1995 Toyota T100 DX 1 TON 2.7L 3RZ-FE PDF

1995 Toyota T100 DX 1 Ton
2.7L 4-CYL 1995-96 ENGINES Toyota - 2.7L 4-Cylinder
2.7L 4-CYL
1995-96 ENGINES Toyota - 2.7L 4-Cylinder
ENGINE IDENTIFICATION
Engine serial number is stamped on cylinder block, behind alternator.
ENGINE IDENTIFICATION CODE SPECIFICATIONS
ENGINE IDENTIFICATION CODE

Engine Code
4-Cylinder 3RZ-FE
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
NOTE: Adjust valve clearance with engine cold.
1. Disconnect control cables at throttle body, and cruise control actuator (if equipped). Remove air cleaner
cap and airflow meter with air cleaner hose.
2. Remove intake air connector. See Fig. 5. Disconnect PCV hoses. Disconnect spark plug wires at spark
plugs. Disconnect necessary electrical connectors and wiring for access to valve cover.
3. It may be necessary to remove throttle body for access to valve cover. If necessary to remove throttle
body, drain cooling system. Remove throttle body and gasket.
4. Remove valve cover and gasket. Rotate crankshaft clockwise (viewed from front of engine) so cylinder
No. 1 (front cylinder) is at TDC on compression stroke.
5. Ensure timing mark on crankshaft pulley aligns with "0" mark on front cover. Ensure timing marks on
camshaft gears are aligned. See Fig. 1. If timing marks are not aligned, rotate crankshaft clockwise one
full revolution (360 degrees).
Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

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10:40:32 AM Page 1 © 2011 Mitchell Repair Information Company, LLC.
Fig. 1: Checking Camshaft Timing Mark Alignment

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Using feeler gauge, measure and record valve clearance between valve lifter and camshaft on intake
valves of cylinders No. 1 and 2 and exhaust valves on cylinders No. 1 and 3. Rotate crankshaft clockwise
one full revolution (360 degrees) so timing mark on crankshaft pulley aligns with "0" mark on front
cover.
7. Using feeler gauge, measure and record valve clearance between valve lifter and camshaft on intake
valves of cylinders No. 3 and 4 and exhaust valves on cylinders No. 2 and 4. Ensure valve clearance is
within specification. See VALVE CLEARANCE SPECIFICATIONS table.
8. If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted is facing upward,
away from valve lifter. Position notch on valve lifter toward spark plug side of cylinder head.
9. Using Valve Clearance Adjuster (SST 09248-55040), remove adjusting shim. Using SST "A" of valve
clearance adjuster, push downward on valve lifter. See Fig. 2.
10. Place SST "B" between camshaft and valve lifter with side marked with a "9" in proper location. See Fig.
2. Using small screwdriver and magnet, remove adjusting shim.
11. Measure and record thickness of removed adjusting shim. Using measured clearance and adjusting shim
thickness, select proper replacement adjusting shim. See Fig. 3 and Fig. 4.
12. Install replacement adjusting shim. Recheck valve clearance. To install remaining components, reverse
removal procedure. Use NEW gaskets. Fill cooling system.
VALVE CLEARANCE SPECIFICATIONS (1)

Application In. (mm)

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Intake Valve .006-.010 (.15-.25)

Exhaust Valve .010-.014 (.25-.35)
(1) Adjust valve clearance with engine cold.
Fig. 2: Adjusting Valve Clearance


Fig. 3: Intake Valve Adjusting Shim Selection Chart


Fig. 4: Exhaust Valve Adjusting Shim Selection Chart

REMOVAL & INSTALLATION
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.
WARNING: To prevent air bag deployment, disconnect negative battery cable at least
90 seconds before working on vehicle.
FUEL PRESSURE RELEASE
Ensure ignition is off. Disconnect negative battery cable. Place an approved gasoline container under fuel line
connection. Cover fuel line connection with shop towel. Slowly loosen fuel line connection, allowing fuel
pressure to be released. Once fuel pressure is released, fuel system components may be serviced.
ENGINE
Removal
1. Engine and transmission are removed as an assembly. Release fuel pressure. See FUEL PRESSURE
RELEASE. Remove hood, battery and battery tray. Drain cooling system, engine oil and transmission
oil.
2. Remove front grill and coolant reservoir tank. Remove accessory drive belts. Remove cooling fan, fan
clutch, water pump pulley and fan shroud. Remove radiator.
3. Disconnect control cables at throttle body. Remove air cleaner cap and airflow meter with air cleaner
hose. Remove air cleaner case. Remove intake air connector. See Fig. 5.
4. Remove A/C compressor with hoses attached and secure aside. Remove A/C compressor mounting
bracket from cylinder block. Disconnect necessary electrical connectors, coolant hoses, vacuum hoses and
fuel lines for engine removal.
5. Remove power steering pump drive belt. Remove nut and pulley from power steering pump. Remove
power steering pump with hoses attached and secure aside. Remove scuff plate from passenger's side door
opening. Remove passenger's side kick panel for access to Engine Control Module (ECM).
6. Remove ECM mounting bolts. Disconnect electrical connectors from ECM. Disconnect remaining
electrical connectors so engine wiring can be pulled out from passenger's corner on firewall.
7. On M/T models, remove bolts, shift lever and gasket from transmission. Raise and support vehicle.
Remove lower engine cover. Remove nuts, bushings and separate stabilizer bar from lower control arm.
8. Remove stabilizer bar-to-frame bolts and mounts. Remove stabilizer bar. Place reference marks on drive
shaft flanges at rear axle. Remove drive shaft with drive shaft center bearing. Disconnect speedometer
cable and electrical connectors from transmission. DO NOT lose felt protector and washers when
disconnecting speedometer cable.
9. Remove front exhaust pipe from between exhaust manifold and catalytic converter. On M/T models,
disconnect fluid line at clutch release cylinder. Remove clutch release cylinder.
10. On A/T models, disconnect shift linkage cross shaft. Support transmission with floor jack. Remove rear
engine mount-to-crossmember bolts. Support engine with hoist. Remove engine mount-to-frame
bolts/nuts. Lift engine and transmission from vehicle.
Installation
1. To install, reverse removal procedure. Ensure all engine mount bolt/nuts are installed before tightening to
specification. See TORQUE SPECIFICATIONS.
2. Use NEW gaskets and NEW nuts when installing front exhaust pipe. Use NEW nuts when installing
stabilizer bar on lower control arm.
3. When installing drive shaft, ensure reference marks are aligned on drive shaft flanges. Ensure drive shaft
center bearing is perpendicular to drive shaft before tightening bolts.
4. Tighten all bolts/nuts to specification. See TORQUE SPECIFICATIONS. Adjust fluid levels. Fill
transmission with Dexron-II on A/T models or 75W-90 gear oil with GL-5 rating on M/T models.

CYLINDER HEAD & MANIFOLDS
Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE. Drain cooling system.
2. Disconnect control cables at throttle body and cruise control actuator (if equipped). Remove air cleaner
cap and airflow meter with air cleaner hose. Remove intake air connector and A/C idle-up valve (if
equipped). See Fig. 5.
3. Remove power steering pump drive belt. Remove power steering pump idler pulley. Remove nut and
pulley from power steering pump.
4. Remove bolts and power steering pump with hoses attached and secure aside. Remove bolts and power
steering pump bracket from cylinder head.
5. Disconnect PCV hoses. Disconnect spark plug wires at spark plugs. Remove distributor hold-down bolts
and distributor (if equipped). Remove ignition coils (if equipped). Remove bolts, coolant outlet and
gasket from front of cylinder head. See Fig. 5.
6. It may be necessary to remove throttle body for access to valve cover. Remove throttle body and gasket.
7. Remove bolts, cylinder head rear cover and gasket from rear of cylinder head. See Fig. 5.
8. Disconnect necessary coolant hoses, vacuum hoses and engine wiring connectors for removal of cylinder
head and manifolds. Remove EGR pipe and gaskets. Remove EGR valve and vacuum modulator with
gasket (if necessary).
9. Remove intake manifold brace from bottom of air intake chamber. See Fig. 5. Remove air intake chamber
and gasket from intake manifold.
10. Disconnect electrical connectors at injectors. Remove union bolts, fuel inlet pipe and gaskets. See Fig. 5.
Disconnect fuel lines and remove fuel return pipe.
CAUTION: DO NOT allow injectors to fall from delivery pipe when removing
delivery pipe.
11. Remove delivery pipe bolts. Remove delivery pipe with injectors. DO NOT allow injectors to fall from
delivery pipe. Remove insulators located on top of spacers, located in cylinder head.
12. Remove injectors from delivery pipe (if necessary). Remove intake manifold and gasket. Remove front
exhaust pipe from exhaust manifold.
13. Remove heat insulator from exhaust manifold. Remove exhaust manifold and gasket. Remove bolts and
No. 1 and 2 engine hangers from cylinder head.
14. Remove valve cover and gasket. Remove spark plugs. Remove camshafts. See CAMSHAFT.
CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent

cylinder head warpage.
15. Remove 2 cylinder head-to-front cover bolts, located on cylinder head, in front of camshaft sprocket area.
Loosen cylinder head-to-cylinder block bolts in sequence using several steps. See Fig. 7.
16. Remove cylinder head-to-cylinder block bolts with washers, cylinder head and cylinder head gasket. Note
location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and valve
lifters from cylinder head (if necessary).
Fig. 5: Exploded View Of Typical Intake Manifold & Components

Fig. 6: Exploded View Of Cylinder Head & Components

Fig. 7: Cylinder Head Bolt Removal Sequence


Fig. 8: Cylinder Head Bolt Installation Sequence

Inspection
1. Inspect cylinder head warpage at cylinder block and manifold areas. Replace cylinder head if warpage
exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
2. Using caliper, measure cylinder head-to-cylinder block bolt outside diameter at center of bolt thread area.
Replace bolt if bolt outside diameter is less than .409" (10.40 mm).
3. Inspect air intake chamber-to-intake manifold surface for warpage. Replace air intake chamber if warpage
exceeds .008" (.20 mm).

4. Inspect intake manifold-to-cylinder head and intake manifold-to-air intake chamber surfaces for warpage.
Replace intake manifold if warpage exceeds .008" (.20 mm).
5. Inspect exhaust manifold-to-cylinder head surface for warpage. Replace exhaust manifold if warpage
exceeds .020" (.50 mm).
6. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck surface warpage exceeds
specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
7. Inspect camshaft and components. See CAMSHAFT. Inspect cylinder block orifice for damage or
restriction. Cylinder block orifice is located in top of cylinder block. See Fig. 30.
Installation
1. Install adjusting shims and valve lifters in original location on cylinder head (if removed). Ensure
cylinder block orifice is located in top of cylinder block. See Fig. 29.
2. Apply Sealant (08826-00080) at both front corners of cylinder block-to-front cover areas. See Fig. 9.
Fig. 9: Applying Sealant At Cylinder Block-To-Front Cover Areas

3. Install NEW cylinder head gasket. Ensure all holes in cylinder head gasket align with holes in cylinder
block.
4. Install cylinder head. Apply engine oil on cylinder head-to-cylinder block bolt threads and bolt-to-

cylinder head contact surfaces. Ensure washers are installed on cylinder head-to-cylinder block bolts.
5. Install and tighten cylinder head-to-cylinder block bolts to specification in sequence. See Fig. 8. See
TORQUE SPECIFICATIONS.
6. Install and tighten 2 cylinder head-to-front cover bolts to specification. See TORQUE
SPECIFICATIONS. Install camshafts using proper procedure. See CAMSHAFT.
7. Adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. Apply
sealant on rear of semi-circular plug and install in front of cylinder head. See Fig. 6.
8. To install remaining components, reverse removal procedure. Use NEW gaskets, NEW insulators and
NEW "O" rings. Tighten all bolts/nuts to specification. See TORQUE SPECIFICATIONS.
9. If installing replacement cylinder head, it may be necessary to install spacers in cylinder head. Spacers are
installed between cylinder head and insulators for fuel injectors.
10. If installing spacer, install NEW "O" ring on spacer. Coat "O" ring with gasoline. Install spacers in
cylinder head. On all cylinder head applications, if installing injector in delivery pipe, replace "O" ring
and grommet on fuel injector.
11. Coat "O" ring on injector with gasoline. Using twisting motion, install injector into fuel delivery pipe.
Install insulators on spacers in cylinder head.
12. When installing injectors and delivery pipe, ensure electrical connector on injector is facing upward,
toward top of engine. Install and slightly tighten delivery pipe bolts.
13. Ensure all injectors rotate smoothly. If injector fails to rotate smoothly, check for damaged or improperly
installed "O" rings. Tighten delivery pipe bolts to specification. See TORQUE SPECIFICATIONS.
14. If spark plug tube gasket in valve cover requires replacement, pry spark plug tube gasket from valve
cover. DO NOT scratch valve cover sealing surface.
15. Install spark plug tube gasket in valve cover. Coat spark plug tube gasket sealing area with grease.
16. If equipped with distributor, rotate crankshaft clockwise (viewed from front of engine) so cylinder No. 1
(front cylinder) is at TDC on compression stroke.
17. Ensure timing mark on crankshaft pulley aligns with "O" mark on front cover. Ensure timing marks on
18. Install NEW "O" ring on distributor (if equipped). Align groove on distributor gear with protrusion on
distributor housing. See Fig. 10. Install distributor. Tighten distributor hold-down bolts to specification.
See TORQUE SPECIFICATIONS. Fill cooling system. Adjust ignition timing.

Fig. 10: Installing Distributor

FRONT COVER OIL SEAL
Removal & Installation (Oil Pump Installed)
1. Remove accessory drive belts and crankshaft pulley. Pry oil seal from oil pump cover. DO NOT damage
sealing surfaces.
2. To install, apply grease to lip of NEW oil seal. Using hammer and Oil Seal Installer (SST 09223-50010),
install oil seal until oil seal surface is even with edge of oil pump cover. To install remaining components,
reverse removal procedure.
Removal & Installation (Oil Pump Removed)
Using hammer and drift, remove oil seal from oil pump cover. To install, use hammer and Oil Seal Installer
(SST 09223-50010). Install NEW oil seal until oil seal surface is even with edge of oil pump cover. Apply
grease to lip of oil seal.
TIMING CHAINS
NOTE: No. 1 and 2 timing chains are used. No. 2 timing chain is used to operate
balance shafts.

NOTE: Cylinder head must be removed for servicing timing chains, as cylinder head
gasket seals on front cover.
Removal
1. Remove cylinder head. See CYLINDER HEAD & MANIFOLDS. Raise and support vehicle. Remove
lower engine cover.
2. Remove accessory drive belts. Remove cooling fan, fan clutch, water pump pulley and fan shroud.
3. Remove A/C compressor with hoses attached and secure aside. Remove A/C compressor mounting
bracket from cylinder block. Remove generator, generator adjusting bar and generator mounting bracket.
4. Remove bolts, crankshaft position sensor and "O" ring from front cover. See Fig. 11. Remove oil pan and
oil pick-up tube. See OIL PAN.
5. Remove bolts and accessory drive pulleys from front of crankshaft pulley. Using Pulley Holder (SST
09213-54015) and Handle (SST 09330-00021), hold crankshaft pulley and remove crankshaft pulley bolt.
6. Using puller, remove crankshaft pulley. Remove No. 1 coolant by-pass pipe nuts from rear of front cover.
CAUTION: When removing front cover, ensure 2 front cover bolts located on
rear of front cover on cylinder block, near No. 1 coolant by-pass pipe
are removed. See Fig. 11.
7. Remove bolts/nuts, front cover and gaskets. Note location of timing chains and components. See Fig. 11.
Remove No. 1 timing chain and camshaft sprocket. Remove No. 1 crankshaft sprocket from crankshaft. It
may be necessary to use puller to remove No. 1 crankshaft sprocket.
8. Remove No. 1 timing chain tensioner slipper and No. 1 vibration damper. See Fig. 11.
9. Install pin in No. 2 timing chain tensioner to lock plunger in place. See Fig. 12. Remove No. 2 and 3
vibration dampers.
10. Remove No. 2 timing chain tensioner. Remove bolt and balance shaft drive gear with balance shaft drive
gear shaft. Remove No. 2 timing chain along with No. 2 crankshaft sprocket. Remove bolts and No. 4
vibration damper.

Fig. 11: Exploded View Of Timing Chains & Components (Typical)


Fig. 12: Installing Pin In No. 2 Timing Chain Tensioner

Inspection
1. Inspect components for damage and wear.

2. Measure wear on No. 1 timing chain tensioner slipper and all vibration dampers at timing chain contact
areas. See Fig. 13. Replace components if wear exceeds .039" (1.00 mm) from original surface.
3. Timing chain length must be measured on No. 1 timing chain and on No. 2 timing chain. Using caliper,
measure timing chain length at 16 links with timing chain fully stretched. See Fig. 14. Repeat
measurement in at least 3 areas on each timing chain. Replace timing chain if length exceeds
specification. See TIMING CHAIN & SPROCKET SPECIFICATIONS table.
4. Timing chain and sprocket outside diameter must be checked. Wrap timing chain completely around each
sprocket that timing chain fits on. On balance shaft drive gear, sprocket is located on rear of gear.
5. Using caliper, measure outside diameter of timing chain and sprocket. See Fig. 14. Ensure caliper
contacts rollers on timing chain when measuring outside diameter.
6. Replace timing chains and sprockets or gear if outside diameter is less than specified. See TIMING
CHAIN & SPROCKET SPECIFICATIONS table.
7. Ensure plunger moves freely inward and outward on No. 2 timing chain tensioner when pawl is raised
upward. See Fig. 15. Release pawl and ensure plunger is locked and does not move when pressure is
applied on plunger.
8. Ensure oil jet on rear of No. 2 timing chain tensioner is not clogged or damaged by applying air pressure
to rear of No. 2 timing chain tensioner. Air should pass out holes on body of No. 2 timing chain tensioner.
See Fig. 15. Replace No. 2 timing chain tensioner if operation is not as specified.
TIMING CHAIN & SPROCKET SPECIFICATIONS

Timing Chain Length
No. 1 Timing Chain 5.807 (147.50)
No. 2 Timing Chain 4.866 (123.60)
Timing Chain & Sprocket Outside Diameter
No. 1 Timing Chain & Camshaft Sprocket 4.480 (113.80)
No. 1 Timing Chain & Crankshaft Sprocket 2.339 (59.40)
No. 2 Timing Chain & Balance Shaft Drive Gear 2.988 (75.90)
No. 2 Timing Chain & No. 2 Crankshaft Sprocket 3.807 (96.70)

Fig. 13: Measuring No. 1 Timing Chain Tensioner Slipper & Vibration Damper Wear

Fig. 14: Measuring Timing Chain & Sprockets


Fig. 15: Checking No. 2 Timing Chain Tensioner Operation

Installation
1. Ensure cylinder No. 1 (front cylinder) is at TDC and weights on balance shafts are facing toward bottom
of cylinder block. Install No. 4 vibration damper.
2. Install No. 2 timing chain on No. 2 crankshaft sprocket and balance shaft sprocket so marked link on
timing chain aligns with timing mark on No. 2 crankshaft sprocket and balance shaft sprocket. Perform
STEP 1. See Fig. 16.
3. Install No. 2 timing chain on balance shaft drive gear so marked link is positioned directly behind large
timing mark on balance shaft drive gear. Perform STEP 2. See Fig. 16.
4. Insert balance shaft drive gear shaft through balance shaft drive gear so shaft engages hole on thrust plate
at front of balance shaft. Align small timing mark on balance shaft drive gear with small timing mark on
balance shaft timing gear. Perform STEP 2.
5. Install and tighten balance shaft drive gear bolt to specification. See TORQUE SPECIFICATIONS.
Ensure all marked links and timing marks are aligned. Perform STEP 3. See Fig. 16.

Fig. 16: Installing No. 2 Timing Chain & Components

6. Ensure pin is installed in No. 2 timing chain tensioner. See Fig. 12. Install No. 2 timing chain tensioner.
Install and tighten nut to specification. See TORQUE SPECIFICATIONS. Install No. 3 vibration
damper. Install and tighten bolts to specification.
CAUTION: When installing No. 2 vibration damper, DO NOT push No. 2 vibration
damper against No. 2 timing chain.
7. Install No. 2 vibration damper. DO NOT push No. 2 vibration damper against No. 2 timing chain. Tighten
bolt to specification. See TORQUE SPECIFICATIONS. Remove pin from No. 2 timing chain
tensioner.
8. Install No. 1 vibration damper and No. 1 timing chain tensioner slipper. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS. Ensure No. 1 timing chain tensioner slipper moves
freely.
CAUTION: When installing No. 1 crankshaft sprocket, ensure flat side (teeth
side) is toward cylinder block and flange side is toward front of
engine. See Fig. 11.
9. Install No. 1 crankshaft sprocket with flat side (teeth side) toward cylinder block. See Fig. 11. It may be
necessary to use hammer and Sprocket Installer (SST 09636-20010) for installing No. 1 crankshaft
sprocket.
10. Align marked links on No. 1 timing chain with timing mark on camshaft sprocket and No. 1 crankshaft
sprocket. Perform STEP 1. See Fig. 17. Place tie around No. 1 timing chain, just below camshaft
sprocket. Perform STEP 2. See Fig. 17.

Fig. 17: Aligning No. 1 Timing Chain With Timing Marks & Installing

11. Install NEW gaskets for front cover on cylinder block. Install NEW gasket on No. 1 coolant by-pass pipe.
Install front cover. Install and tighten bolts/nuts to specification. See Fig. 18.
12. Install and tighten No. 1 coolant by-pass pipe nuts to specification. See TORQUE SPECIFICATIONS.
Remove tie from No. 1 timing chain. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to
specification. See TORQUE SPECIFICATIONS.
13. To install remaining components, reverse removal procedure. Ensure proper procedure is used when
installing cylinder head and oil pan. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS.

Fig. 18: Tightening Front Cover Bolts/Nuts


VALVE LIFTER
Removal
Remove camshaft. See CAMSHAFT. Note location of adjusting shims and valve lifters for reassembly
reference. Remove adjusting shims and valve lifters from cylinder head.
Inspection
Inspect components for damage. Measure valve lifter diameter and bore diameter. Ensure oil clearance is within
specification. Replace components if not within specification. See VALVE LIFTERS table under ENGINE
SPECIFICATIONS.
Installation
To install, reverse removal procedure. Ensure components are installed in original location. If camshaft,
adjusting shims or valve lifters are replaced, check valve clearance. See VALVE CLEARANCE
ADJUSTMENT under ADJUSTMENTS.
CAMSHAFT
Removal
1. Disconnect control cables at throttle body and cruise control actuator (if equipped). Remove air cleaner
cap and airflow meter with air cleaner hose.
2. Remove intake air connector. See Fig. 5. Disconnect PCV hoses. Disconnect spark plug wires at spark
plugs. Disconnect necessary electrical connectors and wiring for access to valve cover.
3. It may be necessary to remove throttle body for access to valve cover. If necessary to remove throttle
body, drain cooling system. Remove throttle body and gasket.
4. Remove valve cover and gasket. Rotate crankshaft clockwise (viewed from front of engine) so cylinder
No. 1 (front cylinder) is at TDC on compression stroke.
5. Ensure timing mark on crankshaft pulley aligns with "O" mark on front cover. Ensure timing marks on
6. Remove distributor hold-down bolts and distributor (if equipped). Remove ignition coils (if equipped).
Remove nuts and No. 1 timing chain tensioner. Remove gasket from cylinder head. See Fig. 6. Remove
both semi-circular plugs from cylinder head. See Fig. 6.
7. Place alignment marks on camshaft sprocket and No. 1 timing chain for reassembly reference. Hold
exhaust camshaft from rotating by holding camshaft with wrench on hexagonal area at center of exhaust
camshaft. Remove bolt and distributor gear from exhaust camshaft (if equipped). See Fig. 6.
8. Hold intake camshaft from rotating by holding camshaft with wrench on hexagonal area at center of
intake camshaft. Remove camshaft sprocket bolt from intake camshaft.
CAUTION: DO NOT allow No. 1 timing chain to become disengaged from No. 1
crankshaft sprocket on crankshaft during removal.

9. Remove camshaft sprocket with No. 1 timing chain from intake camshaft. Allow No. 1 timing chain and
camshaft sprocket to set in front cover and No. 1 timing chain tensioner slipper and No. 1 vibration
damper located on each side of timing chain. DO NOT allow No. 1 timing chain to become disengaged
from No. 1 crankshaft sprocket.
10. Secure sub-gear on exhaust camshaft to main gear with a 6 x 1.0 x 18 mm service bolt. See Fig. 19.
Before removing camshaft bearing cap bolts, ensure torsional spring force of sub-gear is held by service
bolt.
Fig. 19: Installing Service Bolt To Secure Sub-Gear

CAUTION: When removing camshaft, proper procedure must be used to hold

camshaft level. If camshaft is not held level, cylinder head thrust area
may be damaged, causing camshaft to seize or break. Camshaft
bearing cap bolts must be removed in proper sequence to prevent
damage to cylinder head and camshaft.
11. Note location of camshaft bearing caps. Camshaft bearing caps are numbered for location on top of

camshaft bearing cap on all except No. 1 camshaft bearing caps. Camshaft bearing cap is also stamped
with either an "I" for intake camshaft or an "E" for exhaust camshaft. Arrows on top of camshaft bearing
caps must point toward front of engine. See Fig. 20.
12. Remove exhaust camshaft bearing cap bolts in sequence. See Fig. 21. If exhaust camshaft is not lifted
upward when removing camshaft bearing cap bolts, reinstall camshaft bearing cap bolts on No. 3
camshaft bearing cap, and then alternately loosen so camshaft will be lifted upward. Remove camshaft
bearing caps and exhaust camshaft.
13. Remove intake camshaft bearing cap bolts in sequence. See Fig. 21. If intake camshaft is not lifted
upward when removing camshaft bearing cap bolts, reinstall camshaft bearing cap bolts on No. 3
camshaft bearing cap and then alternately loosen so camshaft will be lifted upward. Remove camshaft
bearing caps and intake camshaft.
14. If removing sub-gear from exhaust camshaft, mount hexagonal area of camshaft in soft-jawed vise. Using
spanner wrench, rotate sub-gear clockwise and remove service bolt. See Fig. 22. Remove snap ring, wave
washer, sub-gear and gear spring from exhaust camshaft. See Fig. 6.

Fig. 20: Identifying Camshaft Bearing Caps

Fig. 21: Camshaft Bearing Cap Removal Sequence


Fig. 22: Removing & Installing Sub-Gear

Inspection
1. Inspect components for damage. Check camshaft journal diameter, lobe height and journal runout.
Replace camshaft if not within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS.
2. Install camshaft in cylinder head using proper installation procedure. See CAMSHAFT. Check camshaft
oil clearance with camshaft bearing cap bolts tightened to specification in sequence. See Fig. 23. See
3. Replace camshaft and/or cylinder head if oil clearance is not within specification. See CAMSHAFT table
under ENGINE SPECIFICATIONS.
4. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if end play is not within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS.
5. Install both camshafts without sub-gear installed on exhaust camshaft. Tighten camshaft bearing cap bolts
to specification. Check gear backlash between camshaft gears.
6. Replace camshaft if gear backlash exceeds specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS. Measure distance between ends of gear spring. Replace gear spring if distance is
not .886-.902" (22.50-22.90 mm).
7. Ensure plunger on No. 1 timing chain tensioner moves freely when pawl is pushed downward to released
position. Release pawl and ensure plunger locks and will not move. Replace No. 1 timing chain tensioner
if defective.

Installation
1. If installing sub-gear on exhaust camshaft, install gear spring, sub-gear, wave washer and snap ring.
Ensure pins on main gear and sub-gear align with ends of gear spring.
2. Using spanner wrench, rotate sub-gear clockwise until holes in main gear and sub-gear are aligned. Install
service bolt. See Fig. 22.
3. Apply grease to thrust surfaces and journals of camshafts. Install intake camshaft in cylinder head, with
pin in front of camshaft at 12 o'clock position. Install intake camshaft bearing caps in numerical order,
with arrow on top of camshaft bearing cap pointing toward front cover. See Fig. 20.
4. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install
and tighten intake camshaft bearing cap bolts to specification in sequence using several steps. See Fig.
23. See TORQUE SPECIFICATIONS.
5. Install exhaust camshaft in cylinder head, with pin in front of camshaft at 12 o'clock position and timing
marks on camshaft gears aligned. See Fig. 1.
6. Install exhaust camshaft bearing caps in numerical order, with arrow on top of camshaft bearing cap
pointing toward engine front cover. See Fig. 20.
7. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install
and tighten exhaust camshaft bearing cap bolts to specification in sequence using several steps. See Fig.
23. See TORQUE SPECIFICATIONS.

Fig. 23: Camshaft Bearing Cap Installation Sequence


CAUTION: Ensure service bolt is removed from exhaust camshaft after camshaft
installation.
8. Remove service bolt from exhaust camshaft. Ensure No. 1 (front cylinder) is at TDC on compression
stroke and timing mark on crankshaft pulley aligns with "O" mark on front cover. Rotate crankshaft
clockwise (viewed from front of engine) if necessary to align timing mark. DO NOT allow No. 1 timing
chain to become disengaged from crankshaft.
9. Rotate camshafts so timing marks on camshaft gears are aligned (if necessary). See Fig. 1. Ensure
alignment mark on camshaft sprocket and No. 1 timing chain made during disassembly are aligned.
10. Install camshaft sprocket on intake camshaft. Ensure camshaft sprocket engages with pin in intake
camshaft. Install and tighten camshaft sprocket bolt to specification while holding intake camshaft by
using wrench on hexagonal area at center of intake camshaft. See TORQUE SPECIFICATIONS.
11. Install distributor gear on exhaust camshaft (if equipped). Install and tighten distributor gear bolt to
specification while holding exhaust camshaft by using wrench on hexagonal area at center of intake
camshaft. See TORQUE SPECIFICATIONS.
12. Install NEW gasket for No. 1 timing chain tensioner on cylinder head. Ensure front mark on gasket is
toward front cover. See Fig. 24.
13. Release pawl on No. 1 timing chain tensioner and push plunger inward so pin engages hook. See Fig. 24.
Ensure plunger remains in retracted position.

Fig. 24: Installing Gasket & Retracting No. 1 Timing Chain Tensioner
14. Rotate crankshaft clockwise (viewed from front of engine) to provide slack in No. 1 timing chain. DO
NOT rotate crankshaft counterclockwise. Install No. 1 timing chain tensioner on cylinder head.
15. Hold No. 1 timing chain tensioner against cylinder head. Install and tighten nuts to specification. See
TORQUE SPECIFICATIONS. Ensure plunger remains in retracted position. If plunger extends during
No. 1 timing chain tensioner installation, tensioner must be removed and plunger reset to retracted
position.
16. Rotate crankshaft counterclockwise (viewed from front of engine) until hook disengages pin and plunger
on No. 1 timing chain tensioner extends outward and No. 1 timing chain tensioner slipper is pushed
against No. 1 timing chain.
17. If plunger does not extend, use finger pressure to push No. 1 timing chain tensioner slipper toward
plunger until hook is released from pin. Release No. 1 timing chain tensioner slipper and ensure plunger
extends.
18. Rotate crankshaft clockwise (viewed from front of engine) so cylinder No. 1 (front cylinder) is at TDC on
compression stroke. Ensure timing mark on crankshaft pulley aligns with "O" mark on front cover.
19. Ensure timing marks on camshaft gears are aligned. See Fig. 1. If timing marks are not aligned, rotate
crankshaft clockwise one full revolution (360 degrees) and recheck alignment.
20. Check and adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under
ADJUSTMENTS. Install and tighten spark plugs to specification. See TORQUE SPECIFICATIONS.
21. Apply sealant on grooves at rear of semi-circular plugs and install in cylinder head. See Fig. 6. Before
installing distributor, place cylinder No. 1 (front cylinder) at TDC on compression stroke so timing mark
on crankshaft pulley aligns with "O" mark on front cover (if equipped).
22. Ensure timing marks on camshaft gears are aligned. See Fig. 1. Install NEW "O" ring on distributor (if
equipped). Align groove on distributor gear with protrusion on distributor housing. See Fig. 10.
23. Install distributor. Tighten distributor hold-down bolts to specification. See TORQUE
SPECIFICATIONS. To install remaining components, reverse removal procedure. Use NEW gaskets
and tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS. Adjust ignition timing.
BALANCE SHAFTS
NOTE: Balance shafts are used. Manufacturer lists balance shaft servicing procedure
with engine removed from vehicle and all timing chains removed. Balance
shafts are located on each side of cylinder block. See Fig. 25.
Removal
1. Before removing balance shafts from cylinder block, balance shaft end play should be checked. Attach
dial indicator on front of cylinder block with stem of dial indicator against timing gear or sprocket on
balance shaft.
2. Move balance shaft back and forth, noting balance shaft end play. Replace thrust plate or balance shaft if
balance shaft end play is not within specification. See BALANCE SHAFT SPECIFICATIONS table.
3. Note location of balance shafts for reassembly reference. No. 1 (right) balance shaft contains indentation
areas and No. 2 (left) balance shaft does not.
4. Remove balance shaft thrust plate-to-cylinder block bolt(s) from balance shaft thrust plate. Support
balance shaft and remove from cylinder block. DO NOT scratch bearing surfaces during balance shaft
removal.
5. If removing components from balance shaft, clamp balance shaft in soft-jawed vise at square area on
balance shaft, just below thrust plate. Remove bolts and components from balance shaft.
Inspection
1. Inspect balance shafts and balance shaft bearings in cylinder block for damage. Replace components if
damaged.
2. Using dial bore gauge, measure inside diameter of balance shaft bearings on cylinder block. Balance shaft
bearings are numbered with No. 1 at front of cylinder block and No. 2 at rear.
3. Measure balance shaft journal diameter. No. 1 journal is at front of balance shaft and No. 2 journal is at
rear of balance shaft. Determine oil clearance. Replace components if not within specification. See
BALANCE SHAFT SPECIFICATIONS table.

BALANCE SHAFT SPECIFICATIONS
BALANCE SHAFT SPECIFICATIONS

Balance Shaft Bearing Inside Diameter
No. 1 (Front) Bearing 1.4970-1.4978 (38.025-
38.045)
No. 2 (Rear) Bearing 1.4774-1.4781 (37.525-
37.545)
Balance Shaft End Play
Standard .0027-.0051 (.070-.130)
Wear Limit .0079 (.200)
Balance Shaft Journal Diameter
No. 1 (Front) Journal 1.4948-1.4955 (37.969-
37.985)
No. 2 (Rear) Journal 1.4744-1.4750 (37.449-
37.465)
Balance Shaft Oil Clearance
No. 1 (Front) Journal
Standard .0016-.0030 (.040-
.076)
Wear Limit .0059 (.150)
No. 2 (Rear) Journal
Standard .0024-.0038 (.060-
.096)
Wear Limit .0059 (.150)
Installation
1. If installing components on balance shaft, ensure components are installed on correct balance shaft. See
Fig. 25. Install components on balance shaft. Install and tighten balance shaft bolt to specification. See
2. Support balance shaft and install in cylinder block. DO NOT scratch bearing surfaces during installation.
Ensure balance shaft is installed in correct location, as No. 1 (right) balance shaft contains indentation
areas and No. 2 (left) balance shaft does not. See Fig. 25.
3. Install and tighten balance shaft thrust plate-to-cylinder block bolts to specification. See TORQUE
SPECIFICATIONS.

Fig. 25: Exploded View Of Balance Shafts & Components

CRANKSHAFT REAR OIL SEAL
Removal
With transmission, clutch assembly (if equipped) and flywheel/drive plate removed, using a knife, cut off oil
seal lip. Pry oil seal from crankshaft rear oil seal housing. DO NOT damage sealing surfaces.
Installation
1. Ensure all sealing surfaces are clean. Apply grease to seal lip of oil seal. Using Oil Seal Installer (SST
09223-15030), install oil seal in crankshaft rear oil seal housing until oil seal is even with housing
surface.
2. On A/T models, apply Loctite to flywheel/drive plate bolt threads before installing. On M/T models, use
NEW bolts when installing flywheel/drive plate.
3. On all applications, tighten flywheel/drive plate bolts to specification in a crisscross pattern. See
WATER PUMP
Removal & Installation
1. Drain cooling system. Remove upper radiator hose from radiator. Remove accessory drive belts. Remove
cooling fan, fan clutch and water pump pulley. Remove fan shrouds. Remove water pump and gasket.
2. To install, reverse removal procedure. Use a NEW gasket. Tighten bolts/nuts to specifications. See
TORQUE SPECIFICATIONS. Fill cooling system.
OIL PAN
Removal
1. Raise and support vehicle. Drain engine oil. Remove lower engine cover (if necessary).
2. Remove oil pan bolts/nuts. Install Seal Cutter (SST 09032-00100) between oil pan and cylinder block.
Carefully tap seal cutter around oil pan to loosen seal. DO NOT damage sealing surfaces. Remove oil
pan. Remove bolts/nuts oil pick-up tube and gasket (if necessary).
Installation
1. Using NEW gasket, install oil pick-up tube (if removed). Install and tighten bolt/nuts to specification. See
2. Ensure sealing surfaces are clean. Apply sealant to oil pan flange surface. Ensure sealant is on inside of
bolt holes and in groove at center of oil pan flange.
3. Install oil pan. Install and tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS. Install
lower engine cover (if necessary). Fill crankcase with oil.
OVERHAUL
CYLINDER HEAD
Cylinder Head
1. Inspect cylinder head warpage at cylinder block, exhaust manifold and intake manifold areas. Replace
cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
2. Using Plastigage, check camshaft oil clearance with camshaft properly installed. See CAMSHAFT under
REMOVAL & INSTALLATION.
3. Replace camshaft and/or cylinder head if oil clearance is not within specification. See CAMSHAFT table
under ENGINE SPECIFICATIONS.
4. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if camshaft end play is not within specification. See CAMSHAFT under ENGINE
SPECIFICATIONS.
5. Install both camshafts without sub-gear installed on exhaust camshaft. Tighten camshaft bearing cap bolts
to specification. Check gear backlash between camshaft gears.
6. Replace camshaft if gear backlash exceeds specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS. Ensure valve lifter bore diameter in cylinder head is within specification. See
VALVE LIFTERS table under ENGINE SPECIFICATIONS.
7. If installing spark plug tubes in NEW cylinder head, apply sealant on spark plug tube bore of cylinder
head. Using press, install spark plug tube until distance between from top surface of spark plug tube to
camshaft bearing cap surface on cylinder head is 1.850" (47.00 mm).
Valve Springs
Ensure valve spring pressure and out-of-square are within specification. See VALVES & VALVE SPRINGS
table under ENGINE SPECIFICATIONS.
CAUTION: Different type valve stem oil seals are used. Intake valve stem oil seal
contains "H" identification mark. Exhaust valve stem oil seal does not
contain identification mark. Ensure proper valve stem oil seal is installed.
Valve Stem Oil Seals
Intake valve stem oil seal contains "H" identification mark. Exhaust valve stem oil seal does not contain
identification mark. Ensure proper valve stem oil seal is installed. Lubricate valve stem oil seal with engine oil.
Install valve stem oil seal using Oil Seal Installer (SST 09236-00101).
Valve Guides
1. Ensure valve guide inside diameter is within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification.
2. To replace valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and Valve Guide
Remover/Installer SET (SST 09201-01060), drive valve guide from cylinder block side of cylinder head.
3. Measure cylinder head valve guide bore inside diameter. If bore inside diameter is .4331-.4341" (11.000-
11.027 mm), use standard valve guide. If bore inside diameter is .4350-.4361" (11.050-11.077 mm), use
oversize valve guide.
4. If bore inside diameter exceeds .4341" (11.027 mm), machine valve guide bore to .4350-.4361" (11.050-
11.077 mm) for oversize valve guide. If bore inside diameter exceeds .4361" (11.077 mm), replace
cylinder head.
5. To install valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and valve guide
remover/installer, drive valve guide in from camshaft side of cylinder head until valve guide installed
height is within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve
guide installed height is measured from top of valve guide to cylinder head surface, right next to valve
guide.
6. Using .236" (6.00 mm) reamer, ream valve guide to obtain correct valve stem-to-guide oil clearance. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Seat
Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Valve seat replacement information is not available at time of publication.
Valves
Ensure minimum refinish length, stem diameter and valve margin are within specification. See VALVES &
VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Seat Correction Angles
Use 30-degree and 45-degree stones to lower valve seat contact area. Use 45-degree and 60-degree stones to
raise valve seat contact area.
VALVE TRAIN
Valve Lifters
Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS
table under ENGINE SPECIFICATIONS.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Piston and connecting rod must be installed with front marks toward front of engine. See Fig.
26.
2. Note direction of connecting rod cap installation on connecting rod before removing. Connecting rod cap
must be installed on connecting rod with front mark toward front of engine. See Fig. 26.
3. Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace
piston and piston pin if any movement is felt.
4. When removing piston from connecting rod, remove snap rings from piston. Heat piston to 176-194°F
(80-90°C) in water. Remove piston pin. Separate piston from connecting rod.
5. Ensure piston pin diameter is within specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS. Ensure connecting rod crankpin bore, bend, twist and piston pin bushing bore
diameter are within specification. See CONNECTING RODS table under ENGINE SPECIFICATIONS.
NOTE: Crankpin bore diameter is identified by size mark ("4", "5" or "6") stamped
on connecting rod. See Fig. 28.
6. Piston pin bushing in connecting rod may be replaced if bore diameter is not within specification. Ensure
bushing oil holes align with connecting rod oil holes. Bushing must be honed to obtain correct piston pin-
to-rod clearance. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

NOTE: With piston at 176-194°F (80-90°C), piston pin should be able to be pressed
into piston using thumb pressure.
7. Measure piston skirt diameter 1.47" (37.5 mm) from top of piston at 90-degree angle to piston pin.
8. Ensure piston diameter is within specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS.
9. Ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use caliper to measure
connecting rod bolt outside diameter at .91" (23.0 mm) from bottom of connecting rod bolt. Replace
connecting rod bolt and nut as an assembly if bolt outside diameter is less than .2992" (7.600 mm).
10. To reassemble, install piston on connecting rod so front mark on top of piston aligns with front mark on
connecting rod. See Fig. 26.
11. Install one NEW snap ring in piston. Heat piston to 176-194°F (80-90°C) in water. Coat piston pin with
engine oil. Install piston pin into piston and connecting rod using thumb pressure. Install remaining NEW
snap ring.
Fig. 26: Identifying Front Marks & Aligning Piston With Connecting Rod
Fitting Pistons

1. To determine piston-to-cylinder clearance, measure piston skirt diameter. Measure piston skirt diameter
1.47" (37.5 mm) from top of piston at 90-degree angle to piston pin.
2. Ensure piston diameter is within specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS. Replace piston if necessary.
3. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm) from top and
bottom of cylinder bore and at center of cylinder bore. Ensure cylinder bore diameter is within
specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. Determine piston
clearance.
4. Replace piston or bore cylinder block for oversize pistons if clearance is not within specification. See
PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Pistons are available in .20" (.50
mm) oversize.
Piston Rings
Ensure piston ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table
under ENGINE SPECIFICATIONS. Position piston ring with ring end gaps in proper areas with identification
mark on piston ring toward top of piston. See Fig. 27.
NOTE: No. 1 compression ring may contain a 1N or 1T identification mark and No. 2
compression ring may contain a 2N or 2T identification mark. Ensure ring is
installed in correct location.

Fig. 27: Positioning Piston Rings

Rod Bearings
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Piston and connecting rod must be installed with front marks toward front of engine. See Fig.
26.
2. Connecting rod cap and rod bearing are stamped with size mark ("4", "5" or "6"). See Fig. 28. Ensure size
marks on connecting rod cap and rod bearing are same.
NOTE: If replacing rod bearing, ensure size mark on replacement rod bearing is
same as size mark on original rod bearing.
3. Rod bearing thickness is determined by size mark. See ROD BEARING SPECIFICATIONS table.
4. Ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use caliper to measure
connecting rod bolt outside diameter at .91" (23.0 mm) from bottom of connecting rod bolt. Replace
connecting rod bolt and nut as an assembly if bolt outside diameter is less than .2992" (7.600 mm).
5. Ensure piston and connecting rod are installed with front marks toward front of engine. See Fig. 26.
Install connecting rod cap with front mark toward front of engine. See Fig. 26.
6. Coat threads of connecting rod bolts and nut-to-connecting rod cap surface with engine oil before
tightening nuts to specification. See TORQUE SPECIFICATIONS.
7. Ensure bearing oil clearance and connecting rod side play are within specification. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS table under ENGINE
SPECIFICATIONS.
ROD BEARING SPECIFICATIONS
ROD BEARING SPECIFICATIONS

Bearing Size Mark Bearing Thickness In. (mm)
"4" .0583-.0585 (1.482-1.485)
"5" .0585-.0586 (1.485-1.488)
"6" .0586-.0587 (1.488-1.491)
Fig. 28: Identifying Connecting Rod Cap & Rod Bearing Size Marks
Crankshaft & Main Bearings
1. Main bearing caps are numbered on top of cap for location reference. No. 1 main bearing cap is at front of
engine and No. 5 is at flywheel end of engine. Arrow on top of main bearing cap must point toward front
of engine.
2. Remove main bearing cap bolts in sequence. See Fig. 29. Remove main bearing caps, crankshaft, thrust
bearings and main bearings.
3. Using caliper, measure outside diameter of main bearing cap bolts at center of thread area on bolt.
Replace main bearing cap bolt if bolt outside diameter is less than .4094" (10.400 mm).
4. Cylinder block main bearing bore inside diameter is identified by size mark ("1", "2" or "3") stamped on
cylinder block flange area. See Fig. 30. Front size mark indicates No. 1 main bearing bore and rear size
mark indicates No. 5 main bearing bore.

5. Ensure crankshaft journal diameter, taper and out-of-round are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
6. Main bearing size mark ("1", "2" or "3") is located on side of main bearing. See Fig. 30. If replacing main
bearing, ensure size mark on replacement main bearing is same as size mark on original main bearing.
Size mark on main bearing and cylinder block must be same.
7. Main bearing thickness is determined by size mark. See MAIN BEARING SPECIFICATIONS table.
Install main bearings, thrust bearings, crankshaft and main bearing caps.
8. Ensure main bearings caps are properly installed in numerical sequence with No. 1 at front of engine and
No. 5 at flywheel end of engine. Ensure arrow on top of main bearing cap points toward front of engine.
9. Coat bolt threads and bolt-to-main bearing cap contact surfaces of main bearing cap bolts with engine oil
before installing. Install and tighten main bearing cap bolts to specification in sequence. See Fig. 29. See
10. Ensure crankshaft main bearing oil clearance and crankshaft end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS. Replace thrust bearing if end play is not within specification.
MAIN BEARING SPECIFICATIONS
MAIN BEARING SPECIFICATIONS

Bearing Size Mark Bearing Thickness In. (mm)
"1" .0782-.0783 (1.987-1.990)
"2" .0784-.0785 (1.991-1.993)
"3" .0785-.0786 (1.993-1.996)


Fig. 29: Main Bearing Cap Bolt Removal & Installation Sequence
Fig. 30: Identifying Cylinder Block & Main Bearing Size Marks
Thrust Bearing
Install thrust bearing on No. 3 main bearing with grooves facing toward crankshaft, away from cylinder block
and main bearing cap. Replace thrust bearing if crankshaft end play is not within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Cylinder Block
1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck surface warpage exceeds
specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm) from top and
bottom of cylinder bore and at center of cylinder bore. Ensure cylinder bore diameter is within
specification. Bore cylinder block for oversize pistons if bore diameter exceeds specification. Pistons are
available in .20" (.50 mm) oversize.
3. Note location of cylinder block orifice in top of cylinder block. See Fig. 31. Inspect cylinder block orifice
for damage or restriction. Replace cylinder block orifice if necessary.
4. Install main bearing caps in numerical sequence with No. 1 at front of engine and No. 5 at flywheel end
of engine. Ensure arrow on top of main bearing cap points toward front of engine.
5. Install and tighten main bearing cap bolts to specification in sequence. See Fig. 29. See TORQUE
SPECIFICATIONS.
6. Ensure main bearing bore inside diameter is within specification. See CYLINDER BLOCK table under
ENGINE SPECIFICATIONS.
NOTE: Main bearing bore inside diameter is identified by size mark ("1", "2" or "3")
stamped on cylinder block. See Fig. 30.
Fig. 31: Identifying Cylinder Block Orifice

ENGINE OILING
ENGINE LUBRICATION SYSTEM
Crankshaft driven oil pump provides pressurized engine lubrication.
Crankcase Capacity
See CRANKCASE CAPACITIES table.
CRANKCASE CAPACITIES SPECIFICATIONS
CRANKCASE CAPACITIES (1)

Application Qts. (L)
T100 5.6 (5.3)

(1) Approximate capacity listed is with oil filter replacement.
Oil Pressure
With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm2 ) at idle and 36-
71 psi (2.5-5.0 kg/cm2 ) at 3000 RPM.
OIL PUMP
NOTE: Oil pump is mounted on front cover. Manufacturer lists oil pump servicing
information with front cover removed.
Removal & Disassembly
1. Remove front cover. See TIMING CHAINS under REMOVAL & INSTALLATION. To disassemble,
remove oil pump cover bolts, oil pump cover and "O" ring. See Fig. 32.
2. Note direction of drive and driven rotor installation. Remove drive and driven rotors from front cover.
Remove snap ring, retainer, spring(s) and relief valve from front cover. See Fig. 32. Remove front cover
oil seal from oil pump cover (if necessary).

Fig. 32: Exploded View Of Oil Pump

Inspection
1. Inspect components for damage. Coat relief valve with engine oil and ensure relief valve slides freely in
bore of front cover. Replace relief valve and/or front cover if relief valve fails to slide freely.
2. Install both rotors in front cover. Using feeler gauge, measure driven rotor-to-front cover clearance
between driven rotor and front cover. Replace rotor assembly and/or front cover if clearance exceeds
specification. See OIL PUMP SPECIFICATIONS table.
3. Using feeler gauge, measure rotor tip clearance between outside edge of tip on drive rotor and inside edge
of tip on driven rotor. Replace rotor assembly if clearance exceeds specification. See OIL PUMP
SPECIFICATIONS table.
4. Place straightedge across front cover, above both rotors. Using feeler gauge, measure rotor end clearance
between straightedge and rotor surface. Replace rotor assembly or oil pump body if clearance exceeds
specification. See OIL PUMP SPECIFICATIONS table.
OIL PUMP SPECIFICATIONS
OIL PUMP SPECIFICATIONS


Driven Rotor-To-Front Cover Clearance
Standard .0039-.0069 (.100-.175)
Wear Limit .0118 (.300)
Rotor End Clearance
Standard .0012-.0035 (.030-.090)
Wear Limit .0059 (.150)
Rotor Tip Clearance
Standard .0043-.0094 (.110-.240)
Wear Limit .0098 (.250)
Reassembly & Installation
1. To reassemble, reverse disassembly procedure. Use a NEW "O" ring. Ensure rotors are installed in
original direction of installation.
2. Using hammer and Oil Seal Installer (SST 09223-50010), install front cover oil seal until oil seal surface
is even with edge of oil pump cover (if removed). To install, reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Compressor Bolt 18 (24)
A/C Compressor Mounting Bracket Bolt 32 (43)
Accessory Drive Pulley Bolt 18 (24)
Air Intake Chamber Bolt/Nut 15 (20)
Balance Shaft Bolt 26 (35)
Balance Shaft Drive Gear Bolt 18 (24)
Balance Shaft Thrust Plate-To-Cylinder Block Bolt 13 (18)
Camshaft Bearing Cap Bolt (1) 12 (16)
Camshaft Sprocket Bolt 55 (75)
Connecting Rod Nut
Step 1 33 (45)
Step 2 Additional 90
Degrees
Cooling Fan & Fan Clutch-To-Water Pump Nut 15 (20)
Coolant Outlet Bolt 15 (20)
Crankshaft Pulley Bolt 193 (260)
Cylinder Head-To-Cylinder Block Bolt (2)
Step 1 29 (39)

Degrees
Degrees
Cylinder Head-To-Front Cover Bolt 16 (22)
Delivery Pipe Bolt 15 (20)
Distributor Gear Bolt 34 (46)
Distributor Hold-Down Bolt 14 (19)
Drive Shaft Center Bearing Bolt 27 (37)
Drive Shaft Flange Bolt 54 (73)
EGR Pipe Bolt/Nut
Bolt 13 (18)
Nut At EGR Valve 14 (19)
Nut At Exhaust Manifold 15 (20)
EGR Valve Nut 14 (19)
Engine Mount-To-Frame Bolt/Nut 28 (38)
Exhaust Manifold Nut 36 (49)
Fluid Line-To-Clutch Release Cylinder Bolt 29 (39)
Flywheel/Drive Plate Bolt
A/T 55 (75)
M/T
Step 1 19 (26)
Degrees
Front Cover Bolt/Nut (3)
Front Exhaust Pipe Support Bracket Bolt 29 (39)

Front Exhaust Pipe-To-Catalytic Converter Bolt/Nut 29 (39)
Front Exhaust Pipe-To-Exhaust Manifold Nut 46 (62)
Fuel Inlet Pipe Union Bolt 21 (29)
Generator Mounting Bracket Bolt
Front Bolt At Front Cover 13 (18)
Side Bolt At Cylinder Block 55 (75)
Intake Air Connector Bolt 13 (18)
Intake Manifold Bolt/Nut 21 (29)
Intake Manifold Brace Bolt 15 (20)
Knock Sensor 27 (37)
Main Bearing Cap Bolt (4)
Step 1 29 (39)
Degrees
No. 1 Coolant By-Pass Pipe Nut 15 (20)
No. 1 Timing Chain Tensioner Nut 15 (20)
No. 1 Timing Chain Tensioner Slipper Bolt 20 (27)

No. 1 Vibration Damper Bolt/Nut 22 (29)
No. 1 & 2 Engine Hanger Bolt 30 (41)
No. 2 Timing Chain Tensioner Nut 13 (18)
No. 2 Vibration Damper Bolt 20 (27)
No. 3 Vibration Damper Bolt 13 (18)
Oil Filter Bracket-To-Cylinder Block Bolt/Nut 21 (29)
Oil Jet Bolt 13 (18)
Oil Pick-Up Tube Bolt/Nut 13 (18)
Power Steering Pump Bolt 43 (58)
Power Steering Pump Bracket Bolt 15 (20)
Power Steering Pump Idler Pulley Bolt 15 (20)
Power Steering Pump Pulley Nut 32 (43)
Rear Engine Mount-To-Crossmember Bolt 19 (26)
Rear Engine Mount-To-Mounting Bracket Bolt 13 (18)
Rear Plate-To-Cylinder Block Bolt
Top Bolt Near Starter Opening 15 (20)
All Others 13 (18)
Spark Plug 15 (20)
Throttle Body Bolt/Nut 15 (20)
Water Pump Bolt
12-mm (5)
14-mm 18 (24)
INCH Lbs. (N.m)
Clutch Release Cylinder Bolt 120 (12.0)
Crankshaft Position Sensor Bolt 75 (8.5)
Crankshaft Rear Oil Seal Housing Bolt 119 (13.5)
Cylinder Head Rear Cover Bolt 119 (13.5)
Exhaust Manifold Heat Insulator Bolt/Nut 49 (5.5)
Oil Pan Bolt/Nut 111 (12.5)
(1) Tighten bolts to specification in sequence. See Fig. 23.

(3) Tighten bolts/nuts to specification. See Fig. 18.
(5) Tighten bolts 79 INCH lbs. (8.9 N.m).
ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS

Application Specification
Displacement 165 Cu. In.
Bore 3.74" (95.0 mm)
Stroke 3.74" (95.0 mm)
Compression Ratio 9.5:1
Fuel System MFI
Horsepower @ RPM 150 @ 4800
Torque Ft. Lbs. @ RPM 177 @ 4000
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft
End Play
Standard .0008-.0087 (.020-.220)
Wear Limit .012 (.30)
Runout .0012 (.030)
Main Bearings
Journal Diameter
No. 3 Journal 2.3615-2.3620 (59.981-59.994)
All Other Journals 2.3617-2.3622 (59.987-60.000)
Journal Out-Of-Round .0002 (.005)
Journal Taper .0002 (.005)
Oil Clearance
Standard Crankshaft Journal
No. 3 Journal
Standard .0012-.0022 (.030-.055)
Wear Limit .0039 (.100)
All Other Journals
Standard .0009-.0019 (.024-.049)
Wear Limit .0039 (.100)
.010" Undersize Crankshaft Journal
No. 3 Journal
Standard .0012-.0028 (.030-.070)
Wear Limit .0039 (.100)
All Other Journals
Standard .0010-.0026 (.025-.065)
Wear Limit .0039 (.100)
Connecting Rod Bearings

Journal Diameter 2.0861-2.0866 (52.987-53.000)

Journal Out-Of-Round .0002 (.005)
Journal Taper .0002 (.005)
Oil Clearance
Standard Crankshaft Journal
Standard .0012-.0022 (.030-.055)
Wear Limit .0039 (.100)
.010" Undersize Crankshaft Journal
Standard .0012-.0027 (.030-.071)
Wear Limit .0039 (.100)
CONNECTING RODS SPECIFICATIONS
CONNECTING RODS
Bore Diameter
Pin Bushing Bore .9452-.9455 (24.008-24.017)
Crankpin Bore (1)
Size Mark "4" 2.2047-2.2050 (56.000-
56.006)
Size Mark "5" 2.2050-2.2052 (56.006-
56.012)
Size Mark "6" 2.2052-2.2054 (56.012-
56.018)
Maximum Bend .0020 Per 3.940 (.050 Per 100.00)
Maximum Twist .0059 Per 3.940 (.150 Per 100.00)
Side Play
Standard .0063-.0123 (.160-.312)
Wear Limit .0138 (.350)
(1) Crankpin bore diameter is identified by size mark on connecting rod cap. See Fig. 28.
PISTONS, PINS & RINGS SPECIFICATIONS
PISTONS, PINS & RINGS

Pistons
Clearance .0019-.0028 (.047-.070)
Diameter 3.7375-3.7379 (94.933-94.943)
Pins
Diameter .9449-.9452 (24.000-24.009)
Piston Fit (1)

Rod Fit
Standard .0002-.0004 (.005-.010)
Wear Limit .0006 (.015)
Rings
No. 1
End Gap .0120-.0157 (.300-.400)
Side Clearance .0008-.0028 (.020-.070)
No. 2
End Gap .0157-.0196 (.400-.500)
Side Clearance .0012-.0028 (.030-.070)
(1) Piston pin should slide in piston using thumb pressure with piston heated to 176-194°F (80-90°C).
CYLINDER BLOCK SPECIFICATIONS
CYLINDER BLOCK
Cylinder Bore
Standard Diameter 3.7398-3.7403 (94.990-
95.003)
Maximum Diameter 3.7425 (95.060)
Main Bearing Bore Inside Diameter (1)
Size Mark "1" 2.5198-2.5201 (64.004-
64.010)
Size Mark "2" 2.5201-2.5203 (64.010-
64.016)
Size Mark "3" 2.5203-2.5205 (64.016-
64.022)
Maximum Deck Warpage .0020 (.050)
(1) Main bearing bore inside diameter is determined by size mark on cylinder block. See Fig. 30.
VALVES & VALVE SPRINGS

Intake Valves
Face Angle 44.5°
Minimum Margin .020" (.50 mm)
Minimum Refinish Length 4.0531" (102.950 mm)
Stem Diameter .2350-.2356" (5.970-
5.985 mm)
Exhaust Valves
Face Angle 44.5°
Minimum Margin .020" (.50 mm)
Minimum Refinish Length 4.0590" (103.100 mm)

Stem Diameter .2348-.2354" (5.965-
5.980 mm)
Valve Springs
Out-Of-Square .079" (2.00 mm)
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed 40-46 @ 1.406 (18-21 @
35.70)
CYLINDER HEAD SPECIFICATIONS
CYLINDER HEAD
Maximum Warpage
Cylinder Block Surface .0020" (.050 mm)
Manifold Surface .0039" (.100 mm)
Valve Seats
Intake Valve
Seat Angle 45°
Seat Width .039-.055" (1.00-1.40 mm)
Exhaust Valve
Seat Angle 45°
Seat Width .039-.055" (1.00-1.40 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide .4331-.4341" (11.000-
11.027 mm)
Oversize Valve Guide .4350-.4361" (11.050-
11.077 mm)
Valve Guide I.D. .2366-.2374" (6.010-6.030
mm)
Valve Guide Installed Height .323-.339" (8.20-8.60 mm)
Valve Stem-To-Guide Oil Clearance
Standard .0010-.0024" (.025-.060
mm)
Wear Limit .0031" (.080 mm)
Exhaust Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide .4331-.4341" (11.000-
11.027 mm)
Oversize Valve Guide .4350-.4361" (11.050-

11.077 mm)
Valve Guide I.D. .2366-.2374" (6.010-6.030
mm)
Valve Guide Installed Height .323-.339" (8.20-8.60 mm)
Valve Stem-To-Guide Oil Clearance
Standard .0012-.0026" (.030-.065
mm)
Wear Limit .0039" (.100 mm)
CAMSHAFT SPECIFICATIONS
CAMSHAFT
End Play
Standard .0016-.0037 (.040-.095)
Wear Limit .0047 (.120)
Journal Diameter 1.0614-1.0620 (26.959-26.975)
Journal Runout .0024 (.060)
Lobe Height
Intake 1.7839-1.7878 (45.310-45.410)
Exhaust 1.7740-1.7779 (45.060-45.160)
Oil Clearance
Standard .0010-.0024 (.025-.062)
Wear Limit .0031 (.080)
Gear Backlash
Standard .0008-.0079 (.020-.200)
Wear Limit .012 (.30)
VALVE LIFTERS SPECIFICATIONS
VALVE LIFTERS
Bore Diameter 1.2205-1.2211 (31.000-31.016)
Lifter Diameter 1.2191-1.2195 (30.966-30.976)
Oil Clearance
Standard .0009-.0022 (.024-.055)
Wear Limit .0028 (.070)


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1995 Toyota T100 DX 1 Ton

2.7L 4-CYL 1995-96 ENGINES Toyota - 2.7L 4-Cylinder

1995-96 ENGINES Toyota - 2.7L 4-Cylinder

ENGINE IDENTIFICATION CODE SPECIFICATIONS

ENGINE IDENTIFICATION CODE

NOTE: Adjust valve clearance with engine cold.

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 1: Checking Camshaft Timing Mark Alignment

VALVE CLEARANCE SPECIFICATIONS (1)

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Intake Valve .006-.010 (.15-.25)

Fig. 2: Adjusting Valve Clearance

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 3: Intake Valve Adjusting Shim Selection Chart

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 4: Exhaust Valve Adjusting Shim Selection Chart

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

FUEL PRESSURE RELEASE

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

CYLINDER HEAD & MANIFOLDS

CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent

Fig. 5: Exploded View Of Typical Intake Manifold & Components

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 6: Exploded View Of Cylinder Head & Components

Fig. 7: Cylinder Head Bolt Removal Sequence

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 8: Cylinder Head Bolt Installation Sequence

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 9: Applying Sealant At Cylinder Block-To-Front Cover Areas

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 10: Installing Distributor

FRONT COVER OIL SEAL

Removal & Installation (Oil Pump Installed)

Removal & Installation (Oil Pump Removed)

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 11: Exploded View Of Timing Chains & Components (Typical)

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 12: Installing Pin In No. 2 Timing Chain Tensioner

1. Inspect components for damage and wear.

TIMING CHAIN & SPROCKET SPECIFICATIONS

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 14: Measuring Timing Chain & Sprockets

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 15: Checking No. 2 Timing Chain Tensioner Operation

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 16: Installing No. 2 Timing Chain & Components

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 18: Tightening Front Cover Bolts/Nuts

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 19: Installing Service Bolt To Secure Sub-Gear

CAUTION: When removing camshaft, proper procedure must be used to hold

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69

Fig. 20: Identifying Camshaft Bearing Caps

Fig. 21: Camshaft Bearing Cap Removal Sequence

Afinacion de Motor y Diagnostico, OBDII,VW ,Audi 044 664 252 34 69