolts in several passes in the sequence shown.(e) Remove the 4 bearing caps and camshaft.

NOTE: If the camshaft is not lifted out straight and level, reinstall the No. 2 bearing cap with the 2 bolts. Then alternately loosenand remove the bearing cap bolts with the camshaft gear pulled up.


B. Remove exhaust camshaft.

(a) Set the exhaust camshaft so the knock pin is located slightly counterclockwise from the vertical axis of the camshaft.

NOTE: The above angle allows the No. 1 and No. 3 cylinder cam lobes of exhaust camshaft to push their valve lifters evenly.


(b) Remove the 2 bolts; front bearing cap and oil seal.

CAUTION: The front bearing cap is difficult to remove, do not use a hammer and chisel as this may damage the bearing cap.

(c) Uniformly loosen and remove the 8 bearing cap bolts in several passes in the sequence shown.(d) Remove the 4 bearing caps and camshaft.

NOTE: If the camshaft is not being lifted out straight and level, reinstall the No. 3 bearing cap with the 2 bolts.

Then alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.


35. Disassemble intake camshaft.

(a) Mount the hexagonal wrench head portion of the camshaft in a vise.


(b) Insert service bolts (A) and (B) into the service holes of the camshaft sub-gear. (c) Using a screwdriver, turn the sub-gear clockwise, and remove service bolt (C).


(d) Using snap ring pliers, remove the snap ring.


(e) Remove the following parts: (1) Wave washer. (2) Camshaft sub-gear.(3) Camshaft gear spring.

36. Remove semi-circular plug.37. Remove cylinder head.

(a) Using Special Service Tool (SST) Cylinder Head Bolt Wrench # 09205 - 16010 or equivalent, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.

CAUTION: Cylinder head warpage or cracking could result from removing bolts in incorrect order.

(b) Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks on a bench.

NOTE: If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block saliences.

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


Cylinder Head Assembly: Service and RepairDissemble

1. Remove valve lifters and shims.

NOTE: Arrange the valve lifters and shims in correct order.

2. Remove valves.

(a) Using Special Service Tool (SST) Valve Spring Compressor # 09202 - 70020 or equivalent, compress the valve spring and remove the 2keepers.

NOTE: Arrange the valves, valve springs, spring seats and spring retainers in correct order.

(b) Using needle-nose pliers, remove the oil seal.


Cylinder Head Assembly: Service and RepairCleaning

1. Clean top surfaces of pistons and cylinder block.

(a) Turn the crankshaft, and bring each piston to Top Dead Center (TDC). Using a gasket scraper, remove all the carbon from the piston topsurface.

(b) Using a gasket scraper, remove all the gasket material from the cylinder block surface.(c) Using compressed air, blow carbon and oil from the bolt holes.

WARNING: Protect your eyes when using high-pressure compressed air.

2. Clean cylinder head.

A. Remove gasket material.Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.


B. Clean combustion chambers.Using a wire brush, remove all the carbon from the. combustion chamber.



C. Clean valve guide bushings.Using a valve guide bushing brush and solvent, clean all the guide bushings.

D. Clean cylinder head.Using a soft brush and solvent, thoroughly clean the cylinder head.


Cylinder Head Assembly: Service and RepairAssemblyNOTE:

^ Thoroughly clean all parts to be assembled. ^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces. ^ Replace all gaskets and oil seals with new ones.

1. Install spark plug tubes.

NOTE: When using a new cylinder head, spark plug tubes must be installed.

(a) Apply adhesive to the spark plug tube hole of the cylinder head.Adhesive: Part No. 08833 - 00070, Adhesive 1324, THREE BOND 1324 or equivalent.

(b) Using a press, press in a new spark plug tube.(c) Check that there is 46.8 - 47.6 mm (1.843 - 1.874 inch) protruding from the camshaft bearing cap installation of the cylinder head.

2. Install valves.

(a) Using Special Service Tool (SST) Valve Stem Oil Seal Replacer # 09201 - 41020 or equivalent, push in a new oil seal.

NOTE: The intake valve oil seal is brown and the exhaust valve oil seal is black.


(b) Install these parts: (1) Valve.(2) Spring seat.(3) Valve spring.(4) Spring retainer.

(c) Using SST Valve Spring Compressor # 09202 - 70020 or equivalent, compress the valve spring and place the 2 keepers around thevalve stem.

(d) Using a plastic-faced hammer, lightly tap the valve stem tip to assure a proper fit.3. Install valve lifters and shims.

(a) Install the valve lifter and shim.(b) Check that the valve lifter rotates smoothly by hand.


Cylinder Head Assembly: Service and RepairCylinder Head Installation

1. Install cylinder head.

A. Place cylinder head on cylinder block.(a) Place a new cylinder head gasket in position on the cylinder block.

CAUTION: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder head gasket.B. Install cylinder head bolts.

NOTE: ^ The cylinder head bolts are tightened in 3 progressive steps (b), (d) and (e)).^ If any bolts is broken or deformed, replace it.

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

(b) Using Special Service Tool (SST) Cylinder Head Bolt Wrench # 09205 - 16010 or equivalent, install and uniformly tighten the cylinder head bolts, in several passes, in the sequence shown.Torque: 29 Nm (22 ft. lbs.)If any one of the bolts does not meet the torque specification, replace the bolt.

NOTE: Cylinder head bolts are in lengths of 90 mm (3.54 inch) and 108 mm (4.25 inch). Install the 90mm (3.54 inch) bolts (A)in intake manifold side positions. Install the 108 mm (4.25 inch) bolts (B) in exhaust manifold side positions.

(c) Mark the front of the cylinder head bolt with paint.


(d) Tighten the cylinder head bolts by an additional 90° in the numerical order shown.(e) Tighten cylinder head bolts by an additional 90°.(f) Check that the painted mark is now facing rearward.

2. Assemble intake camshaft.

(a) Mount the hexagon wrench head portion of the cam shaft in a vise.


(b) Install these parts:(1) Camshaft gear spring.(2) Camshaft sub-gear.(3) Wave washer.

NOTE: Align the pins on the gears with the spring ends.

(c) Using snap ring pliers, install the snap ring.


(d) Insert service bolts (A) and (B) into the service hole of the camshaft sub-gear.(e) Using a screwdriver, align the holes of the camshaft drive gear and sub-gear by turning camshaft sub-gear clockwise, and install a

service bolt (C).


(f) Remove service bolts (A) and (B).3. Install camshafts.

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft isnot kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. Toavoid this, the following steps should be carried out.

A. Install exhaust camshaft.(a) Apply Multipurpose (MP) grease to the thrust portion of the camshaft.

(b) Place the exhaust camshaft so that the knock pin is located slightly counterclockwise from the vertical axis of the camshaft.

NOTE: The above angle allows the No. 1 and No. 3 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.

(c) Remove any old packing Formed In Place Gasket (FIPG) material.

(d) Apply seal packing to the cylinder head as shown in the illustration.Seal packing: Part No. 08826 - 00080 or equivalent.




(h) Apply MP grease to a new oil seal lip.

(i) Using SST Crankshaft Front Oil Seal Replacer # 09223 - 46011 or equivalent, tap in the oil seal.

NOTE: ^ Do not install the oil seal with the lip facing the wrong direction. ^ Insert the oil seal into the deepest part of the cylinder head.

B. Install intake camshaft.

(a) Set the intake camshaft so that the knock pin is slightly above the top of the cylinder head.(b) Apply MP grease to the thrust portion of the camshaft.

(c) Engage the intake camshaft gear to the exhaust camshaft gear by matching the assembly installation marks on each gear.

CAUTION: There are also timing marks (for Top Dead Center (TDC)) on each gear as shown in the illustration. Do not use thesemarks.

(d) Roll down the intake camshaft onto the bearing journals while engaging gears with each other.





(h) Remove the service bolt (C).

(i) Install the No. 1 bearing cap with the arrow mark facing forward.

CAUTION: If the No. 1 bearing cap does not fit properly, push the camshaft gear backwards by prying apart the cylinder head andcamshaft gear with a screwdriver.

(j) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.(k) Install and alternately tighten the 2 bolts in several passes.



(l) Turn the exhaust camshaft clockwise, and set it with the knock pin facing upward.

(m) Check that the timing marks of the camshaft gears are aligned.

NOTE: The assembly installation marks are on the upside.

4. Check and adjust valve clearance. 5. Install water inlet No. 2.

(a) Connect the water inlet to the water inlet hose.(b) Install the water inlet with the 2 nuts.

Torque: 15 Nm (11 ft. lbs.)6. Install oil dipstick guide and dipstick.

(a) Install a new O-ring to the dipstick guide.(b) Apply a small amount of engine oil to the O-ring.(c) Push in the dipstick guide together with the dipstick.(d) Install the dipstick guide and bracket with the bolt.

Torque: 9 Nm (82 inch lbs.)(e) Connect the crankshaft position sensor connector to the dipstick guide.

7. Install generator bracket. Install the bracket with the 3 bolts. Torque: 26 Nm (20 ft. lbs.)

8. Install camshaft timing pulley. 9. Install timing belt and timing belt covers.

10. Install spark plugs.11. Install semi-circular plug.

(a) Remove any old packing FIPG material.

(b) Apply seal packing to the circular plug. Seal packing: Part No. 08826 - 00080 or equivalent.

(c) Install the semi-circular plug to the cylinder head.12. Install cylinder head cover.

(a) Remove any old packing FIPG material.

(b) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 08826 - 00080 or equivalent.

(c) Install the gasket to the head cover.(d) Install the head cover with the 4 seal washers, and cap nuts.

Torque: 5.9 Nm (52 inch lbs.)13. Install RH engine mounting insulator. 14. Install intake manifold.

(a) Place a new intake manifold gasket to the cylinder head.


(b) Place a new Exhaust Gas Recirculation (EGR) inlet gasket to the cylinder head, facing the protrusion downward.

(c) Install the intake manifold with the 7 bolts, ground strap and 4 nuts. Informally tighten the bolts and nuts in several passes. Torque:

A: 13 Nm (9 ft. lbs.)Others: 19 Nm (14 ft. lbs.)

15. Connect engine wire.

(a) Connect the engine wire with the bolt and 2 nuts.(b) Connect the clamp for the wire harness bracket.

(c) Connect the engine wire to cylinder head cover, and install the engine wire cover with the 2 bolts.(d) Connect these connectors:

^ w/ A/C: A/C compressor connector.^ Oil pressure switch connector.^ Crankshaft position sensor connector.^ Injector connector.

16. Install injectors and delivery pipe. Refer to Powertrain Management.17. Install air intake chamber. Refer to Powertrain Management. 18. Install throttle body. Refer to Powertrain Management.19. Install air pipe.


(a) Install the air pipe and fuel hose clamp with the 2 bolts and nut.

NOTE: Attach the clamp claw of the fuel hose to the intake manifold.

(b) Connect these hoses:^ Fuel return hose to pressure regulator.^ Air hose (from Idle Air Control (IAC) valve) to air pipe.

20. Install intake manifold stay.Torque:

12 mm head bolt: 19 Nm (14 ft. lbs.)14 mm head bolt: 39 Nm (29 ft. lbs.)

21. Install EGR vacuum modulator and Vacuum Switching Valve (VSV).

22. Connect hoses.Connect these hoses to the intake chamber:(1) Manifold Absolute Pressure (MAP) sensor vacuum hose from gas filter on intake manifold.(2) Power Steering (PS) air hose from intake manifold.(3) PS air hose from air pipe.(4) Brake booster vacuum hose from intake manifold.

23. Connect ground strap connector.24. Install water inlet and inlet housing assembly.

(a) Remove any aid packing FIPG material and be careful not to drop any oil on the contact surfaces of the inlet housing and cylinder head.^ Using a razor blade and gasket scraper, remove all the old packing FIPG material from the gasket surfaces and sealing groove.^ Thoroughly clean all components to remove all the loose material.^ Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the inlet-housing groove.Seal packing: Part No. 08826 - 00100 or equivalent.^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.

NOTE: Avoid applying an excessive amount to the surface.

^ Parts must be assembled within 15 minutes of application. Otherwise the material must be removed and reapplied.^ Immediately remove nozzle from' the tube and reinstall cap.

(c) Install the water inlet and inlet housing assembly with the bolt and 2 nuts.Torque: 20 Nm (14 ft. lbs.)


(d) Connect these hoses:(1) Radiator outlet hose.(2) 2 water bypass hoses.(3) 2 heater water hoses.(4) 2 Evaporative Emission (EVAP) Thermal Vacuum Valve (TVV) vacuum hoses.

(e) Connect these connectors:^ Engine Coolant Temperature (ECT) sensor connector.^ ECT switch connector.^ IAC valve connector.

25. Install water outlet.(a) Remove any old packing FIPG material and be careful not to drop any oil on the contact surfaces of the water outlet and cylinder head.

^ Using a razor blade and gasket scraper, remove all the old packing FIPG material from the gasket surfaces and sealing groove.^ Thoroughly clean all components to remove all the loose material.^ Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the water outlet groove.Seal packing: Part No. 08826 - 00100 or equivalent.^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.

NOTE: Avoid applying an excessive amount to the surface.

^ Parts must be assembled within 15 minutes of application. Otherwise the material must be removed and reapplied.^ Immediately remove nozzle from the tube and reinstall cap.

(c) Install the water outlet with the 2 bolts.Torque: 20 Nm (14 ft. lbs.)

(d) Connect the radiator upper hose to the water outlet.26. Install exhaust manifold.

(a) Install the lower heat insulator to the exhaust manifold with the 3 bolts.Torque: 9.3 Nm (82 inch lbs.)

(b) Install a new gasket and the exhaust manifold with new 5 nuts. Uniformly tighten the nuts in several passes.Torque: 34 Nm (25 ft. lbs.)

(c) Install the upper heat insulator with the 3 bolts.Torque: 9.3 Nm (82 inch lbs.)

(d) Connect the main oxygen sensor connector.27. Install front exhaust pipe. Refer to Exhaust System.28. Install water pump pulley.

Temporarily install the water pump pulley with the 4 bolts.29. Install PS pump adjusting bracket and drive belt.30. W/ A/C: Install A/C idler pulley and drive belt.31. Install generator and drive belt. Refer to Starting and Charging.32. Tighten water pump pulley bolts.

Torque: 9.3 Nm (82 inch lbs.)33. Install distributor. Refer to Powertrain Management.34. Install air cleaner cap.35. Connect these cables:

(1) Accelerator cable.(2) A/T: Throttle cable.(3) W/ Cruise control system: Cruise control actuator cable.


36. Refill engine coolant.37. Start engine and check for leaks.38. Perform engine adjustment.39. Install RH engine under cover.40. Road test vehicle.

Check for abnormal noise, shock, slippage, correct shift points and smooth operation.41. Recheck engine coolant level.


Valve Clearance: AdjustmentsNOTE: Inspect and adjust the valve clearance when the engine is cold.

1. Disconnect wire and clamp from generator.2. Disconnect high-tension cord from cylinder head cover.3. Remove cylinder head cover.

Remove the 4 cap nuts, seal washers, head cover and gasket.4. Set No. 1 cylinder to Top Dead Center (TDC)/Compression.

(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No. 1 timing belt cover.

(b) Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap.If not, turn the crankshaft 1 revolution (360°).

5. Inspect valve clearance.

(a) Check only the valves indicated.^ Using a feeler gauge, measure the clearance between the valve lifter and camshaft. ^ Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement

adjusting shim.Valve clearance (Cold):


(b) Turn the crankshaft one revolution (360°) and align its groove with timing mark "0" of the No. 1 timing belt cover.


(c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)).6. Intake: Adjust valve clearance.


B. Remove adjusting shim Remove the adjusting shim with a small screwdriver.C. Determine the replacement adjusting shim size by following the Formula or Chart:

(a) Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve clearancecomes within the specified value.T: Thickness of removed shim.A: Measured valve clearance.N: Thickness of new shim.N = T + (A - 0.20 mm (0.008 inch))

(c) Select a new shim with a thickness as close as possible to the calculated value.


Adjusting Shim Selection Chart (Intake)

NOTE: Shims are available in 16 sizes in increments of 0.05 mm (0.0020 inch), from 2.55 mm (1.0039 inch) to 3.30 mm (0.1299inch).

D. Install new adjusting shim Place a new adjusting shim on the valve lifter.E. Install intake camshaft.F. Recheck valve clearance.

7. Exhaust: Adjust valve clearance.A. Remove the adjusting shim.


(a) Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve points upward.(b) Position the notch of the valve lifter facing the front of the vehicle.

(c) Using Special Service Tool (SST) Valve Clearance Adjust Tool Set # 09248 - 55040 or (A) (Valve Lifter Press # 09248 - 05410),press down the valve lifter and place SST (B) Valve Lifter Stopper # 09248 - 05420 or equivalents between the camshaft and valvelifter. Remove SST (A).

NOTE:^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration.^ When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake

side, at a slight angle.

^ The shape of the cam makes it difficult to insert SST (B), from the intake side to the No. 3 rear. For this shim, it is best approachedfrom the exhaust side instead.

(d) Remove the adjusting shim with a small screwdriver and magnetic finger.B. Determine the replacement adjusting shim size according to these Formula or Charts:


(a) Using a micrometer, measure the thickness of the removed shim.(b) Calculate the thickness of a new shim so that the valve clearance comes within the specified value.

T = Thickness of used shim.A = Measured valve clearance.N = Thickness of new shim.N = T + (A - 0.30 mm (0.012 inch))

(c) Select a new shim with a thickness as close as possible to the calculated value.

Adjusting Shim Selection Chart (Exhaust)

NOTE: Shims are available in 16 sizes in increments of 0.05 mm (0.0020 inch), from 2.55 mm (1.0039 inch) to 3.30 mm (0.1299inch).


C. Install a new adjusting shim.(a) Place a new adjusting shim on the valve lifter.

(b) Using SST Valve Clearance Adjust Tool Set # 09248 - 55040 or (A) (Valve Lifter Press # 09248 - 05410), press down the valvelifter and remove SST (B) Valve Lifter Stopper # 09248 - 05420 or equivalents.

D. Recheck the valve clearance.8. Install cylinder head cover.9. Connect high-tension cord to cylinder head cover.

10. Connect wire and clamp to generator.


Valve Seat: Testing and InspectionINSPECT AND CLEAN VALVE SEATS

1. Using a 45° carbide cutter, resurface the valve seats.Remove only enough metal to clean the seats.

2. Check the valve seating position.Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve.

3. Check the valve face and seat for the following:^ If blue appears 360° around the face, the valve is concentric. If not, replace the valve.^ If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.^ Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 inch)If not, correct the valve seats as follows:

(1) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

(2) If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.


4. Hand-lap the valve and valve seat with an abrasive compound.5. After hand-lapping, clean the valve and valve seat.


Valve Spring: Testing and Inspection

1. Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 inch)If the deviation is greater than maximum, replace the valve spring.

2. Using a vernier caliper, measure the free length of the valve spring.Free length: 38.57 mm (1.5185 inch)If the free length is not as specified, replace the valve spring.

3. Using a spring tester, measure the tension of the valve spring at the specified installed length.Installed tension: 166 N (37.3 lbs) at 31.7 mm (1.248 inch)If the installed tension is not as specified, replace the valve spring.


Valve: Testing and InspectionInspection

1. Inspect and grind valves.(a) Grind the valve enough to remove pits and carbon.

(b) Check that the valve is ground to the correct valve face angle.Valve face angle: 44.5°

(c) Check the valve head margin thickness.Standard margin thickness: 0.8 - 1.2 mm (0.031 - O.047 inch)Minimum margin thickness: 0.5 mm (0.020 inch)If the margin thickness is less than minimum, replace the valve.

(d) Check the valve overall length.Standard overall length:

Intake: 87.45 mm (3.4429 inch)Exhaust: 87.84 mm (3.4583 inch)

Minimum overall length:Intake: 86.95 mm (3.4232 inch)Exhaust: 87.34 mm (3.4386 inch)

If the overall length is less than minimum, replace the valve.

(e) Check the surface of the valve stem tip for wear.If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

CAUTION: Do not grind off more than the minimum length.


Valve: Testing and InspectionValve Clearance InspectionNOTE: Inspect and adjust the valve clearance when the engine is cold.

1. Disconnect wire and clamp from generator.2. Disconnect high-tension cord from cylinder head cover.3. Remove cylinder head cover.

Remove the 4 cap nuts, seal washers, head cover and gasket.4. Set No. 1 cylinder to Top Dead Center (TDC)/Compression.

(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No. 1 timing belt cover.

(b) Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap.If not, turn the crankshaft 1 revolution (360°).

5. Inspect valve clearance.

(a) Check only the valves indicated.^ Using a feeler gauge, measure the clearance between the valve lifter and camshaft. ^ Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement

adjusting shim.Valve clearance (Cold):


(b) Turn the crankshaft one revolution (360°) and align its groove with timing mark "0" of the No. 1 timing belt cover.


(c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)).6. Adjust valve clearance.

7. Install cylinder head cover.8. Connect high-tension cord to cylinder head cover.9. Connect wire and clamp to generator.


Valve: Testing and InspectionValve Stems and Guide Bushings Inspection

1. Using a caliper gauge, measure the inside diameter of the guide bushing.Bushing inside diameter: 6.010 - 6.030 mm (0.2366 - 0.2374 inch)

2. Using a micrometer, measure the diameter of the valve stem.Valve stem diameter:


3. Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.Standard oil clearance:


Maximum oil clearance:Intake: 0.08 mm (0.0031 inch)Exhaust: 0.10 mm (0.0033 inch)

If the clearance is greater than maximum, replace the valve and guide bushing.


Drive Belt: Testing and InspectionA/CDRIVE BELT TENSION INSPECTION / 7A-FE

1. INSPECT DRIVE BELT INSTALLATION CONDITIONCheck that the drive belt fits properly in the ribbed grooves.

2. INSPECT DRIVE BELT TENSIONUsing a belt tension gauge, check the drive belt tension.

Belt tension gauge:Nippondenso BTG-20 (95506-00020) orBorroughs No. BT-33-73F

New belt: 160 ± 25 lbfUsed belt: 100 ± 20 lbf

HINT:- "New belt" refers to a belt which has been used less than 5 minutes on a running engine.- Used belt refers to a belt which has been on a running engine for 5 minutes or more.- After installing the drive belt, check that it fits properly in the ribbed grooves.


Drive Belt: Testing and InspectionAlternator

GENERATOR DRIVE BELT

INSPECT DRIVE BELT1. Visually check the belt for excessive wear, frayed cords etc.

If any defect has been found, replace the drive belt.

HINT: Cracks on the rib side of a belt are considered acceptable.

If the belt has chunks missing from the ribs, it should be replaced.

2. Using a belt tension gauge, measure the belt tension.

Belt tension gauge:Nippondenso BTG-20 (95506-00020)Borroughs No. BT-33-73F

Drive belt tension:New belt: 175 ± 5 lbfUsed belt: 115 ± 20 lbf

If the belt tension is not as specified, adjust it.

HINT:- New belt refers to a belt which has been used less than 5 minutes on a running engine.- Used belt refers to a belt which has been used on a running engine for 5 minutes or more.


- After installing a belt, check that it fits properly in the ribbed grooves.- Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.- After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.


Drive Belt: Testing and InspectionPower Steering

Check belt tension.Using either a Nippondenso BTG-20 (95506 - 00020) or a Borroughs NO. BT-33 - 73F belt tension gauge, check the tension.

7A-FE and 5S-FE Engines;The tension for a new belt should be: 99 - 121 ft.lbf.The tension for a used belt it should be: 44 - 77 ft.lbf..

Notice: After installing the belt, check that it fits properly in the ribbed grooves.

Hint: A"New belt" refers to a belt which has been less than five minutes on a running engine and a "used belt" refers to a belt which has beenused on a running engine for five minutes or more.


Drive Belt: Service and RepairDRIVE BELT REMOVAL / 7A-FE

1. REMOVE ALTERNATOR DRIVE BELT

2. LOOSEN IDLE PULLEY LOCK NUT

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

3. LOOSEN ADJUSTING BOLT AND REMOVE COMPRESSOR DRIVE BELT

INSTALLATIONInstallation is in the reverse order of removal.


Intake Manifold: Testing and InspectionINSPECT MANIFOLD

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.Maximum warpage: 0.20 mm (0.0079 inch)If warpage is greater than maximum, replace the manifold.


Crankshaft Main Bearing Seal: Service and RepairNOTE: There are 2 methods (A and B) to replace the oil seal which are as follows:

1. Replace crankshaft rear oil seal.A. If rear oil seal retainer is removed from cylinder block:

(a) Using a screwdriver and hammer, tap out the oil seal.

(b) Using Special Service Tool (SST) Oil Seal & Bearing Replacer # 09223 - 15030, Replacer Set "B" # 09550 - 10012 (No. 2 ReplacerHandle # 09552 - 10010) or equivalents and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retaineredge.

(c) Apply Multipurpose (MP) grease to the oil seal lip.B. If rear oil seal retainer is installed to cylinder block:

(a) Using a knife, cut off the oil seal lip.(b) Using a screwdriver, pry out the oil seal.

CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver tip.

(c) Apply MP grease to a new oil seal lip.

(d) Using SST Oil Seal & Bearing Replacer # 09223 - 15030, Replacer Set "B" # 09550 - 10012 (No. 2 Replacer Handle # 09552 -10010) or equivalents and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

Manual de Taller Toyota Celica 1.8 st

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