Engine Mechanical

EM–1
ENGINE MECHANICAL – CO/HC
CO/HC EM09G–02
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses should be properly connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing set correctly
(h) Transmission in neutral range
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST

40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
CO/HC Meter IDLE AND/OR 2,500 RPM
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow
the measurement order prescribed by the applicable local regu-
lations.
P20718
2000 LEXUS LS400 (RM717U)
Author: Date: 1183

EM–2
ENGINE MECHANICAL – CO/HC
6. TROUBLESHOOTING
If the CO/HC concentration does not comply with regulations,
perform troubleshooting in the order given below.
See the table below for possible causes, and then inspect and
correct the applicable causes if necessary.
CO HC Problems Causes
Normal High Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
Low High Rough idle 1. Vacuum leaks:

(fluctuating HC reading) PCV hoses
Intake manifold
Throttle body
Brake booster line
2. Lean mixture causing misfire
High High Rough idle 1. Restricted air filter

(Black smoke from exhaust) 2.Faulty SFI systems:
Faulty pressure regulator
Defective ECT sensor
Faulty ECM
Faulty injectors
Faulty throttle position sensor
Faulty MAF meter
Author: Date: 1184

EM–3
ENGINE MECHANICAL – COMPRESSION
COMPRESSION EM09H–02
INSPECTION
HINT:
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. REMOVE SPARK PLUGS (See page IG–1)
3. 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.
HINT:
Always use a fully charged battery to obtain engine speed of
Compression 250 rpm or more.
Gauge A02105 (d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,226 kPa (12.5 kgf/cm2, 178 psi) or more
Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm2, 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 plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS (See page IG–1)
Author: Date: 1185

EM–4
ENGINE MECHANICAL – VALVE CLEARANCE
VALVE CLEARANCE EM09I–02
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY CLAMP COVER
3. REMOVE AIR CLEANER INLET
4. REMOVE V–BANK COVER
5. REMOVE AIR CLEANER AND INTAKE AIR CONNEC-
TOR ASSEMBLY
6. REMOVE NO.3 TIMING BELT COVERS
(See page EM–15)
7. REMOVE IGNITION COILS (See page IG–7)
8. REMOVE RH CYLINDER HEAD COVER
Remove the 9 bolts, 9 seal washers and cylinder head cover.
9. REMOVE LH CYLINDER HEAD COVER
(a) Remove the oil dipstick for the transmission.
(b) Disconnect the PCV hose.
(c) Disconnect the engine wire clamp from the wire bracket
on the delivery pipe.
(d) Remove the 9 bolts, 9 seal washers and cylinder head
cover.
10. SET NO.1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley, and align its groove with timing
mark ”0” of the No.1 timing belt cover.
A02205
(b) Check that the timing marks of the camshaft timing pul-
leys and timing belt rear plates are aligned.
If not, turn the crankshaft 1 revolution (360°) and align the mark
as above.
A02206
Author: Date: 1186

EM–5
11. INSPECT VALVE CLEARANCE

RH Cylinder Head
(a) Check only the valves indicated.
Using a feeler gauge, measure the clearance be-
tween 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):
Intake 0.15 – 0.25 mm (0.006 – 0.010 in.)
Front
LH Cylinder Head Exhaust 0.25 – 0.35 mm (0.010 – 0.014 in.)
A02207
A02208 A02209
(b) Turn the crankshaft 1 revolution (360°) and align the mark
RH Cylinder Head as above. (See procedure in step 10)
(c) Check only the valves indicated as shown. Measure the
valve clearance. (See procedure in step (a))
12. ADJUST VALVE CLEARANCE
(a) Remove the timing belt. (See page EM–15)
(b) Remove the camshafts. (See page EM–34)
(c) Remove the valve lifter and adjusting shim.
Front
LH Cylinder Head
A02210
A02211 A02212
(d) Determine the replacement adjusting shim size according

to these Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so that the
valve clearance comes within the specified value.
T ........... Thickness of removed shim
A ........... Measured valve clearance
A02213 N ........... Thickness of new shim
Author: Date: 1187

EM–6
Intake:
N = T + (A – 0.20 mm (0.008 in.))
Exhaust:
N = T + (A – 0.30 mm (0.012 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 41 increments of 0.020 mm (0.0008 in.),
from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102 in.).
(e) Place a new adjusting shim on the valve.
(f) Place the valve lifter.
(g) Reinstall the camshafts. (See page EM–58)
(h) Reinstall the timing belt. (See page EM–22)
(i) Recheck the valve clearance.
13. REINSTALL CYLINDER HEAD COVERS
14. REINSTALL IGNITION COILS
15. REINSTALL NO.3 TIMING BELT COVERS
(See page EM–22)
16. REINSTALL AIR CLEANER AND INTAKE AIR CON-
NECTOR ASSEMBLY
17. REFILL WITH ENGINE COOLANT
18. START ENGINE AND CHECK FOR LEAKS
19. RECHECK ENGINE COOLANT LEVEL
20. REINSTALL V–BANK COVER
21. REINSTALL AIR CLEANER INLET
22. REINSTALL BATTERY CLAMP COVER
Author: Date: 1188

Adjusting Shim Selection Chart (Intake)
Installed shim thickness

mm (in.)
Measured clearance
mm (in.)
ENGINE MECHANICAL
–
VALVE CLEARANCE
Author:
New shim thickness mm (in.)

Shim No. Thickness Shim No. Thickness Shim No. Thickness
Date:
Intake valve clearance (Cold):

0.15 – 0.25 mm (0.006 – 0.010 in.)
EXAMPLE:
The 2.300 mm (0.0906 in.) shim is installed,
and the measured clearance is 0.440 mm
(0.0173 in.). Replace the 2.300 mm (0.0906
in.) shim with a No. 54 shim.
EM–7
1189
A03111
EM–8
Adjusting Shim Selection Chart (Exhaust)
Installed shim thickness

mm (in.)
Measured clearance
mm (in.)
ENGINE MECHANICAL
–
VALVE CLEARANCE
Author:
New shim thickness mm (in.)

Shim No. Thickness Shim No. Thickness Shim No. Thickness
Date:
Exhaust valve clearance (Cold):

0.25 – 0.35 mm (0.010 – 0.014 in.)
EXAMPLE:
The 2.300 mm (0.0906 in.) shim is installed,
and the measured clearance is 0.440 mm
(0.0173 in.). Replace the 2.300 mm (0.0906
in.) shim with a No. 44 shim.
A03112
1190
EM–9
ENGINE MECHANICAL – IGNITION TIMING
IGNITION TIMING EM09J–02
INSPECTION
Remove the 2 cap nuts, bolt and V–bank cover.
4. WARM UP ENGINE
A01892
Allow the engine to warm up to normal operating temperature.
LEXUS Hand–Held Tester 5. CONNECT LEXUS HAND–HELD TESTER OR OBD II

SCAN TOOL
(a) Connect the hand–held tester or OBD II scan tool to the
DLC3.
(b) Please refer to the hand–held tester or OBD II scan tool
operator’s manual for further details.
DLC3 Q06528
6. CONNECT TIMING LIGHT TO ENGINE

Connect the tester probe of a timing light to the yellow lead wire
of the ignition coil connector for No.1 cylinder.
7. CHECK IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 se-
conds.
Yellow (b) Check the idle speed.
Wire Idle speed: 750 ± 50 rpm
A03219
SST 8. INSPECT IGNITION TIMING

E1
(a) Using SST, connect terminals TC and E1 of the DLC1.
SST 09843–18020
TC
A02001
(b) Using a timing light, check the ignition timing.

Ignition timing: 8 – 12° BTDC @ idle
(Transmission in neutral position)
(c) Remove the SST from the DLC1.
SST 09843–18020
9. DISCONNECT TIMING LIGHT FROM ENGINE
10. DISCONNECT LEXUS HAND–HELD TESTER OR OBD
II SCAN TOOL
A02002 11. REINSTALL V–BANK COVER
12. REINSTALL AIR CLEANER INLET
Author: Date: 1191

EM–10
ENGINE MECHANICAL – IGNITION TIMING
13. REINSTALL BATTERY CLAMP COVER
Author: Date: 1192

EM–11
ENGINE MECHANICAL – IDLE SPEED
IDLE SPEED
EM09K–02
INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses should be properly connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing set correctly
(h) Transmission in neutral position
(i) Air conditioning switched OFF
2. CONNECT LEXUS HAND–HELD TESTER OR OBD II SCAN TOOL (See page EM–9)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed: 750 ± 50 rpm
If the idle speed is not as specified, check the air intake system.
4. DISCONNECT LEXUS HAND–HELD TESTER OR
OBD II SCAN TOOL
Author: Date: 1193

EM–12
ENGINE MECHANICAL – TIMING BELT
TIMING BELT
EM09L–02
COMPONENTS
Air Cleaner and Intake

Air Connector Assembly
EVAP Hose
Air Cleaner Inlet
MAF Meter Connector PCV Hose Clip

Upper Radiator Support
PS Air Hose
Battery Clamp Cover
ECT Switch Connector

for A/C Cooling Fan
Radiator Assembly
V–Bank Cover
Lower Radiator Support
Fan Pulley
Fan and Fluid

Coupling Assembly
A/C Compressor
A/T Oil Cooler Hose A/C Compressor Connector

Generator Drive Belt Wire Bracket
A/C Compressor Stay
49 (500, 36)
x7
Engine Under Cover
Ground Cable
x 11
x8
Oil Pan Protector
N·m (kgf·cm, ft·lbf) : Specified Torque

A02232
Author: Date: 1194

EM–13
RH No.3 Timing Belt Cover

PS Air Hose
Radiator Reservoir
Outlet Pipe 7.5 (80, 66 in.·lbf) Gasket
No.2 Timing
Belt Cover
16 (160, 12)
Drive Belt Idler Pulley
37 (380, 27) Cover Plate
Camshaft Position
Sensor Connector
Engine Wire
Gasket
7.5 (80, 66 in.·lbf)
LH No.3 Timing Belt Cover
N·m (kgf·cm, ft·lbf) : Specified Torque A01862
Camshaft Timing Pulley
Timing Belt 7.5 (80, 66 in.·lbf)
Camshaft Timing
Pulley
245 (2,500, 181)
16 (160, 12)
Timing Belt Tensioner
32 (330, 24)
Fan Bracket
N·m (kgf·cm, ft·lbf) : Specified Torque A01863
Author: Date: 1195

EM–14
Generator Wire
Drive Belt Tensioner
Generator Connector
No.1 Timing Belt Cover
Crankshaft Pulley
Wire Clamp
Generator
39 (400, 29)
No.1 Idler Pulley
34.5 (350, 25)
Timing Belt
Crankshaft Timing Pulley
No.2 Idler Pulley

34.5 (350, 25)
Timing Belt Guide

(Crankshaft Angle Sensor Plate)
Gasket

Precoated part Timing Belt Cover Spacer
A01864
Author: Date: 1196

EM–15
EM09M–02
REMOVAL
1. REMOVE OIL PAN PROTECTOR
2. REMOVE ENGINE UNDER COVER

Remove the bolt, 2 cap nuts and V–bank cover.
TOR ASSEMBLY
A01892
8. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND

FAN PULLEY
(a) Loosen the 4 nuts holding the fluid coupling to the fan
bracket.
(b) Remove the generator drive belt. (See page CH–8)
(c) Remove the 4 nuts, the fan, fluid coupling assembly and
fan pulley.
9. REMOVE RADIATOR ASSEMBLY (See page CO–21)
A02247 10. REMOVE DRIVE BELT IDLER PULLEY
Remove the pulley bolt, cover plate and idler pulley.
11. REMOVE RH NO.3 TIMING BELT COVER
(a) Disconnect the PS air hose from the clamp of the timing
belt cover.
(b) Disconnect the wire clamp.
(c) Disconnect the radiator reservoir outlet hose from the wa-
ter inlet housing.
(d) Remove the bolt and nut, disconnect the outlet pipe from
the timing belt cover and LH cylinder head.
A01865
(e) Remove the 3 bolts, timing belt cover and gasket.
A01866
Author: Date: 1197

EM–16
12. REMOVE LH NO.3 TIMING BELT COVER

(a) Disconnect the engine wire from the 2 wire clamps.
(b) Remove the 4 bolts and nut.
(c) Disconnect the camshaft position sensor wire from the
wire clamp on the timing belt cover.
(d) Disconnect the sensor connector from the connector
bracket.
(e) Disconnect the sensor connector.
A01867 (f) Remove the wire grommet from the timing belt cover.
(g) Remove the timing belt cover and gasket.
13. REMOVE NO.2 TIMING BELT COVER
Remove the 2 bolts and No.2 timing belt cover.
14. DISCONNECT A/C COMPRESSOR FROM ENGINE
(See page EM–77)
15. REMOVE FAN BRACKET
Remove the 2 bolts, 2 nuts and fan bracket.
16. IF RE–USING TIMING BELT, CHECK INSTALLATION

MARKS ON TIMING BELT
Check that there are 3 installation marks on the timing belt by
turning the crankshaft pulley as shown in the illustration.
HINT:
If the installation marks have disappeared, place a new installa-
tion mark on the timing belt before removing each part.
A01870
17. LOOSEN CRANKSHAFT PULLEY BOLT

Using SST, loosen the pulley bolt.
SST 09213–70010 (90105–08076),
09330–00021
SST
P20740
18. SET NO.1 CYLINDER TO APPROX. 50° ATDC/COM-

PRESSION
(a) Turn the crankshaft pulley and align its groove with timing
mark ”0” of the No.1 timing belt cover.
Turn A01871
Author: Date: 1198

EM–17
(b) Check that the timing marks of the camshaft timing pul-
leys and timing belt rear plates aligned.
If not, turn the crankshaft 1 revolution (360°).
A01872
(c) Turn the crankshaft pulley approx. 50° clockwise, and put
Approx. 50° the timing mark of the crankshaft pulley in line with the
No.2 Idler centers of the crankshaft pulley bolt and the idler pulley
Pulley Bolt bolt.
NOTICE:
Timing If the timing belt is disengaged, having the crankshaft
Mark
pulley at the wrong angle can cause the piston head and
Crankshaft valve head to come into contact with each other when you
Pulley Bolt Turn
A01874 remove the camshaft timing pulley (step 19), causing dam-
age. So always set the crankshaft pulley at the correct
angle.
(d) Remove the crankshaft pulley bolt.
NOTICE:
Do not turn the crankshaft pulley.
19. REMOVE TIMING BELT TENSIONER

HINT:
When re–using timing belt:
If the installation marks have disappeared, before remove
the timing belt, place 2 new installation marks on the tim-
ing belt to match the timing marks of the camshaft timing
pulleys.
A01875
When replacing timing belt tensioner only:

To avoid meshing of the timing pulley and timing belt, se-
cure one of them with string. And place matchmarks on
the timing belt and RH camshaft timing pulley.
String
A01876
Author: Date: 1199

EM–18
Alternately loosen the 2 bolts, and remove them, the belt ten-
sioner and dust boot.
A02103
20. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-

ING PULLEYS
Slightly Turn (a) Using SST, loosen the tension spring between the LH and
RH camshaft timing pulleys by slightly turning the RH
camshaft timing pulley clockwise.
SST
SST 09960–10010 (09962–01000, 09963–00350)
(b) Disconnect the timing belt from the camshaft timing pul-
leys.
A04195
SST 21. REMOVE CAMSHAFT TIMING PULLEYS

Hold
Using SST, remove the 4 bolts and timing pulley. Remove the
2 timing pulleys.
SST 09960–10010 (09962–01000, 09963–00350)
22. REMOVE GENERATOR (See page CH–8)
23. REMOVE DRIVE BELT TENSIONER
Remove the bolt, 2 nuts and belt tensioner.
A03351
24. REMOVE CRANKSHAFT PULLEY

Using SST, remove the crankshaft pulley.
SST SST 09950–50012 (09951–05010, 09952–05010,
09953–05010, 09953–05020, 09954–05020)
NOTICE:
Do not turn the crankshaft pulley.
25. REMOVE NO.1 TIMING BELT COVER
Remove the 4 bolts, timing belt cover.
A01879 26. REMOVE TIMING BELT GUIDE
27. REMOVE TIMING BELT COVER SPACER
28. REMOVE TIMING BELT
HINT:
If re–using the belt and the installation mark has disappeared
from it, place a new installation mark on the timing belt to the
match the dot mark of the crankshaft timing pulley.
29. REMOVE NO.2 IDLER PULLEY
Remove the bolt and idler pulley.
A01880
Author: Date: 1200

EM–19
30. REMOVE NO.1 IDLER PULLEY

Plate Washer
10 mm Using a 10 mm hexagon wrench, remove the bolt, idler pulley
Hexagon and plate washer.
Wrench
A03232
31. REMOVE CRANKSHAFT TIMING PULLEY

Using SST, remove the timing pulley.
SST 09950–50012 (09951–05010, 09952–05010,
09953–05010, 09953–05020, 09954–05010)
NOTICE:
Do not turn the timing pulley.
SST
A03233
Author: Date: 1201

EM–20
EM09N–02
INSPECTION
NO ! 1. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with
oil, water or steam.
Do not utilize timing belt tension when installing or re-
moving the mount bolt of the camshaft timing pulley.
EM3336
If there are any defects, as shown in the illustrations, check
these points:
(a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock and water pump.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check timing
cover for damage and check gasket has been installed
correctly and for foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS

(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
P20079
3. INSPECT TIMING BELT TENSIONER

(a) Visually check the seal portion of the tensioner for oil leak-
age.
HINT:
If there is only the faintest trace of oil on the seal on the push
rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
P20633
Author: Date: 1202

EM–21
(b) Hold the tensioner with both hands and push the push rod
strongly as shown to check that it doesn’t move.
If the push rod moves, replace the tensioner.
NOTICE:
Never hold the tensioner push rod facing downward.
P20634
(c) Measure the protrusion of the push rod from the housing
end.
Protrusion
Protrusion: 10.5 – 11.5 mm (0.413 – 0.453 in.)
If the protrusion is not as specified, replace the tensioner.
4. INSPECT WATER PUMP (See page CO–9)
P20635
Author: Date: 1203

EM–22
EM109–01
INSTALLATION
Inward
1. INSTALL CRANKSHAFT TIMING PULLEY
SST (a) Align the timing pulley set key with the key groove of the
pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the flange side inward.
SST 09223–46011
A03235
Plate Washer 2. INSTALL NO.1 IDLER PULLEY

10 mm
(a) Apply adhesive 2 or 3 threads of the pivot bolt.
Hexagon
Wrench Adhesive Adhesive:
Part No. 08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer
and idler pulley with the pivot bolt.
Torque: 34.5 N·m (350 kgf·cm, 25 ft·lbf)
A03906 (c) Check that the pulley bracket moves smoothly.
3. INSTALL NO.2 IDLER PULLEY
(a) Install the idler pulley with the bolt.
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Remove any oil or water on the crankshaft pulley, oil
pump pulley, water pump pulley, No.1 idler pulley and
No.2 idler pulley, and keep them clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Align the installation mark on the timing belt with the tim-
ing mark of the crankshaft timing pulley.
(c) Install the timing belt on the crankshaft timing pulley, No.1
idler pulley and No.2 idler pulley.
A01880
Author: Date: 1204

EM–23
5. INSTALL TIMING BELT COVER SPACER

(a) Install the gasket to the cover spacer.
(b) Install the cover spacer.
A03234
6. INSTALL TIMING BELT GUIDE

Install the belt guide, facing the cup side outward.
7. INSTALL NO.1 TIMING BELT COVER
Install the timing belt cover with the 4 bolts.
A01881
8. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the crank-
shaft pulley.
SST (b) Using SST and a hammer, tap in the crankshaft pulley.
SST 09223–46011
9. INSTALL DRIVE BELT TENSIONER
Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
P21317 HINT:
Use a bolt 106 mm (4.18 in.) in length.
10. INSTALL GENERATOR (See page CH–18)
11. CHECK CRANKSHAFT PULLEY POSITION

No.2 Idler Pulley Bolt Check that the timing mark of the crankshaft pulley is aligned
with the centers of the crankshaft pulley and the idler pulley bolt.
Timing
Mark
A01890
Author: Date: 1205

EM–24
Hold 12. INSTALL LH CAMSHAFT TIMING PULLEY

(a) Align the camshaft timing tube knock pin with the knock
pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube, fac-
ing the ”L” mark forward.
(c) Using SST, install the 4 pulley bolts.
SST SST 09960–10010 (09962–01000, 09963–00350)
A03350
13. INSTALL RH CAMSHAFT TIMING PULLEY

(a) Align the camshaft timing tube knock pin with the knock
Hold pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube, fac-
ing the ”R” mark forward.
SST (c) Using SST, install the 4 pulley bolts.
SST 09960–10010 (09962–01000, 09963–00350)
A03352
14. CONNECT TIMING BELT TO LH CAMSHAFT TIMING

PULLEY
Turn
(a) Remove any oil or water on the LH camshaft timing pulley,
and keep it clean.
NOTICE:
SST (b) Using SST, turn the timing pulley. Align the installation
mark on the timing belt with the timing mark of the timing
A03354 pulley, and hang the timing belt on the timing pulley.
SST 09960–10010 (09962–01000, 09963–00350)
(c) Using SST, turn the LH camshaft timing pulley counter-
Turn clockwise until there is tension between the crankshaft
timing pulley and LH camshaft timing pulley.
SST 09960–10010 (09962–01000, 09963–00350)
SST
Tension
A03353
15. CONNECT TIMING BELT TO RH CAMSHAFT TIMING

PULLEY
(a) Remove any oil or water on the RH camshaft timing pulley
Turn and water pump pulley, and keep them clean.
NOTICE:
SST (b) Using SST, turn the timing pulley. Align the installation
mark on the timing belt with the timing mark of the timing
A03355 pulley, and hang the timing belt on the timing pulley.
SST 09960–10010 (09962–01000, 09963–00350)
Author: Date: 1206

EM–25
16. SET TIMING BELT TENSIONER

(a) Using a press, slowly press in the push rod using 981 –
9,807 N (100 – 1,000 kgf, 220 – 2,205 lbf) of pressure.
(b) Align the holes of the push rod and housing, pass a 1.27
mm hexagon wrench through the holes to keep the set-
ting position of the push rod.
1.27 mm (c) Release the press.
Hex ago n (d) Install the dust boot to the belt tensioner.
Wrench
P20636
17. INSTALL TIMING BELT TENSIONER

1.27 mm
Hex ago n (a) Temporarily install the belt tensioner with the 2 bolts.
Wrench (b) Alternately tighten the 2 bolts.
(c) Using pliers, remove the 1.27 mm hexagon wrench from
the belt tensioner.
A02104
18. CHECK VALVE TIMING

(a) Temporarily install the crankshaft pulley bolt.
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft pulley clockwise.
Turn
A01871
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
A01872
19. TIGHTEN CRANKSHAFT PULLEY BOLT

Using SST, install the pulley bolt.
SST 09213–54015 (90119–08216),
09330–00021
Torque: 245 N·m (2,500 kgf·cm, 181 ft·lbf)
SST
P21316
Author: Date: 1207

EM–26
20. INSTALL FAN BRACKET

Install the fan bracket with the 2 bolts and 2 nuts.
Torque:
12 mm head: 16 N·m (160 kgf·cm, 12 ft·lbf)
B
HINT:
Each bolt length is indicated in the illustration.
Bolt Length:
A A01891 106 mm (4.17 in.) for 12 mm head (A)
114 mm (4.49 in.) for 14 mm head (B)
21. INSTALL A/C COMPRESSOR (See page EM–82)
22. INSTALL NO.2 TIMING BELT COVER
Install the No.2 timing belt cover with the 2 bolts.
23. INSTALL RH NO.3 TIMING BELT COVER

(a) Install the gasket to the timing belt cover.
(b) Fit the timing belt cover, matching it with the fan bracket.
(c) Install the timing belt cover with the 3 bolts.
Torque: 7.5 N·m (80 kgf·cm, 66 in.·lbf)
A01866
(d) Install the radiator reservoir outlet pipe to the RH cylinder

head and timing belt cover with the bolt and nut.
(e) Connect the outlet hose to the water inlet housing.
(f) Connect the wire clamp.
(g) Connect the PS air hose to the clamp of the timing belt
cover.
A01865
24. INSTALL LH NO.3 TIMING BELT COVER

(a) Install the gasket to the timing belt cover.
(b) Run the camshaft position sensor wire through the timing
belt cover hole.
(c) Fit the timing belt cover, matching it with the fan bracket.
(d) Install the timing belt cover with the 4 bolts and nut.
(e) Install the wire grommet to the timing belt cover.
A01867 (f) Install the sensor connector to the connector bracket.
(g) Connect the sensor connector.
Author: Date: 1208

EM–27
(h) Install the sensor wire to the wire clamp on the timing belt
cover.
(i) Install the engine wire to the 2 wire clamps on the timing
belt cover.
25. INSTALL DRIVE BELT IDLER PULLEY
Install the idler pulley and cover plate with the bolt.
26. INSTALL RADIATOR ASSEMBLY (See page CO–27)
27. INSTALL FAN PULLEY, FAN, FLUID COUPLING

AND DRIVE BELT
(a) Temporarily install the fan pulley, the fan, fluid coupling
assembly with the 4 nuts.
(b) Install the generator drive belt. (See page CH–18)
(c) Tighten the 4 nuts holding the fluid coupling to the fan
bracket.
A02247 28. INSTALL AIR CLEANER AND INTAKE AIR CONNEC-
TOR ASSEMBLY
29. INSTALL V–BANK COVER
30. FILL WITH ENGINE COOLANT
32. RECHECK ENGINE COOLANT LEVEL
33. INSTALL AIR CLEANER INLET
34. INSTALL BATTERY CLAMP COVER
35. INSTALL ENGINE UNDER COVER
36. INSTALL OIL PAN PROTECTOR
Author: Date: 1209

EM–28
ENGINE MECHANICAL – CYLINDER HEAD
CYLINDER HEAD
EM09P–02
COMPONENTS
Air Cleaner and Intake

Air Connector Assembly
EVAP Hose
Air Cleaner Inlet
MAF Meter Connector PCV Hose Clip

PS Air Hose
Battery Clamp Cover

for A/C Cooling Fan
Radiator Assembly
V–Bank Cover
Fan Pulley
Fan and Fluid

Coupling Assembly
A/C Compressor
A/T Oil Cooler Hose A/C Compressor Connector

Generator Drive Belt Wire Bracket
A/C Compressor Stay
49 (500, 36)
x7
Engine Under Cover
Ground Cable
x 11
x8
Oil Pan Protector

A02232
Author: Date: 1210

EM–29
PS Pump
Accelerator cable
O–Ring
Oil Dipstick and

Guide for A/T
RH Heat Insulator
for RH TWC
RH Heat Insulator
for Front Side of
61.8 (630, 46) Front Exhaust Pipe
Gasket
Front Exhaust Pipe
43.1 (440, 32)
Gasket
TWC
43.1 (440, 32)

Gasket
Pipe Support
Bracket
LH Heat Insulator
61.8 (630, 46)
for Front Side of
RH Heat Insulator Front Exhaust Pipe
for RH TWC
N·m (kgf·cm, ft·lbf): Specified Torque
Non–reusable part A02841
Author: Date: 1211

EM–30
RH No.3 Timing Belt Cover
PS Air Hose
Gasket
7.5 (80, 66 in.·lbf)
No.2 Timing
Belt Cover
Radiator Reservoir
Outlet Pipe 16 (160, 12)
Drive Belt Idler Pulley
37 (380, 27)
Cover Plate
Camshaft Position
Sensor Connector Gasket
Engine Wire
7.5 (80, 66 in.·lbf)

Camshaft Position Sensor
LH No.3 Timing Belt Cover
A02842
Camshaft Timing Pulley
Timing Belt 7.5 (80, 66 in.·lbf)
Camshaft Timing
Pulley
245 (2,500, 181)
16 (160, 12)
Timing Belt Tensioner
32 (330, 24)
Fan Bracket
A01863
Author: Date: 1212

EM–31
Engine Wire
Heater Hose
EVAP Pipe
EVAP Hose Engine Wire
EVAP Hose
Engine Wire Rear Water

Bypass joint
PS Air Hose
VSV Connector for ACIS
Gasket
Accelerator
Pedal Noise Filter Connector
Position
Brake Booster Vacuum Hose
Sensor
Injector Connector
Throttle Control
Motor Connector EVAP Hose
Water Inlet and
Inlet Housing VSV Connector for
Assembly EVAP
Water Bypass
Hose Fuel Inlet Tube
Throttle
Position
Sensor
Connector V–Bank Cover
Gasket VVT Sensor Bracket
Connector
Heater Hose
VVT Sensor
Front Water VVT Sensor
V–Bank
Bypass Joint Connector
Cover
Bracket VVT Sensor
Ignition
Gasket
Coil Connector
RH No.2 Timing Belt

Rear Plate
Ignition Coil
LH No.2 Timing
Belt Rear Plate
RH No.1 Timing Belt

Rear Plate LH No.1 Timing Belt Rear Plate
Author: Date: 1213

EM–32
RH Camshaft Timing Oil Control Valve LH Cylinder Head Cover

Spark Plug
RH Cylinder Head Cover
Spark Plug
LH Camshaft Timing Oil Control Valve Tube Gasket
O–Ring
O–Ring
16 (160, 12)
Gasket Gasket
16 (160, 12)
Bearing Cap Camshaft
Bearing Cap Oil Feed
7.5 (80, 66) Drive Gear
Camshaft Oil Seal Pipe
Camshaft Timing Tube Camshaft Camshaft LH Intake
78 (790, 58) Drive Gear Oil Seal Camshaft
RH Intake
Camshaft
Camshaft Timing Bearing LH Exhaust
Tube Cap Camshaft
Camshaft Gear Spring
Camshaft Sub Gear
Wave Washer Engine
Snap Ring Hanger Ground Camshaft Sub Gear
RH Exhaust Camshaft Cable Wave Washer
Camshaft Timing Snap Ring Camshaft Gear Spring
Oil Control Valve Filter Camshaft Housing
Camshaft Timing
Semi–Circular Plug
Oil Control Valve Filter
Camshaft Plug Semi–Circular Plug
Housing
Plug
Engine Ground Cable
Hanger
RH Cylinder Head and Exhaust Engine Wire

Manifold Assembly Protector
RH Cylinder Head LH Cylinder

Gasket Head and Exhaust
Manifold Assembly
1st 39 (400,29)
2nd Turn 90°
Oil Dipstick and Guide

for Engine
Heated Oxygen
Sensor (Bank 2 Sensor 1)
Heated Oxygen Sensor
Connector
(Bank 1 Sensor 1) Connector
LH Cylinder Head
N·m (kgf·cm, ft·lbf) : Specified Torque Gasket
Author: Date: 1214

EM–33
RH Cylinder Head
Gasket
Valve Lifter
RH Exhaust Manifold
Adjusting Shim
Keeper
x8 Spring Retainer
44 (450, 32)
Valve Spring
Spring Seat
Oil Seal
Valve Guide Bushing
Valve
Heat Insulator
LH Cylinder Head
Gasket
LH Exhaust Manifold
x8
Heat Insulator
Author: Date: 1215

EM–34
EM09Q–02
REMOVAL
1. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEYS (See page EM–15)
2. REMOVE CAMSHAFT TIMING PULLEYS
(See page EM–15)
3. REMOVE CAMSHAFT POSITION SENSOR
(See page IG–10)
4. DISCONNECT PS PUMP FROM ENGINE
(See page EM–77)
5. DISCONNECT FRONT EXHAUST PIPE FROM TWC

(a) Remove the 4 bolts and 4 nuts holding the front exhaust
pipe to the TWC.
(b) Disconnect the front exhaust pipe from the 2 TWC, and
remove the 2 gaskets.
(c) Remove the 2 bolts and pipe support bracket.
P21961
6. REMOVE TWC
Remove the 3 nuts, TWC and gasket. Remove the 2 TWC.
7. REMOVE IGNITION COILS (See page IG–7)
8. REMOVE TIMING BELT REAR PLATES
(a) Remove the 3 bolts, stud bolt, and RH No.1 and No.2 tim-
ing belt rear plates.
(b) Disconnect the wire clamp from the LH timing belt rear
plate.
A02246 (c) Remove the 3 bolts, LH No.1 and No.2 timing belt rear
plates.
NOTICE:
Be careful not to drop anything inside the timing belt
cover.
Do not allow the belt to come into correct with oil, wa-
ter or dust.
9. DISCONNECT FUEL INLET HOSE (See page SF–23)
10. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the accelerator cable.
A02844 (b) Disconnect the throttle position sensor connector.
Author: Date: 1216

EM–35
(c) Disconnect the accelerator pedal position sensor con-

nector.
(d) Disconnect the throttle motor connector.
(e) Disconnect the VSV connector for EVAP.
(f) Disconnect the VSV connector for ACIS.
(g) Disconnect the 8 injector connectors.
(h) Disconnect the noise filter connector.
(n) (i) (i) Disconnect the brake booster vacuum hose from the
union on the intake manifold.
(m) (l) (j) Disconnect the PCV hose from the PCV valve on the LH
cylinder head.
(j)
(k) Disconnect the EVAP hose (from the charcoal canister)
from the VSV for EVAP.
(l) Disconnect the EVAP hose (from the charcoal canister)
from the EVAP pipe on the intake manifold.
(k) A02846 (m) Disconnect the EVAP hose (from the intake air connector)
from the EVAP pipe on the intake manifold.
(n) Disconnect the PS air hose from the intake manifold.
(o) Disconnect the No.1 water bypass hose (from the water
inlet housing) from the throttle body.
(p) Disconnect the No.7 water bypass hose (from the front
water bypass joint) from the throttle body.
(q) Disconnect the 2 wire clamp from the throttle body.
(p)
(o)
A02847
(r) Remove the 2 bolts and EVAP pipe from the intake man-
ifold.
(s) Remove the 2 nuts and accelerator cable bracket.
(t) Disconnect the VSV connector for ACIS from the No.1 V–
bank cover bracket.
(u) Remove the 4 bolts and 3 V–bank cover brackets.
(v) Remove the bolt and VSV for EVAP.
A02866
Author: Date: 1217

EM–36
(w) Disconnect the engine wire from the RH delivery pipe,

rear water bypass joint, intake manifold and cylinder
head.
(1) Disconnect the 2 wire clamps from the wire clamp
bracket on the RH delivery pipe.
B01208
(2) Remove the 3 bolts, and disconnect the engine wire

protector from the rear water bypass joint and RH
cylinder head.
A02845
(3) Remove the 3 bolts, and disconnect the engine wire

protector and wire clamp bracket from the intake
manifold.
B01210
(x) Remove the 6 bolts, 4 nuts, intake manifold assembly and

2 gaskets.
11. REMOVE WATER INLET AND INLET HOUSING AS-
SEMBLY (See page CO–8)
A04269
12. REMOVE FRONT WATER BYPASS JOINT

(a) Disconnect the ECT sensor connector.
(b) Remove the 4 nuts, water bypass joint and 2 gaskets.
A02849
Author: Date: 1218

EM–37
13. REMOVE REAR WATER BYPASS JOINT

Remove the 4 nuts, water bypass joint and 2 gaskets.
14. REMOVE VVT SENSORS
15. REMOVE ENGINE HANGERS
16. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
(See page EM–77)
17. REMOVE OIL DIPSTICK AND GUIDE FOR ENGINE
(See page LU–9)
A02860
18. REMOVE CYLINDER HEAD COVERS

Remove the 9 bolts, 9 seal washers, cylinder head cover and
gasket. Remove the 2 cylinder head covers.
19. IF NECESSARY, REMOVE SEMI–CIRCULAR PLUGS
AND CAMSHAFT HOUSING PLUGS
20. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
(See page SF–51)
21. REMOVE CAMSHAFTS
A04475 NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
No.2 Idler Pulley Bolt (a) Check the crankshaft pulley position.
Check that the timing mark of the crankshaft pulley is in
aligned with the centers of the crankshaft pulley bolt and
idler pulley bolt.
NOTICE:
Having the crankshaft pulley at the wrong angle can cause
Timing
the piston head and valve head to come into contact with
Mark
Crankshaft each other when you remove the camshaft, causing dam-
Pulley Bolt
A03218 age. So always set the crankshaft pulley at the correct
angle.
(b) Rotate the VVT–i pulley from left to right 2 to 3 times within
Rotate (25°)
its range of movement (25° <50° CA> ) and use a waste
cloth to collect the oil from the camshaft timing oil control
valve installation hole.
NOTICE:
Approximately 20 cc (1.2 cu in.) of oil will be ejected, so
take care not to spill it.
A02852
Author: Date: 1219

EM–38
(c) Remove the RH camshafts.

(1) Boring the service bolt hole of the sub–gear upward
by turning the hexagon wrench head portion of the
exhaust camshaft with a wrench.
(2) Secure the sub–gear to the main gear with a service
bolt.
Recommended service bolt:
Thread diameter 6 mm
Service Bolt A02853
Thread pitch 1.0 mm
Bolt length 16 – 20 mm
HINT:
When removing the camshafts, make sure that the torsional
spring force of the sub–gear has been eliminated by the above
operation.
(3) Set the timing mark (1 dot mark) of the camshaft

main gear at approx. 10° angle by turning the hexa-
gon wrench head portion of the exhaust camshaft
with a wrench.
10°
A02854
9 15 17 11 (4) Uniformly loosen and remove the 22 bearing cap

2 bolts in several passes, in the sequence shown.
10 16 18 12 21
22 (5) Remove the oil feed pipe, 9 bearing caps, cam shaft
timing oil control valve and camshafts.
20
19
6 14 4 8
5 13 3 7 1
A02855
(d) Remove the LH camshafts.

(1) Boring the service bolt hole of the sub–gear upward
by turning the hexagon wrench head portion of the
exhaust camshaft with a wrench.
(2) Secure the sub–gear to the main gear with a service
bolt.
A02856
Author: Date: 1220

EM–39
Recommended service bolt:

Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 – 20 mm
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub–gear has been eliminated by the above
operation.
(3) Align the timing mark (2 dot marks) of the camshaft

drive gear by turning the hexagon wrench head por-
tion of the exhaust camshaft with a wrench.
Align
A02857
2 13 17 9 11
(4) Uniformly loosen and remove the 22 bearing cap
bolts in several passes, in the sequence shown.
22 14 18 10 12
(5) Remove the oil feed pipe, 9 bearing caps, cam shaft
timing oil control valve filter and camshafts.
HINT:
21
Arrange the bearing caps in correct order.
20
19
6 16 4 8
1 5 15 3 7 A02858
22. DISASSEMBLE EXHAUST CAMSHAFTS

(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
A02859
(b) Using SST, turn the sub–gear clockwise, and remove the
Service Bolt
service bolt.
SST 09960–10010 (09962–01000, 09963–00500)
Turn
SST
A02850
Author: Date: 1221

EM–40
(c) Using snap ring pliers, remove the snap ring.

(d) Remove the wave washer.
(e) Remove the camshaft sub–gear.
(f) Remove the camshaft gear spring.
HINT:
Arrange the camshaft sub–gears and gear spring (RH and LH
sides).
A02861
23. REMOVE CAM SHAFT TIMING TUBES

(a) Mount the hexagon wrench head portion of the intake
camshaft in a vise.
NOTICE:
The 4 bolts shown in the illust ration determine the
Do not Remove
backlash of the gear in the timing tube, so do not re-
move them. If any of the 4 bolts are removed, install
A02862 a new camshaft timing tube assembly.
(b) Remove the straight screw plug and seal washer.

(c) Using a 10 mm hexagon wrench, and remove the set bolt
and camshaft timing tube.
A02863
(d) Using a 5 mm hexagon wrench, and remove the 4 bolts,

camshaft drive gear and oil seal.
NOTICE:
Be careful not to damage the camshaft timing tube.
24. REMOVE SPARK PLUGS
A02865
25. REMOVE CYLINDER HEAD AND EXHAUST MAN-

IFOLD ASSEMBLIES
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Remove the bolt, and disconnect the ground cable from
the RH cylinder head.
Ground Cable
A02867
Author: Date: 1222

EM–41
(c) Remove the bolt, and disconnect the ground cable from
the LH cylinder head.
Ground (d) Remove the bolt, and disconnect the engine wire protec-
Cable tor from the LH cylinder head.
Wire Protector A02868
(e) Uniformly loosen the 10 cylinder head bolts on one side

of each cylinder head in several passes, in the sequence
shown, then do the other side as shown. Remove the 20
cylinder head bolts and plate washers.
NOTICE:
Cylinder head warpage or cracking could result from
removing bolts in incorrect order.
RH Cylinder Head
1 7 9 6 4
3 5 10 8 2
LH Cylinder Head Front
2 8 10 5 3
4 6 9 7 1
A02869
RH Cylinder Head A Do not drop the plate washer for cylinder head bolt
into portion A of the cylinder head. If dropped into
portion A, the plate washer will pass through the cyl-
inder head and cylinder block into the oil pan.
LH Cylinder Head
A02872
Author: Date: 1223

EM–42
(f) Lift the cylinder head from the dowels on the cylinder
block, and place the 2 cylinder heads on wooden blocks
on a bench.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the
A02871 cylinder head and cylinder block.
The cylinder head should not be tilted so as to secure
the valve lifter. If the cylinder head is tilted, remove
the valve lifter and check that the adjusting shim is
set correctly.
26. REMOVE RH EXHAUST MANIFOLD FROM CYLINDER

HEAD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the 8 nuts, exhaust manifold and gasket.
A02883
27. REMOVE LH EXHAUST MANIFOLD FROM CYLINDER

HEAD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the 8 nuts, exhaust manifold and gasket.
A02884
Author: Date: 1224

EM–43
EM09R–02
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in correct order.
SST 2. REMOVE VALVES

(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202–70020
(b) Remove the spring retainer.
(c) Remove the valve spring.
(d) Remove the valve.
(e) Remove the spring seat.
A03191 HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers incorrect order.
(f) Using needle–nose pliers, remove the oil seal.
A03192
Author: Date: 1225

EM–44
EM09S–02
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
A03194
(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.
CAUTION:
Protect your eyes when using high pressure compressed
air.
A03193
2. REMOVE GASKET MATERIAL

Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
EM6323
3. CLEAN COMBUSTION CHAMBERS

Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
EM6324
4. CLEAN VALVE GUIDE BUSHINGS

Using a valve guide bushing brush and solvent, clean all the
guide bushings.
P21861
Author: Date: 1226

EM–45
5. CLEAN CYLINDER HEAD

Using a soft brush and solvent, thoroughly clean the cylinder
head.
EM6325
6. 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: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
A02876
A02877
A02878 A02879
7. 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.
EM6327
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.
EM0580
Author: Date: 1227

EM–46
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS

(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
5.510 – 5.530 mm (0.2169 – 0.2177 in.)
P21862
(b) Using a micrometer, measure the diameter of the valve

stem.
Valve stem diameter:
Intake 5.470 – 5.485 mm (0.2154 – 0.2159 in.)
Exhaust 5.465 – 5.480 mm (0.2152 – 0.2157 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Z00052
Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.)
Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing. (See Page EM–54)
10. 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°
44.5°
Z00054
(c) Check the valve head margin thickness.

Margin thickness:
Standard 1.0 mm (0.039 in.)
Minimum 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
Margin Thickness
EM0181
Author: Date: 1228

EM–47
(d) Check the valve overall length.

Standard overall length:
Intake 95.05 mm (3.7421 in.)
Exhaust 95.10 mm (3.7441 in.)
Overall Length
Minimum overall length:
Intake 94.55 mm (3.7224 in.)
Exhaust 94.60 mm (3.7244 in.)
EM2534
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.
NOTICE:
Do not grind off more than minimum.
EM0255
11. INSPECT AND CLEAN VALVE SEATS

45° Carbide Cutter (a) Using a 45° carbide cutter, resurface the valve seats. Re-
move only enough metal to clean the seats.
EM6330
(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:
Width 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
Z00055 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:
30° 1.0 – 1.4 mm (0.039 – 0.055 in.)
45°
If not, correct the valve seats as follows:
If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
1.0 – 1.4 mm
Z03988
Author: Date: 1229

EM–48
If the seating is too low on the valve face, use 60°

60° 45°
and 45° cutters to correct the seat.
1.0 – 1.4 mm
Z03989
(d) Hand–lap the valve and valve seat with an abrasive com-
pound.
(e) After hand–lapping, clean the valve and valve seat.
EM6331
12. INSPECT VALVE SPRINGS

Deviation
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
EM0988
(b) Using vernier calipers, measure the free length of the

valve spring.
Free length: 54.05 – 54.15 mm (2.1279 – 2.1319 in.)
If the free length is not as specified, replace the valve spring.
EM0801
(c) Using a spring tester, measure the tension of the valve

spring at the specified installed length.
Installed tension:
204 – 226 N (20.8 – 23.0 kgf, 45.9 – 50.7 lbf)
at 35.0 mm (1.378 in.)
If the installed tension is not as specified, replace the valve
spring.
EM0281
Author: Date: 1230

EM–49
13. 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: 0.08 mm (0.0031 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
A03202
14. 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 in.)
Exhaust 42.630 – 42.730 mm (1.6783 – 1.6823 in.)
Minimum cam lobe height:
Intake 42.46 mm (1.6717 in.)
Exhaust 42.48 mm (1.6724 in.)
EM2011
If the cam lobe height is less than minimum, replace the cam-
shaft.
15. INSPECT CAMSHAFT JOURNALS

Using a micrometer, measure the journal diameter.
Journal diameter:
Intake camshaft (A) 30.984 – 31.000 mm (1.2198 – 1.2205 in.)
Others 26.954 – 26.970 mm (1.0612 – 1.0618 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
EM2538
A02880 A03222
Author: Date: 1231

EM–50
16. INSPECT CAMSHAFT TIMING TUBE JOURNALS

Knock Pin
Red Painted HINT:
Mark There are 2 size of the camshaft timing tube journal diameter,
Green green and red painted mark accordingly. The mark is painted
Painted on the face of the camshaft timing tube.
Mark
A03217
Using a micrometer, measure the journal diameter.

Journal diameter:
Green painted mark 39.958 – 39.964 mm (1.5731 – 1.5734 in.)
Red painted mark 39.964 – 39.970 mm (1.5734 – 1.5736 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
A03203
17. INSPECT CAMSHAFT GEAR SPRING

Using vernier calipers, measure the free distance between the
spring ends.
Free distance: 18.2 – 18.8 mm (0.712 – 0.740 in.)
If the free distance is not as specified, replace the gear spring.
18. INSPECT CAMSHAFT BEARINGS
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
EM3322 inder head as a set.
LH Cylinder Head RH Cylinder Head 19. INSPECT CAMSHAFT TIMING TUBE AND CAMSHAFT
JOURNAL OIL CLEARANCE
Front HINT:
There are 2 size of the camshaft timing tube journal oil clear-
ance, Marked ”A” and ”B” accordingly. The mark is stamped on
the top of the cylinder heads.
Mark (a) Install the camshaft timing tube. (See page EM–58)
A or B
(b) Clean the bearing caps and camshaft journals.
A03216 (c) Place the camshafts on the cylinder head.
(d) Lay a strip of Plastigage across each of the camshaft jour-

nals.
Plastigage
A03204
Author: Date: 1232

EM–51
(e) Install the bearing caps. (See page EM–58)

NOTICE:
Do not turn the camshaft.
(f) Remove the bearing caps.
A03205
(g) Measure the Plastigage at its widest point.

Standard Oil clearance:
Camshaft timing tube
0.036 – 0.050 mm (0.0014 – 0.0020 in.)
Mark ”A”
Camshaft timing tube

0.038 – 0.052 mm (0.0015 – 0.0021 in.)
Mark ”B”
Others 0.030 – 0.067 mm (0.0012 – 0.0026 in.)

Maximum oil clearance:
A03206
Camshaft timing tube 0.085 mm (0.0033 in.)
Others 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-

shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(h) Completely remove the plastigage.
(i) Remove the camshafts.
(j) Remove the camshaft timing tube.
20. IF NECESSARY REPLACE CAMSHAFT TIMING TUBE
Select a camshaft timing tube according to mark on the cylinder
head.
Cylinder Head Camshaft timing tube
Mark ”A” Green painted mark
Mark ”B” Red painted mark
21. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshaft timing tube. (See page EM–58)
(b) Install the camshaft. (See page EM–58)
(c) Using a dial indicator, measure the thrust clearance while

moving the camshaft back and forth.
Standard thrust clearance:
Intake 0.060 – 0.100 mm (0.0024 – 0.0039 in.)
Exhaust 0.040 – 0.090 mm (0.0016 – 0.0035 in.)
Maximum thrust clearance:
Intake 0.13 mm (0.0051 in.)
Exhaust 0.12 mm (0.0047 in.)
A03207
Author: Date: 1233

EM–52
If the thrust clearance is greater than maximum, replace the

camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
(d) Remove the camshafts.
(e) Remove the camshaft timing tube.
22. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshaft timing tube. (See page EM–58)
(b) Install the camshafts without installing the exhaust cam
sub–gear and front bearing cap. (See page EM–58)
(c) Using a dial indicator, measure the backlash.

Backlash:
Standard 0.020 – 0.200 mm (0.0008 – 0.0079 in.)
Maximum 0.30 mm (0.0188 in.)
If the backlash is greater then maximum, replace the cam-
shafts.
(d) Remove the camshafts.
A03208
23. 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 – 31.016 mm (1.2205 – 1.2211 in.)
A03209
(b) Using a micrometer, measure the lifter diameter at the

valve lifter center line, 12.3 – 12.7 mm (0.484 – 0.500 in.)
12.3 – 12.7 mm
from the valve lifter head.
Lifter diameter:
30.966 – 30.976 mm (1.2191 – 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
A03201 Standard 0.024 – 0.050 mm (0.0009 – 0.0020 in.)
Maximum 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
Author: Date: 1234

EM–53
24. INSPECT INTAKE MANIFOLD

(a) Upper intake manifold:
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the lower intake manifold for
warpage.
If warpage is greater than maximum, replace the upper intake
manifold.
A02881
(b) Lower intake manifold:

Upper Intake Manifold Side
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head and upper
intake manifold for warpage.
If warpage is greater than maximum, replace the lower intake
manifold.
Cylinder Head Side
A02882
25. INSPECT EXHAUST MANIFOLD

surface contacting the cylinder head for warpage.
If warpage is greater than maximum, replace the manifold.
P21864
26. INSPECT CYLINDER HEAD BOLTS

Measuring Point Using vernier calipers, measure the thread outside diameter of
the bolt.
Outside diameter:
Standard 9.770 – 9.960 mm (0.3846 – 0.3921 in.)
Minimum 9.60 mm (0.3780 in.)
If the diameter is less than minimum, replace the bolt.
2.5 mm
(0.98 in.) A02825
Author: Date: 1235

EM–54
EM09T–02
80–100°C REPLACEMENT
1. REPLACE VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 – 100°C (176 –
212°F).
A03195
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201–01055, 09950–70010 (09951–07100)
SST
A03196
(c) Using a caliper gauge, measure the bushing bore diame-

ter of the cylinder head.
A03197
Both intake and exhaust (d) Select a new guide bushing (STD or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
Bushing bore diameter
Bushing size 10.306 mm (0.4057 in.), machine the bushing bore to the fol-
mm (in.)
lowing dimension:
10.285 – 10.306
Use STD 10.335 – 10.356 mm (0.4069 – 0.4077 in.)
(0.4049 – 0.4057)
10.335 – 10.356
If the bushing bore diameter of the cylinder head is greater than
Use O/S STD 10.356 mm (0.4077 in.), replace the cylinder head.
(0.4069 – 0.4077)
Intake Exhaust HINT:

Different the bushings are used for the intake and exhaust.
40.5 mm
34.5 mm (1.594 in.)
(1.358 in.)
P21844
Author: Date: 1236

EM–55
(e) Gradually heat the cylinder head to 80 – 100°C (176 –

SST 212°F).
(f) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
Protrusion height:
Intake 9.2 – 9.8 mm (0.362 – 0.386 in.)
Exhaust 8.2 – 8.8 mm (0.323 – 0.346 in.)
SST 09201–01055, 09950–70010 (09951–07100)

A03198
Sharp 5.5 mm Reamer (g) Using a sharp 5.5 mm reamer, ream the guide bushing
to obtain the standard specified clearance (See page
EM–44) between the guide bushing and valve stem.
A03199 A03200
2. REPLACE SPARK PLUG TUBE GASKETS

(a) Bend the 4 ventilation case claw installed on the cylinder
head cover to an angle of 90° or more.
(b) Using a screwdriver, pry out the gasket.
NOTICE:
Be careful not to damage the cylinder head cover, Tape the
Bend Pry screwdrive tip.
Claw A04107
(c) Using SST and a hammer, tap in a new gasket until its sur-
SST face is flush with the upper edge of the cylinder head cov-
er.
SST 09950–60010 (09551–00240, 09951–00440,
09952–06010), 09950–70010 (09951–07100)
NOTICE:
Return Be careful of the installation direction.
SST
(d) Apply a light coat of MP grease to the gasket lip.
Claw Down Ward (e) Return the ventilation case claw to its original position.
A04108
Author: Date: 1237

EM–56
EM09U–02
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES

Adhesive
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Apply adhesive to the end of the spark plug tube.
Adhesive:
Part No. 08833–00070, THREE BOND 1324
or equivalent
15 mm (0.59 in.)
P08885
(b) Using a wooden block and hammer, tap in a new spark

tube until there is 48.4 – 49.6 mm (1.906 – 1.953 in.) pro-
truding from the camshaft bearing cap installation surface
Protrusion of the cylinder head.
NOTICE:
Avoid tapping a new spark plug tube in too far by measur-
ing the amount of the protrusion while tapping.
A03212
2. INSTALL VALVES
SST (a) Using SST, push in a new oil seal.
SST 09201–41020
A03213
(b) Install the valve.

(c) Install the spring seat.
(d) Install the valve spring.
(e) Install the spring retainer.
A03214
Author: Date: 1238

EM–57
SST (f) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202–70020
A03191
(g) Using a plastic–faced hammer and the valve stem (not in

use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
3. INSTALL SHIMS AND VALVE LIFTERS
(a) Install the shim and valve lifter.
(b) Check that the valve lifter rotates smoothly by hand.
A04277
Author: Date: 1239

EM–58
EM108–01
INSTALLATION
1. INSTALL RH EXHAUST MANIFOLD TO CYLINDER
HEAD
(a) Place a new gasket on the cylinder head with the white
White painted marks facing the manifold side.
Painted
Mark
NOTICE:
Be careful of the installation direction.
A02885
(b) Install the exhaust manifold with 8 new nuts. Uniformly

tighten the nuts in several passes.
(c) Install the heat insulator with the 3 bolts.
A02883
2. INSTALL LH EXHAUST MANIFOLD TO CYLINDER

HEAD
(a) Place a new gasket on the cylinder head with the white
painted marks facing the manifold side.
NOTICE:
White Painted Mark

A02886
(b) Install the exhaust manifold with 8 new nuts. Uniformly

tighten the nuts in several passes.
(c) Install the heat insulator with the 3 bolts.
A02884
Author: Date: 1240

EM–59
RH Cylinder Block 3. PLACE CYLINDER HEAD ON CYLINDER BLOCK

(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
HINT:
On the rear side of the cylinder head gasket are marks to distin-
guish the LH and RH banks, a ”R” mark for the RH bank and a
”L” mark for the LH bank.
NOTICE:
LH Cylinder Block (b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
A02887
4. INSTALL CYLINDER HEAD BOLTS

HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (c) and (e)).
If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
RH Cylinder Head the heads of the cylinder head bolts.
5
10 4 2 7
(b) Install the plate washer to the cylinder head bolt.
(c) Install and uniformly tighten the 10 cylinder head bolts on
one side of the cylinder head in several passes in the se-
8 6 1 3 9 quence shown, then do the other side as shown.
1 6 If any one of the cylinder head bolts does not meet the torque
9 3 8 specification, replace the cylinder head bolt.
7 5 2 4 1
10
A02870
Author: Date: 1241

EM–60
RH Cylinder Head NOTICE:

Do not drop the plate washer for cylinder head bolt into por-
A tion A of the cylinder head. If dropped into portion A, the
plate washer will pass through the cylinder head and cylin-
der block into the oil pan.
LH Cylinder Head
A02872
(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts by 90° in the numerical
90° 90° order shown.
(f) Check that the painted mark is now at a 90° angle to front.
Painted Mark
Z15621
5. INSTALL ENGINE WIRE

(a) Install the ground cable to RH cylinder head with the bolt.
A02867
(b) Install the engine wire protector to the LH cylinder head

with the bolt.
(c) Install the ground cable to LH cylinder head with the bolt.
(d) Connect the 2 heated oxygen sensor connectors.
6. INSTALL SPARK PLUGS
A02868
Author: Date: 1242

EM–61
7. ASSEMBLE EXHAUST CAMSHAFT

(a) Install the camshaft gear spring.
(b) Install the camshaft sub–gear.
HINT:
Attach the pins on the gears to the gear spring ends.
(c) Install the wave washer.
A02888
(d) Using snap ring pliers, install the snap ring.
A02861
(e) Mount the hexagon wrench head portion of the camshaft

in a vise.
NOTICE:
A02859
Sub Gear (f) Using SST, align the holes of the camshaft main gear and
Service Bolt sub–gear by turning camshaft sub–gear counterclock-
SST wise, and temporarily install a service bolt.
SST 09960–10010 (09962–01000, 09963–00500)
Main Gear (g) Align the gear teeth of the main gear and sub–gear, and
tighten the service bolt.
Turn
A02889
8. INSTALL CAMSHAFT TIMING TUBES

(a) Place a new oil seal to the timing tube.
NOTICE:
Be careful installation direction.
A03172
Author: Date: 1243

EM–62
(b) Align the timing tube knock pin with the knock pin groove
3 Align of the camshaft drive gear, and temporarily install the
1
camshaft drive gear with the 4 bolts.
2
4 (c) Using a 5 mm hexagon wrench, uniformly tighten the 4
bolts.
NOTICE:
Be careful not to damage the camshaft timing tube.
A03223
(d) Mount the hexagon wrench head portion of the intake

camshaft in a vise.
NOTICE:
A03173
(e) Align the camshaft knock pin with the camshaft timing
Align tube, and push the camshaft timing tube by hand until you
feel it touch the bottom.
A03174
(f) Using a 10 mm hexagon wrench, install the set bolt.

(g) Install the seal washer and straight screw plug.
A02863
9. INSTALL CAMSHAFT HOUSING PLUGS

Seal Packing
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the camshaft housing plug grooves.
Seal packing:
Part No. 08826–00080 or equivalent
A02890
Author: Date: 1244

EM–63
(c) Install the 2 camshaft housing plugs to the cylinder heads.

10. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
RH Cylinder Head receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
A03185
Timing No.2 Idler Pulley Bolt (a) Set the crankshaft pulley position.
Mark Turn the crankshaft pulley clockwise or counterclockwise,
and put the timing mark of the crankshaft pulley in line with
the centers of the crankshaft pulley bolt and idler pulley
bolt.
NOTICE:
Having the crankshaft pulley at the wrong angle can cause
the piston head and valve head to come into contact with
Turn A01874 each other when you install the camshaft, causing dam-
age. So always set the crankshaft pulley at the correct
angle.
(b) Install the RH camshafts.

(1) Apply MP grease to the thrust portion of the intake
and exhaust camshafts.
(2) Place the intake and exhaust camshafts.
(3) Set the timing mark (1 dot mark) of the camshaft
main gear at approx. 10° angle.
Approx. 10°
A03178
Author: Date: 1245

EM–64
Upward (4) Place the camshaft oil control valve filter to the cylin-
der head.
NOTICE:
A03182
Seal Packing
(5) Remove any old packing (FIPG) material from front
Seal Width bearing cap.
1.5 mm (6) Apply seal packing to the front bearing cap as
shown in the illustration.
Seal packing:
Install a nozzle that has been cut to a 1.5 mm
(0.06 in.) opening.
Groove
A03176 Parts must be assembled within 5 minutes of
application. Otherwise the material must be
removed and reapplied.
Immediately remove nozzle from the tube
and reinstall cap.
NOTICE:
Do not apply seal packing to the front bearing cap grooves.
(7) Install the front bearing cap.

HINT:
Installing the front bearing cap will determine the thrust portion
of the camshaft.
(8) Install the other bearing cap in the sequence shown
with the arrow mark facing forward.
HINT:
Align the arrow marks at the front and rear of the cylinder head
Front
A03179 with the mark on the bearing cap.
Push (9) Push in the camshaft oil seal.
A03186
Author: Date: 1246

EM–65
E D E (10) Apply a light coat of engine oil on the threads and

C
A under the heads (D and E) of the bearing cap bolts.
HINT:
Do not apply engine oil under the heads of the bearing cap bolt
B (A), (B) and (C).
C
D E
E
A02855
E D E (11) Install the oil feed pipe and the 22 bearing cap bolts
C
A as shown.
HINT:
Each bolt length is indicated in the illustration.
B Bolt length:
94 mm (3.70 in.) for A
C 72 mm (2.83 in.) for B
D E
E 25 mm (0.98 in.) for C
A02855 52 mm (2.05 in.) for D
38 mm (1.50 in.) for E
21 (12) Uniformly tighten the 22 bearing cap bolts in several
14
8 12 passes, in the sequence shown.
13 7 2
5 6 11 Torque:
1
Bolt C: 7.5 N·m (80 kgf·cm, 66 in.·lbf)
3
Others: 16 N·m (160 kgf·cm, 12 ft·lbf)
4
17
9 19 15
18 10 20 16 22
Front
A03180
(13) Boring the service bolt installed in the driven sub–

gear upward by turning the hexagon wrench head
portion of the camshaft with a wrench.
(14) Remove the service bolt.
A02853
(c) Install the LH camshafts.

(1) Apply MP grease to the thrust portion of the intake
and exhaust camshafts.
(2) Place the intake and exhaust camshafts.
(3) Engage the intake to the exhaust gear by meeting
the timing marks (2 dot marks) on each gear.
A03181
Author: Date: 1247

EM–66
(4) Place the camshaft oil control valve filter to the cylin-
Upward der head.
NOTICE:
A03175
(5) Remove any old packing (FIPG) material.

Seal Packing
Seal Width (6) Apply seal packing to the front bearing cap.
1.5 mm Seal packing:
Install a nozzle that has been cut to a 1.5 mm
(0.06 in.) opening.
Parts must be assembled within 5 minutes of
application. Otherwise the material must be
Groove
A03177 removed and reapplied.
Immediately remove nozzle from the tube
and reinstall cap.
NOTICE:
Do not apply seal packing to the front bearing cap grooves.
(7) Install the front bearing cap.

HINT:
Installing the front bearing cap will determine the thrust portion
of the camshaft.
(8) Install the other bearing cap in the sequence shown
with the arrow mark facing forward.
Front HINT:
Align the arrow marks at the front and rear of the cylinder head
A03183 with the mark on the bearing cap.
Push (9) Push in the camshaft oil seal.
A03187
Author: Date: 1248

EM–67
E D E (10) Apply a light coat of engine oil on the threads and

C
A under the heads (D and E) of the bearing cap bolts.
HINT:
Do not apply engine oil under the heads of the bearing cap bolt
(A), (B) and (C).
B (11) Install the oil feed pipe and the 22 bearing cap bolts
as shown.
D HINT:
C E E
A02858 Each bolt length is indicated in the illustration.
Bolt length:
94 mm (3.70 in.) for A
72 mm (2.83 in.) for B
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E
10 6 14 (12) Uniformly tighten the 22 bearing cap bolts in several

21
12 passes, in the sequence shown.
1 9 11
5 13 Torque:
2 Bolt C: 7.5 N·m (80 kgf·cm, 66 in.·lbf)
Others: 16 N·m (160 kgf·cm, 12 ft·lbf)
3
4
18 17 8 7 20 19 16 15
22
Front A03184
(13) Boring the service bolt installed in the driven sub–

gear upward by turning the hexagon wrench head
portion of the camshaft with a wrench.
(14) Remove the service bolt.
11. CHECK AND ADJUST VALVE CLEARANCE
(See page EM–4)
Service
Bolt Turn the camshaft and position the cam lobe upward, and
check and adjust the valve clearance.
A02856
12. INSTALL SEMI–CIRCULAR PLUGS

Seal Packing (b) Apply seal packing to the semi–circular plug grooves.
Seal packing:
EM7143
Author: Date: 1249

EM–68
RH Cylinder Head (c) Install the 4 semi–circular plugs to the cylinder heads.
LH Cylinder Head
A03188
RH Cylinder Head 13. INSTALL CYLINDER HEAD COVER

(b) Apply seal packing to the cylinder heads as shown in the
illustration.
Seal packing:
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts. Uniformly
LH Cylinder Head tighten the bolts in several passes. Install the 2 cylinder
head covers.
14. INSTALL ENGINE HANGERS
15. INSTALL VVT SENSORS
16. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
(See page SF–51)
17. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
A03189 (See page LU–16)
18. INSTALL OIL DIPSTICK AND GUIDE FOR A/T
(See page EM–82)
Author: Date: 1250

EM–69
19. INSTALL REAR WATER BYPASS JOINT

(a) Install 2 new gaskets to the cylinder head.
(b) Install the 4 nuts holding the water bypass joint to the cyl-
inder heads. Alternately tighten the nuts.
A02860
20. INSTALL FRONT WATER BYPASS JOINT

(a) Install 2 new gaskets and the water bypass joint with the
4 nuts. Alternately tighten the nuts.
(b) Connect ECT sensor connector.
21. INSTALL WATER INLET AND INLET HOUSING AS-
SEMBLY (See page CO–10)
A02849
White Painted 22. INSTALL INTAKE MANIFOLD ASSEMBLY

Mark (a) Place 2 new gaskets on the cylinder heads with white
painted mark facing upward.
NOTICE:
Align the port holes of the gasket and cylinder head.
A03190
(b) Place the intake manifold assembly on the cylinder

heads.
(c) Install and uniformly tighten the 6 bolts and 4 nuts in sev-
eral passes.
A04269
(d) Connect the engine wire to the RH delivery pipe, rear wa-
ter bypass joint, intake manifold and RH cylinder head.
(1) Connect the wire clamp bracket and wire protector
to the intake manifold with the 3 bolts.
B01210
Author: Date: 1251

EM–70
(2) Connect the wire protector to the rear water bypass

joint and RH cylinder head with the 3 bolts.
A02845
(3) Connect the 2 wire clamp to the wire clamp bracket

on the RH delivery pipe.
(e) Install the 3 V–bank cover brackets with the 4 bolts.
(f) Connect the VSV connector for ACIS to the No.1 V–bank
cover bracket.
(g) Install the accelerator cable bracket with the 2 nuts.
B01208 (h) Install the VSV for EVAP with the bolt.
(i) Install the EVAP pipe to the intake manifold with the 2
bolts.
A02866
(o) (j) (j) Connect the brake booster vacuum hose to the union on
the intake manifold.
(n) (m) (k) Connect the PCV hose to the PCV valve on the LH cylin-
(k) der head.
(l) Connect the EVAP hose (from the charcoal canister) to
the VSV for EVAP.
(m) Connect the EVAP hose (from the charcoal canister) to
the EVAP pipe on the intake manifold.
(l) A02846 (n) Connect the EVAP hose (from the intake air connector) to
the EVAP pipe on the intake manifold.
(o) Connect the PS air hose to the intake manifold.
Author: Date: 1252

EM–71
(p) Connect the No.1 water bypass hose (from the water inlet
housing) to the throttle body.
(q) Connect the No.7 water bypass hose (from the front water
bypass joint) to the throttle body.
(r) Connect the 2 wire clamp to the throttle body.
(p) (s) Connect the throttle position sensor connector.
(t) Connect the accelerator pedal position sensor connector.
(u) Connect the throttle motor connector.
(q)
A02847 (v) Connect the VSV connector for EVAP.
(w) Connect the VSV connector for ACIS.
(x) Connect the 8 injector connectors.
(y) Connect the noise filter connector.
(z) Connect the accelerator cable.
23. CONNECT FUEL INLET HOSE (See page SF–23)
24. INSTALL TIMING BELT REAR PLATES
(a) Install the RH timing belt rear plates.
(1) Install the No.1 timing belt rear plate to the cylinder
head with the bolt and stud bolt.
(2) install the No.2 timing belt rear plate to the No.1 tim-
ing belt rear plate with the 2 bolts.
(b) Install the LH timing belt rear plates.
(1) Connect the wire clamp to the No.1 timing belt rear
plate.
(2) Install the No.1 timing belt rear plate to the cylinder
head with the bolt.
(3) install the No.2 timing belt rear plate to the No.1 tim-
ing belt rear plate with the 2 bolts.
25. INSTALL IGNITION COILS (See page IG–7)
26. INSTALL TWC

Install a new gasket and the TWC with 3 new nuts. Install the
2 TWC.
A02246
Author: Date: 1253

EM–72
27. CONNECT FRONT EXHAUST PIPE TO TWC

(a) Temporarily install the pipe support bracket to the trans-
mission with the 2 bolts.
(b) Install a new gasket to each rear end of the TWC.
(c) Connect the front exhaust pipe to the 2 front TWC and
pipe support bracket with the 4 bolts and 4 new nuts.
(d) Tighten the 2 bolts holding the pipe support bracket to the
P21961 transmission.
28. INSTALL PS PUMP (See page EM–82)
29. INSTALL CAMSHAFT POSITION SENSOR
(See page IG–11)
30. INSTALL CAMSHAFT TIMING PULLEYS
(See page EM–22)
31. CONNECT TIMING BELT TO CAMSHAFT TIMING PUL-
LEYS (See page EM–22)
32. CHECK ENGINE OIL LEVEL
Author: Date: 1254

EM–73
ENGINE MECHANICAL – ENGINE UNIT
ENGINE UNIT
EM09W–02
COMPONENTS
Air Cleaner and Hood

Intake Air Connector
Assembly
V–Bank Cover
Air Cleaner Inlet
Battery Hold–Down
Battery Clamp
Clamp
Cover
MAF Meter PCV Hose

Connector PS Air EVAP Hose
Hose
Positive Cable
from Engine
Accelerator Cable Wire
Radiator Assembly Battery

Insulator
for A/C Cooling Fan
Battery
Fan and Fluid Coupling
Assembly
Engine Mount Member

Bracket Plate
x7
x 11
Lower Front Suspension
Generator x8 Member Protector
Oil Pun Protector
Drive Belt
Engine Under Cover
A02231
Author: Date: 1255

EM–74
Cowl Wire
Connector
Grove Compartment
ECM Connector
Under Cover
Brake Booster Vacuum Hose

Engine Wire Grommet Heater Hose
Ground
Strap
Fuel Inlet Hose
Ground
Engine Oil Strap
Level Sensor
Connector
Generator
Connector
Wire Bracket Oil Pressure Switch
Connector
Generator Wire
A02234
Author: Date: 1256

EM–75
Engine and Transmission Assembly
PS Pump
Rear Engine Mounting

13.5 (135, 10) Member
Wire Bracket
Wire Clamp 25 (250, 19)
A/C Compressor Stay A/C Compressor Rear Center Floor
Connector Crossmember Brace
ABS Actuator Ground Cable
Adjusting Washer
Propeller Shaft
Adjusting Washer
Heat Insulator
for Rear Side of
Heated Oxygen Sensor Front Center Floor
Front Exhaust Pipe
(Bank 2 Sensor 2) Crossmember Brace
RH Heat Insulator for

Front Side of Front Exhaust Pipe
Gasket Gasket 43.1 (440, 32)

Gasket
61.8 (630, 46)
Front Exhaust Pipe

LH Heat Insulator for
Front Side of Front
Exhaust Pipe
Pipe
Support Gasket
Bracket
43.1 (440, 32)
Gasket (Bank 1 Sensor 2)
61.8 (630, 46)
Gasket

Center Exhaust Pipe
Author: Date: 1257

EM–76
PNP Switch connector
Clamp Clamp Clamp

Stay Clamp VSS Connector
Solenoid
Connector
Stay
Direct Clutch
Speed Sensor
Stay Connector
Oil Cooler Pipe

for Transmission
Transmission
Oil Dipstick and Guide

for Transmission
O–Ring
Engine
x8
83 (850, 61)
Rear Plate
x6 Drive Plate
414 (420, 30)
Front spacer
Flywheel Housing Under Cover

Precoated part
Author: Date: 1258

EM–77
EM09X–02
REMOVAL
1. REMOVE HOOD
2. REMOVE OIL PAN PROTECTOR
3. REMOVE ENGINE UNDER COVER
4. REMOVE LOWER FRONT SUSPENSION MEMBER
PROTECTOR
5. REMOVE ENGINE MOUNT MEMBER BRACKET
PLATE
7. DRAIN ENGINE OIL
TOR ASSEMBLY
12. REMOVE BATTERY
13. REMOVE DRIVE BELT, FAN FLUID COUPLING AND
FAN PULLEY (See page EM–15)
14. DISCONNECT ACCELERATOR CABLE TO
THROTTLE BODY
15. REMOVE RADIATOR ASSEMBLY (See page CO–21)
16. REMOVE V–BANK COVER BRACKETS FROM EN-
GINE HANGERS
17. DISCONNECT CONNECTORS, WIRE, STRAPS,
CLAMPS AND HOSES
(a) Disconnect the engine oil level sensor connector.
(b) Disconnect the generator connector.
(c) Disconnect the generator wire.
(d) Disconnect the engine wire clamp from the bracket on
generator.
(e) Disconnect the ground strap from the RH engine mount-
ing bracket.
(f) Disconnect the ground strap from under of the LH fender
apron.
(g) Disconnect the engine wire clamp from the cowl panel.
(h) Disconnect the radiator reservoir hose from the water by-
pass pipe.
(i) Disconnect the brake booster vacuum hose from the in-
take manifold.
(j) Disconnect the heater hose from the heater water valve.
(k) Disconnect the heater hose from the water bypass pipe.
(l) Disconnect the fuel inlet hose from the fuel inlet pipe.
(m) Disconnect the PS air hose from the intake manifold.
(n) Disconnect the 2 EVAP hoses from the pipes (from char-
coal canister).
(o) Disconnect the oil pressure switch connector.
18. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the under cover.
(b) Remove the glove compartment.
Author: Date: 1259

EM–78
(c) Disconnect the 3 ECM connectors.

(d) Disconnect the cowl wire connector from the connector
on the bracket.
(e) Disconnect the engine wire clamp from the bracket.
(f) Disconnect the grommet from the cowl panel, and pull out
the engine wire.
NOTICE:
Be careful not to damage the engine wire.
19. DISCONNECT PS OIL COOLER PIPE FROM OIL PAN
P21352
20. DISCONNECT HEATED OXYGEN SENSORS FROM

FRONT EXHAUST PIPE
(a) Disconnect the 2 wire grommets from the floor panel.
(b) Disconnect the 2 oxygen sensors from the exhaust pipe.
P21962
21. REMOVE FRONT EXHAUST PIPE

(a) Loosen the clamp bolt holding the front exhaust pipe to
the center exhaust pipe.
(b) Remove the 4 bolts and 4 nuts holding the front exhaust
pipe to the TWC.
(c) Remove the front exhaust pipe and 3 gaskets.
(d) Remove the 2 bolts and pipe support bracket.
22. REMOVE TWC
A02237 Remove the 3 nuts, TWC and gasket. Remove the 2 TWC.
23. REMOVE CENTER EXHAUST PIPE

(a) Loosen the 2 clamp bolts, and disconnect the center ex-
haust pipe from the tailpipes.
(b) Disconnect the exhaust pipe from the 2 rings on the body
brackets, and remove the center exhaust pipe and 2 gas-
kets.
24. REMOVE HEAT INSULATOR FOR REAR SIDE OF
FRONT EXHAUST PIPE
P21965 25. REMOVE FRONT AND REAR CENTER FLOOR
CROSSMEMBER BRACES
Author: Date: 1260

EM–79
26. REMOVE PROPELLER SHAFT (See page PR–3)
Wire Clamp 27. DISCONNECT A/C COMPRESSOR FROM ENGINE

(a) Disconnect the A/C compressor connector.
(b) Disconnect the wire clamp from the wire bracket on the
A/C compressor.
(c) Remove the bolt, and disconnect the ground cable from
Wire the A/C compressor stay.
Bracket
(d) Remove the bolt, nut and A/C compressor stay.
(e) Remove the bolt, and disconnect the wire bracket from
Ground Cable A02238 the A/C compressor.
(f) Remove the bolt, and disconnect the A/C compressor
from the engine.
28. REMOVE ABS ACTUATOR
29. REMOVE PS PUMP AND OIL RESERVOIR

(a) Remove the 2 bolts, nut and PS pump from the engine.
(b) Remove the 3 bolts and PS oil reservoir from the RH fend-
er apron.
30. REMOVE HEAT INSULATORS FOR FRONT SIDE OF
FRONT EXHAUST PIPE
A02239
31. REMOVE ENGINE AND TRANSMISSION ASSEMBLY

FROM VEHICLE
(a) Remove the 2 nuts, and disconnect the heater water
valve from the cowl panel.
(b) Attach the engine chain hoist to the engine hangers.
(c) Remove the 2 nuts holding the engine mounting insula-
tors to the front suspension crossmember.
A02240
Author: Date: 1261

EM–80
(d) Remove the nut, and disconnect the transmission control

rod from the shift lever.
(e) Remove the 4 bolts, 4 nuts and rear engine mounting
member.
P21349
(f) Lift the engine out of the vehicle slowly and carefully.
HINT:
Make sure the engine is clear of all wiring, hoses and cables.
NOTICE:
Be careful not hit the PS gear housing and PNP switch.
(g) Place the engine and transmission assembly onto the
stand.
32. DISCONNECT ENGINE WIRE FROM TRANSMISSION
A02241 (a) Disconnect the VSV connector.
(b) Disconnect the PNP switch connector.
(c) Disconnect the solenoid connector.
(d) Disconnect the direct clutch speed sensor connector.
(e) Disconnect the 4 engine wire clamps from the bracket.
33. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR

TRANSMISSION
Pull
(a) Remove the bolt.
(b) Pull out the dipstick guide and dipstick from the port of
transmission.
O–Ring
(c) Remove the O–ring from the dipstick guide.
34. REMOVE OIL COOLER PIPES FOR TRANSMISSION
A02243
35. REMOVE TORQUE CONVERTER CLUTCH BOLTS

(a) Remove the 2 bolts and flywheel housing under cover.
(b) Turn the crankshaft pulley bolt to gain access to each bolt.
(c) Hold the crankshaft pulley bolt with a wrench, and remove
the 6 bolts.
A02244
Author: Date: 1262

EM–81
36. REMOVE TRANSMISSION

(a) Remove the 10 bolts and engine wire bracket.
(b) Remove the transmission together with the torque con-
verter clutch from the engine.
Bracket
P21341
37. REMOVE DRIVE PLATE

Remove the 8 bolts, front spacer, drive plate and rear spacer.
P20614
Author: Date: 1263

EM–82
EM09Y–02
INSTALLATION
1. INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive:
Adhesive or equivalent
P08755
(b) Install the front spacer, drive plate and rear plate on the
crankshaft.
(c) Install and uniformly tighten the mounting bolts in several
1
8 5 passes, in the sequence shown.
4 3
6 7
2
P20614
2. INSTALL TRANSMISSION TO ENGINE

(a) Attach the transmission to the engine.
(b) Install the engine wire bracket and 10 bolts.
Torque:
Bracket
3. INSTALL TORQUE CONVERTER CLUTCH BOLTS
(a) Apply adhesive to 2 or 3 threads of the bolt end.
P21341 Adhesive:
or equivalent
(b) Hold the crankshaft pulley bolt with a wrench, and install
the 6 bolts evenly.
HINT:
First install the dark green colored bolt, install the other bolts.
(c) Install the flywheel housing under cover with the 2 bolts.
4. INSTALL OIL COOLER PIPE FOR TRANSMISSION
A02244
Author: Date: 1264

EM–83
5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR

Connect TRANSMISSION
(a) Install a new O–ring to the dipstick guide.
(b) Apply soapy water to the O–ring.
(c) Connect the dipstick guide end to the dipstick tube of the
oil pan.
New
O–Ring (d) Install the dipstick guide with the bolt.
(e) Install the dipstick.
A02245 6. CONNECT ENGINE WIRE TO TRANSMISSION
(a) Connect the VSV connector.
(b) Connect the PNP switch connector.
(c) Connect the solenoid connector.
(d) Connect the direct clutch speed sensor connector.
(e) Connect the 4 wire clamps to bracket.
7. INSTALL ENGINE AND TRANSMISSION ASSEMBLY

IN VEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine and transmission assembly into
the engine compartment.
NOTICE:
Be careful not to hit the PS gear housing and PNP switch.
(c) Insert the stud bolts of the front engine mounting brackets
A02242 into the stud bolt holes of the front suspension crossmem-
ber.
(d) Keep the engine level.
Control (e) Install the rear engine mounting member with the 4 bolts
Rod and 4 nuts.
Torque:
Bolt: 25 N·m (250 kgf·cm, 19 ft·lbf)
Nut : 13.5 N·m (135 kgf·cm, 10 ft·lbf)
NOTICE:
Be careful of installation direction.
P21350
Author: Date: 1265

EM–84
(f) Connect the transmission control rod to the shift lever with
the nut.
(g) Install the 2 nuts holding the engine mounting brackets to
the front suspension crossmember.
(h) Remove the engine chain hoist.
(i) Install the heater water valve with the 2 nuts.
A02240 8. INSTALL HEAT INSULATORS FOR FRONT SIDE OF
FRONT EXHAUST PIPE
Wire Clamp 9. INSTALL A/C COMPRESSOR
(a) Install the A/C compressor, compressor stay and wire
bracket with the 3 bolts and nut.
Torque:
Nut : 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Connect the ground cable to the compressor stay with the
Ground bolt.
Cable Wire Bracket
A02238 (c) Install the wire clamp to the bracket on the A/C compres-
sor.
(d) Connect the A/C compressor connector.
10. INSTALL PS PUMP AND OIL RESERVOIR

(a) Install the PS pump with the 2 bolts and nut. Alternately
tighten the bolts and nut.
Torque:
Nut : 43 N·m (440 kgf·cm, 32 ft·lbf)
(b) Install the PS oil reservoir with the 3 bolts.
11. INSTALL ABS ACTUATOR
A02239 12. INSTALL PROPELLER SHAFT (See page PR–9)
13. INSTALL FRONT CENTER FLOOR CROSSMEMBER
BRACE
14. INSTALL HEAT INSULATOR FOR REAR SIDE OF
FRONT EXHAUST PIPE
Author: Date: 1266

EM–85
15. INSTALL CENTER EXHAUST PIPE

(a) Install 2 new gaskets.
(b) Install the center exhaust pipe to the rings on the body
brackets.
(c) Connect the center exhaust pipe to the tailpipes.
(See page EM–120)
P21965
16. INSTALL TWC

Install a new gasket and the TWC with 3 new nuts. Install the
2 TWC.
A02246
17. INSTALL FRONT EXHAUST PIPE

(a) Temporarily install the pipe support bracket with the 2
bolts.
(b) Install 2 new gaskets to the rear end of the TWC.
(c) Install a new gasket to the rear of the front exhaust pipe.
(d) Temporarily connect the front exhaust pipe to the center
exhaust pipe.
(e) Install the front exhaust pipe to the TWC and pipe support
A02237 bracket with 4 new nuts and the 4 bolts.
Torque:43.1 N·m (440 kgf·cm, 32 ft·lbf)
(f) Tighten the clamp bolt holding the front exhaust pipe to
the center exhaust pipe. (See page EM–120)
(g) Tighten the 4 bolts holding the pipe support bracket to the
transmission.
18. INSTALL HEATED OXYGEN SENSORS

Install the 2 oxygen sensors to the front exhaust pipe.
HINT:
Before installing the oxygen sensor, twist the sensor wire
counterclockwise 3 and 1/2 turns.
After installing the oxygen sensor, check that the sensor
wire is not twisted. If it is twisted, remove the oxygen sen-
P21962 sor and reinstall it.
19. INSTALL PS OIL COOLER PIPE
Author: Date: 1267

EM–86
20. CONNECT ENGINE WIRE TO CABIN

(a) Push in the engine wire through the cowl panel. Install the
grommet.
(b) Connect the 3 ECM connectors.
(c) Connect the cowl wire connector to the connector on the
bracket.
(d) Connect the engine wire clamp to the bracket.
(e) Install the glove compartment.
P21352 (f) Install the under cover.
21. CONNECT CONNECTORS, WIRE, STRAPS, CLAMPS
AND HOSES
(a) Connect the engine oil level sensor connector.
(b) Connect the generator connector.
(c) Connect the generator wire.
(d) Connect the engine wire clamp to the bracket on the gen-
erator.
(e) Connect the ground strap to the RH engine mounting
bracket.
(f) Connect the ground strap to under of the LH fender
apron.
(g) Connect the engine wire clamp to the bracket on the cowl
panel.
(h) Connect the radiator reservoir hose to the water bypass
pipe.
(i) Connect the brake booster vacuum hose to the intake
manifold.
(j) Connect the heater hose to the heater water valve.
(k) Connect the heater hose to the water bypass pipe.
(l) Connect the fuel inlet hose to the fuel inlet pipe.
(See page SF–23)
(m) Connect the PS air hose to the intake manifold.
(n) Connect the 2 EVAP hoses to the pipes (from the char-
coal canister).
(o) Connect the oil pressure switch connector.
22. INSTALL V–BANK COVER BRACKETS TO ENGINE
HANGERS
23. INSTALL RADIATOR ASSEMBLY (See page CO–27)
24. INSTALL BATTERY
25. CONNECT ACCELERATOR CABLES TO THROTTLE
BODY
26. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND
DRIVE BELT (See page EM–22)
27. INSTALL AIR CLEANER AND INTAKE AIR CONNEC-
TOR ASSEMBLY
28. INSTALL AIR CLEANER INLET
29. INSTALL BATTERY CLAMP COVER
30. FILL WITH ENGINE COOLANT
31. FILL WITH ENGINE OIL
Author: Date: 1268

EM–87
33. INSTALL ENGINE MOUNT MEMBER BRACKET

PLATE
34. INSTALL LOWER FRONT SUSPENSION MEMBER
PROTECTOR
35. INSTALL V–BANK COVER
36. INSTALL ENGINE UNDER COVER
37. INSTALL OIL PAN PROTECTOR
38. INSTALL HOOD
39. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS
Author: Date: 1269

EM–88
ENGINE MECHANICAL – CYLINDER BLOCK
CYLINDER BLOCK
EM09Z–02
COMPONENTS
Knock Sensor 2
Connector
Water Bypass Pipe Starter
O–Ring
Water Pump
Starter
Cable
Engine Wire
Starter
18 (185, 13)
Connector
RH Engine Coolant
Drain Plug Knock Sensor 1
RH Engine Mounting Bracket
Knock Sensor 2 Connector
(with Insulator)
Knock Sensor 1
Water Seal Plate
15.5 (160, 11) Engine Wire
O–Ring
Oil Pump
Engine Wire
30.5 (310, 22) Cover
Gasket
LH Engine
Crankshaft Coolant Drain
Front Oil Seal Union
Oil
Crankshaft
Strainer LH Engine Mounting
Position Sensor
Connector Bracket (with Insulator)
No.1 Oil Pan
x 12
Oil Pan Baffle Plate
Gasket
Drain Plug No.2 Oil Pan
x 12

Non–reusable part
Precoated part A02106
Author: Date: 1270

EM–89
No.1 Piston Ring

No.2 Piston Ring
Side Rail
Oil Ring Expander
Side Rail
Snap Ring
Snap Ring Piston Pin
Piston
Connecting Rod
Connecting Rod Bearing
Connecting Rod Cap
1st 25 (250, 18) O–Ring

2nd Turn 90°
Crankshaft
Rear Oil Seal
Cylinder Block
Rear Oil seal
Retainer
Upper Crankshaft Thrust Washer

Upper Main Bearing
Lower Main Bearing Lower Crankshaft

Thrust Washer
Seal Washer
Main Bearing Cap
1st 27 (275, 20) Seal Washer

2nd Turn 90°
49 (500, 36)

Author: Date: 1271

EM–90
EM0A0–02
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
2. REMOVE TIMING BELT AND PULLEYS
(See page EM–15)
3. REMOVE CYLINDER HEAD (See page EM–34)
4. REMOVE RH ENGINE MOUNTING BRACKET
5. REMOVE LH ENGINE MOUNTING BRACKET
6. REMOVE WATER BYPASS PIPE

Pull
O–Ring (a) Disconnect the engine wire clamp from the bracket on the
water bypass pipe.
(b) Remove the bolt.
(c) Pull out the water bypass pipe from the water pump.
(d) Remove the O–ring from the water bypass pipe.
7. REMOVE STARTER (See page ST–5)
8. REMOVE KNOCK SENSORS (See page SF–85)
P21860
RH Side 9. REMOVE ENGINE WIRE

(a) Disconnect the crankshaft position sensor connector.
(b) Remove the 2 bolts, and disconnect the engine wire from
the RH side of the cylinder block.
P20615
LH Side (c) Remove the 2 bolts and engine wire cover from the LH
Ground Cable side of the cylinder block.
Bracket Bracket (d) Remove the 4 bolts and engine wire.
10. REMOVE WATER PUMP (See page CO–8)
11. REMOVE NO.2 OIL PAN (See page LU–9)
12. REMOVE OIL PAN BAFFLE PLATE
(See page LU–9)
13. REMOVE NO.1 OIL PAN (See page LU–9)
Wire Protector Cover A01878 14. REMOVE OIL STRAINER (See page LU–9)
15. REMOVE OIL PUMP (See page LU–9)
Coolant Drain Union 16. REMOVE WATER SEAL PLATE
Remove the 2 bolts and seal plate.
17. REMOVE ENGINE COOLANT DRAIN UNIONS
Remove the RH and LH drain unions.
Water Seal Plate P20616
Author: Date: 1272

EM–91
18. REMOVE REAR OIL SEAL RETAINER

Pry
(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
(c) Remove the O–ring.
A01899
19. CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back an forth.
Thrust clearance:
Standard 0.160 – 0.290 mm (0.0063 – 0.0138 in.)
Maximum 0.35 mm (0.0138 in.)

connecting rod assembly(s). If necessary, replace the crank-
A02220
shaft.
Connecting rod thickness:
22.880 – 22.920 mm (0.9008 – 0.9024 in.)
20. 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 bolts.
A01900
(c) Using the 2 removed connecting rod cap bolts, remove

the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
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
A02221 necessary, replace the crankshaft.
Author: Date: 1273

EM–92
Plastigage (f) Lay a strip of Plastigage across the crank pin.
A02222
(g) Install the connecting rod cap with the 2 bolts.

(See page EM–110)
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure (b) and (c) above)
A02114
(i) Measure the Plastigage at its widest point.

Oil clearance:
Standard 0.027 – 0.053 mm (0.0011 – 0.0021 in.)
Maximum 0.065 mm (0.0026 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.
A02223
HINT:
If using a standard bearing, replace it with one having the same
Num ber number. If the number of the bearing cannot be determined, se-
Mark lect the correct bearing by adding together the numbers im-
printed on the connecting rod cap and crankshaft, then select-
ing the bearing with the same number as the total. There are 6
No.4
sizes of standard bearings, marked ”2”, ”3”, ”4”, ”5”, ”6” and ”7”.
No.3
No.1 Number mark
No.2
Connecting rod cap 1 1 2 1 2 3 2 3 4 3 4 4
Num ber Crankshaft 1 2 1 3 2 1 3 2 1 3 2 3
Mark
Use bearing 2 3 4 5 6 7
EXAMPLE:
Connecting rod cap ”3” + Crankshaft ”1”
= Total number 4 (Use bearing ”4”)
Num ber
Mark
Z14349
Author: Date: 1274

EM–93
Reference
Connecting rod big end inside diameter:
Mark ”1” 55.000 – 55.006 mm (2.1654 – 2.1656 in.)
Mark ”2” 55.006 – 55.012 mm (2.1656 – 2.1658 in.)
Mark ”3” 55.012 – 55.018 mm (2.1658 – 2.1661 in.)
Mark ”4” 55.018 – 55.024 mm (2.1661 – 2.1663 in.)
Crankshaft crank pin diameter:
Mark ”1” 51.994 – 52.000 mm (2.0470 – 2.0472 in.)
Mark ”2” 51.988 – 51.994 mm (2.0468 – 2.0470 in.)
Mark ”3” 51.982 – 51.988 mm (2.0465 – 2.0468 in.)
Standard sized bearing center wall thickness:

Mark ”2” 1.484 – 1.487 mm (0.0584 – 0.0585 in.)
Mark ”3” 1.487 – 1.490 mm (0.0585 – 0.0587 in.)
Mark ”4” 1.490 – 1.493 mm (0.0587 – 0.0588 in.)
Mark ”5” 1.493 – 1.496 mm (0.0588 – 0.0589 in.)
Mark ”6” 1.496 – 1.499 mm (0.0589 – 0.0590 in.)
Mark ”7” 1.499 – 1.502 mm (0.0590 – 0.0591 in.)
(j) Completely remove the Plastigage.
21. 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.
HINT:
Ridge Keep the bearings, connecting rod and cap together.
Mark EM6412 Arrange the piston and connecting rod assemblies in cor-
rect order.
22. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Thrust clearance:
Standard 0.020 – 0.220 mm (0.0008 – 0.0087 in.)
Maximum 0.30 mm (0.0118 in.)
thrust washers as a set.
P20722
Thrust washer thickness:
2.440 – 2.490 mm (0.0961 – 0.0980 in.)
Author: Date: 1275

EM–94
23. REMOVE MAIN BEARING CAPS AND CHECK OIL

CLEARANCE
(a) Remove the 10 main bearing cap bolts.
P20674
3
(b) Uniformly loosen and remove the 20 main bearing cap
13
9
7
17
bolts in several passes, in the sequence shown.
19 14
5 4
15 18
1 8
11 20
16 10
6
12
2
A01901
(c) Using 2 screwdrivers, pry out the main bearing cap, and
remove the 5 main bearing caps, 5 lower bearings and 2
lower thrust washers (No.3 main bearing cap only).
NOTICE:
Be careful not to damage the cylinder block.
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
A01902 in correct order.
(d) Lift out the crankshaft.
(e) Remove the 2 upper thrust washers.
HINT:
Arrange the upper thrust washers in correct order.
Keep the upper bearings together with the cylinder block.
(f) Clean each main journal and bearing.
(g) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(h) Install the 10 main bearings and 5 main bearing caps with
the 30 bolts. Do not install the crankshaft.
(See page EM–110)
A01903
Author: Date: 1276

EM–95
(i) Using a cylinder gauge, measure the inside diameter of

the main bearing.
Bearing inside diameter:
66.986 – 67.000 mm (2.6372 – 2.6378 in.)
(j) Measure the diameter of the main journal.
(See page EM–100)
(k) Subtract the main journal diameter measurement from
the main bearing inside diameter measurement.
A01904 Standard clearance:
No.1 and No.5 0.017 – 0.033 mm (0.0007 – 0.0013 in.)
Others 0.029 – 0.045 mm (0.0011 – 0.0018 in.)
Maximum clearance:
No.1 and No.5 0.043 mm (0.0017 in.)
Others 0.055 mm (0.0022 in.)
No.5
If the oil clearance is greater than maximum, replace the bear-
No.4
No.3 ings. If necessary, replace the crankshaft.
Num ber HINT:
Mark
If using a standard bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, se-
No.2 lect the correct bearing by adding together the numbers im-
No.1 printed on the cylinder block and crankshaft, then refer to the
Number
Mark
table below for the appropriate bearing number. There are 5
sizes of the standard bearings. For No.1 and No.5 position
No.5 bearings, use bearings marked ”3”, ”4”, ”5”, ”6” and ”7”. For oth-
ers position bearings, use bearings marked ”1”, ”2”, ”3”, ”4” and
No.2
”5”.
No.1
No.4
No.3
Num ber
Mark
Z14350
Author: Date: 1277

EM–96
No.1, No.5:
Use bearing
Upper Lower
0–5 3 3
6–8 3 4
9 – 11 4 4
Cylinder block (A) 12 – 14 4 5
+ 15 – 17 5 5
Crankshaft (B)
18 – 20 5 6
21 – 23 6 6
24 – 26 6 7
27 – 28 7 7
EXAMPLE:
Cylinder block ”08” + Crankshaft ”06”
= Total number 14 (Use bearing ”4” (Upper), ”5” (Lower))
Others:
Use bearing
Upper Lower
0–5 1 1
6–8 1 2
9 – 11 2 2
Cylinder block (A) 12 – 14 2 3
+ 15 – 17 3 3
Crankshaft (B)
18 – 20 3 4
21 – 23 4 4
24 – 26 4 5
27 – 28 5 5
EXAMPLE:
Cylinder block ”08” + Crankshaft ”06”
= Total number 14 (Use bearing ”2” (Upper), ”3” (Lower))
Author: Date: 1278

EM–97
Reference
Cylinder block main journal bore diameter (A):
Mark ”00” 72.000 mm (2.8346 in.)
Mark ”01” 72.001 mm (2.8347 in.)
Mark ”02” 72.002 mm (2.8347 in.)
Mark ”03” 72.003 mm (2.8348 in.)
Mark ”04” 72.004 mm (2.8348 in.)
Mark ”05” 72.005 mm (2.8348 in.)
Mark ”06” 72.006 mm (2.8349 in.)
Mark ”07” 72.007 mm (2.8349 in.)
Mark ”08” 72.008 mm (2.8350 in.)
Mark ”09” 72.009 mm (2.8350 in.)
Mark ”10” 72.010 mm (2.8350 in.)
Mark ”11” 72.011 mm (2.8351 in.)
Mark ”12” 72.012 mm (2.8351 in.)
Mark ”13” 72.013 mm (2.8352 in.)
Mark ”14” 72.014 mm (2.8352 in.)
Mark ”15” 72.015 mm (2.8352 in.)
Mark ”16” 72.016 mm (2.8353 in.)
Crankshaft main journal diameter (B):

Mark ”00” 67.000 mm (2.6378 in.)
Mark ”01” 66.999 mm (2.6378 in.)
Mark ”02” 66.998 mm (2.6377 in.)
Mark ”03” 66.997 mm (2.6377 in.)
Mark ”04” 66.996 mm (2.6376 in.)
Mark ”05” 66.995 mm (2.6376 in.)
Mark ”06” 66.994 mm (2.6376 in.)
Mark ”07” 66.993 mm (2.6375 in.)
Mark ”08” 66.992 mm (2.6375 in.)
Mark ”09” 66.991 mm (2.6374 in.)
Mark ”10” 66.990 mm (2.6374 in.)
Mark ”11” 66.989 mm (2.6374 in.)
Mark ”12” 66.988 mm (2.6373 in.)
Standard bearing center wall thickness:
No.1 and No.5
Mark ”3” 2.492 – 2.495 mm (0.0981 – 0.0982 in.)
Mark ”4” 2.495 – 2.498 mm (0.0982 – 0.0983 in.)
Mark ”5” 2.498 – 2.501 mm (0.0983 – 0.0985 in.)
Mark ”6” 2.501 – 2.504 mm (0.0985 – 0.0986 in.)
Mark ”7” 2.504 – 2.507 mm (0.0986 – 0.0987 in.)
Author: Date: 1279

EM–98
Others
Mark ”1” 2.486 – 2.489 mm (0.0979 – 0.0980 in.)
Mark ”2” 2.489 – 2.492 mm (0.0980 – 0.0981 in.)
Mark ”3” 2.492 – 2.495 mm (0.0981 – 0.0982 in.)
Mark ”4” 2.495 – 2.498 mm (0.0982 – 0.0983 in.)
Mark ”5” 2.498 – 2.501 mm (0.0983 – 0.0985 in.)
(l) Remove the 10 bolts, 20 nuts, 5 main bearing caps and

5 lower main bearing.
(See procedure (a) to (c) above)
(m) Remove the 5 upper main bearings from the cylinder
block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
correct order.
A01905
24. CHECK FIT BETWEEN PISTON AND PISTON PIN

Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
A01906
25. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the piston rings in correct order only.
A02090
26. DISCONNECT CONNECTING ROD FROM PISTON

(a) Using a small screwdriver, pry out the 2 snap rings.
A01908
Author: Date: 1280

EM–99
(b) Gradually heat the piston to approx. 60°C (140°F).

60°C
A01909
(c) Using a plastic–faced hammer and brass bar, lightly tap

out the piston pin and pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.
A02068
Author: Date: 1281

EM–100
EM0A1–02
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
NOTICE:
EM6413
If the cylinder is washed at high temperatures, the cylinder
liner sticks out beyond the cylinder block, so always wash
the cylinder block at a temperature of 45° or less.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR

FLATNESS
surface contacting the cylinder head gasket for warpage.
If warpage is greater than maximum, replace the cylinder block.
Z04007
4. INSPECT CYLINDER FOR VERTICAL SCRATCHES

Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
EM6414
Author: Date: 1282

EM–101
5. INSPECT CYLINDER BORE DIAMETER

HINT:
There are 3 sizes of the standard cylinder bore diameter,
No.2 No.4 No.6 No.8
Front marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the
: Mark 1, 2,or 3 top of the cylinder block.
No.1 No.3 No.5 No.7
A02069
Thrust Using a cylinder gauge, measure the cylinder bore diameter at

1 1
Direction positions A, B and C in the thrust and axial directions.
Front 2
Axial Standard diameter:
2
Direction
Mark ”1” 87.500 – 87.510 mm (3.4449 – 3.4453 in.)
10 mm Mark ”2” 87.510 – 87.520 mm (3.4453 – 3.4457 in.)
A (0.39 in.)
Mark ”3” 87.520 – 87.530 mm (3.4457 – 3.4461 in.)
B
Maximum diameter: 87.73 mm (3.4539 in.)
C
10 mm
(0.39 in.) If the diameter is greater than maximum, replace the cylinder
block.
Z04009
6. REMOVE CYLINDER RIDGE

If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
Ridge
Reamer
EM6412
7. INSPECT MAIN BEARING CAP BOLTS

Using vernier calipers, measure the tension portion diameter of
the bolt.
Diameter:
Standard 7.500 – 7.600 mm (0.2953 – 0.2992 in.)
Minimum 7.20 mm (0.2835 in.)
If the diameter is less than minimum, replace the stud bolt.
EM6347
Author: Date: 1283

EM–102
8. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
A02071
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
A02072
(c) Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.
A02073
RH Piston
9. INSPECT PISTON OIL CLEARANCE
HINT:
There are 3 sizes of the standard piston diameter, marked ”1”,
”2” and ”3” accordingly. The mark is stamped on the piston top.
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 26.5 mm (1.04 in.)
26.5 mm from the piston head.
Piston diameter:
Mark 1, 2, or 3 Mark ”1” 87.406 – 87.416 mm (3.4411 – 3.4416 in.)
Mark ”2” 87.416 – 87.426 mm (3.4416 – 3.4420 in.)
Mark 1, 2, or 3 Mark ”3” 87.426 – 87.436 mm (3.4420 – 3.4424 in.)
LH Piston
(b) Measure the cylinder bore diameter in the thrust direc-
tions. (See step 5 above)
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Oil clearance:
Standard 0.084 – 0.104 mm (0.0033 – 0.0041 in.)
A02074
A02075 A02076 Maximum 0.124 mm (0.0049 in.)
Author: Date: 1284

EM–103
If the oil clearance is greater than maximum, replace all the 8

pistons. If necessary, replace the cylinder block.
Cylinder Block
HINT
Use new cylinder block:
Use a piston with the same number mark as the cylinder
diameter marked on the cylinder block.
No.2 No.4 No.6 No.8
Front The shape of the piston varies for the RH and LH banks.
: Mark 1, 2,or 3 The RH piston is marked with ”R”, the LH piston with ”L”.
No.1 No.3 No.5 No.7
Mark
RH Piston LH Piston 1, 2, or 3
Mark
1, 2, or 3
A02069
A02077 A02075 A02078
10. INSPECT PISTON RING GROOVE CLEARANCE

Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the ring groove.
Ring groove clearance:
No.1 0.020 – 0.070 mm (0.0008 – 0.0028 in.)
No.2 0.010 – 0.050 mm (0.0004 – 0.0020 in.)
If the clearance is not as specified, replace the piston.
A02079
11. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 105 mm (4.13 in.) from the top of the
cylinder block.
105 mm
A02081
Author: Date: 1285

EM–104
(c) Using a feeler gauge, measure the end gap.

Standard end gap:
No.1 0.250 – 0.450 mm (0.0098 – 0.0177 in.)
No.2 0.500 – 0.700 mm (0.0197 – 0.0276 in.)
Oil (Side rail) 0.150 – 0.500 mm (0.0059 – 0.0197 in.)
Maximum end gap:
No.1 1.05 mm (0.0413 in.)
EM7639
No.2 1.30 mm (0.0512 in.)
Oil (Side rail) 1.10 mm (0.0433 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.
12. INSPECT PISTON PIN FIT

At 60°C (140°F), you should be able to push the piston pin into
60°C the piston pin hole with your thumb.
A02080
13. INSPECT CONNECTING ROD ALIGNMENT

Using a rod aligner and feeler gauge, check the connecting rod
alignment.
Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
Z14454
Check for twist

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
Z14455
Author: Date: 1286

EM–105
14. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 – 22.014 mm (0.8663 – 0.8667 in.)
EM6525
(b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter:
21.997 – 22.006 mm (0.8660 – 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Oil clearance:
Standard 0.005 – 0.011 mm (0.0002 – 0.0004 in.)
Maximum 0.05 mm (0.0020 in.)
EM0227
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.
15. INSPECT CONNECTING ROD BOLTS

Using vernier calipers, measure the tension portion of the con-
necting rod bolt.
Diameter:
Standard 7.200 – 7.300 mm (0.2835 – 0.2874 in.)
Minimum 7.00 mm (0.2756 in.)
If the diameter is less than minimum, replace the bolt.
EM6347
16. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT

(a) Place the crankshaft on V–blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.08 mm (0.0031 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
P20662
Author: Date: 1287

EM–106
17. INSPECT MAIN JOURNALS AND CRANK PINS

(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Diameter:
Main journal 66.988 – 67.000mm (2.6373 – 2.6378 in.)
Crank pin 51.982 – 52.000 mm (2.0465 – 2.0472 in.)
If the diameter is not as specified, check the oil clearance (See
disassembly). If necessary, replace the crankshaft.
(b) Check each main journal and crank pin for taper and out–
of–round as shown.
Maximum taper and out–of–round:
0.02 mm (0.0008 in.)
If the taper and out–of–round is greater than maximum, replace
the crankshaft.
Z14536
Author: Date: 1288

EM–110
EM0A3–02
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O–rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring on one
A02085
side of the piston pin hole.
(b) Gradually heat the piston to about 60°C (140°F).

60°C
A02086
RH Piston (c) Coat the piston pin with engine oil.

(d) Position the piston front mark with respect to the outside
mark on the connecting rod as shown in the diagram.
NOTICE:
Front Mark
(2 Cavities) The installation directions of the piston and connecting rod
are different for the RH and LH banks. The RH piston is
marked with ”R”, the LH piston with ”L”.
(e) Align the piston pin holes of the piston and connecting
Outside
Mark rod, and push in the piston pin with your thumb.
LH Piston
Front Mark
(1 Cavity)
A02087
A02088
Outside Mark
A02089
(f) Using a small screwdriver, install a new snap ring on the

other side of the piston pin hole.
A01908
Author: Date: 1292

EM–111
2. INSTALL PISTON RINGS

No.1 Code Mark (a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code Mark
Code mark:
No.2
No.1 1R
No.2 2R
A02230
RH Piston (c) Position the piston rings so that the ring ends are as
No.2 shown.
Lower Compression
Side NOTICE:
Rail Do not align the ring ends.
Expander
Front
Mark
(2 Cavities)
No.1
Upper Compression
Side Rail A02091
LH Piston
No.2
Lower
Compression
Side
Rail
Expander
Front
Mark
(1 Cavity)
No.1
Upper
Compression
Side Rail
A02092
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
EM6484
No.1 and No.5 Others 4. INSTALL MAIN BEARINGS

HINT:
Upper Main bearings come in widths of 19.5 mm (0.768 in.) and
22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bear-
Lower
ings in the No.1 and No.5 cylinder block journal positions
with the main bearing cap. Install the 19.5 mm (0.768 in.)
bearings in the other positions.
19.5 mm
Upper bearings have an oil groove and oil holes; lower
22.5 mm
Z04019 bearings do not.
Author: Date: 1293

EM–112
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
A02093
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
Mark
1, 2, 3, 4, or 5
A02094
5. 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.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
A02095
7. PLACE MAIN BEARING CAPS AND LOWER THRUST

WASHERS ON CYLINDER BLOCK
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
A02107
(b) Install the 5 main bearing caps in their proper locations.
A02096
Author: Date: 1294

EM–113
HINT:
Place the bearing caps level and let them return to their original
position by their own weight.
NOTICE:
Do not install the main bearing cap by tapping it.
A02097
8. INSTALL MAIN BEARING CAP BOLTS

HINT:
14
18
8 The main bearing cap bolts are tightened in 2 progressive
4
16 6 12 2 7
17 steps (steps (b) and (d)).
3
20
10 1 13 If any one of the main bearing cap bolts is broken or de-
5 11
9 15 formed, replace it.
19
the main bearing cap bolts.
A02108 (b) Install and uniformly tighten the 20 main bearing cap bolts
in several passes, in the sequence shown.
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
90° ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
90°
Front front.
Painted
Mark
A02109
(f) Install a new seal washer to the main bearing cap bolt.
(g) Install and uniformly tighten the 10 main bearing cap
bolts.
(h) Check that the crankshaft turns smoothly.
9. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM–90)
P20674
Author: Date: 1295

EM–114
10. 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 of the piston facing forward.
NOTICE:
The shape of the piston varies for the RH and LH banks. The
RH piston is marked with ”R”, the LH piston with ”L”.
Front
Front Mark
(2 Cavities)
PH
Piston
Front Mark
(1 Cavity) Front
LH
Piston
EM6422
A02098
A02099 A02100
11. PLACE CONNECTING ROD CAP ON CONNECTING

ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin groove of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod
cap.
A02110
RH Bank (c) Check that the outside mark of the connecting rod cap is
facing in correct direction.
Front
LH Bank Outside Mark (Protrusion)

Front
A02111
A02112 Outside Mark (Protrusion) A02113
Author: Date: 1296

EM–115
12. INSTALL CONNECTING ROD CAP BOLTS

HINT:
The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any one of the connecting rod cap bolts is broken or de-
formed, replace it.
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap

bolts in several passes.
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the connecting rod cap bolts.
A02114
(c) Mark the front of the connecting cap bolt with paint.
90° (d) Retighten the cap bolts 90° as shown.
90°
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
Front 13. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM–90)
14. INSTALL REAR OIL SEAL RETAINER
A02115 (a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.
Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non–residue solvent, clean both sealing
surfaces.
Seal Width (b) Apply seal packing to the oil seal retainer as shown in the
2 – 3 mm A illustration.
A
Seal packing:
B Install a nozzle that has been cut to a 2 – 3 mm (0.08
– 0.12 in.) opening.
B Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
A02101 and reapplied.
Author: Date: 1297

EM–116
Immediately remove nozzle from the tube and rein-

stall cap.
(c) Install a new O–ring to the cylinder block.

(d) Install the oil seal retainer with the 7 bolts.
New
O–Ring
A02102
15. INSTALL ENGINE COOLANT DRAIN UNIONS

Seal Packing
(a) Apply seal packing to 2 or 3 threads.
Seal packing:
P12477
(b) Install the RH and LH drain unions.

HINT:
After applying the specified torque, rotate the drain union clock-
Front
wise until its drain port is facing forward.
16. INSTALL WATER SEAL PLATE
Port (a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the seal plate
P20642 and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non–residue solvent, clean both sealing
surfaces.
Author: Date: 1298

EM–117
(b) Apply seal packing to the seal plate as shown in the il-
A lustration.
Seal packing:
A Install a nozzle that has been cut to a 2 – 3 mm (0.08
B
– 0.12 in.) opening.
Seal Width Parts must be assembled within 5 minutes of ap-
2 – 3 mm plication. Otherwise the material must be removed
B and reapplied.
EM6687
Immediately remove nozzle from the tube and rein-

stall cap.
(c) Install the seal plate with the 2 nuts. Alternately tighten the
nuts in several passes.
17. INSTALL OIL PUMP (See page LU–16)
18. INSTALL OIL STRAINER (See page LU–16)
19. INSTALL NO.1 OIL PAN (See page LU–16)
20. INSTALL OIL PAN BAFFLE PLATE
(See page LU–16)
21. INSTALL NO.2 OIL PAN (See page LU–16)
22. INSTALL WATER PUMP (See page CO–10)
LH Side Ground Cable 23. INSTALL ENGINE WIRE

(a) Install the engine wire to the LH side of the cylinder block
with the 4 bolts.
Bracket Bracket
(b) Install the engine wire cover with the 2 bolts.
Cover
Wire Protector A01878
RH Side (c) Install the engine wire to the RH side of the cylinder block
with the 2 bolts.
(d) Connect the crankshaft position connector.
24. INSTALL KNOCK SENSORS (See page SF–85)
25. INSTALL STARTER (See page ST–17)
P20615
Author: Date: 1299

EM–118
Push 26. INSTALL WATER BYPASS PIPE

New (a) Install a new O–ring to the water bypass pipe.
O–Ring (b) Apply soapy water to the O–ring.
(c) Push the water bypass pipe end into the pipe hole of the
water pump.
(d) Install the water bypass pipe with the bolt.
(e) Install the engine wire clamp to the bracket on the water
P20655 bypass pipe.
27. INSTALL RH ENGINE MOUNTING BRACKET

Install the mounting bracket with the 4 bolts.
HINT:
The RH mounting bracket is marked with ”R”.
A02224
28. INSTALL LH ENGINE MOUNTING BRACKET

Install the mounting bracket with the 4 bolts.
HINT:
The LH mounting bracket is marked with ”L”.
29. INSTALL CYLINDER HEADS (See page EM–58)
30. INSTALL TIMING BELT AND PULLEYS
(See page EM–22)
A02225 31. DISCONNECT ENGINE FROM ENGINE STAND
Author: Date: 1300

EM–119
ENGINE MECHANICAL – EXHAUST SYSTEM
EXHAUST SYSTEM
EM0A4–02
COMPONENTS
Heat Insulator Bracket
Ring Heat Insulator
Bracket
RH Tailpipe
Ring Ring
Center Exhaust Pipe Gasket
Ring LH Tailpipe
Gasket
HINT:
Before installing the oxygen sensor, Heat Insulator
twist the sensor wire counterclockwise 3
and 1/2 turns.
After installing the oxygen sensor, check Heat Insulator
that the sensor wire is not twisted.
If it is twisted, remove the oxygen sensor
and reinstall it.
Heat Insulator Heat Insulator
Gasket

Gasket (Bank 2 Sensor 2)
43.1 (440, 32)
Gasket
TWC
61.8 (630, 46) Damper
Front Exhaust Pipe
Heat Insulator
TWC
Damper 43.1 (440, 32)

Pipe Support Bracket
Gasket
61.8 (630, 46) (Bank 1 Sensor 2)
Heat Insulator
Author: Date: 1301

EM–120
ENGINE MECHANICAL – EXHAUST SYSTEM
EM0A5–02
Protrusion INSTALLATION
Hole CONNECT CENTER EXHAUST PIPE TO FRONT EXHAUST
PIPE AND TAILPIPES
Front
HINT:
Tighten Install a new gasket to the exhaust pipe in the correct
A direction.
Fit together the clamp protrusion and pipe hollow, and
New Touch tighten the clamp bolt until A and B of the clamp are just
Hollow Gasket B P21361 touching.
Author: Date: 1302

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EM–1

ENGINE MECHANICAL – CO/HC

4. INSERT CO/HC METER TESTING PROBE AT LEAST

2000 LEXUS LS400 (RM717U)

Author: Date: 1183

Low High Rough idle 1. Vacuum leaks:

High High Rough idle 1. Restricted air filter

2000 LEXUS LS400 (RM717U)

Author: Date: 1184

3. CHECK CYLINDER COMPRESSION PRESSURE

2000 LEXUS LS400 (RM717U)

Author: Date: 1185

VALVE CLEARANCE EM09I–02

10. SET NO.1 CYLINDER TO TDC/COMPRESSION

2000 LEXUS LS400 (RM717U)

Author: Date: 1186

11. INSPECT VALVE CLEARANCE

(d) Determine the replacement adjusting shim size according

2000 LEXUS LS400 (RM717U)

Author: Date: 1187

2000 LEXUS LS400 (RM717U)

Author: Date: 1188

Installed shim thickness

New shim thickness mm (in.)

Intake valve clearance (Cold):

Installed shim thickness

New shim thickness mm (in.)

Exhaust valve clearance (Cold):

IGNITION TIMING EM09J–02

LEXUS Hand–Held Tester 5. CONNECT LEXUS HAND–HELD TESTER OR OBD II

6. CONNECT TIMING LIGHT TO ENGINE

SST 8. INSPECT IGNITION TIMING

(b) Using a timing light, check the ignition timing.

Author: Date: 1191

13. REINSTALL BATTERY CLAMP COVER

2000 LEXUS LS400 (RM717U)

Author: Date: 1192

2000 LEXUS LS400 (RM717U)

Author: Date: 1193

Air Cleaner and Intake

Air Cleaner Inlet

MAF Meter Connector PCV Hose Clip

ECT Switch Connector

Fan and Fluid

A/T Oil Cooler Hose A/C Compressor Connector

Oil Pan Protector

N·m (kgf·cm, ft·lbf) : Specified Torque

2000 LEXUS LS400 (RM717U)

Author: Date: 1194

RH No.3 Timing Belt Cover

N·m (kgf·cm, ft·lbf) : Specified Torque A01862

Camshaft Timing Pulley

Timing Belt 7.5 (80, 66 in.·lbf)

245 (2,500, 181)

2000 LEXUS LS400 (RM717U)

Author: Date: 1195

No.1 Idler Pulley

34.5 (350, 25)

Crankshaft Timing Pulley