Install Chain Subassembly

(a) Set the No. 1 cylinder to TDC/ compression.

(1) Align the timing marks of the camshaft timing gears and bearing caps.

(2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

M102 Timing Mark

(b) Align the yellow mark link with the timing mark of the crankshaft timing link.

(c) Align the orange mark links with the timing marks of the camshaft timing gears, and install the chain.

4. INSTALL NO.2 CHAIN VIBRATION DAMPER

(a) Install the 2 chain vibration dampers No. 2.

5. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to rotating surface of the idle gear shaft No. 1.

1kz Turbo Fuel Pump Timing Gear Setting

(b) Temporarily install the idle gear shaft No. 1 together with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block.

NOTICE:

Be careful of the idle gear direction.

(c) Using 10 mm hexagon wrench, tighten the idle gear shaft No. 2.

(d) Remove the bar from the chain tensioner.

6. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (See page EM-236)

7. INSTALL TIMING CHAIN OR BELT COVER SUBASSEMBLY (See page LU-20)

8. INSTALL VVT SENSOR (See page IG-8)

9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-408)

10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See page EM-68)

11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-68)

12. INSTALL IGNITION COIL ASSEMBLY (See page IG-7)

13. INSTALL INTAKE AIR SURGE TANK (See page EM-69)

14. INSTALL OIL PAN SUB-ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

(b) Install a new O-ring onto the oil pump.

(c) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration.

Seal packing:

Part No. 08826-00080 or equivalent NOTICE:

Install the oil pan within 3 minutes of applying the seal packing. Tighten the oil pan bolts and nuts within 15 minutes of installing the oil pan. Otherwise, the seal packing must be removed and reapplied.

(d) Install the oil pan with the 17 bolts and 2 nuts, and tighten the bolts and nuts uniformly in several steps. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) for 10

21 N*m (214 kgf*cm, 16 ft.*lbf) for 12 mm (0.47 in.) head

HINT:

Each bolt length is as follows:

Bolt

Length

A

25 mm (0.98 in.)

B

45 mm (1.77 in.)

C

14 mm (0.55 in.)

(e) Install the 4 housing bolts.

(f) Install the flywheel housing under cover.

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15. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install a new gasket and the oil strainer with the 2 nuts.

16. INSTALL NO.2 OIL PAN SUB-ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No. 2.

(b) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.

Seal packing:

Part No. 08826-00080 or equivalent NOTICE:

Install the oil pan No. 2 within 3 minutes of applying the seal packing. Tighten the oil pan No. 2 bolts and nuts within 15 minutes of installing the oil pan No. 2. Otherwise, the seal packing must be removed and reapplied.

(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolts 10 N*m (102 kgf*cm, 7.4 in.*lbf) for nut

M102 Oilpump Tensioner

17. INSTALL CRANKSHAFT PULLEY

(a) Using SST, install the pulley set bolt.

SST 09213-54015 (91651-60855), 09330-00021 Torque: 250 N*m (2,549 kgf*cm, 184 ft.*lbf)

18. INSTALL NO.1 IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley with the bolt.

HINT:

DOUBLE is marked on the idler pulley No. 1 to distinguish it from the idler pulley No. 2.

19. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the 2 idler pulleys with the 2 bolts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)

20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY NOTICE:

A bolt in position A is not reusable.

HINT:

Each bolt length is as follows:

Position

Length

A

70 mm (2.76 in.)

B, C, D and E

33 mm (1.30 in.)

(b) Finger-tighten the bolts in positions A and E and install the bracket.

(c) Tighten the bolts in positions A and E. Torque: 36 N*m (267 kgf*cm, 27 ft.*lbf)

(d) Tighten the bolts in positions B, C and D. Torque: 36 N*m (267 kgf*cm, 27 ft.*lbf)

21. INSTALL COOLER COMPRESSOR ASSEMBLY (See page ES-410)

22. INSTALL GENERATOR ASSEMBLY (See page CH-13)

23. INSTALL VANE PUMP ASSEMBLY

(a) Install the vane pump with the 2 bolts.

(b) Connect the power steering pressure switch connector.

Do not hit the pulley with other parts when installing the vane pump.

(c) Connect the power steering pressure switch connector.

24. INSTALL WATER INLET (See page CO-10)

25. INSTALL OIL LEVEL GAGE GUIDE

(a) Install a new O-ring onto the oil level gauge guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push the oil level gauge guide end into the guide hole of the oil pan.

(d) Install the oil level gauge guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

(e) Install the oil level gauge guide.

26. INSTALL AIR CLEANER ASSEMBLY (See page ES-416)

27. INSTALL FAN SHROUD (See page C0-20)

28. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH

29. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

30. INSTALL POWER STEERING LINK ASSEMBLY

31. INSTALL BATTERY

32. ADD ENGINE OIL (See page LU-5)

33. ADD ENGINE COOLANT (See page CO-3)

34. ADD DIFFERENTIAL OIL (for 4WD)

35. INSPECT DIFFERENTIAL OIL (for 4WD) (See page DF-8)

36. ADD POWER STEERING FLUID

37. BLEED POWER STEERING FLUID (See page PS-2)

38. CHECK FOR ENGINE OIL LEAKAGE

39. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-4)

40. CHECK FOR POWER STEERING FLUID LEAKAGE

41. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

42. INSTALL V-BANK COVER (See page ES-416)

43. INSPECT IGNITION TIMING (See page EM-1)

Do It Yourself Car Diagnosis

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