GP) TOYOTA REPAIR MANUAL Sep., 2002 nn i ) S& Pub. No. RM993EINTRODUCTION PREPARATION SERVICE SPECIFICATIONS FUEL ENGINE MECHANICAL COOLING LUBRICATION STARTING & CHARGING ALPHABETICAL INDEX sao ms iz =01-7 IWTRODUCTION TERMS °° | TERMS ABBREVIATIONS USED IN THIS MANUAL ‘breviations meaning ABS ‘Anti-Lock Brake AG ‘Ar Gondionor AC ‘Alorrating Curent L aCe ‘Ascossoy ACIS ‘Acoustic Contra nducion System ASD ‘Aulonvails Cota Sian Devoe ADD. ‘Automates Dsconnecting Diflerertal Air ‘Ai-Fuel Ratio ABC ‘Aalive Height Gontol Suspension ALR Automalis Lacking Retractor ALT ‘Allornater ANP. Anlior ANT Antenna APPROX Appronioatly ASSY ASSEN arr Automat Transmission {Iransaday AIF Auioiratis Transmission Fad [AUTO Automate AUK Asiiany AVG. Averane AVE, [Adantive Vara Suspension Be Batery Votage BAGS Blopat Alive Compensation 5 BAT Balen BDO Boon Dead Gorter a Ei Lpvel BS Bore-Siroke Rao are Belore Too Dead Center BySy Bimotalic Vacuum Switching Valve cB Sireuit Broaker (G60) Clavie Convorier For Oxtaton on Bompact Dice cr Gomemngroee eo Genter Ot Gravity oH Bhannal CK Bomplete Knack Down come: Combination OPE Coune ops ‘Conibustian Pressure Sensor PU Gorival Processing Unit ens. Shik Restiant System em ‘artr ow (Chock Valve Ww Control Waive ow ‘Curb Weight DC Direst Curent DEF Beleaner DEL Detistor01-8 INTRODUCTION — TERMS Abraviations Meaning DIFF, Difforeatial DIFF, LOGK Diffrential Leck DAN Direct inestion Bue Data Link Comnestor ou DBiaributoroas ignition DOHG Double Overhead Cam DF. Dash Pot 0S Dead Soak DSP Digital Signal Prosessor DIE Diagnostic Trouble Code EGAN Engine Gontiol And Measwemani Syston FD) Eloctronie Controlled Divs ony Feléy Crna Dynamamster ECT Eleetronie Control ‘Tanamission Eau Eroetonie Gonteal Unit ED. Eresiro-Deposites Goatng EDU Ereetion Onving Unit EDIC Eleatrie Diesel Ijpotion Control EFI Elgetrovie Fuel nection EG Engine EGR Fxtwuel Gas Rareslation EGRVAT EGR. acum Modulator ELA Emergonoy Leckng Reliactor ENG Engine ESA Elpetonie Spark Aavance ETS Electronic Motte Contol System EVAP, Evaporative Emission Gontol EVP Evaporator Evy Electric Vanuurn Regulating Vawe x Exhaust FE Ful Faonany Te Front-Engne Fron Wheel Dive FG Fue Gauge FPG Formed in Plage Gasket FusbieLine FP, Fuel Pump FPU Fuel Pressure Up [FR Front FW Fiywhea Pw) Flywheel Damper WO. Frort- Wheel Orive Gasoline ‘OND Ground HAG High Aide Gai Fe Hatchback FUSE High Current Fuse HE High HIG High Intandiy Discha ge (Head ann) Hse Houring a Haid Too Ws Heaiod winashials Syste01-9 INTRODUCTION — TERMS ‘Abbreviations Meaning ic Integrated Girt Il Tnditect Dinsel njasion 1S, Independent Front Suspancion 1c Tgnition A Integrated Ignition ASSOMDIy W Intake (Mano, Valve} iNT Thtermitiant ie Tnslrument Panel IRS Iiniependont Rear Suspension SC Tee Spaeel Control 8 “Junetion Book we “Juneton Canncotor i Kik-Down TaN oval Avwa fetwark te Litoack LoD Liquid Gystal Display LED Tight Emitting Diode 7 LeftHand LAD Lett Hard Drive LHW Length Height, Width ir} Leng Lif Coolant ENG Liquifed Naural Gas Lo) Low LPs) Uguited Petoleum Gas 180 Limited Stip Diforential LSPaPv Load Sensirg Propartoning And Bypass Valve SPV Load Sensing Proportoning Valve MAP ‘Manifold Absolute Prassure MAX. Maximnarn Me Microphone ale Malfunction ndcalor Lam ma, aot Me Multigurpose MeL Multipoint Eleavonis iyeetion MPX Multiplex Communication Sysiom wr Manual Transmission MT Moun MIG Bountng N Neuta NA Natural Aspratin NO. Number a5 ‘Oxygen Sensor Ow. Owerctive OEM Orginal Equipment Manutachring HG [Overhead Casta ony [Ovartinad Valve opr [Option OS Overaes Paov Propoiloning Ara Bypass valve Pos Power Gontol System Pav Posilive Grarkcase Ventlaliono1-10 IvTRODUCTION — TERNS Abbreviations ‘Meaning PRE Parking Brake PPE Progreseiva Power Slowing PS. Power Steering PIO Power Take-Oh PAW Power Window Rap. Rack And Pinon Ri Relay Blogs RBS Recirculating Ball Type Steering RE Reinforcorient Za Rigi Froni Suspension TRS Figid Roar Suspension it Fighi-Hana RHO Fight Hand Dive RLY Relay ROM ead Only Memory BR, Fler RRS, Rear-Wheol Drive Rw ear-Wheel Drive DN Sedan SEW Berson SIS Slarting injeoton Gone! Systern 300 ‘ale OF Charge SOHC ‘Single Overhead Camshalt SPEC. Speciication SPI ‘Single Point Injection SRS ‘Supplemental Restraint System set ‘Special Service Materials S81 ‘Spacial Service Tooke S10 [Stonciord SW [Gol Siar Fuel Hjestion Sw Switch SYS Syste TA, Transaie TAGH Tachometer Tel Thictle Body Electronic Fuel injection Te. Turbocharger To6s TOVOTA Computer-Controlled System T3¥ Timing Genial Valve Too Top Dead Gane! TEMP, Tenperature TEMS: TOYOTA Electronic Modulaled Suspension TFT Toyota Free Tronic TS Total Information System For Veliele Development TH Transnission | TMG TOYOTA Moir Corporation TMi TOYOTA Moior Manulaciuing Kentucky. Ine THO Traction Goniol System TURBO FTumoenaige Two Tiveo-Way Catalyst ua Underanne Us UniersizeINTRODUCTION TERMS om ‘Abbreviations Meaning vov ‘Vaccum Central Valve VENT Ventilator VIN Vise Idenitinaton Number VPS: Variable Power Steering vSC Wohicle Skid Cantiot vav ‘Vacuum Switching Vaive viv Vacuum Transmiting Valve we Variable Valve Tiring-intligant we rit Wan Wagon wit Wire Harness wo wiivout ist Fist eNO Seconet WD. “Two Wheel Drive Vehisle 4 » 2) aRD Thiel 4TH Fourth wo Four WheelDrive Vahele(a x) aus Four Whoo Steering Syatom STH Fi01-12 INTRODUCTION Tenn GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE—J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. SAE TOYOTA TERMS ABBREVIATIONS SSETERNS (_} ABBREVIATIONS: NC ‘Ar Condtioning ‘Ad Gondtioner ACL ‘Nr Geaner ‘Ai Coane, AGL NR Secondary nection Aictrieton fA P ‘Aecaertor Pedal Be Battery Postive Vege “1 Eatery vonage ARO Barometie Presse HAG cat Gharge ir Coslor Inecenor AR Carburetor Carburetor oF Contnunus Fu ijecion = oP Crankstatt Postion Crank Angle oo Glos Loop Gozed Loop MP) ‘Camshelt Poston camAngle cpp Chueh Pedal Positon = rox Continue Ten Oise ~ cre ‘losed trate Psion UL ON ale ON oF Ditoet Fue njeton (iese Died miecton (09 1 Distbuior tion Do Data Lisk Connect + Check Connector cuce Data isk Connector 2 2 Talal Diagnosis Comuicaion Link (TDCL} ted Data Link Cormactor a 8 08D I agnostic Camecor ore Diagrostie Trove Gade Blagnestc Cove rw Diagnostic Tas Mode = Ea Engine Control Level = ECM Engine Gort Mode Engine EGU (Electonie Corot Und) eoT Engine Coolant Temperaire oolnt Tempera. water Yonperature TH) lecrically Erasable Programmable Read Only Menory EEPROM Electrical Erosable Proyrammable ReadOnly Memory | (EEPROM) Erasable Pocrammasle Read! Only Memory |EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve HCV} EGR Exhaust Gas Recut haus! Goe Ractuaton (EGR) a ledronio Woon TOYOTA Dstrbulmess gntion (70H eM Engine Mosiicaton Engine woication (EM) EPROM Eracable Programmable Road Oni Memory Programmable Read Only Memory (PROM EVA Evaporative Emission Evayorative Emission Canto VAP) Fo Fan Conte = resenoni _ |Terms aera FEPROM Flash Erasable Programmable Read Only Memory fF Fleible Fuel iP Fuel Pun FuelPump GEN Ganerator ‘Aerator ‘GND ‘roe oun (GND) mca1-13 wrsgoucrion res ar ‘Manifold Absolute Fressute heeweee et ona ae AC WRN ale Ronan SS Ho oe Soy ChB Degen tun 80 pe Pre Tap Over Diesel Pata i ra Paya z 5a Sil ul ni sal Se 2 st Senos rh ros Fo cn Segoe0114 w|i a jaarSERVICE SPECIF.CATIONS — FUEL TORQUE SPECIFICATION Pat Tightens ha rotten oh homie reainng wut njecan nb2zie holder a7 ave ra [Shubbor valve xinjestion pump bode Ey B00 @ Distributive headplug x ivecton pura bod gq 300 Fudl tenperature sensor x injection pump body 2 220 Fuel inet tolow serew x nection pump bods Ed 375 Fu iter to injection pump fuel pipe » Fuel niet holon sciew a on 20. 2 eal 20 ‘vel cove x njation pump body02-6 SERVICE SPECIFICATIONS — ENGINE MECHANICAL SERVICE DATA ENGINE MECHANICAL Idler tension sping Frea tongtt 444 48.4 mm (1,748 ~ 1.787 in. Installs iension b80.4 mm 2.051 in) [5958 [5.42 ~5.68 wa 11.9 19.2 Gyinder headset bat Outer alamoter Standaid | 11-80-1200 mm {0.4846 ~0.4724 in} Hisar | 19.60 mm (0.4567 in} ‘Byinger head gasket New irstaledaylinder head gasko! thokness eak B | 1-40 — 1.80 mir 0.0551 ~ 0.0591 in [+50 — 1.60 mm (0.0591 — 0.0600 in F | 160 — 1.20 rum (0.0830 ~ 0.0668 in ‘Vaive cloerance ot 601d 0.20—0.80 nm (0.008 -O012iny 0.49 —0.59 rm (9.016 - 9020. Inetallad tansion at37.0mmt asring [Syndr news warpage Maximum | 0.20 mm (0.00780. Triake Val Yaw stern diameter 7.996 mn (0.3140 ~ 03146 in} awe face angle 4a." Hasigin thickness stardad | 1.6 mr 0.0889 Wiionarn 1-4 mm 1.048 in vera ena Starcara | 04.10 — 104.50. (4.0904 ~ 4.1148 in) teinimum | 103.60 rm (4.0707 in.) araust Valve ave stem damater 7.900 979 1m (0.8134 0.0140 in) Valve face angle sas" Margin thickness Standard | 1.7 mn (0.087 1) Minis | 1-2 rom (0.047 in (Overall engin Stanclare | 103.95 — 104.35 nm (4.0925 ~ 41083 in} Minimum | 103.45 em 4.0728 in. Thierconpresson spring Deviation axernim | 2.0 rn (0.079 ind Fioe length Type A | 46.20 mm (1.8189 in} B | a8.54mm (9110 hd 01 922 N(90.7 ~ 98:9 kg, 87 7 — 74.7 Intake valve guide bush Inside diametor 8.010~8.080 rum (0.9154 9.3161 ind Mexinnum Ol clearance Standace mn 0.0008 ~ 0.0022in, Maximum [0.98 mm {0.9081 i.) Bushbbore dameter SID | 13.004 - 13.025 mn p.5120~0.5128 in} 098 005 | 13.054 - 1.075 mm (0.5199 -0.6148 n.) Protrusian bight 10.8 11,2 mm {0.426 — 0.444 in} Exhaust valve guide bash Inside diameter 8016 ~ 8.000 mm (0.3154 0.8181 in) il ebarance Standard | 6.095 ~0.070 ev (0.0014 —0.0128 in, Maximurn | 0.30.mar (0.0099 in.) bush bore dlarveter STD | 13.004 - 1.025 mm 10.5120 ~ 0.5128 1m} 05 0095 | 13.054 — 19.075 mm (0.5139 ~0.5148in.) Pratiscion height 10.8~ 11.2mmn (0425 —0.444 in} Tilaka valve seats Gonactny wich 4.51.9 mm {0.089 -0.075in.) Exhaust vaWe sea Goniacting wc 1-22 mm (0.071 ~0.087in4} Yale iter Luter ameter 4.992 ~ 40.902 mm [1.6099 —1.6103in,) Liter bere diameter 14.960 ~ 40.980 mm 1.6126 ~ 1.6194} il dewanco Standard | (.086 ~0.088 mm {0.9023 ~ 0.0088 inj 6.10 mm (0.0038)SERVICE SPECIFICATIONS ENGINE MECHANICAL 03-7 Camanati Circle rurout aimum | 0.10 nur 0.0039 in) (Gam bbe heaht Staierd Intake | $4,890 64.910 mm (2.16102 1618 ing Exhaust | 54.999 ~98.010 mm j2.1650~2 1657 in.) ‘airienum Intaxo | $439 mm {2.1413 Exhaust | 52.49 nn (2.1488 9.) ameter STD No.t | 98.969 ~24:985 mm (1.8767—1.9774 in) Others | 27.960 27.085 mm {)-1011 — 1.1018} iS 0.128 Not | 92.800 ~24.a60 mm (1 971819724 in} Others | 27 84d ~27:860 mm (0962 ~ 1.0988 in) ss 0.250 No.1 | 84.719 ~34.735 mm (1.3669 — 1.9675 in.) ‘others | 27.719 ~27.735 mm (1.0913 1.0919 in} Oil etearence Standard | 0.022 — 0.074 mim (0.0008 ~ 9.0029.) Maximum | 0.10 mm (0.0038 i,j ‘Thaust clearance ‘Standard | 0.080 —0.260 mm (0,003" ~ 0.110in.) Masinuen | 0.35 an {0.0196 in} Gamtuston chamber Shim thigsness 0.03 mum (0.0012) Protusion Minus 0.53 ~ Pls 0.03: (Minus 0.0012 ~ Plus 0.0912 in Gonnesting od Thiust clearance standatd | 0.080 - 0.300 mn (0.0081 ~0.0118in,) ‘asimam | 0.98 sm (0.0198 i.) i clearence Stoner $1 | 0.036 0,04 men (0.0014 ~ 0.0025in } iS 0.25, LIS 0.50 } 0.093 ~ 0.078 mm (0.0013 ~0.0081 in, Maximum | 6.10 mm (0.0038 0.) Connecting tod bearing canter wall thickness (Relerence) Standard Mark 1 | 1476 1.482 rum (0.0582 — 0.058 in 2 | 1.482 — 1.486 mm (0.0588 — 0.0586 i, 3 | 14v5 — 490 ram (0.0585 — 0.0887 in.) Fog bent Frod twist Bush inside diamotor ‘axirnui per 400 mn (3.94 Fy} ‘Maxirum per 190 min (8.94 i 16.98 mn (0.0020 in.) 8.18 menj0.0069 in.) 28,008 -20.020 mm {1 1420— 1.14251n.) Conaveting 10d bol tonsion portion diameter Standard | 8400 ~8.600 rum (0.2907 ~0.8986in j Minimum | 820 mm (0.3228 in.) Granvahat Thaustclonranco Standard | 0.040 — 0.280 mm 6.0018 D.009Bin,) Maximum | 0.90 mm (0.0118 in.) ‘Thaust washer thickness STD | 2430 —2.480 mm (0.095? ~0.0976in.) 098.125 | 2.490 ~ 2.543 mm (0.098% ~0.1901 in.) 08 0.250 | 2558 ~ 2.605 min (0.7008 -0.1026in.) Maia joumal oil clearance Standard SID | 0030 ~0,085 mm (0.6013 0.9026 1} U's 0.25, 0.50 | 0.959 ~ 0.078 mm {0.0013 ~0.0081 in, tasimum | 0.10 mm (0.9080 in} Main boering centor wall hielnese (Roforonce} Stange Markt | 1.978 — 1.983 rn (0.0779 0.0781 in 2 | 1.889 ~ 1.987 mm (0.0781 ~ 0.0782 in.) 3 | 1 987 — 1.961 mm (0.0782 0.0784 in Grecie runout Maximum | 0.98 mm (0.0024 in, ‘Main oumal diameter STD | 67.985 ~ 62.000 mm 2.4408- 2.44081.) uss 025 | 61.745 ~ 61.755 mm (2.4509 - 24413 n1) iS 0.50 | 6.495 — 61.809 min 24211 24215 In.) Grank pin diameter STD | 54.988 — 96 000 mn 2.1849 ~ 2.1054 1) Urs 0.25 | 54.745 54.755 mm (2.1869 2.1957 9.) UrS. 0850 | 81.405 54.505 mm (2.1455~ 2.1459.) Main journal taper andoutoliound Maxima | 02 mm io.a00R in Crank pin anor and aut-ol-rount Maximum | 9.02 mm {0.000803-3 SERVICE SPECIFICATIONS ~ ENGINE MECHANICAL ‘Gylinder block Warpace Maxim | 0.20 mm {0.0079 9. yin bore dlantor Standard Mask || 29.990 92.510 mm .817a~3.91771N) 2 | se.s10 ~ 98.520 mm 9.9177 ~ 3.918110) 3 | e0.520 99.500 mm 3.018) — 3.9165i0,) axiom STD | 99.73 mm (2.9264 in 08 0.80 | 10.23 mm (3.9485 in.) Piston Piston darter sib Maik 1 | 99.450 99.460 mm i8.9153~-3.9157in,) 2 | 99.480 ~9¢,470 mm (3.9157 -.9161 in} 3 | 99.470 ~9¢,480 mm (3.9181 ~3.9165in) 0:8 0.80 | 99.950 ~ 98.980 mm 13,8950 ~3.9962in} Ol cearance sstanaare | 0,040 ~0,080 mm {0.0018 ~0.002¢ ing ‘Maximum | 013mm (0.0081 1) Piston protrusion lom eyindsr block 0.88— 0.97 am (0.0208 — 0.9968 in.) Piston BA Bianter 23,000 28.012 mm (3.4417 — 1-1422in,) Piston gin ail loaranco Standuid | 0001 ~0,012 min {0.0002 ~0.c008 inj Maximum | 0.05 me {0.0020 in. Piston ing set Footen ring groove eloarance Standare No.1 | 0087 —0.301 mm (0.0022--0.c040 in. No.2 | 9.:080~—0.100 mm (6.0024 - 0.00389 in 011 | 9.039 ~0.070 mm (0.0012 ~0.0028 in Maximum | 020mm (0.0079 i, Piston ring end gap Standard No.1 | 0.350 ~ 0.690 mn (0.0138 —0.0282 in} No | 0.470 — 9.720 mm {0.0185 — 0.0285 in ‘0 | 0200 ~ 0.520 mm (a.9078 —u.0208 ins Maximum No.1 | 129mm (0.0508 in No2 | 142mm {00889 in} it | 1.22 mm (0.0480 in.)SERVICE SPECIFICATIONS — ENGINE WECHANICAL, TORQUE SPECIFICATION 03-9 Pari ightened) Na gem ot Eg earl seal retainer x Cylnelor block 18 130 10 Tin cer case x Cylinder block 2 230 7 alanine x Ondo: blook @ 180) a Olsaner x Tmng gear case 2 210 19 [Gl aanx Oyler block | ie 180 B lpn x Timing year ease 18 180 8 [ol nan x Engine rear oll sea retainer 180) 19 Water pump x Timing gear case 230 7 Tining bol idler No.2 x Timing qoar case 340 2 ining bet dlr No. 1 Timing goar cae zm hoa 12 198 us Gyinder mead x Cylinder block 15 78 800 200] Tun go" Tun sa) Tun 30" se] Twn so Tun 99° un 30" [Gansta heaving cap x Oyinder had 25 255 18 Canta ol seal retainer x Cynder baad 8 185, 8 Tiningbol No.2 cover » Gylindor hoe 1 188 8 Casha ining pulley x Camstatt % 1.000 2 (Gylnder head cover x Oyinder head 2 120 per eevon pag Nat» Gylindor locke 20 200 uu er oain cook x Gylintor black a8 800 8 [Gyinder block aoriice x Cylinder blosk 1 10) a Ditnozele x Gvinder block 26 280 1B [cranksnatiboaring cap x Cylinder block 108 11050 n [Connecting 103 cap x Gannectng wa 18 54 350 4 ene] tun ao! Tun 90° “um 90"FUEL —_INJECTIONNOZZLE SUB-ASSY (51-£) INJECTION NOZZLE SUB-ASSY (5L-E) COMPONENTS Ring Packing Seting Nut + Washer Y Injection Nozzle Holder AY Nozzle Holder Pressure Spiny Washer —©) Nozzle Holder Pressure ary & Nozzle Holder Puressure Pin ) Nozzle Distance Piece 7 & Injection Nozzle [are 3H = Nozzle Retaining Nut \ Nim (kghem, fib | : Specified torque & © Non-reusable part11-6 FUEL ~_ INJEOTICN PUMP ASSY GL-E} INJECTION PUMP ASSY (5L-E) COMPONENTS S— ¢ Washer ' 2 Fuel Filler to Injection Pump Fuel Pipe Q— ¢ Washer Fuel Inlet Holow Screw = [87 (975, 27) oe Washer Overllow Screw ; (arian. | tive Head Plug / raeenos : @ Washer Nozzle Leakage Pipe No. 4 [2 0,16) | Fst Temperature ‘Sensor t Sabber ate bo Ring — 220600, 8) Delay ae ¢ Gasiet Injoction Pump Delivery Valve Injection Pump Timer Control Valve [Nim tkgtom, itlef) |: Specified torque + Non-reusable partP. ENGINE MECHANICAL —_ PARTIALENGINE ASSY (SL-E) PARTIAL ENGINE ASSY (5L-E) COMPONENTS 144 Oil <2. 42 (120, 9) I ax Gylinder Head Gover — } Cylinder Head Cover Gasket — foe (Bea HF i; ie Camshaft Bearing Cap 1 ; & 7 ‘Camshaft Bearing i aig Camshalt ‘Camshatt Bearing 7s [ist 78 00, 58) [Seoremares—| i x4 2nd: Tun 90 i 1 ‘rc Turn 90° ee # Gasket Camshaft Oil Seal Retainer Timing Gear Woodruff Key 7 P = 5 wit Cylinder Head — Cylinder Head \ £70 85,731 ] Gasket \_@ Oil Seal Retainer No. 2 0i Seal Camehatt Timing Pulley ae i, Timing Belt No.2 Cover (3, YS P SS, Specified torque @ Non-reusable partENGINE MECHANICAL — PARTIAL ENGINE ASSY s5L-F} + Engine Rear Oil Seal Engine Rear Ol Seal Retainer : Gasket —{ Sal (120,70) | 14 | # Gasket x6 5: ‘Ss — Tension Spring Bracket (Be) i Pacet 4 Timing Geai Case oF Timing Chain Gase Ol seal Timing Belt Idler No. 2 [338802] tL [aaa] il Strainer (ee 3] | Timing Belt ldler Tension Spin idler No. 1 ere | Crankshaft Timing Pulley ‘om. HBF) | Specified torque > _¢ Nor-reusatie part14-3 ENGINE MECHANICAL —_ PARTIAL ENGINE ASSY (SL-E) OVERHAUL 4. REMOVE OIL FILLER CAP SUB-ASSY 2. REMOVE CYLINDER HEAD COVER SUB-ASSY (a) Remove the 9 bolts, nut, cylinder head cover and gasket. 3. REMOVE CAMSHAFT TIMING PULLEY (a) Set the No. 1 cylinder to approx. 90° 8TDC/compression. HINT: Set the No.1 cylinder to 90° BTDCicompression to avoid inter- ference with the piston top and valve head (1) Using the crankshaft pulley bol, turn the crankshaft 90° counterclockwise, and pul the timing mark of the timing belt case. (b) Using SST, loosen the pulley bolt. SST 09960-10010 (09962-01000, 09962-01000) {c) Using SST. separate the timing pulley from the camshaft. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05021) (d) Remove the pulley bolt and timing pulley. (ec) Remove the timing gear woodrutf key. 4. REMOVE TIMING BELT NO.2 COVER (a) Remove the 4 bolts and timing belt cover. 5. REMOVE CAMSHAFT OIL SEAL RETAINER (a) Remove tho 4 bolts, retainer and gasket. 6. _ REMOVE OIL SEAL RETAINER, NO.2 OIL SEAL HINT: There are 2 methods (a) and (b)) to remove the cil seal (@) If the camshaft oil seal retainer is removed from the cylin- der head (1) Using a screwdriver and hammer, tap out the oil seal. the crankshatt timing pulley with the protrusion of z44 ENGINE MECHANICAL PARTIAL ENGINE ASSY (6.-E) (b) _ Ifthe camshatt oil seal retainer is installed to the cylinder head: (1) Using a knife, cut off the oil seal lip. (2) Using a screwairiver, pry out the oil seal NOTICE: Be careful not to damage the camshalt. Tape the screwdri ertip. Cut Position 7. REMOVE CAMSHAFT (a) Set the key groove of the camshaft, facing upward by turning the camshaft with a wrench. key Groove - (b) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (c)_ Remove the 5 bearing caps and camshatt (¢) Remove the 10 bearings from the bearing caps and cylin- der head. HINT: Atrango the bearings incorrect order. 8. REMOVE CYLINDER HEAD SUB-ASSY (a) Uniformly loosen and remove the 18 cylinder head bolts, in several passes, in the sequence shown NOTICE: Head warpage or cracking could result from removing bolts in incorrect order. (b) Lift the cylinder head from the dowels on the cylinder biock, and place the cylinder head on wooden blocks on abench HINT: Ifthe cylinder head is difficult to liftoff, pry with a screwdriver be- tween the cylinder head and block, NOTICE: Be careful not to damage the contact surfaces of the cylin- "sonal Ger head and cylinder block,14-5 ENGINE MECHANICAL PARTIAL ENGINE ASSY (5L-E) 9. REMOVE CYLINDER HEAD GASKET 10. REMOVE TIMING BELT IDLER SUB-ASSY NO.1 (a) Remove the 2 bolts (A and 8} (b) Loosen the bolt (©), and remove the timing belt idler No.1 14. REMOVE TIMING BELT IDLER SUB-ASSY NO.2 (a) Remove the bolt, timing belt idler No.2 and spacer. 12. INSPECT TIMING BELT IDLER SUB-ASSY NO.1 (2) _ Visually check the seal portion of the timing bolt idler No.1 for oil leakage. leakage is found, replace the timing belt idler No.1. (b) Check that the timing belt idler No. 1 turns smoothly. I necessary, replace the timing belt idler No.1 13. INSPECT TIMING BELT IDLER SUB-ASSY No.2 (@) Check that the timing belt idler No.2 tums smoothly. MW necessary, replace the timing belt idler No.2, 14. INSPECT IDLER TENSION SPRING {a) Measure the free length of tension spring. Free length: 44.4 — 45.4 mm (1.748 — 1.787 in.) | the free length is not as specified. replace the tension spring (b) Measure the tension of the tension spring at the Specified installed length, Installed tension: 53-59 N (5.42 - 5.98 kgf, 11.9— 13.2 Ibf) at 52.1 mm (2.051 in.) I the installed tension is not as specified, replace the tension spring, \ |. Froo Length - 3 15, REMOVE WATER PUMP ASSY (a) Remove the 6 bolts, tension spring bracket, water pump and gasket.14-10 ENGINE MECHANICAL — PARTIAL ENGINE ASSY (SLE) 31. INSTALL WATER PUMP ASSY (a) Install a new gasket, the water pump and tension spring bracket with the 6 bolts. Torque: 23 N.m (230 kgf.em, 17 tt-lbf) le 32, INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (a) Install the spacer and timing belt idler No.2 with the bolt. Torque: 33 Nim (340 kaf-cm, 24 ftibf) (b)_ Check that the timing belt idler No.2 moves smoothly. —— 38. INSTALL TIMING BELT IDLER SUB-ASSY NO.1 {mn HT + The bolt lengths or bolt types A, B and G shown in the il- +} lustration are: B {——m A: 76.5 mm (3.012 in.) B: 42.9 mm (1.689 in.}, Color: Yollow ie C:41.3 mm (1.626 in.), Color: Silver c fl + Boll Cis combined with the timing belt idler No.1. 1 ase fa) Install the timing belt idler No.1 with the 3 bolts (b) Tighten the bolt (C). Torque: 19 N-m (195 kgf-cm, 14 ft-bf) P 34, INSTALL CYLINDER HEAD GASKET (a) Check the piston protusions for each cylinder (1) Clean the cylinder block with solvent. (2) Set the piston of the cylinder to be measured to slightly before TOC. § (3) Place a dial indicator on the cylinder block, set the 2mm 5 measuring tip as shown in the illustration. (0.98in.) » “ov (4) Sot the dial indicator at 0 mm (0 in.). e aS ee asane] HINT. Use a dial indicator measuring tip as shown in the illustra- tion. Make sure thal the measuring tip is square to the cylinder block gasket surface and piston head when taking the measurements.14-1 ENGINE MECHANICAL — PARTIAL ENGINE ASSY (5L-© (5) Find where the piston head protrudes most by siow- ly turning the crankshaft clockwise and counter- clockwise Measuring Tip Protrucion (6) Measure each cylinder at 2 places as shown in the illustration, making a total of 8 measurements. (7) Forthe piston protrusion value of each cylinder, use the average of the 2 measurements of each cylin der. Piston protrusion: 0.68 — 0.97 mm (0.0268 — 0.0382 in.) HINT: When removing piston and connecting rod assembly: FS X:Measuting Poirt | sie] It the protrusion is not as specitied, remove the piston and con- necting rod assembly and reinstall it (See page 14-38) (>) Select a new cylinder head gasket. HINT: ‘There are 3 sizes of new cylinder head gaskets, marked B, D of F accordingly New installed cylinder head gasket thickness: e 5.80 1.60 mm (0.085% — 0.0501 in A 4.80 1.80 min (0.059% — 0.08301 E 1.60 — 170 me (0.0690 — 0.0869 in (1) Select the largest pision protrusion value fram the measurements made, then select a new appropri- ale gasket according to the table below. Piston protrusion Gasket size (0.58 ~ 0.77 men (0.0268 ~ 0.6808 in} Use 8 (0.78 ~ 0.87 mm (0.0807 ~ 0.6348 in} Use 0 (0.88 — 0.97 mm(0.0948 0.0382 in} Use F (c) Place anew cylinder head gasket in position on the oylin- der block, NOTICE: Bo careful of the installation direction. 35. INSTALL CYLINDER HEAD SUB-ASSY (a) Place the cylinder head in position on tne cylinder head gasket.Va-te ENGINE MECHANICAL — PARTIAL ENGINE ASSY (5L-E) 18. B SS (b) HINT: + The cylinder head bolis are tightened in 3. progressive steps (steps (2), (4) and (5)). + any bolts is broken or deformed, replace it. Install the cylinder head bolis. (1) Apply a light coat of engine cil on the threads and under the heads of the cylinder head bolts. (2) Install and uniformly tighten the 18 cylinder head bolts, in several passes, in the sequence shown Torque: 78 N-m (800 kgf.cm, 58 ft bf) HINT: Each bolt length is indicated in the illustration: Bolt length: 107 mm (4.12in) for A 127 mm (5.00 in.) for B I any one of the cylinder head bolts does not meot the torque specification, replace the cylinder head bolt (3) Mark the front of the cylinder hoad bolt with paint. (4) Retighton the cylinder head bolts 90° in the numer cal order shown Retighten cylinder head bolts by an additional $0”. ) Check thal the painted markis now facing rearward. 36. INSTALL CAMSHAFT {a} __ Setthe No. 1 cylinder to 90° BTDCicompression HINT: Set the No. 1 cylinder to 90° BTDC/compression to avoid iner- ference with the piston top and valve head (1) Using the crankshaft pulley bolt, turn the crank: shaft, and put the timing mark of the crankshaft tim: ing pulley with the protrusion of the timing belt case. (b) HINT: Different the bearing are used for the No. 1 and ojhers. Install the camshaft.1413 ENGINE MECHANICAL — PARTIAL ENGINE ASSY (8! —E) (1) _ Install the 10 bearings to the bearing caps and cylin- der head. (2) Place the camshatt on the cylinder head, facing the key groove upward. S (2) Install the 5 bearing caps in their proper locations. Se foyest & (4) Apply a light coat of engine oil on the throads and under the heads of the bearing cap bolts. (5) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 25 N.m (255 kgf-cm, 18 ft-Ibf) 37. _ INSTALL OIL SEAL RETAINER, NO.2 OIL SEAL HINT: There are 2 methods ({a) and (b)) to install the oil seal \ | (@)_ Ifthe camshart oil seal retainer is removed from the cylin= iM der head: (1) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oii seal retainer edge. SST 09223-46011 97048] (2) Apply MP grease to the oil seal lip.14-14 ENGINE MECHANICAL ~ PARTIAL ENGINE ASS (SL-E: (b) Ifthe camshaft oil seal retainer is installed to the cylinder head: (1) Apply MP grease to a new oil seal lip. (2) Using SST and a hammer, tap in the oil seal untilits surface is flush with the oil seal retainer edge. SST 09223-46011 B ates 38. INSTALL CAMSHAFT OIL SEAL RETAINER (a) Install a new gasket and the retainer with the 4 bolts, Torque: 18 Nm (185 kgf-cm, 13 ft-Ibf) 39. INSTALL TIMING BELT NO.2 COVER {a) _ Install {he timing belt cover with the 4 bolts. Torque: 18 N.m (185 kgt-cm, 13 ft-Ibf) 40. INSTALL CAMSHAFT TIMING PULLEY (a) Install the woodruff key to the key groove of the camshalt, (9) Align the pulley set key with the timing mark outward. (©) Using SST, install the pulley with the bolt SST 09960-10010 (09962-01000, 09983-01000) Torque: 98 N-m (1,000 kgf-em, 72 ftlbf) 41. INSPECT VALVE CLEARANCE (a) Align the timing mark of the camshait timing pulley with the arrow mark of the timing belt No. 2 cover. (b) Check only the valves indicated. (1) Using a feeler gauge, measure the clearance be- tween the valve lifter and camshaft. (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 6.20-0.30 nm (0.008— 012 In) Exhaust 0.40 0.50 mm (0.016— 0029 inj14415 ENGINE MECHANICAL —_ PARTIAL ENGINE ASSY (SLE) (c) Tur the camshatt 42 revolutions (180°) (@) Chock only the valves indicaled as shown. Measure the valve clearance (See procedure (b) ebave) 8 ADJUST VALVE CLEARANCE (a) Remove the adjusting shim. (1) Turn the crankshaft so that the cam lobe of the cam- shafl on the adjusting valve points upward. (2) _ Using SST, press down the valve lifter. SST 09248-84011 (3) Position the notch of the valve lifter facing the ex- haust manifold side, (4) Remove the adjusting shim with a small screwdriver and magnetic finger, {b) Determine the replacement adjusting shim size by follow. ing the Formula or Charts: (1) Using a micrometer, measure the thickness of the removed shim, (2) Caloulate the thickness of a new shim so that the valve clearance comes within specitied value. T = Thickness of removed shim A = Measured valve clearance 0010 N= Thickness of new shim Intake NET = (A— G25 mm (OID In Extaust Ne Ts 1A— 045 mm (0.018 ny) (3) Selecta new shim with a thickness as close as pos- sible to the calculated value. HINT: Shims are available in 17 sizes in increments of 0.05 mm {0.0020 in.), from 2.60 mm (0.0964 in.) t0.3.30 mm (0.1299 in,)..14-16 ENGINE MECHANICAL — PARTIAL ENGINE ASSY (5L-£) Adjusting Shim Selection Using Chart (Intake) Tiny Measured tlearance ao ghoase dey) | tata bse Sp 209 020 9.0 S50 ago 019 6 Bt ao 02068 New shim thickness mm (in Thickness 2.95 (0.1761)| 26 3.00 (0.118 473.05 (0.4201) [aler asm cot Seam 1 See asbol 34 0 (0.120 aT aoe “zsone) — seas all |_| 8.10 (i120 Tor -Teimcoss sau, — pl if | 2:7070.1063)| 469.15 (0.1240) [Feta oor eer srs! — a 2.75 (0.1083)| 36 [3.20 (0.1260)| 280 (0.1102) | 49 "3.25 (0.1280) | 2.85 (0.1122) | "41 [3.30 (0.1299) 2,80 (0.1142) | Inteke valve clearance (Cold): 0.20 — 0.90 mm (0.008 ~0.012 in.) EXAMPLE: ‘The 2.800 mm (0.1102in. shiny is installed and the measured clearance is 0.350 mm (0.0138 in.). Replace the 2.800 mim {0.1102 in.) shim with ¢ No. 21 chimV7 ENGINE MECHANICAL — PARTIAL ENGINE ASSY (51-€ Adjusting Shim Selection Using Chart (Exhaust) Tagalog Menoured clearance (“nga saie eon eo, ber. (e9000 Dist aru e000 Ban _a.wo eon nore) wo a j.oTe0 B08 a ene? aan i Serve ons ser Saar—panenos 3008) fs San —ouo 00a Fo) Sapa uated EE fea New shim thickness _mm {in.) Saas 1S aise ia ‘Thickness 2.95 (0.1161) 2.55 (0.1004) 3.00 ( Ty] 6 | 2.60 (0.1024) 47 | 3.05 (0.1201) 2.65 (0.1043) | 31_|3.10 (0.1220) | 2.70 (0.1063) | 48 13.15 (0.1240)] } [2.75 (0.1083) | 3613.20 (0.1260) 1a 16/280 (0.1102) | 49 a2! irae jose goss i [45/285 (0.1102) | aV [9.90 (0.1209) ar [2a0ter43y | Exhaust valve clearance (Cold): 0,40 -0.50 mm (0.016—0.020in,) EXANPLE: ‘The 2.800 mm (0.1102 in, shim is installed and the measured is 0.350 mm (0.0138 in.). Replace the 2.800 mm (0. 1102 in.) shim with a No. 11 shim,18 ENGINE MECHANICAL — PARTIAL ENGINE ASSY (SL-E @ :Seal Packing |. INSTALL OIL FILLER CAP SUB-ASSY install a new adjusting shim. (1) Place a new adjusting shim on the valve lifter. (2) Remove the SST. Recheck tho valve clearance. INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing (FIPG) material. Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gaskei to the cylinder head cover. Install the oylinder head cover with 9 bolls and nul, Unl- formly tighten the bolts and nuts in several passes. Torque: 12 N.m (120 kgf-cm, 9 ftlbf) age ae 1ENGINE MECHANICAL — CYLINDER HEAD ASSY (SLE) CYLINDER HEAD ASSY (5L-E) | COMPONENTS 14-19 Valve Adjusting Shim a) Valve Lifter —__ ab Valve Spring Retainer Lock Valve Spring Ratainer OQ S Valve Spring 4 Z _— Valve Spring Seat Plate Washer @ Valve Stem Oil © Sealor Ring ————© Semicircular Plug @ Valve Guide Bush_——f] Cylincler Head ‘Adjusting Shim Combustion Chamber Valve |» Non-rouseble part14-30 ENGINE MECHANICAL —_ CYUNDERHEAD assy 51-F) 4s 22. REPAIR EXHAUST VALVE SEATS {a) If the seating is too high on the valve face, use 30° and 45° culters to correct the seat. (b) _ Ifthe seating is too low on the valve face, use 60° and 45° cutters to correct the seat. {c} Hand-lap the valve and valve seat with an abrasive com- pound. (d) After hand~apping, clean the valve and valve seat. 23. INSPECT VALVE LIFTER {a) Using a micrometer, measure the liter diameter. Litter diameter: 40.892 — 40.902 mm (1.6099 — 1.6103 in.) (0) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 40,960 - 40.980 mm (1.6126 ~ 1.6134 in.)14-91 ENGINE MECHANICAL CVLINDER HEAD ASSY (51-€} (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement Standard oil clearance: 0.058 — 0.088 mm (0.0023 - 0.0035 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) {the oil clearance is greater than maximurn, replace the lifter. Inecessary, teplace the cylinder head. 24. INSPECT CAMSHAFT (a) Inspect the circle runout. (1) Place the camshait on V-blocks (2) Using a dial indicator, measure the circlo runout at the conter journal Maximum circle runout: 0.10 mm (0.0039 in) Ifthe circle runout is greater than maximum, replace the cam- shatt (b) Using a micrometer, measure the cam lobe height. Standard cam lobe height: hake 54.900 — 54 ¢10mm (91610 —2.1610 in) Exhaust 54.98 — 55.010 ni (21650-21657 in) Minimum cam lobe height: Irate 54.39 mm (2 1479 in) Exhaust 54.98 mm (21485 ny Ifthe cam lobe height Is less than minimum, replace the cam- shat (c}__ Inspect the journal diamotor of the camshatt. (1) Using a micrometer, measure the journal diameter of the camshaft for the camshaft bearing Journal diameter: No. 1 34.969 ~ 34.985 mm (1.3767— 147741 | Gihers 27.069 2785 mn (11071 1010 Not 3.044 04060 mn (/ SIO 1a724 hy} hers 27.0427 60 mi (1.0962 1.0968 m) sto Us 0.125, Ho 7934739 mn (1-30GI- 1967S Mi} uis0250, ones 2179 —27.795 mm {1.03 10919 hp If the joumal diameter is not as specified, check the cil clear- ance.— ENGINE MECHANICAL — OVLINDET HEAD ASSY i616) (A) Check the oil clearance. (1) Clean the bearing caps and journals, (2) Check that bearings for flaking and scoring. lithe bearings are damaged, If the bearings are damaged, re- place the bearings. {3) Install the bearings to the bearing caps and cylinder head (4) Place the camshaft on the cylinder head. P 308% (©) Laya strip of Piastigage across each of the journals. (6) Install the bearing caps (See page 14-3). NOTICE: Do not turn the camshatt. (7) Remove the bearing caps. (8) Measure the Plastigage at its widest point. Standard oil clearance: 0.022 — 0.074 mm (0.0008 — 0.0029 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) 'f the oil clearance is greater than maximum, replace the bear- ings. If necessary, grind or replace the camshatt {9} Compietely remove the Plastigage. (10) Remave the camshatt. {e) Ifnecossary, grind and hone camshaft journals. (1) Grind and hone the journals to U'S diameter (See Procedure (c) above). Install new journal US bear- ings. (}) Check the thrust clearance. (1) Install the camshait (See page14—3) (2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.080 — 0.280 mm (0.0031 0.0110 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) | the thrust clearance is greater than maximum, roplace the No.1 bearing. If necessary replace tho camshaft 25. REMOVE SEMICIRCULAR PLUG14-33 ENGINE MECHANICAL CYLINDER HEAD ASSY (SLE) Adhesive 26. fa) (b| INSTALL TIGHT PLUG Apply adhesive to the tight plug. ‘Adhesive: Part No. 08833-00070, THREE BOND 1324 or equiva- lent Using SST and a hammer, tap in a new tight plug as shown in the illustration. SST Position A: 09950-60010 (09951-00250), 08950-70010 (09951-07100) Position B: (09950-60010 (09951-00300), 09950-70010 (09951-07100) Position C 09950-80010 (09951-00450), 02950-70010 (09951-07100) Front Side Rear Side 1 fait lee HOKE H Cylinder Head Cover Si StopsSA ENGINE MECHANICAL — CYLINDER HEAD ASSY (51-£: 27. INSTALL STUD BOLT Intake Manifold Side Exhaust Manifold if ek Torque: 26 Nm (265 kgf-cm, 19 fbf) for A 12 Nm (120 kaf.cm, 9 fbf) for B 6.0 Nom (60 kef-om, 53 in-Ibf} for C | Hamm if. I (os5in) a aie u 36 mm Fomine oa (142in) (0.35 In} 625 mm Fie tam Fri mm 8mm — |(0.98inj A (Thread ciameier: 10 mm) B {Thread diameter: 8 mm) C (Thread diameter: 6 mm) 28. INSTALL RING PIN Front Side a OCR Mor \ 3 7h 1 oe ae Avot 11mm {0.43 in.) ) Until pin stops14-35 ENGINE MECHANICAL —_ CYLINDER HEAD ASSY (S.-F), Seal Packing z aces x he Fig 20 29. INSTALL SEMICIRCULAR PLUG (a) Remove any old packing (FIPG) material (b) Apply seal packing to the serriciccular plug as shown in the illustration Seal packing: Part No. 08826-00080 or equivalent (6) _Insiall the semicircular plug to the oylinder head. 30. INSTALL COMBUSTION CHAMBER SUB-ASSY (a) _ Select the number of shim, depending on the table below. Number ark of vind head Turbo of shen fi a 2 a a Shim thickness: 0.03 mm (0.0012 in.) (b) Align the combustion chamber knook pin with the cylinder head notch: (0) Using a plastic-faced hammer, tap in the combustion chamber. (@) Using a dial indicator. check the combustion chamber protrusion Combustion chamber protrusion: Minus 0.03 ~ Plus 0.03 mm (Minus 0.0012 - Plus 0.0012 in.) Ifthe protrusion is less than specified, adjust with shims. Ifthe protrusion is greater than specified, replace the chamber and recheck the protrusion. 31. INSTALL VALVE STEM OIL O SEAL OR RING14-96 ENGINE MECHANICAL — OY INDER HEAD ASSY (5L-£) 34, INSTALL VALVE LIFTER (a) _ Install the valve lifter and shim. 32. INSTALL INTAKE VALVE (a) Install the valve, spring seat, valve spring and spring re- tainer. (b) Using SST, compross the valve spring and place the 2 re- lainer locks around the valve stem. SST 99202-70020 (09202-00030) (©) Using aplasiic-faced hammer, tightly tap the valve stem tip to assure a proper fit NOTICE: Be careful not do damage the valve stem tip. 33. INSTALL EXHAUST VALVE (a) _|nstall the valve, spring seat, valve spring and spring re- tainer. (b) Using SST, compress the valve spring and place the 2 re- tainer locks around the valve stem, SST 09202-70020 (09202-00030) (c) Using a plastic-taced hammer, lightly tap the valve stem tip to assure a proper fit. NOTICE: Be careful not do damage the valve stem tip. (b} Check that the valve lifter rotates smoothly by hand.ENGINE MECHANICAL —_GYLINDER BLOCK ASSY (51F) CYLINDER BLOCK ASSY (5L-E) COMPONENTS 14-37 No. 1 Piston Ring ——¢=, No. 2 Piston Ring ——© Gil Bing Coilfor Oi Fing PHBA, ) 2D &— #5nap Ring Snap Ring ~}— ¢@ Connecting Rod Small End Bush Connecting Rod Piston Pin T Connecting Rod Bearing [Bain 1a) ] *) & Wi Head Taper Scrow Plug No. 4 Connecting Rod Cay [see page ‘st: 5¢ (550, 40) 2nd Tuer 90 [Ficii9. 37 Cylinder Blook Oil Orifice Ye oo0.38) x Cylinder Block Cylinder Block — = Water Drain Cock Oil Nozzle No. ie (25 080,767} a a4 ry: UeerCranshatThust Washer Oil Check Valve 5 Upper Cranshafl Thrust washer \ Lower Crankshalt Bearing UE Lower Crankshaft Thrust Washer IF crantshat Bearing Cap Nem (kgFem, (tHbf} |: Specified torque | I Xm rater 105 (3,080, 77) ‘@ Non-eusable part Lower Crankshaft Thrust Washer— My lp Precoatad part14-38 ENGINE MECHANICAL GVLINDER PLOSKASSY /5L-F) OVERHAUL HINT: + Thoroughly clean all paris to be assembled. + Before installing the parts, apply new engine oii te all sliding and rotating surfaces. * — Replace all gaskets, O-rings and oil seals with new parts. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth Standard thrust clearance: 0.080 — 0.300 mm (0.0031 — 0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) if the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshatt (ch INSPECT CONNECTING ROD OIL CLEARANCE Check the matchmarks on the connecting tod and cap to ensure correct reassembly. Remove the 2 connecting rod cap nuts. Using a plastic-faced hammer, lightly tap the connecting od bolts and lift off the connecting rod cap. HINT: Keep the lower bearing inserted with the connecting rod cap. (a) (9) ) Cover the connecting rod bolts with a short piece of hose | fo protect the crankshaft irom damage. Clean tho erank pin and bearing, | Check the crank pin and bearing for pitting and scratches. I" the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshalt |14-29 ENGINE MECHANICAL — CYLINDER BLOG ASS¥ (5L-E) e »Y fom Siar, 1.2078 “Ridge Reamer (9) Layastrip of plastigage across the crank pin. (h) Install the connecting rod cap with the 2 nuts (See siep 40), NOTICE: Do not turn the crankshaft. (i) Remove tho 2 nuts, connecting rod cap and lower bearing (See procedure {b) and (c) above), (i) Measure the plastigage at its widest point. ‘Standard oil clearance: S10. 0.036 0.064 mn (0.0074 — 00026) Us 080 0.639 0070 mm (.0053-0.0091 hy Maximum oil clearance: 0.10 mm (0.0039 in.) if the oil clearance is greater than maximum, replace the bear- ings. If necessary, grind or replace the crankshaft HINT: \Vusing a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly. Standard sized bearing center wall thickness: Maric 1.470— 1.402 min (6.0582 — 00985 in) Mark? 1.482 1.486 mm (0.0583 — 00586 in) Marke 1486 1,490 mm (0.0585 - 0.0587 in) (1) Completely remove the plastigage. 3, REMOVE PISTON AND CONNECTING ROD (@) Using a ridge teamer, remove all the carbon from the top of th oylindor.14-40 ENGINE MECHANICAL _— CYLINDER BLOGK ASSY (81 -F {b) Cover the connecting rod bolts with @ short piece of hose to protect the crankshaft from damage. (c) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: + Keep the bearings, connecting 10d and cap together. + Arrange the piston and comecting rod assembies in cor- rect order. 4 REMOVE W/PIN PISTON SUB-ASSY (a) Check fit between the piston and piston pin. (1) Try to move the piston back and forth on the piston pin. IF any movement is felt, replace the piston and pin as a cet. (0) Remove the piston rings. (1) Using a piston ring expander, remove the 2 com- pression rings. (2) Remove the oil ring and coil by hand, HINT: Arrange the piston rings in correct order only, (©) Disconnect the connecting rod from the piston. (1) Using snap ring pliers, remove the snap rings. (2) Gradually heat the piston to aprox. 60°C (140°F)14-41 ENGINE NECHANICAL — CYLINDER BLOGK ASSY (5L-E} (3) Using a plastio-faced hammer and brass bar. lightly tap out the pision pin and pin and remove the con- necting rod. HINT: + The piston and pin are a matched set. + Arrange the pistons, pins, rings, connecting rods and bearings in correct order. 5. _ INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using adial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.040 — 0.250 mm (0.0016 ~ 0.0098 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set Thrust washer thickness: 51D) 2.450 ~2.480 mm (0.0957 ~0.0976 in} 08 0.125 2.498 —2.543 mm{0.0981 —0.1001 in} oS 0.280 2.555 ~2.605 mm (0.1008 0.1026 in} 6. INSPECT CRANKSHAFT OIL CLEARANCE (a) Remove the 10 crankshaft bearing cap bolts. {b) Using the removed crankshaft bearing cap bolts, pry the cap back and forth, and remove the crankshaft bearing caps, lower bearings and lower thrust washers (No. 3 crankshaft bearing cap only) HINT: + Keep the lower beating and crankshaft bearings cap to- gether. + Arrange the thrust washers in correct order (c) _ Lift out the crankshatt. HINT; Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block. (d) Clean each main journal and bearing.1402 ENGINE MECHANICAL — CYLINDER BLOCK AgSY (SL_<) {e) Check each main journal and bearing for pitting and seratches. If the journal or bearing is damaged, replace the bearings. li necessary, grind or replace the crankshaft. (f) Place the crankshaft on the cylinder block. (g) Lay a strip of Plastigage across each joumal. Plastigage: (h) Install the crankshaft bearing caps with the 10 bolts (See step 39) NOTICE: Do not turn the crankshaft () Remove the 10 bolts and § crankshaft bearing caps (See procedure (a) and (b) above) } sina (i) Measure the plastigage at its widest point. Siandard oil clearance: STD 0,034 — 1985 mm (6.0013 0.0026 in UrG 0.06, UG 0.60 0.039 — 0.078 mm (0.0019 — 0.0001 in Maximum clearance: 0.10 mm (0.0039 in.) lf the oil clearance is greater than maximum, replace the bear- ings. If necessary, grind or replace the crankshaft. HINT: an Mark \fusing a standard bearing, replace it with one having the same 2) number marked on the connecting fod cap. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly. Standard sized bearing center wall thickness: Mark | 1.978 1 985mm (00779-0076) mn) ark 2 1.983 1.887 mn (0.078% 0.0782 mn) Wark 3 1.987 — 1.981 mm (0.0782 - 0.0764 in) {k) Completely remove the plastigage.443 ENGINE MECHANICAL — CYLINDER 8LOGK ASSV (5.-€; 7. REMOVE CRANKSHAFT (a) __ Lift out the crankshaft. (b] _ Remove the upper bearings and upper thrust washers from the cylinder block HINT: Arrange the crankshaft bearing caps, bearings and thus! washers in correct ode 8. REMOVE SUB-ASSY OIL NOZZLE NO.1 (a) Remove the 4 check vaives and cil nozzles. 9, INSPECT OIL CHECK VALVE SUB-ASSY (a) Push the vaive with a wooden stick to check if itis stuck. If stuck, replace the check valve. 10. INSPECT SUB-ASSY OIL NOZZLE NO.1 (a) Check the oil nozzles for damage or clogging I necessary, replace the oll nozzle. 11, REMOVE CYLINDER BLOCK OIL ORIFICE (a) Using a 6 mm hexagon wrench, remove the oil orifice 12, INSPECT CYLINDER BLOCK OIL ORIFICE (a) Check the oil orifice for damage or clogging Wnecessaty, replace the oil orifice 13, REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY 14. REMOVE W/HEAD TAPER SCREW PLUG NO.1 15. CLEAN CYLINDER BLOCK SUB-ASSY (a) Using a gasket scraper, remove alll the gasket material from the top surface of the cylinder block (0) Using a soft brush and solvent, thoroughly clean the cylin- der block. 16. INSPECT CYLINDER BLOCK SUB-ASSY (a) Inspect for flatness, (1) Using a precision straight edge and fecler gauge, measure the surface contacting the cylinder head cap for warpage. Maximum warpage: 0.20 mm (0.0079 in.) lIwarpageis greater than maximum, replace the cylinder block.14-44 | ENGINE MECHANICAL — CYLINDER BLOCK ASSY i6L-E) (b) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylinders. If nec- essary, replace the cylinder block. (©) _ Inspect the cylinder bore diameter. HINT: There are 3 sizes of the standard cylinder bore diameter, marked 1, 2 and 3 accordingly. The mark is stamped on the low- er left tear of the cylinder block. mT aot Sark (1) Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and fe axial directions. fie Standard diameter: ps Markt ‘99.500 — 99.510 mm (39173-39177 in) : Mark 2 9015 10-00.520 mm (20177 ~0.6184 int + Mark 3 99.520 — 99.530 mm (39181 - 3.9185 in) ea Maximum diameter: go tiest ot 2079 mm (o0e04in) precbin 08.080 700.23 mn (39461 in Front (ys ip Axial Irthe diameter is greater than maximum, rebore all the 4 oylin- © Direction | ders. ifnecessary, replace the cylinder block 40mm fF (0.39in) A LB 410mm (0.39 in.) —¢1448, ENGINE MECHANICAL —_ CVLINDER BLOOK ASSY s51-£) Ridge (d) Remove the cylinder ridge. the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, gtind the top of the cylinder. 17. CLEAN WIPIN PISTON SUB-ASSY (@) Using a gasket scraper, remove the carbon from the pis- ton top. {b) Using a groove cleaning tool or broken ring, clean the pis ton ring grooves. {c]__ Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush.14-46, ENGINE MECHANICAL — _GYLINDERBLOG« ASSr (5L-£) 18. INSPECT WiPIN PISTON SUB-ASSY (a) _ Inspect the piston oil clearance. HINT: There are 3 sizes o! the standard piston diameter, marked "1" '2" and "3" accordingly. The mark is stamped on the piston top. (1) Using a micrometer, measure the piston diameter at Distance fight angles to the piston center line, the indicated distance from the piston head. Asmaaa| Distance: 61.27 — 61.33 mm (2.4122 — 2.4146 in.) Piston diameter: sid) Mark 1 99.450 — 99.460 mm (3.9153 -3.9157 in) Mack 2 89.460 99.470 mm (3.9157 ~3.916% in) Mark3 98.470 99.480 mm 3.9161 3.3168 in} os 050 8.650 = 99.980 mm (3.9950 —8.9362 in} (2) Measure the cylinder bore diamotor in tho thrust directions (See step 16) (2) Subtract the piston diameter measurement trom the cylinder bore diameter measurement Standard oil clearance: 0.040 — 0.080 mm (0.0016 — 0.0024 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oll clearance is greater than maximum, replace all the 4 pistons and rebore all the 4 cylinders. I necessary, replace the cylinder biock.ENGINE MECHANICAL — Oe? Front Marke (Arrow) Mark 1,208 14-47 CYLINDER BLOCK ASSY {51-E) HINT: Use a piston with the same number mark as the cyli ciameter marked on the cylinder block. {b) Inspect the piston pin fit. (1) At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb. It the pin can be installed at a lower temperature, replace the piston and pin as set. (c)_ Using a micrometer, measure the piston pin diameter. Piston pin diameter: 29,000 — 29.012 mm (1.1417 — 1.1422 in.)14-48 ENGINE MECHANICAL ~ CYLINDER BLOCK ASSY (5L-E) No. 7 Ring 19, INSPECT PISTON RING SET (a) _ Inspect the piston ring groove clearance. (1) No. 4 Ring: install a new piston ring to the piston. Using a feeler gauge, measure the clearance between the piston ting and the wall of the ring groove ‘Standard groove clearance: 0.057 — 0.101 mm (0.0022 — 0.0040 in.) Maximum groove clearance: 0.20 mm (0.0079 in.) If the clearance is greater than maximum, roplace the piston. (2) No. 2and Oil Rings: Using a feeler gauge, measure the clearance be- tween @ new piston ring and the wall of the ring grcove, Standard groove clearance: No.2 (0.060 0.100 mm (0.0924 0.0039in) oll 0.030~ 0.070 nm (0.0012 — 0.0026.) asa Maximum groove clearance: 0.20 mm (0.0079 in.) If the clearance is greater than maximum, replace the piston (b]__ Ingpect the piston ring end gap. (1) Insert the piston ring into the cylinder bore. (2) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 140 mm (5.51 in.] from the top of the cylinder block (3) Usinga feeler gauge, measure the end gap Standard end gap: Not (0.960 0.580 mm (0.0108 ~0.0232 n} No.2 (0.470 - 0.720 mm (0.0185— 0.0289) oi 0.200 0520 mn (0.0070 00006 in} Maximum end gap: No. 1.28 mm (9.0808in.) asniea No. a 42 mm (0.08500. it 1.28 mm (0.0480 in) If the end gap is greater than maximum, replace the piston ring if the end gap is greater than maximum, even with anew piston fing, rebore all the 4 cylinders or replace the cylinder block14-49 ENGINE NECHANICAL — CYLINDER BLOCK ASSY (51_—F) 20. INSPECT CONNECTING ROD SUB-ASSY (a) Using arod aligner and feeler gauge, check the connect. ing red alignment. (1) Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) bend is greater than maximum, replace the connecting rod sub-assy. (2) 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 sub-asey. 21. INSPECT PISTON PIN OIL CLEARANCE (a) _ Inspect the piston pin oil clearance. (1) Using acaliper gauge, measure the inside diameter of the connecting rod bush. Bush inside diameter: 29.008 — 29.020 mm (1.1420 - 1.1425 in.) (2) Subtract the piston pin diameter measurement (See step 18) from the bush inside diameter mea- surement Standard oil clearance: 0.004 — 0.012 mm (0.0002 — 0.0005 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) I the oll clearance is greater than maximum, replace the bush It necessary, replace the piston and piston pin as a set. 22, REMOVE CONNECTING ROD SMALL END BUSH (a) Using SST and a press, press out the bush. SST 09222-54011 (09222-09016, 09222-03026)14-50 ENGINE MECHANICAL — CYLINDER BLOGK ASSY (SL-E) Fon Wak (arow)\ Size Mad 5 Distance 23. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the tension portion of the conneeting rod boll. Standard diameter: 8.400 — 8.600 mm (0.3307 ~ 0.3986 in.) Minimum diameter: 8.20 mm (0.3228 in.) It the diameter is less than minimum, replace the bolt. 24. BORE CYLINDER HINT: + Bore all the 4 cylinders for the OS piston outside ciame- ter. + Replace all the piston rings with ones to match the O'S pistons. (a) Keep 4 new OVS pistons. O/S 0.50 piston diameter: 99.950 — 99.980 mm (3.9350 ~ 3.9362 in.) (b) Usinga micrometer, measure the piston diameter at right angles to the piston pin center line, the indicated distance from the piston head. Distance: 61.27 — 61.33 mm (2.4122 — 2.4146 in.) (©) Calculate the amount each cylinder is to be rebored as fot lows: Size to be rebored = P4C—H P = Piston diameter C = Piston clearance: 0.040 — 0.060 mm (0.0015 — 0.0024 in.) H = Allowance for honing: 0.02 mm (0.0008 in.) or less () Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Excess honing will destroy the finished roundness. 25. INSPECT CRANKSHAFT (a) Inspect for circle runout (1) Place the crankshaft on V—blocks. (2) Using a dial indicator, measure the circle runout at the center journal Maximum circle runout: 0.06 mm (0.0024 in.) Ifthe circle runout is greater than maximum, replace the crank- shaft.1481 ENGINE WECHANICAL CYLINDER ELOCK ASSY (SIE) Adhesiv ahesive {) Inspect the main journals and crank pins. (1) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: SID) 161.985~ 62000 mm (2.4403- 24409 in) urs0.25) 61.745 ~61 755 mm (2.4909- 24913} ws 0.50 1.495 Crank pin diameter: =07 805 mm (24281 — 24215 19 sin 54088 — 55.000 mm (2.1640 2.1854 In us0.25, 94.745 —54.758 mm (2.1653 2.1557 in) ws 9.50 54.496 — 54.505 mm (2.1455~ 2 1459 in} Ifthe diameter is not as specified, check the oll clearance (Sea sieps 2 and 6). If necassary, grind or replace the crankshatt (2) 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.) Ifthe taper and cut-of-round is greater than maximum, replace the crankshaft () lH necessary, grind and hone the main journals and/or crank pins. (1) Grind and hone the main journals ancfor crank pins to the finished undersized diameter (See procedure in step (b) above) (2) Install new main journal and/or crankshaft pin un: dersized bearing. 26. INSTALL TIGHT PLUG (a) Apply achesive to a new tight plug. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equiva- lent14-54 ENGINE MECHANICAL — CYLINDER BLOCK ASSY (SL-E) 31. (a) (b) HINT: INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Apply adhesive to 2 or 3 threads. Adhesi Part No. 08833-00070, THREE BOND 1324 or equiva- lent Install the drain union Torque: 49 N-m (500 kgf-cm, 36 fbf) After applying the specified torque, rotate the drain union clockwise until its drain portis facing downward, The drain port may be set within 45° of either side oi the prescribed position. e re oe “ ea ae 32. INSTALL CYLINDER BLOCK OIL ORIFICE (a) Using a 6 mm hexagon wrench, install the oil orifice. Torque (Reference): 11 Nem (110 kgf-cm, 8 ftIbf) sssre INSTALL SUB-ASSY OIL NOZZLE NO.1 Align the pin of the oil nozzle with the pin hole of the oylin- der block. Install the oil nozzle with the check valve. Install the 4 oil nozzles and check valves. Torque: 26 N-m (260 kgf-cm, 18 ft.lbf) INSTALL CONNECTING ROD SMALL END BUSH Using a round file, lightly file off any roughness from the small end of the connecting rod.14-55 ENGINE MECHANICAL — CYLINDER BLOCK ASSY (SLE) Ye &. Attach a new bush to SST with the ball of SST inside the cil hole of the bush. SST 09222-54011 (09222-03021) Align the oil holes of the bush and connecting rod. Using SST and a press, press in the bush. SST 09222-54011 (09222-03016, 09222-08021 09222-03026) Using a pin hole grinder, hone the bush to obtain the slan- dard specified clearance (See step 21) between the bush and piston pin Chock the piston pin fit al normal room temperature. Coat the piston pin with engine oil, and push it into the connect- ing rod with your thumb.14-57 ENGINE MECHANIGAL — CYLINDER BLOCK ASSY (51-€) Oi Ring Ends soc Pp 650 (b) Install the piston rings. (1) Install the coil and oil ring by hand. HINT: Face tho ond gap of the oll ring in the opposite direction coil joint. (2) Using a piston ring expander, install the No. 1 and No.2 piston rings with the code mark facing upward Code mark: Not aN No.2 2N (8) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. 36. INSTALL CONNECTING ROD BEARING (a) Align the bearing olaw with the groove of the connecting rod or connecting cap. (©) _ Install the bearings in the connecting rod and connecting rod cap. 37. INSTALL CRANKSHAFT BEARING HINT: Upper bearings have an oil groove and oil hole; lower bearings do not. (a) Align the bearing claw with the claw groove of thé cylinder black, and push in the 5 upper bearings.EMS: ENGINE MECHANICAL — CYLINDER BLOGK ASSY (51-E (b) Align the bearing claw with the claw groove of the crank: shaft bearing cap, and push in the 5 lower bearings, 38. INSTALL CRANKSHAFT THRUST WASHER SET (@) Install the 2 thrust washers under the No. 3 journal posi- tion of the cylinder block with the oii grooves facing out- ward. (b} Install the 2 thrust washers on the No. 3 ankshafi bear- ing cap with the grooves facing outward. 39. INSTALL CRANKSHAFT (a) Place the crankshaft on the cylinder block {o) _ Install the S crankshaft bearing caps in their proper loca- tions. {) _ Install the crankshaft bearing cap bolts. (1) Apply a light coat of the engine oll on the threads and under the bolt hoads of the crankshait be caps. (2) Install and uniformly tighten the 10 bolts of the crankshaft bearing caps, in several passes, in the sequence shown, Torque: 105 Nem (1,050 kgf-cm, 77 ft.lbf) (d) Check that the crankshaft tums smoothly. {e) Check the crankshaft thrust clearance (See step 5).14-59 ENGINE MECHANICAL — CYLINDER BLOCK ASSY (51-E) Front Mark (Proirusion) 40. INSTALL PISTON AND CONNECTING ROD (a) Cover the connecting tod bolts with a short piece of hose to protect the crankshaft and cylinder bore from damage. (0) _ Using a piston ring compressor, push the correctly num- dered piston and connecting rod assembly into the cylin- der with the front mark of the piston facing forward. {c) Place the connecting rod cap on the connecting rod. (1) Match the numbered connecting rod cap with the connecting rod. (2) Install the connection rod cap with the front mark facing forward (@) _ Install the connecting rod cap nuts. HINT: + The connecting rod cap nuts are tightened in 2 progres- sive steps (steps (2) and (4)). + If any connecting rod bolt is broken or deformed, replace it (1) Apply a light of engine oil on the threads and under the heads of the connecting rod cap nuts. (2) Install and alternately tighten the nuts of the con- necting rod cap in several passes. Torque: 54 N-m (550 kgf-cm, 40 ft-lbf) If any one of the connecting rod cap nuts does not meet the torque specification, replace the cap nuts.14-60 ENGINE MECHANICAL — > Painted Mark {e) 0) CYLINDER 800K ASSY /5L_E} (3) Mark the front of the connecting rod cap nuts with paint. Retighten the connecting rod cap nuts 90° as shown. ‘Check thal the painted mark is now at a 90° angle to the front. Check that the crankshalt tums smoothly, ‘Check the connecting rod thrust clearance {See step 4) (4) (5)LUBRICATION ~ OL PUMP ASSY (SLE) OIL PUMP ASSY (5L-E) COMPONENTS 171 ‘il Pump Gover Oil Pumo Drive Gear Timing Gear Gate | Oi Pump Driven Gear Oil Pump Reliaf Valve eg Oil Pump Relief Valve Spring Timing Gear Case or Timing Chain Case Oil Seal @ Gasket TA) © cirpumo Rotor Valve Plug arom, ib)] : Specified torque Non-reusable part y_# Precosted part x8 a7-2 Ovi LUBRICATION ERHAUL Clearance Ta mim Hexagon Wrench eF i 3. @ REMOVE OIL PUMP DRIVE GEAR Remove the 8 screws, pump body c (OIL PUMP ASSY 5L-E} REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver and hammer, tap out the cil seal. 2. REMOVE OIL PUMP RELIEF VALVE (@)_ Place the timing belt case on wooden blocks. NOTICE: Be careful not to damage the timing pointer. (b) Using a 12 mm hexagon wrench, remove the plug, gas: kel, spring and roliof valvo. ‘over, the drive and driven ratars. 4, (a) INSPECT OIL PUMP RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its awn weight Hit doesn't, replace the relief valve. Ifnecessary, replace the oil pump assembly.Wes LUBRICATION —_O1L PUMP ASSY (5L-E} Fe 5. INSPECT OIL PUMP DRIVE GEAR (a) _ Inset the drive and driven rotors into timing beltcase with the marks facing the pump body caver side (See step 6) (0) Inspect the rotar tip clearance (1) Using a fecler gauge, measure the clearance be- tween the drive and criven rotor tips. ‘Standard tip clearance: 0.110 — 0.240 mm (0.0043 — 0.0094 in.} Maximum tip clearance: 0.30 mm (0.0118 in.) IF tho tip clearance is greater than maximum, replace the rotors as sel (0) _ Inspect the rotor body clearance. (1) Using a iecler gauge, measure the clearance be tween the driven rotor and gear case. Standard body clearance: 0.144 — 0.219 mm (0.0057 — 0.0086 in.) Maximum body clearance: 0.40 mm (0.0157 in.) II the body clearance ie greator than maximum, replace the ro- lors as set, If necessary, replace the oil pump assembly. {d) Inspect the rotor side clearance. (1j Using a feeler gauge and precision straight edge, measure the clearance between the rotors and pro- cision straight edge. Standard side clearance: 0.035 - 0.085 mm (0.014 - 0.0033 in.) Maximum side clearance: 0.15 mm (0.0053 in.) IF the side clearance is greator than maximum, replace the 1o- lors as sel. If necessary, replace the oil pump assembly. 6. INSTALL OIL PUMP DRIVE GEAR (a) Place the timing belt case on wooden blocks (See step 2). NOTICE: Be careful not to damage the timing pointer. (b) Insert the drive and driven rotors into timing belt case with the marks facing the oil pump cover side— LUBRICATION — SST HL PUMP ASSY (51) Apply adhesive to 2 or 3 threads of the screws Adhesive: Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent Install the oil pump cover with the 8 screws. Torque: 10 Nim (105 kgf-cm, 7 ftlbf) INSTALL OIL PUMP RELIEF VALVE Insert the reliei valve and spring into the installation hole of the timing bett case. Using a 12 mm hexagon wrench, install a nev gasket and the plug, Torque: 37 N-m (375 kgf-cm, 27 ftlbf) INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using SST and a hammer, tap in a new oil seal to the Gepth of 0.5 mm (0.020 in.) from the ail pump case edge. 09214-60010 Apply MP grease to the oil seal lip.75 LUBRICATION __ OlL COOLEN ASSY j5L-E) OIL COOLER ASSY (5L-E) COMPONENTS Oil Cooler, — 4S © Gasket. ——¢y" x \ SS” a | Oil Fiter Bracket — LEDS), 2 © Dy —— ¢ Gasket aes © [se 2} $@)"|_ 6 satoty Vane C+ casket Oi Filter Union } Oil Fiter Compression Spring 2 ‘ Gil Filter Plug Gasket (eran |-Q) Oil Filter Plag [Nem (kgFom, ibA |: Specified torque ¥__® Non-reusable part sesT7-6 OVERHAUL 4, (a) 2 (a) 3. (a) LUBRICATION ~ Ci COOLER ASSY (5L-F) REMOVE OIL COOLER ASSY Remove the 4 nuts, oil cooler and 2 gaskets. REMOVE OIL SAFETY VALVE SUB-ASSY Remove the plug, gasket, spring and safety valve. REMOVE OIL FILTER UNION Using a 12 mm socket hexagon wrench, remove the union —~ 4 INSPECT OIL SAFETY VALVE SUB-ASSY (a) Coat the valve with engine oil and check that it falls smoothly into the oil fiter bracket by its own weigh If is not. replace the valve. If necessary, replace the oil fiter bracket 5. INSPECT OIL COOLER ASSY (a) Check the oil cooler for damage or clogging Ir necessary, replace the oil cooler. 6. la) % fa) 8. a) INSTALL OIL FILTER UNION Using a 12 mm socket hexagon wrench, install the union. Torque: 32 N.m (326 kgf-cm, 24 it Ibf) INSTALL OIL SAFETY VALVE SUB-ASSY Install the safety valve and spring with a new gasket and the plug. Torque: 36 N-m (367 kgf-cm, 27 ftlbf) INSTALL OIL COOLER ASSY Install 2 new gaskets and the oil cooler with the 4 nuts. Torque: 16 N-m (160 kgf-cm, 11 fbf)