1B Engine Mechanical Rz4e

Camshaft removal (RZ4E-TC)
1. Component views
Camshaft
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Part name
1. Camshaft cap
2. Bolt
3. Camshaft sprocket
4. Bolt
5. Cam angle sensor rotor
6. Bolt
7. Inlet camshaft
8. Bolt
9. Gasket
10. Cylinder head
11. Bolt
12. Vacuum pump
13. Bolt
14. Camshaft carrier
15. Exhaust camshaft
Tightening torque
2: 7.0 N・m { 0.7 kgf・m / 62 lb・in }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
6: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 7.0 N・m { 0.7 kgf・m / 62 lb・in }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Cylinder head cover removal
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Refer to "1.Engine 1B.Mechanical(RZ4E-TC) cylinder head cover removal".
3. Camshaft carrier removal
1) Remove the cam angle sensor rotor from the inlet camshaft.
Note
Referring to the diagram, secure the section indicated by the arrow.
Fixing position
2) Turn the crankshaft in the forward direction (clockwise) to align the inlet camshaft and the exhaust camshaft
notches to the camshaft cap alignment marks.
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Caution
Do not rotate the crankshaft until the camshaft carrier is reinstalled.
Legend
1. Alignment mark
2. Notch
3) Place the paint marking to the timing chain and camshaft sprocket.
Legend
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2. Timing chain
3. Paint marking
4) Remove the timing chain tensioner and gasket from the flywheel housing.
Legend
1. Timing chain tensioner

2. Gasket
5) Remove the timing chain from the camshaft sprocket.
6) Disconnect the vacuum hose from the vacuum pump.
7) Remove the camshaft carrier and gasket from the cylinder head.
8) Remove the dowel pin from the cylinder head.
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4. Vacuum pump removal
1) Remove the vacuum pump from the camshaft carrier.
Caution
Seal the pipes, hoses, and ports to prevent the intrusion of foreign material.
5. Camshaft removal
1) Measure the axial direction clearance of the camshaft gear and camshaft cap using a feeler gauge.
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Note
If the measured value exceeds the limit, replace the camshaft.
Standard: 0.050 to 0.130 mm { 0.0020 to 0.0051 in }
Limit: 0.250 mm { 0.0098 in }
Legend
1. Camshaft
2. Camshaft cap
3. Camshaft gear
2) Use the M5 lock bolt to secure the inlet camshaft gear.

Legend
1. M5 bolt
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3) Remove the camshaft cap from the camshaft carrier.
Note
Check that there are installation position markings on the camshaft caps.
4) Remove the inlet camshaft and exhaust camshaft from the camshaft carrier.
Caution
Take measures to prevent the inlet and exhaust sides from becoming mixed up.
Legend
1. Camshaft cap
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2. Inlet camshaft
3. Exhaust camshaft
5) Remove the camshaft sprocket from the exhaust camshaft.
Legend
2. M8 bolt
Camshaft disassembly (RZ4E-TC)
1. Camshaft gear disassembly
1. Inlet camshaft sub gear disassembly
1) Remove the M5 lock bolt from the inlet camshaft gear.
2) Secure the camshaft in a vise using an aluminum clasp, etc.
3) Remove the snap ring from the inlet camshaft main gear using snap ring pliers.
Caution
Do not damage the cam and journal sections of the camshaft.
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4) Remove the inlet camshaft sub gear and spring from the camshaft main gear.
Legend
1. Inlet camshaft sub gear
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2. Spring
3. Inlet camshaft main gear
Camshaft inspection (RZ4E-TC)
1. Camshaft inspection
1. Visual inspection
1) Inspect the camshaft journal, cam section, and gear sections for the following.
Damage
Wear
Note
Replace the camshaft if an abnormal condition is found.
2) Inspect the camshaft sprocket and inlet camshaft sub gear for the following.
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Damage
Wear
Note
Replace the camshaft sprocket if an abnormal condition is found.
2. Camshaft runout measurement
1) Put the camshaft on the V-block.
2) Slowly turn the camshaft to measure runout of the dial gauge.
Limit: 0.05 mm { 0.0020 in }
Note
3. Cam lobe height measurement
1) Measure the height of the cam lobe using a micrometer.
Note
Cam lobe height

Standard 40.287 mm {
value 1.5861 in }
Inlet
39.287 mm {
Limit
1.5467 in }
Standard 40.552 mm {
value 1.5965 in }
Exhaust
39.552 mm {
Limit
1.5572 in }
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4. Camshaft journal measurement
1) Measure the diameter of the camshaft journal using a micrometer.
Camshaft journal diameter

Standard 23.943 to 23.964 mm {
value 0.9426 to 0.9435 in }
Limit 23.843 mm { 0.9387 in }
0.05 mm { 0.0020 in }
Limit
Uneven wear
Note
2) Measure the inner diameter of the camshaft cap using a cylinder gauge.
3) Calculate the clearance from the camshaft cap inner diameter and journal diameter measurements.
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Clearance between the camshaft
cap inner diameter and the
journal diameter
Standard 0.036 to 0.078 mm {
value 0.0014 to 0.0031 in }
Limit 0.12 mm { 0.0047 in }
Note
If the measured value exceeds the limit, replace the camshaft or camshaft carrier.
Camshaft reassembly (RZ4E-TC)
1. Camshaft gear reassembly
1. Inlet camshaft sub gear assembly
1) Secure the camshaft in a vise using an aluminum clasp, etc.
Caution
Do not damage the cam and journal sections of the camshaft.
2) Install the inlet camshaft sub gear and spring to the camshaft main gear.
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Legend
1. Inlet camshaft sub gear

2. Spring
3. Inlet camshaft main gear
3) Install the snap ring to the inlet camshaft main gear using snap ring pliers.
4) Turn the inlet camshaft sub gear using the special tool until the M5 bolt holes are aligned between the inlet
camshaft main gear and inlet camshaft sub gear.
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5) Tighten the M5 bolt using the special tool, and check that the inlet camshaft sub gear does not move.
SST: 5-8840-3179-0 - scissors gear spring wrench
Legend
1. M5 bolt
Camshaft installation (RZ4E-TC)
1. Component views
Camshaft
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Part name
1. Camshaft cap
2. Bolt
4. Bolt
6. Bolt
7. Inlet camshaft
8. Bolt
9. Gasket
10. Cylinder head
11. Bolt
12. Vacuum pump
13. Bolt
Tightening torque
2: 7.0 N・m { 0.7 kgf・m / 62 lb・in }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
6: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 7.0 N・m { 0.7 kgf・m / 62 lb・in }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Camshaft installation
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1) Install the camshaft sprocket to the exhaust camshaft.
Note
Install so that it is aligned with the pin of the exhaust camshaft gear end surface.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Legend
2. M8 bolt
Fixing position
2) Apply engine oil to the camshaft journal and No. 5 journal thrust receiving section.
3) Install the camshaft to the camshaft carrier with the inlet camshaft and exhaust camshaft markings upward.
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Note
Check that the inlet camshaft gear and the exhaust camshaft gear timing marks are aligned.
Legend
1. Exhaust camshaft gear

2. Inlet camshaft gear
3. Timing mark
4) Apply engine oil to the following parts.
Camshaft cap sliding surface

Camshaft journal
Threaded portion and seating surface of bolts
5) Install the camshaft cap to the camshaft carrier.
Note
Check the journal positions marked on the camshaft caps and install.
Tightening torque: 7.0 N・m { 0.7 kgf・m / 62 lb・in }
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6) Remove the M5 lock bolt from the inlet camshaft gear.
3. Vacuum pump installation
1) Install the vacuum pump to the camshaft carrier.
4. Camshaft carrier installation
1) Install the dowel pin to the cylinder head.
Note
Insert until full contact is made.
2) Check that the inlet camshaft and the exhaust camshaft notches are aligned with the camshaft cap alignment
marks.
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Legend
1. Alignment mark
2. Notch
3) Confirm that the 4 gaskets are installed to the lower surface of the camshaft carrier.
4) Referring to the diagram, apply ThreeBond 1207B to the cylinder head.
Caution
Within 5 minutes of applying the liquid gasket, install the camshaft carrier.
Standard value
a: 4.0 to 5.0 mm { 0.157 to 0.197 in } Bead width
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b: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height
5) Apply engine oil to the threaded portions and seating surfaces of the bolts.
6) Temporarily tighten the camshaft carrier to the cylinder head in the order shown in the diagram.
Note
Check the rocker arm for position misalignment before and after installation.
7) Check that the camshaft carrier has been seated on the cylinder head.
8) Final tighten the camshaft carrier to the cylinder head in the order shown in the diagram.

9) Connect the vacuum hose to the vacuum pump.
10) Align the paint markings and install the timing chain to the camshaft sprocket.
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Note
Align to the marked position before removal.
Legend
2. Timing chain
3. Paint marking
11) Install the timing chain tensioner and gasket to the flywheel housing.
Caution
Do not reuse the gasket.

Legend
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2. Gasket
12) Install the cam angle sensor rotor to the inlet camshaft.
Note
Install by aligning with the positioning pin.
Fixing position
5. Cylinder head cover installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) cylinder head cover installation".
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Crankcase removal (RZ4E-TC)
1. Component views
Crankcase
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Part name
1. Bolt
2. Upper crankcase plate
3. Bolt
4. Lower crankcase plate
5. Crankcase
6. Oil pan
7. Bolt
8. Nut
9. Gasket
10. Drain bolt
Tightening torque
1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
7: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
8: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 83.3 N・m { 8.5 kgf・m / 61 lb・ft }
2. Timing chain removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Timing chain removal".
3. Oil pan removal
1) Remove the oil pan from the crankcase.
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4. Crankcase removal
1) Remove the crankcase from the cylinder block.

2) Remove the baffle plate from the crankcase.
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Crankcase inspection (RZ4E-TC)
1. Crankcase inspection
1. Cleaning
1) Gently remove the liquid gasket from the crankcase installation surface.
Caution
Do not damage the crankcase.
1) Inspect the crankcase for the following.
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Cracking
Damage
Note
Replace the crankcase if an abnormal condition is found.
Crankcase installation (RZ4E-TC)
1. Component views
Crankcase
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Part name
1. Bolt
3. Bolt
5. Crankcase
6. Oil pan
7. Bolt
8. Nut
9. Gasket
10. Drain bolt
Tightening torque
1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
7: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
8: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 83.3 N・m { 8.5 kgf・m / 61 lb・ft }
2. Crankcase installation
1) Install the baffle plate to the crankcase.
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2) Referring to the diagram, apply ThreeBond 1207B to the crankcase.
Standard: 4.0 to 5.0 mm { 0.157 to 0.197 in } Bead width
Standard: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height
Caution
Install the crankcase within 5 minutes of applying the liquid gasket.
3) Referring to the diagram, apply ThreeBond 1207B to the cylinder block and front cover mating surface.
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Legend
1. Front cover
2. Cylinder block
Standard value
a: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height
b: 4.0 to 5.0 mm { 0.157 to 0.197 in } Bead width
4) Install the crankcase to the cylinder block.
Caution
Carefully wipe away any gasket that has leaked out from between the aligning surfaces of the cylinder
block and crankcase.
3. Oil pan installation

1) Referring to the diagram, apply ThreeBond 1207B or equivalent to the oil pan.
Caution
After applying the liquid gasket, install the oil pan within 5 minutes.
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Legend
2) Install the oil pan to the crankcase.
4. Timing chain installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Timing chain installation".

Crankshaft removal (RZ4E-TC)
1. Component views
Crankshaft
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Part name
1. Bolt
2. Bearing cap
3. Thrust bearing
4. Lower crankshaft bearing
5. Crankshaft
6. Upper crankshaft bearing
7. Thrust bearing
Tightening torque
1-1: 50 N・m { 5.1 kgf・m / 36.9 lb・ft }
1-2: 60 to 90 °
2. Piston removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Piston removal".
3. Crankshaft removal
1) Measure the crankshaft thrust clearance using a feeler gauge.
Note
Replace the thrust bearing if the measured value is outside the standard range.
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2) Loosen the bearing cap bolts in the order shown in the diagram.
3) Remove the bearing cap from the cylinder block.

Caution
Do not reuse the bearing cap bolt.
However, only when a new bearing cap bolt is used to measure the oil clearance, the bearing cap bolt
can be reused.
4) Remove the lower crankshaft bearing from the bearing cap.
Note
If reusing the crankshaft bearings, put number tags on the crankshaft bearings.
5) Remove the crankshaft from the cylinder block.
6) Remove the thrust bearing from the cylinder block.
7) Remove the upper crankshaft bearing from the cylinder block.
Note
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Crankshaft disassembly (RZ4E-TC)
1. Crank gear removal
1) Remove the crank gear from the crankshaft.
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Crankshaft inspection (RZ4E-TC)
1. Crankshaft inspection
1. Cleaning
1) Clean the following parts.
Crankshaft journal
Crankshaft lower bearing
Crankshaft upper bearing
Crank pin
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1) Inspect the crankshaft journal and crank pin for the following.
Wear
Damage
Clogged oil port
2) Inspect the crankshaft lower bearing for the following.
Wear
Damage
Note
Replace the bearing as a set if an abnormal condition is found.
3) Inspect the crankshaft upper bearing for the following.
Wear
Damage
Note
Replace the bearing as a set if an abnormal condition is found.
4) Clean the crankshaft with organic solvent.
Caution
Thoroughly wipe up any oil from the journal and crank pin.
5) Prepare a test solution (5 to 10% copper chloride ammonium).
Warning
Do not allow the inspection solution to come in contact with your eyes, hands, clothes, etc.
If the inspection solution has gotten in your eyes, immediately wash with a large amount of fresh
water and seek medical treatment.
6) Apply inspection solution to the journal and crank pin using an oil can.
Caution
Level the crankshaft.
Do not allow any inspection solution to adhere near the oil port.
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Legend
1. Drip prohibited area

2. Test liquid drop section
3. Pin or journal moving surface
7) Let the inspection solution sit for 30 to 40 seconds before inspecting to see if the color has changed.
Note
If the inspection solution changed to a copper color, replace the crankshaft.
8) Wipe away the inspection solution from the crankshaft using a cloth, etc., and clean the crankshaft using water,
steam, etc.
Caution
Perform immediately after inspection.
3. Crankshaft runout measurement
1) While slowly turning the crankshaft, measure the runout at the crankshaft center using a dial gauge.
Note
If the measured value exceeds the limit, replace the crankshaft.
Standard: 0.05 mm or less { 0.0020 in or less }

4. Crankshaft journal and crank pin measurement
Caution
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Because the journal sections and crank pins have undergone soft nitriding (tufftriding) treatment, do
not repair by grinding.
1) Referring to the diagram, measure the 4 crankshaft journal locations using a micrometer.
Standard: 57.909 to 57.924 mm { 2.2799 to 2.2805 in } No. 3 journal section
Standard: 57.923 to 57.938 mm { 2.2804 to 2.2810 in } Other than the No. 3 journal
2) Referring to the diagram, measure the 4 crankshaft crank pin locations using a micrometer.
Standard: 50.915 to 50.930 mm { 2.0045 to 2.0051 in } Pin section
5. Oil clearance measurement
1) Install the crankshaft upper bearing to the cylinder block.
2) Install the crankshaft to the cylinder block.

Caution
Level the crankshaft to install.
3) Place PLASTIGAUGE on the crankshaft journal.
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4) Install the crankshaft lower bearing to the bearing cap.
5) Install the bearing caps to the cylinder block in the order shown in the diagram.
Note
Install so that the bearing cap front mark faces the front of the engine.
Legend
1. No. 1
2. No. 2
3. No. 3
4. No. 4
5. No. 5
6) Apply engine oil to the threaded portions and seating surfaces of the bearing cap bolts.
7) Tighten the bearing cap bolts to the cylinder block in the order shown in the diagram.
Caution
can be reused.
Carefully place the bearing cap on the cylinder block.
Do not rotate the crankshaft after tightening the bearing caps.
Tightening torque: 50 N・m { 5.1 kgf・m / 36.9 lb・ft } 1st time
Tightening Angle : 60 to 90 ° 2nd time
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Caution
Remove carefully.
9) Measure the widest point of the flattened PLASTIGAUGE, and inspect the oil clearance of the crankshaft
journal section.
10) Measure the maximum width portion of the PLASTIGAUGEs crushed by the tightening of the bearing caps.
Note
Replace all of the crankshaft bearings or the crankshaft if the measured value exceeds the limit.
Standard: 0.030 to 0.056 mm { 0.0012 to 0.0022 in } Other than the No. 3 journal
Standard: 0.044 to 0.070 mm { 0.0017 to 0.0028 in } No. 3 journal

11) Remove any PLASTIGAUGE adhering to the following parts.
Crankshaft lower bearing
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Crank pin
Crankshaft reassembly (RZ4E-TC)
1. Crank gear installation
1) Heat the crank gear to the standard temperature.
Standard: 230 ℃ or less { 446 °F or less }
2) Install the crank gear to the crankshaft.
Note
Align the crankshaft pin position and the groove of the crank gear, and then insert until contact is
made with the collar section.
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3) Check the tapping amount of the crank gear.

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Crankshaft installation (RZ4E-TC)
1. Component views
Crankshaft
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Part name
1. Bolt
2. Bearing cap
3. Thrust bearing
5. Crankshaft
7. Thrust bearing
Tightening torque
1-1: 50 N・m { 5.1 kgf・m / 36.9 lb・ft }
1-2: 60 to 90 °
2. Crankshaft installation
If replacing the crankshaft bearing, select the crankshaft bearing grade.
1) Check the cylinder block journal hole inner diameter grade.
Note
Grade 1, 2, or 3 is marked on the bottom surface of the cylinder block.
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Legend
1. No. 1
2. No. 2
3. No. 3
4. No. 4
5. No. 5
Cylinder block journal hole inner

diameter grade
Marking Journal diameter
61.992 to 62.000 mm {
1
2.4406 to 2.4409 in }
61.984 to 61.991 mm {
2
2.4403 to 2.4406 in }
61.976 to 61.983 mm {
3
2.4400 to 2.4403 in }
2) Check the crankshaft journal diameter grade.
Note
The crankshaft journal grade marking is marked on each crankshaft journal.
Legend
1. No. 1
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2. No. 2
3. No. 3
4. No. 4
5. No. 5
Crankshaft journal diameter grade

Journal diameter
Marking Other than
the No. 3 No. 3 journal
journal
57.933 to 57.919 to
57.938 mm { 57.924 mm {
1
2.2808 to 2.2803 to
2.2810 in } 2.2805 in }
57.928 to 57.914 to
57.933 mm { 57.919 mm {
2
2.2806 to 2.2801 to
2.2808 in } 2.2803 in }
57.923 to 57.909 to
57.928 mm { 57.914 mm {
3
2.2804 to 2.2799 to
2.2806 in } 2.2801 in }
3) Inspect the crankshaft bearing for the following.
Size
Lot number
Code
Legend
1. Size
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2. Lot No.
3. Code
4) Select the crankshaft bearing based on the journal hole inner diameter grades of the crankshaft journal and
cylinder block.
Bearing selection table

Crankshaft journal
grade
1 2 3
Code: Code: Code:
1
Cylinder 3 3 4
block Code: Code: Code:
2
journal 2 2 3
grade Code: Code: Code:
3
1 1 2
5) Install the crankshaft upper bearing to the cylinder block.
Note
Check that the crankshaft upper bearing has oil holes and an oil groove.
Caution
Do not confuse the difference of bearing shapes.
6) Apply engine oil to the crankshaft upper bearing surface.
Caution
Do not apply engine oil to the cylinder block installation surface and back surface of the bearing.
7) Thoroughly apply engine oil to the crankshaft journal section.
8) Install the crankshaft to the cylinder block.
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9) Thoroughly apply engine oil to the thrust bearing.
10) Install the thrust bearings to the front and rear sides of the cylinder block No. 4 journal.
Caution
Install so that the oil groove of the thrust bearing touches the crankshaft.
Legend
1. Thrust bearing
11) Install the lower crankshaft bearing to the bearing cap.
12) Apply engine oil to the lower crankshaft bearing surface.
Caution
Do not apply engine oil to the bearing cap installation surface and back surface of the bearing.
13) Install the thrust bearings to the front and rear sides of bearing cap No. 4.
Legend
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1. Thrust bearing
14) Install the bearing caps to the cylinder block in the order shown in the diagram.
Note
Install so that the bearing cap front mark faces the front of the engine.
Legend
1. No. 1
2. No. 2
3. No. 3
4. No. 4
5. No. 5
16) Tighten the bearing cap bolts to the cylinder block in the order shown in the diagram.
Caution
can be reused.
Tightening torque: 50 N・m { 5.1 kgf・m / 36.9 lb・ft } 1st time
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17) Confirm that the crankshaft turns smoothly.
Caution
After installing the piston and connecting rod, rotate the crankshaft and make sure that there is no
interference with the oil jet.
3. Piston installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Piston installation".

Crankshaft pulley removal (RZ4E-TC)
1. Component views
Crankshaft pulley
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Part name
1. Bolt
2. Washer
3. Crankshaft pulley
Tightening torque
1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
1-2: 60 to 90 °
2. Preliminary and post procedures
1. Preliminary procedures
1) Open the engine hood.
2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.
Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function
3) Raise the vehicle.
3. Underguard removal
Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".
4. Coolant drain
Warning
Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
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burns caused by the release of steam or hot water.
When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.
1) Remove the radiator cap from the radiator.
2) Loosen the radiator drain plug, and drain the coolant into a pan.
3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.
Legend
1. Drain plug
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4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.
5) Tighten the drain plug on the cylinder block.
Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }
6) Tighten the radiator drain plug.
5. Starter motor removal
Refer to "1.Engine 1J.Electrical(RZ4E-TC) starter motor removal".
6. Air cleaner removal
1) Disconnect the connector from the MAF and IAT sensor.
2) Disconnect the blow-by hose from the air cleaner duct.
3) Disconnect the air cleaner duct from the air cleaner and turbocharger.
4) Remove the air cleaner from the vehicle.

Legend
1. Air cleaner
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2. MAF and IAT sensor
3. Blow-by hose
4. Air cleaner duct
7. Radiator reserve tank removal
1) Disconnect the radiator reserve tank hose from the radiator.
2) Remove the radiator reserve tank from the upper fan guide.
8. Radiator upper hose removal
1) Remove the radiator upper hose from the water outlet pipe and radiator.
Legend
1. Radiator upper hose
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9. Fan guide removal
1) Remove the fan shroud from the fan guide.
2) Remove the fan guide from the radiator.
Legend
1. Fan guide
2. Clip
3. Fan shroud
10. Cooling fan belt removal
Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt removal".
11. Cooling fan removal

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.
12. Crankshaft pulley removal
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1) Install the special tool to the starter motor installation section of the flywheel housing.
SST: 5-8840-3174-0 - crankshaft stopper
2) Remove the crankshaft pulley from the crankshaft.
Caution
Do not reuse the bolt.
Crankshaft pulley installation (RZ4E-TC)
1. Component views
Crankshaft pulley
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Part name
1. Bolt
2. Washer
Tightening torque
1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
1-2: 60 to 90 °
2. Crankshaft pulley installation
2) Install the crankshaft pulley to the crankshaft in the order shown in the diagram.
Note
Secure the ring gear to prevent the crankshaft from turning when tightening the crankshaft pulley
bolt.
Caution
Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft } 1st time
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3) Remove the special tool from the starter motor installation section of the flywheel housing.
3. Cooling fan installation
1) Install the cooling fan clutch and cooling fan as a set to the water pump.
4. Cooling fan belt installation
Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt installation".

5. Fan guide installation
1) Install the fan guide to the radiator.
2) Install the fan shroud to the fan guide.
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Legend
1. Fan guide
2. Clip
3. Fan shroud
6. Radiator upper hose installation
1) Install the radiator upper hose to the water outlet pipe and radiator.
Legend

7. Radiator reserve tank installation
1) Clean the radiator reserve tank using detergent.
Note
Wash with clean water, and drain the water.
2) Install the radiator reserve tank to the upper fan guide.
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3) Connect the radiator reserve tank hose to the radiator.
8. Air cleaner installation
1) Install the air cleaner to the vehicle.
Legend
1. Air cleaner
3. Blow-by hose
4. Air cleaner duct
2) Referring to the diagram, align the alignment mark positions and connect the air cleaner duct to the air cleaner
and turbocharger.
Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in }
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Legend
1. Alignment mark
3) Connect the blow-by hose to the air cleaner duct.
4) Connect the connector to the MAF and IAT sensor.
9. Underguard installation
Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".
1. Post procedures
1) Lower the vehicle.
2) Connect the battery cable to the battery negative terminal.
3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.
Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".
Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".
4) Close the engine hood.

11. Coolant filling
1) Fill with engine coolant up to the radiator filler neck.
Note
Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
Caution
Fill slowly to prevent air from entering the system.
2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.
Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.
Caution
Repeat the operation until the coolant level no longer drops.
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3) Add engine coolant up to the MAX line of the radiator reserve tank.
Legend
1. Radiator reserve tank

2. MAX line
3. MIN line
4) Install the radiator cap to the radiator.
5) Start and idle the engine.
Caution
Idle the engine for 5 minutes or more.
6) Stop the engine.

Warning
Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.
10) Start the engine.
11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.
12) With the engine running, check that the thermostat valve is open.
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Note
Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.
Caution
Do not try determining it by using only an engine coolant temperature gauge.
13) Idle the engine for 5 minutes.
14) Stop the engine.
Warning
Note
19) Repeat steps 10 to 18 until the coolant level no longer lowers.
Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
12. Starter motor installation

Refer to "1.Engine 1J.Electrical(RZ4E-TC) starter motor installation".
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Crankshaft rear oil seal removal (RZ4E-TC)
1. Component views
Crankshaft rear oil seal
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Part name
1. Crankshaft rear oil seal
2. Flywheel removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Flywheel removal".
3. Crankshaft rear oil seal removal
1) Remove the crankshaft rear oil seal and slinger from the crankshaft using the special tool.
Caution
Do not reuse the crankshaft rear oil seal.
Do not damage the oil seal installation surface of the crankshaft and flywheel housing.
SST: 5-8840-3177-0 - slinger puller
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Crankshaft rear oil seal installation (RZ4E-TC)
1. Component views
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Part name
2. Crankshaft rear oil seal installation
1) Install the crankshaft rear oil seal and slinger to the crankshaft using the special tool.
Caution
SST: 5-8840-3225-0 - oil seal installer
Note
5-8840-3178-0 combined with 5-8840-3221-0 can be used instead of 5-8840-3225-0.
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SST: 5-8840-3221-0 - sleeve
Sleeve dimension
Legend
1. Sleeve (5-8840-3178-0)
2. Sleeve (5-8840-3221-0/5-8840-3225-0)
3. 39 mm {1.54 in}
4. 35 mm {1.38 in}
2) Check the dimension of the crankshaft end face and the crankshaft rear oil seal end face.

Legend
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2. Flywheel housing
3. Standard value
4. Crankshaft rear slinger
5. Crankshaft
3. Flywheel installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Flywheel installation".

Crankshaft front oil seal removal (RZ4E-TC)
1. Component views
Crankshaft front oil seal
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Part name
1. Bolt
2. Oil seal cover
3. Crankshaft front oil seal
Tightening torque
1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Crankshaft pulley removal".
3. Crankshaft front oil seal removal
1) Remove the oil seal cover from the front cover.

2) Remove the crankshaft front oil seal and slinger as a set from the crankshaft using the special tool.
Caution
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Do not damage the oil seal installation surface of the crankshaft and front cover.

Crankshaft front oil seal installation (RZ4E-TC)
1. Component views
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Part name
1. Bolt
2. Oil seal cover
Tightening torque
1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
2. Crankshaft front oil seal installation
1) Install the crankshaft front oil seal and slinger to the crankshaft using the special tool.
Caution
Do not reuse the crankshaft front oil seal.
2) Check the dimension of the crankshaft end face and crankshaft front oil seal end face.
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Legend
1. Stud bolt
2. Washer
3. Sleeve
4. Bolt
5. Front cover
7. Crankshaft
8. Crankshaft front slinger
9. Adapter
Standard value
a: 44.9 to 45.5 mm { 1.768 to 1.791 in }
3) Install the oil seal cover to the front cover.

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Crankshaft pulley installation".
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Cylinder block removal (RZ4E-TC)
1. Component views
Cylinder block
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Part name
1. Cylinder block
2. Front cover removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) front cover removal".
3. Oil pump removal
1) Remove the oil pump from the cylinder block.

4. Piston removal
1) Remove any carbon from the top of the cylinder bore using a scraper.
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2) Turn the crankshaft to align it to bottom dead center.
3) Remove the connecting rod bearing cap from the connecting rod.
4) Remove the connecting rod bearing from the connecting rod bearing cap.
Note
Organize the removed bearings according to the cylinders using tags, etc.
5) Turn the crankshaft to align it to top dead center.
6) Remove the piston and connecting rod from the cylinder block.
Note
Pull out the piston and connecting rod from the cylinder head side.
Push out from the lower end of the connecting rod by using the handle of a hammer, etc., so as not to
damage the bearing.
Caution
When pushing out the connecting rod, do not damage the oil jet and cylinder inner surface.
5. Crankshaft removal
1) Measure the crankshaft thrust clearance using a feeler gauge.
Note
Replace the thrust bearing if the measured value is outside the standard range.
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2) Loosen the bearing cap bolts in the order shown in the diagram.
Caution
can be reused.
4) Remove the lower crankshaft bearing from the bearing cap.
Note
5) Remove the crankshaft from the cylinder block.
6) Remove the thrust bearing from the cylinder block.
7) Remove the upper crankshaft bearing from the cylinder block.
Note
6. Idle gear removal
1) Remove the timing chain guide from the cylinder block.
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2) Apply the dial gauge to the idle gear tooth to be measured, and gently move the gear left and right to measure
the fluctuation of the dial gauge.
Note
If the measured value exceeds the limit, replace the idle gear.
Limit: 0.30 mm { 0.0118 in }
3) Measure the idle gear axial direction clearance using a feeler gauge.
Note
Replace the idle gear or thrust collar if the measured value exceeds the limit.
Limit: 0.20 mm { 0.0079 in }

4) Install the M5 bolts for securing the sub gear to idle gear A.
Legend
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1. M5 bolt
5) Remove the flange from idle gear A.
6) Remove idle gear A from the idle gear A shaft.
7) Remove the idle gear A shaft from the cylinder block.
Legend
1. Front mark
8) Remove the flange from the cylinder block.

Legend
1. Front mark
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7. Fuel supply pump removal
1) Disconnect the connector from the fuel temperature sensor.
2) Disconnect the connector from the FRP regulator.
Legend
1. FRP regulator connector

2. Fuel temperature sensor connector
3) Disconnect the fuel suction hose from the fuel supply pump.
4) Disconnect the fuel leak-off hose from the fuel supply pump.
Legend
1. Fuel leak-off hose
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2. Fuel suction hose
5) Remove the fuel supply pump and adapter from the cylinder block.
Caution
Do not hold the high pressure pipe.
Legend
1. Fuel supply pump

2. Adapter
8. Oil filter removal
1) Remove the oil filter and gasket from the cylinder block.
Legend
1. Oil filter
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2. Gasket
3. Cylinder block
4. Clip
9. EGR cooler water pipe removal
1) Remove EGR cooler water pipe B and EGR cooler water hose from the cylinder block.
Legend
1. EGR cooler water pipe B

2. EGR cooler water hose
10. Engine foot removal
1) Remove the right side engine foot from the cylinder block.
Legend
1. Right side engine foot
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2. Cylinder block
2) Remove the left side engine foot from the cylinder block.
Legend
1. Left side engine foot

2. Cylinder block
11. Piston oil jet removal
1) Remove the piston oil jet from the cylinder block.
Caution
Do not damage or deform the oil jet pipe nozzle.
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Cylinder block inspection (RZ4E-TC)
1. Cylinder block inspection
1. Cleaning
1) Carefully remove the liquid gasket, water stains, or foreign material on the top surface of the cylinder block.
Caution
Do not damage the cylinder block.
1) Inspect the cylinder block for the following.
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Cracking
Damage
Note
Perform a dye penetrant check as necessary.
Replace the cylinder block if cracking or damage is found.
3. Cylinder block deformation measurement
1) Remove the dowel pin from the cylinder block.
2) Measure the 4 sides and 2 locations in a diagonal line of the cylinder block top surface using a simple straight
ruler and feeler gauge.
Note
If the measured value exceeds the limit, replace the cylinder block.
Caution
Do not polish the cylinder block top surface.
Limit: 0.075 mm { 0.00295 in }
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Legend
1. Simple straight ruler

2. Feeler gauge
4. Cylinder block inner diameter measurement
1) Measure the most worn section of the cylinder bore in the measurement area using a cylinder gauge.
Note
Measure the entire circumference in the measurement area, and read the value for the most worn
section.
Legend
1. Measurement area
Legend
a. Thrust direction
b. Radial direction
Measurement position
c: 10 mm { 0.39 in }
d: 15 mm { 0.59 in }
2) Calculate the average based on the measured values in the thrust direction and radial direction.
Limit: 80.055 mm { 3.15177 in }
Note
If the measured value exceeds the limit, replace the cylinder block.
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Cylinder block installation (RZ4E-TC)
1. Component views
Cylinder block
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Part name
1. Cylinder block
2. Piston oil jet installation
1) Install the oil jet pipe to the cylinder block.
Caution
Do not damage or deform the oil jet pipe nozzle.
After installing the crankshaft, piston, and connecting rod, rotate the crankshaft and make sure that
there is no oil jet pipe interference.
Tightening torque: 20 N・m { 2.0 kgf・m / 14.8 lb・ft }

3. Crankshaft installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) crankshaft installation".
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1) Install the connecting rod bearing to the connecting rod.
2) Apply engine oil to the sliding surface of the connecting rod bearing.
Caution
Do not apply engine oil to the connecting rod bearing installation surface and the back surface of the
bearing.
3) Sufficiently apply the engine oil to the following locations.
Piston ring
Piston ring groove
Piston side surface
Cylinder bore surface
4) Turn the crankshaft in the forward direction and align to top dead center.
5) Install the piston to the cylinder block using the special tool.
Note
Face the piston front mark towards the front.
Use the piston ring compressor to insert the piston into the cylinder block.
SST: 5-8840-9018-0 - piston setting tool

Caution
When pushing the piston, do not allow the connecting rod to interfere with the oil jet.
If the crank pin is at bottom dead center, the connecting rod may hit and damage the oil jet.
Do not damage the cylinder block inner surface.
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6) Install the connecting rod bearing to the bearing cap.
Caution
bearing.
9) Temporarily tighten the bearing caps to the connecting rods after matching their cylinder numbers.
Caution
Do not reuse the connecting rod bolts.
10) Final tighten the bearing cap bolts to the connecting rod in the order shown in the diagram, using a torque
wrench and the special tool.
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11) Turn the crankshaft and check that it turns smoothly without interference.
Caution
Check that there is no oil jet deformation and that there is no interference with other parts.
5. Engine foot installation
1) Install the left side engine foot to the cylinder block.
Legend

2. Cylinder block
2) Install the right side engine foot to the cylinder block.
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Legend

2. Cylinder block
6. EGR cooler water pipe installation
1) Install EGR cooler water pipe B and EGR cooler water hose to the cylinder block.
Legend

7. Oil filter installation

1) Install the oil filter and gasket to the cylinder block in the order shown in the diagram.
Caution
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8. Fuel supply pump installation
1) Install the fuel supply pump and adapter to the cylinder block.
Legend
1. Fuel supply pump

2. Adapter
2) Connect the fuel leak-off hose to the fuel supply pump.
3) Connect the fuel suction hose to the fuel supply pump.

Legend
1. Fuel leak-off hose
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2. Fuel suction hose
4) Connect the connector to the FRP regulator.
5) Connect the connector to the fuel temperature sensor.
Legend
1. FRP regulator connector

2. Fuel temperature sensor connector
9. Idle gear installation
1) Apply engine oil to the threaded portions and the bearing surfaces of the bolts.
2) Install the flange to the cylinder block with the front mark facing toward the front.

Legend
1. Front mark
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3) Apply engine oil to the idle gear A shaft.
4) Install the idle gear A shaft to the cylinder block by aligning the cylinder block and idle gear A shaft oil holes.
5) Install idle gear A to the idle gear A shaft by aligning the mark on idle gear A.
Crank gear side alignment mark
Legend
1. Idle gear A
2. Crank gear
Supply pump gear side alignment mark

Legend
1. Supply pump gear
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2. Idle gear A
6) Install the flange to idle gear A with the front mark facing toward the front.
7) Apply engine oil to the threaded portions and seating surfaces of the idle gear A bolts.
8) Temporarily tighten idle gear A to the idle gear A shaft and cylinder block.
Legend
1. Front mark
9) Final tighten idle gear A to the cylinder block.
10) Remove the M5 bolts for securing the sub gear from idle gear A.
Legend
1. M5 bolt
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11) Install the timing chain guide to the cylinder block.
10. Oil pump installation
1) Install the oil pump to the cylinder block.

11. Front cover installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) front cover installation".
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Cylinder head cover removal (RZ4E-TC)
1. Component views
Cylinder head cover
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Part name
1. Oil filler cap

2. Oil filler cap gasket
3. Oil seal
4. Nut
5. Cylinder head cover
6. Gasket
7. O-ring
8. Gasket
9. Gasket
10. Bolt
Tightening torque
4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
2. Injector removal
Refer to "1.Engine 1C.Fuel System(RZ4E-TC) injector removal".
1) Disconnect the blow-by hose from the cylinder head cover.
2) Disconnect the harness clip from the cylinder head cover.
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3) Remove the cylinder head cover and gasket from the cylinder head.
4) Remove the oil seal from the cylinder head cover.

Cylinder head cover installation (RZ4E-TC)
1. Component views
Cylinder head cover
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Part name
1. Oil filler cap

3. Oil seal
4. Nut
6. Gasket
7. O-ring
8. Gasket
9. Gasket
10. Bolt
Tightening torque
4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
1) Install the oil seal to the cylinder head cover.
2) Install the gasket to the camshaft carrier.
Note
Face the protruding section of the gasket toward the camshaft carrier side, and install.
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Legend
1. Gasket
2. Camshaft carrier
3) Apply engine oil to the cylinder head cover O-ring.
Caution
Do not reuse the O-ring.
Legend
1. O-ring
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4) Referring to the diagram, apply ThreeBond 1207B to the cylinder head mating surface.
Caution
Install the cylinder head cover within 5 minutes of applying liquid gasket.
Remove any dirt or dust from the oil seal section on the injector connector side.
Standard value
c: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height
Dimensions
a: 5.0 mm { 0.197 in }
5) Temporarily tighten the cylinder head cover to the cylinder head in the order shown in the diagram.
Caution
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6) Final tighten the cylinder head cover to the cylinder head in the order shown in the diagram.
7) Connect the harness clip to the cylinder head cover.

8) Connect the blow-by hose to the cylinder head cover.
3. Injector installation
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Refer to "1.Engine 1C.Fuel System(RZ4E-TC) injector installation".
Cylinder head removal (RZ4E-TC)
1. Inlet cover removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) inlet cover removal".
2. Injection pipe removal
1) Clean the injector and injector bracket using an air blower.
2) Remove the injection pipes from the injector and common rail (fuel rail).
Caution
Do not reuse the injection pipe.
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3. Injector removal
1) Disconnect the connector from the injector.
2) Remove the injector leak-off hose from the injector leak-off pipe and fuel leak-off pipe.
Legend
1. Injector leak-off hose
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3) Remove the clip from the injector.
4) Remove the injector leak-off pipe from the injector.
Caution
Do not reuse the injector leak-off pipe or clip.
Legend
1. Clip
2. Injector leak-off pipe
3. Injector
5) Remove the injector clamp from the injector.

Legend
1. Washer
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2. Injector clamp
6) Clean the injector clamp bolt hole using an air blower.
Caution
Do not to allow the intrusion of foreign material.
7) Remove the injector from the cylinder head.
Note
Store the removed injectors with the cylinder numbers attached.
Caution
Cover the exposed portion to prevent foreign material from getting into the fuel system.
Do not damage the injector nozzle.
Never touch the electromagnetic section of the injector because it causes performance reduction and
breakage.
8) Remove the gasket from the injector.

Legend
1. Injector
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2. Gasket
1) Disconnect the blow-by hose from the cylinder head cover.
2) Disconnect the harness clip from the cylinder head cover.
3) Remove the cylinder head cover and gasket from the cylinder head.
4) Remove the oil seal from the cylinder head cover.
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Legend
1. Air cleaner
3. Blow-by hose
4. Air cleaner duct
6. Vacuum hose removal

1) Disconnect the vacuum hose from the turbocharger control solenoid valve.
2) Remove the vacuum hose from the turbocharger and vacuum pipe.
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7. Catalytic converter removal
1. Euro4 specifications
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter removal".
8. Exhaust pipe removal
1. Except for Euro4 specifications
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) exhaust pipe removal".
9. Turbocharger water hose disconnect
1) Disconnect the turbocharger water feed hose from the water feed pipe and return pipe.
2) Disconnect the turbocharger water return hose from the water feed pipe and return pipe.
Legend
1. Turbocharger water feed hose
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2. Turbocharger water return hose
10. Turbocharger oil pipe removal
1) Remove the turbocharger oil pipe and gasket from the turbocharger and cylinder block.
Legend
1. Turbocharger oil pipe

2. Gasket
11. Turbocharger bracket removal
1) Remove the turbocharger bracket from the turbocharger and cylinder block.
12. Turbocharger heat protector removal
1) Remove the turbocharger heat protector from the turbocharger.
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13. Turbocharger removal
1) Remove the turbocharger and gasket from the exhaust manifold.

2) Remove the water feed and return pipe, as well as the gasket from the turbocharger.
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14. Exhaust manifold removal
1) Remove the heat protector from the exhaust manifold.

2) Remove the exhaust manifold and gasket from the cylinder head.
Caution
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15. Fuel leak-off pipe removal
1) Disconnect the fuel leak-off hose from the fuel leak-off pipe.
2) Remove the fuel leak-off pipe from the common rail (fuel rail) and flywheel housing.
Caution
Cover the exposed section to prevent the intrusion of foreign material.
Legend
1. Fuel leak-off pipe
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16. Fuel feed pipe removal
1) Remove the clip from the fuel feed pipe.
2) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).
Caution
Do not reuse the fuel feed pipe.
Legend
1. Fuel feed pipe
17. Common rail (fuel rail) removal

1) Remove the bracket from the cylinder head.
2) Disconnect the connector from the FRP sensor.
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3) Remove the common rail (fuel rail) from the cylinder head.
Caution
Do not hold the FRP sensor.
Take care not to damage the connector section of the FRP sensor.
18. Turbocharger control solenoid valve removal
2) Remove the connector from the turbocharger control solenoid valve.
3) Remove the turbocharger control solenoid valve from the bracket.

19. Thermostat housing removal
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1) Disconnect the connector from the engine coolant temperature sensor.
2) Remove the thermostat housing from the cylinder head and front cover.
Note
Fixing position
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2) Turn the crankshaft in the forward direction (clockwise) to align the inlet camshaft and the exhaust camshaft
notches to the camshaft cap alignment marks.
Caution
Do not rotate the crankshaft until the camshaft carrier is reinstalled.
Legend
1. Alignment mark
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2. Notch
3) Place the paint marking to the timing chain and camshaft sprocket.
Legend
2. Timing chain
3. Paint marking
Legend
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2. Gasket

21. Cylinder head removal
1) Disconnect the connector from the CMP sensor.
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2) Remove the plug from the cylinder head.
3) Remove the following parts from the cylinder head.
Timing chain tension lever
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Timing chain guide bolt
Timing chain lever pivot
Legend
1. Timing chain tension lever

2. Timing chain guide bolt
3. Timing chain lever pivot
4) Remove the cylinder head outside bolts from the cylinder head.
5) Loosen the cylinder head bolts in the order shown in the diagram.
Caution
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Do not reuse the cylinder head bolts.
6) Remove the cylinder head gasket from the cylinder head.
Caution
Do not reuse the cylinder head gasket.
Cylinder head disassembly (RZ4E-TC)
1. Component views
Cylinder head
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Part name
1. Valve stem end cap

2. Split collar
3. Spring upper seat
4. Valve spring
5. Valve stem oil seal
6. Spring lower seat
7. Valve
8. Cylinder head bolt
9. Bolt
10. Cylinder head
11. Cylinder head gasket
12. HLA
13. Rocker arm
Tightening torque
8-1: 115 N・m { 11.7 kgf・m / 85 lb・ft }
8-2: 115 N・m { 11.7 kgf・m / 85 lb・ft }
8-3: 90 to 120 °
8-4: 90 to 120 °
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. CMP sensor removal
1) Remove the fuel pipe bracket from the cylinder head.
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Legend
1. Fuel pipe bracket

2. CMP sensor
3. Cylinder head
2) Remove the CMP sensor from the cylinder head.

Legend
1. O-ring
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2. CMP sensor
3. Rocker arm removal
1) Remove the rocker arm from the HLA and valve stem end cap.
Legend
1. Rocker arm
3. HLA
4. HLA removal
1) Remove the HLA from the cylinder head.

Legend
1. HLA
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2. Cylinder head
2) Submerge the HLA into the container which contains the engine oil.
Caution
Do not lay the removed HLA on its side, but store the HLA standing upright.
Use new engine oil.
5. Valve spring removal
1) Remove the valve stem end cap from the valve stem.
2) Remove the split collar from the valve using the special tool.
SST: 5-8840-3171-0 - valve spring compressor
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3) Remove special tool from the cylinder head.
4) Remove the upper spring seat from the valve spring.
5) Remove the valve spring from the cylinder head.
6) Apply number tags to the valve springs.
6. Valve removal
1) Remove the inlet valve and the exhaust valve from the cylinder head.
Note
Store the removed valves with the number tags.
7. Valve stem oil seal removal
1) Remove the valve stem oil seal from the cylinder head using pliers.
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Caution
Do not reuse the valve stem oil seal.
2) Remove the lower spring seat from the cylinder head.
8. Valve seat insert removal
1) Arc weld the entire inner circumference of the valve seat insert.
2) Cool the valve seat insert for about 3 minutes.
Note
The valve seat insert becomes easier to remove due to the contraction caused by cooling.
Caution
Do not damage the cylinder head.
Legend
1. Arc welding
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2. Valve seat insert
3. Welding rod
9. Valve guide removal
1) Tap out the valve guides from the lower side of the cylinder head using the special tool.
SST: 5-8840-3172-0 - valve guide remover and installer

Cylinder head inspection (RZ4E-TC)
1. Valve guide inspection
1) Inspect the valve stem and valve guide inner diameter section for the following.
Scratches
Abnormal wear
Note
Replace the valve and valve guide as a set if a malfunction is found.
2. Valve guide measurement
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1) Measure the valve guide inner diameter using a dial gauge.
Limit: 5.565 mm { 0.2191 in }
Note
Replace the valve and valve guide as a set if a malfunction is found.
2. Valve inspection
1. Valve stem measurement
1) Measure the diameter of the valve stem using a micrometer.
Standard: 5.465 to 5.480 mm { 0.2152 to 0.2157 in } Inlet valve

Limit: 5.455 mm { 0.2148 in } Inlet valve
Standard: 5.459 to 5.474 mm { 0.2149 to 0.2155 in } Exhaust valve
Limit: 5.449 mm { 0.2145 in } Exhaust valve
Note
Replace the valve and valve guide as a set if the measured value is less than the limit.
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2. Clearance measurement between valve guide and valve stem
1) Measure the clearance from the difference between the valve guide inner diameter and the valve stem outer
diameter.
Standard: 0.020 to 0.050 mm { 0.0008 to 0.0020 in } Inlet valve
Standard: 0.026 to 0.056 mm { 0.0010 to 0.0022 in } Exhaust valve
Limit: 0.116 mm { 0.0046 in }
Note
Replace the valve and valve guide as a set if the measured value exceeds the limit.
3. Valve thickness measurement
1) Measure the thickness of the valve.
Standard: 1.0 mm { 0.0394 in } Inlet valve
Standard: 1.0 mm { 0.0394 in } Exhaust valve
Note
Replace the valve and valve guide as a set if the measured value is less than the limit.
4. Valve protrusion amount measurement
1) Remove the carbon and water deposit on the bottom surface of the cylinder head.
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2) Install the valve to the cylinder head.
3) Measure the valve protrusion amount from the cylinder head lower surface at the location where it is the
largest.
Standard: 0.7 mm { 0.0276 in }
Limit: 0.2 mm { 0.0079 in }
Note
Replace the valve seat or cylinder head if the measured value is less than the limit.
5. Valve seat contact width measurement
1) Measure the touching width of the valve seat.
Standard: 1.50 mm { 0.0591 in } Inlet valve

Standard: 1.50 mm { 0.0591 in } Exhaust valve
Note
If the contact surface is damaged or rough, repair the valve seat.
Replace the valve, valve guide, and valve seat as a set, or replace the valve and cylinder head if the
measured value exceeds the limit.
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6. Valve contact surface measurement
1) Measure the valve contact surface.
Standard: 45 °
Note
Replace the valve if the measured value is not the standard value.
3. Valve spring inspection

1) Inspect the valve spring for the following.
Damage
Abnormal wear
Note
If an abnormal condition is found, replace the valve spring.
2. Valve spring free length measurement
1) Measure the free length of the valve spring using a vernier caliper.
Note
Replace the valve spring if the measured value is not the standard value.
Standard: 51.14 mm { 2.0134 in } Inlet spring (Without paint)
Standard: 56.66 mm { 2.2307 in } Exhaust spring (With paint)
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3. Valve spring installation load measurement
1) Install the valve spring to load test equipment.
Standard: 26.0 mm { 1.024 in } Inlet spring height
Standard: 25.5 mm { 1.004 in } Exhaust spring height
Note
Replace the valve spring if the measured value is less than the limit.
Standard: 330.4 N { 33.7 kg / 74 lb } Inlet spring
Limit: 298.2 N { 30.4 kg / 67 lb } Inlet spring
Standard: 402.0 N { 41.0 kg / 90 lb } Exhaust spring
Limit: 362.8 N { 37.0 kg / 82 lb } Exhaust spring

4. Valve seat insert inspection
1. Cleaning
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1) Remove the carbon from the valve seat insert surface.
1) Inspect the valve seat insert for the following.
Scratches
Uneven sections
Note
If there are scratches or uneven sections, adjust the valve seat insert.
3. Valve seat insert adjustment
1) Adjust the valve seat to the standard value using a seat cutter.
Note
Minimize scratches and other uneven sections to adjust the contact width to the specified value.
Caution
Get rid of only the scratches and uneven portions, but be careful not to over-cut.
Use an adjustable valve cutter pilot.
The valve cutter pilot should not be allowed to scrape inside the valve guide.
Standard value
a: 90 ° Angle 1, inlet valve
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a: 90 ° Angle 1, exhaust valve
b: 48 ° Angle 2, inlet valve
b: 60 ° Angle 2, exhaust valve
c: 1.5 mm { 0.059 in } Contact width
2) Apply the compound to the valve seat surface.
3) Fit the valve by turning and lightly tapping.
Caution
Confirm that there is even contact around the entire circumference.
After fitting, completely remove the compound.
5. Cylinder head inspection
1) Measure the deformation of the cylinder block installation surface using a simple straight ruler and feeler
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gauge.
Note
Referring to the diagram, measure the 4 sides and across opposite corners.
If the measured value exceeds the limit, replace the cylinder head.
Caution
Do not polish the cylinder head lower surface.
Limit: 0.075 mm { 0.0030 in }

2) Measure the deformation of the exhaust manifold installation surface using a simple straight ruler and feeler
gauge.
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Note
Measure the 4 sides and across opposite corners.
Limit: 0.20 mm { 0.0079 in }
0.40 mm { 0.0157 in } Repair limit
Note
If the measured value exceeds the repair limit, replace the cylinder head.
6. Valve stem end cap inspection
1) Inspect the valve stem end cap for the following.
Scratches
Abnormal wear
Note
Replace the valve stem end cap if an abnormal condition is found.
7. Rocker arm inspection
1) Inspect the rocker arm for the following.
Wear
Damage
Stuck roller
Rattly roller
Note
Replace the rocker arm if a malfunction is found.
8. HLA inspection
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1) Inspect the HLA for the following.
Scratches
Abnormal wear
Note
Replace the HLA if an abnormal condition is found.
2. Air inclusion inspection
1) Push the HLA plunger with your fingers and inspect for sinking.
Note
If there is a sponge-like feeling and sinking, bleed air in the HLA.
Caution
Do not push the plunger with strong force for a long period of time.
Legend
1. Plunger
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2. Stop ring
3. Check ball
4. Check spring
5. Body
6. Return spring
7. Retainer
3. Bleed the air.
1) Put the HLA into the container vertically.
2) Add clean engine oil until the HLA end is submerged in it.
3) Using a 1 mm {0.04 in} diameter bar, push the plunger with your fingers and move it up and down while pushing
the check ball.
Caution
Do not push the check ball with a strong force.
4) Check that the air stops coming out of the plunger.
5) Perform the air inclusion inspection, and check that there is no sponge-like feeling when depressing with your
fingers.
Note
If sinking persists after repeating several times, replace the HLA.
Legend
1. 1 mm {0.04 in} diameter rod
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2. HLA
3. Check ball
Cylinder head reassembly (RZ4E-TC)
1. Component views
Cylinder head
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Part name

2. Split collar
4. Valve spring
7. Valve
9. Bolt
10. Cylinder head
12. HLA
13. Rocker arm
Tightening torque
8-1: 115 N・m { 11.7 kgf・m / 85 lb・ft }
8-2: 115 N・m { 11.7 kgf・m / 85 lb・ft }
8-3: 90 to 120 °
8-4: 90 to 120 °
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Valve guide installation
1) Tap in the valve guide from the top of the cylinder head to the standard depth using the special tool.
Caution
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When replacing the valve guide, replace as a set with the valve.
Standard: 9.80 to 10.20 mm { 0.3858 to 0.4016 in } Height from the cylinder head top surface to the valve
guide end face
SST: 5-8840-3172-0 - valve guide remover and installer
2) Adjust the valve guide inner diameter to the standard value using a reamer.

Legend
a. Height from the cylinder head top surface to the valve guide end surface
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Standard value
b: 5.500 to 5.515 mm { 0.2165 to 0.2171 in } Valve guide inner diameter
3. Valve seat insert installation
1) Put the dolly block on the valve seat insert.
Note
Carefully place a dolly block having an outer diameter smaller than the valve seat insert on top of the
valve seat insert.
Caution
Check for foreign material or scratches on the press-fitting surface of the cylinder head valve seat
insert.
2) Install the valve seat insert to the cylinder head using a press.
Note
Gradually apply pressure to the dolly block and push in the valve seat insert.
Caution
Do not apply excessive pressure with the press.
Legend
1. Dolly block
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2. Valve seat insert
3. Press
3) Adjust the valve seat to the standard value using a seat cutter.
Note
Minimize scratches and other uneven sections to adjust the contact width to the specified value.
Caution
Get rid of only the scratches and uneven portions, but be careful not to over-cut.
Use an adjustable valve cutter pilot.
The valve cutter pilot should not be allowed to scrape inside the valve guide.
Standard value
a: 90 ° Angle 1, inlet valve
a: 90 ° Angle 1, exhaust valve

b: 48 ° Angle 2, inlet valve
b: 60 ° Angle 2, exhaust valve
c: 1.5 mm { 0.059 in } Contact width
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4) Apply the compound to the valve seat surface.
5) Fit the valve by turning and lightly tapping.
Caution
Confirm that there is even contact around the entire circumference.
After fitting, completely remove the compound.
4. Valve stem oil seal installation
1) Install a lower spring seat to the cylinder head.
2) Apply engine oil to the valve guide outer circumference.
3) Install the valve stem oil seal to the special tool.

SST: 5-8840-3173-0 - valve stem seal installer
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4) Install the valve stem oil seal to the cylinder head using the special tool.
5) Inspect for the following.
Is the valve stem oil seal correctly inserted?

Is it slanted?
Whether the garter spring is removed
5. Valve installation
1) Apply engine oil to the valve stems of the inlet valve and exhaust valve.
2) Install the inlet valve and the exhaust valve to the cylinder head.
Caution
Install the valve so that there is no rubber detaching or scratches.
6. Valve spring installation
1) Install the valve spring to the cylinder head.
2) Install the spring upper seat to the valve spring.
3) Install the split collar to the valve using the special tool.
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SST: 5-8840-3171-0 - valve spring compressor
4) Move the valve spring up and down to check that it moves smoothly.
5) Apply engine oil to the valve stem end cap and valve stem end.
6) Install the valve stem end cap to the valve stem.
7. HLA installation
1) Install the HLA to the cylinder head.
Caution
Install while taking care not to allow the HLA inner oil to spill out.
Check for foreign material or sludge on the HLA mounting hole of the cylinder head.
Legend
1. HLA
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2. Cylinder head
2) Apply engine oil to the HLA.
Note
Apply oil until the hole at the top of the HLA is filled.
8. Rocker arm installation
1) Apply engine oil to the tip of the HLA and the end surface of the valve stem end cap.
2) Install the rocker arm to the HLA and valve stem end cap.
Legend
1. Rocker arm
3. HLA
3) Apply engine oil to the rocker arm roller section.
9. CMP sensor installation
1) Apply soapy water to the O-ring.
2) Install the CMP sensor to the cylinder head.
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Legend
1. O-ring
2. CMP sensor
3) Install the fuel pipe bracket to the cylinder head.
Note
Install so that the fuel pipe bracket detent makes contact with the cylinder head indentation.

Legend
1. Detent
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Cylinder head installation (RZ4E-TC)
1. Cylinder head installation
1) Clean the upper surface of the cylinder block and lower surface of the cylinder head using a scraper.
Caution
Do this carefully so as to not damage the upper surface of the cylinder block or lower surface of the
cylinder head.
2) Prepare a cylinder head gasket with the same grade as the removed gasket.
Caution
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3) Apply ThreeBond 1207B or equivalent to the positions on the cylinder block shown in the diagram.
Caution
After applying the liquid gasket, install the cylinder head within 5 minutes.
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Standard value
4) Place the cylinder head gasket on the cylinder block.
5) Align the dowel positions, and place the cylinder head on the cylinder block.
Caution
Do not damage the cylinder head gasket.
6) Apply engine oil to the following locations.
Cylinder head mounting bolt threaded portion

Cylinder head mounting bolt seating surface
Washer
7) Tighten the cylinder head bolts to the cylinder head using the special tool and a torque wrench in the order
shown in the diagram.
SST: 5-8840-0266-0 - angle gauge
Tightening torque: 115 N・m { 11.7 kgf・m / 85 lb・ft } 2nd time
Note
Retighten to the same torque to prevent variations in the tightening torque.
Tightening Angle : 90 to 120 ° 3rd time
Tightening Angle : 90 to 120 ° 4th time
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8) Install the bolts to the flywheel housing in the order shown in the diagram.
9) Install the following parts to the cylinder head.


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10) Apply LOCTITE 262 to the threaded portion of the plug.
11) Install the plug to the cylinder head.
12) Connect the connector to the CMP sensor.

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Note
marks.
Legend
1. Alignment mark
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2. Notch
Caution
Standard value
Note
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10) Align the paint markings and install the timing chain to the camshaft sprocket.
Note
Align to the marked position before removal.
Legend
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2. Timing chain
3. Paint marking
Caution
Legend

2. Gasket
Note
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Fixing position
3. Thermostat housing installation
2) Install the thermostat housing to the cylinder head and front cover.

3) Connect the connector to the engine coolant temperature sensor.
4. Turbocharger control solenoid valve installation
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1) Install the bracket to the cylinder head.
2) Install the turbocharger control solenoid valve to the bracket.
3) Install the connector to the turbocharger control solenoid valve.
4) Connect the vacuum hose to the turbocharger control solenoid valve.
5. Common rail (fuel rail) installation
1) Install the common rail (fuel rail) to the cylinder head.

Caution
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2) Install the connector to the FRP sensor.
Note
Install so that the detent makes contact with the common rail (fuel rail).
Legend
1. Detent
6. Fuel feed pipe installation

1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).
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Legend
1. Fuel feed pipe
2) Install the clip to the fuel feed pipe.
7. Fuel leak-off pipe installation
1) Install the fuel leak-off pipe to the common rail (fuel rail) and flywheel housing.
Tightening torque: 20.2 N・m { 2.1 kgf・m / 15 lb・ft } Common rail (fuel rail) side
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Flywheel housing side
Legend

2) Connect the fuel leak-off hose to the fuel leak-off pipe.
8. Exhaust manifold installation
1) Install the gasket to the cylinder head.
Note
Face the protruding section of the gasket toward the engine front side.
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Legend
1. Protrusion
Caution
2) Referring to the diagram, temporarily tighten the exhaust manifold to the cylinder head.
Washer installation direction

Legend
1. Stud bolt
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2. Washer
3. Nut
Spacer and washer installation direction
Legend
1. Stud bolt
2. Spacer
3. Washer
4. Nut
3) Securely tighten the exhaust manifold to the cylinder head.
Note
Caution
Do not over-tighten since it will expand or contract due to the heat of the manifold.
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4) Install the heat protector to the exhaust manifold.
9. Turbocharger installation
1) Install the water feed and return pipe, as well as the gasket to the turbocharger.
Caution

2) Inject approx. 1.0 cc {0.00026 US gal / 0.00022 Imp. gal} of engine oil into the oil feed port.
3) Install the turbocharger and gasket to the exhaust manifold.
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Caution
10. Turbocharger heat protector installation
1) Install the turbocharger heat protector to the turbocharger.

11. Turbocharger bracket installation
1) Temporarily tighten the turbocharger bracket to the turbocharger and cylinder block in the order shown in the
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diagram.
2) Final tighten the turbocharger bracket to the turbocharger and cylinder block in the order shown in the diagram.
12. Turbocharger oil pipe installation
1) Install the turbocharger oil pipe and gasket to the turbocharger.

Legend
1. Turbocharger
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2. Gasket
2) Install the turbocharger oil pipe (feed side) to the cylinder block.
Caution
Tightening torque: 22.5 N・m { 2.3 kgf・m / 17 lb・ft } Eyebolt
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Bolt
Legend
1. Turbocharger oil pipe (feed side)

2. Bolt
3. Eyebolt
3) Install the turbocharger oil pipe (return side) and gasket to the cylinder block.
13. Turbocharger water hose connect
1) Connect the turbocharger water return hose to the water feed pipe and return pipe.
2) Connect the turbocharger water feed hose to the water feed pipe and return pipe.
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Legend

14. Catalytic converter installation
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter installation".
15. Exhaust pipe installation
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) exhaust pipe installation".
16. Vacuum hose installation
1) Install the vacuum hose to the turbocharger and vacuum pipe.

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Legend
1. Air cleaner
3. Blow-by hose
4. Air cleaner duct
and turbocharger.

Legend
1. Alignment mark
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1) Install the oil seal to the cylinder head cover.
2) Install the gasket to the camshaft carrier.
Note
Face the protruding section of the gasket toward the camshaft carrier side, and install.
Legend
1. Gasket
2. Camshaft carrier
3) Apply engine oil to the cylinder head cover O-ring.
Caution
Do not reuse the O-ring.
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Legend
1. O-ring
4) Referring to the diagram, apply ThreeBond 1207B to the cylinder head mating surface.
Caution
Install the cylinder head cover within 5 minutes of applying liquid gasket.
Remove any dirt or dust from the oil seal section on the injector connector side.
Standard value
c: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height
Dimensions
a: 5.0 mm { 0.197 in }
5) Temporarily tighten the cylinder head cover to the cylinder head in the order shown in the diagram.
Caution
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6) Final tighten the cylinder head cover to the cylinder head in the order shown in the diagram.
7) Connect the harness clip to the cylinder head cover.

8) Connect the blow-by hose to the cylinder head cover.
19. Injector installation
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1) Clean the injector bracket mounting bolt holes using an air blower.
Caution
Thoroughly clean to eliminate all sand and dust.
2) Clean the cylinder head installation surface and injector.
3) Install the gasket to the injector.
Note
Push until seated evenly against the injector retaining nut section.
Caution
Do not press parts other than the gasket seal surface.
Legend
1. Gasket
2. Retaining nut section
3. Seal surface
4) Install the injector to the cylinder head.
Caution
Do not press the injector connector.
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Threaded section of bolt

Seat surface of the bolt
Washer contact surface on the injector clamp
6) Install the injector clamp to the injector.
Legend
1. Washer
2. Injector clamp
7) Install the injector leak-off pipe to the injector.
8) Install the clips to the injector.
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Legend
1. Clip
2. Injector leak-off pipe
3. Injector
9) Connect the injector leak-off hose to the injector leak-off pipe and fuel leak-off pipe.
Legend
1. Injector leak-off hose
10) Connect the connector to the injector.
1. When replacing the injector

Erase the old cylinder number ID code on the Injector ID Code label attached to the cylinder head cover with a
black pen, etc.
Label on the cylinder head cover (Sample)
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Legend
1. No. 1 cylinder Injector ID Code

5. Injector ID Code label
1) Record the Injector ID Code of the new injector.
Note
Record the 24 characters of the injector ID plate.
The correct order of the ID codes shown in the following injector illustration is as follows.
95 04 F9 F8 F0 00 F0 E7 09 F6 F9 96
Injector (Sample)
Legend
1. Injector ID Code
2. Injector
20. Injection pipe installation
1) Temporarily tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the
diagram.
Caution
Do not reuse the injection pipe.
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2) Final tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the diagram.
21. Inlet cover installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) inlet cover installation".

Engine removal (RZ4E-TC)
Caution
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negative terminal.

3. Coolant drain
Warning
2) Loosen the radiator drain plug, and drain the coolant into a pan.
3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.
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Legend
1. Drain plug
4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.
5) Tighten the drain plug on the cylinder block.
6) Tighten the radiator drain plug.
4. Intake hose removal
1) Remove the intake hose from the turbocharger and air pipe.
Legend
1. Turbocharger
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2. Air pipe
3. Intake hose
2) Remove the intake hose from the intake air duct and air pipe.
Legend
1. Air pipe
2. Intake hose
3. Intake air duct
Legend
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1. Air cleaner
3. Blow-by hose
4. Air cleaner duct
6. Battery removal
1) Disconnect the battery ground cable from the frame.
2) Disconnect the battery cable from the battery.
3) Remove the battery bracket from the frame.
4) Remove the battery from vehicle.
Legend
1. Battery cable
2. Battery bracket
3. Battery ground cable
7. Fuse box disconnect
1) Remove the fuse box cover from the fuse box.
2) Disconnect the engine harness from the fuse box.
3) Disconnect the battery harness from the fuse box.
8. Radiator upper hose removal
1) Remove the radiator upper hose from the water outlet pipe and radiator.
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Legend
9. Radiator reserve tank removal
1) Disconnect the radiator reserve tank hose from the radiator.
2) Remove the radiator reserve tank from the upper fan guide.
10. Heater hose disconnect
1) Remove the 2 heater hoses from the heater pipe and heater evaporator unit.
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Legend
1. Heater hose
2. Heater evaporator unit
11. Fan guide removal
1) Remove the fan shroud from the fan guide.
2) Remove the fan guide from the radiator.

Legend
1. Fan guide
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2. Clip
3. Fan shroud
12. Cooling fan belt removal
Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt removal".
13. Power steering oil pump disconnect
1) Install the bolt and nut to the power steering oil pump shaft.
Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft } M10 x 1.5 nut
Legend
1. M10 x 1.5 bolt

2. M10 x 1.5 nut
3. Power steering oil pump pulley
4. Power steering oil pump shaft
Caution
Do not tighten the bolt to the hole edge of the power steering oil pump shaft, but create a clearance.
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Legend
1. M10 x 1.5 bolt

2. M10 x 1.5 nut
3. Power steering oil pump shaft
4. Power steering oil pump pulley
Legend
a. Gap
2) Remove the power steering oil pump pulley from the power steering oil pump.
Note
Secure the M10 x 1.5 nut with a tool, and loosen the pulley mounting bolt.
3) Disconnect the power steering oil pump from the generator bracket.
Note
Secure with wire at an appropriate position as a set with the hoses.
14. Generator removal
1) Disconnect the connector from the generator.
2) Disconnect the B-terminal from the generator.
3) Remove the generator from the generator bracket.
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15. A/C compressor disconnect
1) Disconnect the pipe clip from the air duct bracket.
2) Disconnect the A/C compressor from the generator bracket.
Note
16. Cooling fan removal
1) Remove the cooling fan and cooling fan clutch as a set from the water pump.
17. Glove box removal
1) Remove the glove box from the instrument panel.
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LHD
Legend
1. Glove box
18. Instrument panel passenger-side lower cover removal
1) Remove the instrument panel passenger-side lower cover from the instrument panel.
LHD
Legend
1. Instrument panel passenger-side lower cover
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19. ECM disconnect
1) Disconnect the connector from the ECM.
2) Pull out the harness to the engine room side.
3) Disconnect the harness from the frame.
20. Vacuum hose disconnect
1) Disconnect the vacuum hose from the vacuum pipe.
21. Catalytic converter removal
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter removal".
22. Exhaust pipe removal
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) exhaust pipe removal".
23. Radiator lower hose disconnect
1) Disconnect the radiator lower hose from the water intake pipe.
Legend
1. Radiator lower hose
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24. Transmission removal
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission removal".
25. Clutch removal
Refer to "5.Transmission, Transaxle 5E.Clutch System(MVL) Clutch removal".
26. Fuel hose disconnect
1) Disconnect the fuel feed hose from the fuel supply pump.
2) Disconnect the fuel return hose from the fuel leak-off pipe.
Legend
1. Fuel feed hose

2. Fuel return hose
27. Engine removal
1) Install the special tool to the generator bracket.
SST: 5-8840-3226-0 - front engine hanger
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Legend
1. 5-8840-3226-0
2) Install special tool to the flywheel housing.
SST: 5-8840-3170-0 - rear engine hanger

Legend
1. 5-8840-3170-0
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3) Install the wire to the engine hanger and hoist.
4) Hold up the engine as high as not to be lifted up.
5) Disconnect the engine foot from the engine mounting.
Note
Loosen the engine mounting fixing bolts from above the engine using an extension bar that is 600
mm {23.6 in} or longer.
Legend
1. Engine foot
2. Engine mounting
6) Remove the engine from vehicle.

Engine installation (RZ4E-TC)
1. Engine installation
1) Install the engine to the vehicle using a hoist.
Note
Slowly operate to move the engine to the installation position.
Slowly operate the hoist so that the transmission side is low, while pulling to the rear of the engine.
2) Connect the engine foot to engine mounting.
Note
Tighten the engine mounting fixing bolts from above the engine using an extension bar that is 600
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Caution
Tighten bolts while the engine foot is securely seated on the engine mounting to prevent bolts from
loosening.
Legend
1. Engine foot
2. Engine mounting
3) Remove the wire from the engine hanger and hoist.
4) Remove special tool from the flywheel housing.
5) Remove the special tool from the generator bracket.

2. Fuel hose connect
1) Connect the fuel return hose to the fuel leak-off pipe.
2) Connect the fuel feed hose to the fuel supply pump.
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Legend
1. Fuel return hose

2. Fuel feed hose
3. Clutch installation
Refer to "5.Transmission, Transaxle 5E.Clutch System(MVL) Clutch installation".
4. Transmission installation
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission installation".
5. Radiator lower hose connect
1) Connect the radiator lower hose to the water intake pipe.

Legend
1. Radiator lower hose
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6. Catalytic converter installation
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter installation".
7. Exhaust pipe installation
Refer to "1.Engine 1G.Exhaust(RZ4E-TC) exhaust pipe installation".
8. Vacuum hose connect
1) Connect the vacuum hose to the vacuum pipe.
9. ECM connect
1) Connect the harness to the frame.
2) Pull in the harness toward inside the room.
3) Connect the connector to the ECM.
10. Instrument panel passenger-side lower cover installation
1) Install the instrument panel passenger-side lower cover to the instrument panel.
LHD
Legend
1. Instrument panel passenger-side lower cover
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11. Glove box installation
1) Install the glove box to the instrument panel.
LHD
Legend
1. Glove box
12. Cooling fan installation
1) Install the cooling fan clutch and cooling fan as a set to the water pump.

13. A/C compressor connect
1) Connect the A/C compressor to the generator bracket.
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2) Connect the pipe clip to the air duct bracket.
14. Generator installation
1) Install the generator to the generator bracket.
2) Connect the B-terminal to the generator.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }
3) Connect the connector to the generator.

15. Power steering oil pump connect
1) Connect the power steering oil pump to the generator bracket.
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2) Install the power steering oil pump pulley to the power steering oil pump.
Note
Secure the M10 x 1.5 bolt with a tool, and tighten the pulley mounting bolt.
3) Remove the bolt and nut from the power steering oil pump shaft.
16. Cooling fan belt installation
Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt installation".
17. Fan guide installation

1) Install the fan guide to the radiator.
2) Install the fan shroud to the fan guide.
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Legend
1. Fan guide
2. Clip
3. Fan shroud
18. Heater hose connect
1) Install the 2 heater hoses to the heater pipe and heater evaporator unit.
Legend
1. Heater hose
2. Heater evaporator unit
19. Radiator reserve tank installation
1) Clean the radiator reserve tank using detergent.
Note
Wash with clean water, and drain the water.
2) Install the radiator reserve tank to the upper fan guide.
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3) Connect the radiator reserve tank hose to the radiator.
20. Radiator upper hose installation
1) Install the radiator upper hose to the water outlet pipe and radiator.
Legend

21. Fuse box connect
1) Connect the battery harness to the fuse box.
2) Connect the engine harness to the fuse box.
3) Install the fuse box cover to the fuse box.
22. Battery installation
1) Install the battery to vehicle.
2) Install the battery bracket to the frame.
Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in } Battery side
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft } Frame side
3) Connect the battery cable to the battery.
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4) Connect the battery ground cable to the frame.
Legend
1. Battery cable
2. Battery bracket
3. Battery ground cable

Legend
1. Air cleaner
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3. Blow-by hose
4. Air cleaner duct
and turbocharger.
Legend
1. Alignment mark
24. Intake hose installation

1) Install the intake hose to the intake air duct and air pipe.
Caution
Align the marks on the pipe side and hose side.
Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp
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Legend
1. Air pipe
2. Intake hose
3. Intake air duct
2) Install the intake hose to the turbocharger and air pipe.
Caution
Legend
1. Turbocharger
2. Air pipe
3. Intake hose
1. Post procedures
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27. Coolant filling
Note
Caution
Fill slowly to prevent air from entering the system.
2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.
Note
Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.
Caution
Repeat the operation until the coolant level no longer drops.
Legend
1. Radiator reserve tank
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2. MAX line
3. MIN line
5) Start and idle the engine.
Caution
Idle the engine for 5 minutes or more.
6) Stop the engine.
Warning
Note
If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.
10) Start the engine.
11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.
12) With the engine running, check that the thermostat valve is open.
Note
Touch the radiator upper hose, and confirm that it has become warm.
If it has not become warm, go back to Step 11.
Caution
Do not try determining it by using only an engine coolant temperature gauge.
13) Idle the engine for 5 minutes.
14) Stop the engine.
Warning
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Note
19) Repeat steps 10 to 18 until the coolant level no longer lowers.
Caution
If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
28. Fuel air bleed
2) Press the priming pump until it becomes hard.
Caution
Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.
Legend
1. Priming pump
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2. Fuel filter with sedimenter
29. ECM setting
If the engine has been replaced, perform Injector ID Code programming, ECM learned value clear, and fuel supply
pump relearning.
1. Injector ID Code programming
Check the label attached to the engine cover at the time of factory shipment or the housing of each injector for the
Injector ID Code.
Label on the cylinder head cover (Sample)
Legend

5. Injector ID Code label
The correct order of the ID codes shown in the following injector illustration is as follows.
95 04 F9 F8 F0 00 F0 E7 09 F6 F9 96
Injector (Sample)
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Legend
1. Injector ID Code
2. Injector
1) Connect the scan tool to the DLC.
2) Turn ON the ignition switch.
3) Select the scan tool item.
Diagnostics
Engine
RZ4E
Programming
Injector ID Code
Program Injector ID Code
4) Program the Injector ID Code into the ECM by following the on-screen instructions.
5) After the programming is completed, turn the ignition switch OFF for 30 seconds.
2. ECM learned value clear
Diagnostics
Engine
RZ4E
Actuator Test
Reset Small Fuel Injection Quantity Learning
4) Perform the ECM learned value clear by following the on-screen instructions.
5) After the learned value clear is complete, turn OFF the ignition switch for 30 seconds.
3. Fuel Supply Pump Relearning
Diagnostics
Engine
RZ4E
Actuator test
Fuel Supply Pump Learn Resetting
4) Reset the Fuel Supply Pump Learning by following the on-screen instructions.
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5) Turn OFF the ignition switch for 30 seconds.
6) Start and idle the engine until the engine coolant temperature reaches 65°C {149°F} or more.
7) Observe the Fuel Supply Pump Learning Status parameter on the scan tool.
8) The procedure is complete when the parameter changes from Not Learned to Learned.
30. Engine vehicle inspection
1. Inspection before starting the engine
Engine oil level

Engine coolant level
Items around the engine that may get caught
2. Inspection after starting the engine
Abnormal noise
Abnormal vibration
Fuel leakage
Oil leakage
Water leakage
Air leakage
Exhaust gas leakage
Exhaust gas color
3. Inspection after stopping the engine

Engine oil level

Engine coolant level
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Engine mounting removal (RZ4E-TC)
1. Component views
Engine mounting
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Part name
1. Bolt
3. Bolt
4. Bolt
5. Right side engine mounting
6. Bolt
8. Bolt
9. Bolt
10. Left side engine mounting
Tightening torque
1: 131 N・m { 13.4 kgf・m / 97 lb・ft }
3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
4: 116 N・m { 11.8 kgf・m / 86 lb・ft }
6: 131 N・m { 13.4 kgf・m / 97 lb・ft }
8: 52 N・m { 5.3 kgf・m / 38 lb・ft }
9: 116 N・m { 11.8 kgf・m / 86 lb・ft }
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Caution
negative terminal.

4. Engine hood removal
Caution
Two people are required to install or remove the engine hood.
1) Remove the engine hood from the hood hinge.
Note
Mark the hood hinge position before removing the engine hood.
5. Wiper linkage removal
Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage removal".
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6. Cowl panel removal
1) Remove the cowl panel from vehicle.
7. Front propeller shaft removal
Refer to "3.Driveline, Axle 3C.Drive Shaft System front propeller shaft removal".
8. Engine mounting removal
1) Install the special tool to the generator bracket.

SST: 5-8840-3226-0 - front engine hanger
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Legend
1. 5-8840-3226-0
2) Install special tool to the flywheel housing.
SST: 5-8840-3170-0 - rear engine hanger

Legend
1. 5-8840-3170-0
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3) Install the wire to the engine hanger and the hoist.
5) Disconnect the engine mounting from the engine foot.
Note
Loosen the engine mounting fixing bolts from above the engine using an extension bar that is 600
Legend
1. Engine foot
2. Engine mounting
6) Slightly raise the engine.

7) Loosen the fixing bolts between the engine mounting and the frame.
8) Remove the engine mounting from the frame.
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Engine mounting installation (RZ4E-TC)
1. Component views
Engine mounting
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Part name
1. Bolt
3. Bolt
4. Bolt
6. Bolt
8. Bolt
9. Bolt
Tightening torque
1: 131 N・m { 13.4 kgf・m / 97 lb・ft }
3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
4: 116 N・m { 11.8 kgf・m / 86 lb・ft }
6: 131 N・m { 13.4 kgf・m / 97 lb・ft }
8: 52 N・m { 5.3 kgf・m / 38 lb・ft }
9: 116 N・m { 11.8 kgf・m / 86 lb・ft }
2. Engine mounting installation
1) Install the engine mounting to the frame.
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3) Lower the engine.
4) Connect the engine mounting to the engine foot.
Note
Tighten the engine mounting fixing bolts from above the engine using an extension bar that is 600
Caution
Tighten bolts while the engine foot is securely seated on the engine mounting to prevent bolts from
loosening.
Legend
1. Engine foot
2. Engine mounting
5) Remove the special tool from the generator bracket and flywheel housing.
3. Front propeller shaft installation
Refer to "3.Driveline, Axle 3C.Drive Shaft System front propeller shaft installation".
4. Cowl panel installation
1) Install the cowl panel to vehicle.
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5. Wiper linkage installation
Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage installation".
6. Engine hood installation
1) Align the engine hood with the marking position placed during removal, and temporarily secure.
2) Adjust the clearance between the engine hood and the fender to the standard value.
Dimensions
a. Clearance: 4.0 mm {0.16 in}
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b. Height, level difference: -1.5 mm ｛-0.06 in｝
3) Final tighten the hinge bolt to the engine hood.
7. Engine hood adjustment
1) Turn the hood rest to adjust its height, and adjust the level difference against the engine hood.
Legend
1. Hood rest

1. Post procedures
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Exhaust manifold removal (RZ4E-TC)
1. Component views
Exhaust manifold
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Part name
1. Gasket
2. Bolt
3. Heat protector
4. Exhaust manifold
5. Nut
6. Bolt
7. Heat protector
8. Bolt
Tightening torque
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
5-2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5-3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
6: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
8-2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
8-3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
Refer to "1.Engine 1F.Induction(RZ4E-TC) Turbocharger removal".
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Caution
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Exhaust manifold inspection (RZ4E-TC)
1. Exhaust manifold inspection
1) Inspect the exhaust manifold for cracks.
2. Deformation measurement
1) Referring to the diagram, put a simple straight ruler on the exhaust manifold.
2) Measure exhaust manifold deformation using a feeler gauge.
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Standard: 0.3 mm or less { 0.012 in or less }
Limit: 0.5 mm { 0.020 in }
Note
If the measured value exceeds the limit, replace the exhaust manifold.
Exhaust manifold installation (RZ4E-TC)
1. Component views
Exhaust manifold
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Part name
1. Gasket
2. Bolt
3. Heat protector
4. Exhaust manifold
5. Nut
6. Bolt
7. Heat protector
8. Bolt
Tightening torque
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
5-2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5-3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
6: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
8-2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
8-3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
Note
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Legend
1. Protrusion
Caution

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Legend
1. Stud bolt
2. Washer
3. Nut

Legend
1. Stud bolt
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2. Spacer
3. Washer
4. Nut
Note
Caution

Refer to "1.Engine 1F.Induction(RZ4E-TC) Turbocharger installation".
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Flywheel removal (RZ4E-TC)
1. Component views
Flywheel
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Part name
1. Bolt
2. CKP sensor
3. Flywheel housing
4. Flywheel (Manual transmission models)
5. Bearing
6. Flywheel washer
7. Bolt
8. Flywheel (Automatic transmission models)
9. Flexible plate
10. Flexible plate washer
11. Bolt
Tightening torque
1: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
7-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
7-2: 60 to 90 °
11-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
11-2: 120 °
11-3: 30 to 60 °
2. Transmission removal
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission removal".
3. Clutch removal
Refer to "5.Transmission, Transaxle 5E.Clutch System(MVL) Clutch removal".
4. CKP sensor removal
1) Disconnect the connector from the CKP sensor.
2) Remove the CKP sensor from the flywheel housing.
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Legend
1. O-ring
2. CKP sensor
5. Flywheel removal
1. Manual transmission models
1) Remove the pilot bearing from the flywheel using the special tool.
SST: 5-8840-2000-0 - Pilot bearing remover
SST: 5-8840-0019-0 - Sliding hammer
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3) Gradually loosen the flywheel mounting bolts in the order shown in the diagram, and remove the washer and
flywheel from the crankshaft.
Note
After loosening all of the bolts, remove the special tool.
Caution
Do not damage the flywheel sensor rotor section.
Legend
1. CKP sensor
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2. Sensor rotor section
3. Ring gear
2. Automatic transmission models
2) Gradually loosen the flywheel mounting bolts in the order shown in the diagram, and remove the following parts
from the crankshaft.
Washer
Flexible plate
Flywheel
Note
Caution
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Legend
1. CKP sensor
3. Ring gear
Flywheel disassembly (RZ4E-TC)
1. Flywheel disassembly
1) Drill a hole in the ring gear between the teeth.
Note
Opening the holes can be made easier by using a punch to make position determination markings
beforehand.
Caution
Do not damage the flywheel.
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2) Remove the ring gear from the flywheel using a chisel.
Flywheel inspection (RZ4E-TC)
1. Flywheel inspection
1) Inspect the flywheel and mounting bolts for the following.
Cracking
Damage
Note
Replace the flywheel or mounting bolt if an abnormal condition is found.
2) Inspect the ring gear for the following.
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Damage
Significant wear
Note
Replace the ring gear if an abnormal condition is found.
2. Flywheel wear measurement
1) Measure the flywheel friction surface depth using a vernier caliper.
Note
The depth from the pressure plate installation surface to the friction surface is indicated.
Standard: 0 mm { 0.00 in }
Legend
1. Ring gear
2. Wear
3. Flywheel
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Flywheel reassembly (RZ4E-TC)
1. Flywheel reassembly
1) Uniformly heat up the inside of the ring gear with a gas burner.
Caution
Perform this with the heating temperature at or below the standard value.
Standard: 200 ℃ { 392 °F }
2) Referring to the diagram, install the ring gear to the flywheel.
Note
When the ring gear is cool, apply 49 kN {5,000 kgf / 11,000 lbf} of load, maintaining evenness.
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Legend
1. Chamfered side
2. Ring gear
3. Flywheel
Flywheel installation (RZ4E-TC)
1. Component views
Flywheel
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Part name
1. Bolt
2. CKP sensor
3. Flywheel housing
5. Bearing
6. Flywheel washer
7. Bolt
9. Flexible plate
11. Bolt
Tightening torque
1: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
7-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
7-2: 60 to 90 °
11-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
11-2: 120 °
11-3: 30 to 60 °
2) Temporarily tighten the washer and flywheel to the crankshaft in the order shown in the diagram.
Note
Verify that the washer does not rotate on the flywheel.
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Legend
1. Flywheel
2. Washer
3. Bolt
Caution
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4) Final tighten the flywheel to the crankshaft in the order shown in the diagram.
6) Place the pilot bearing so that it crosses the crankshaft bearing installation hole perpendicularly.
7) Install the pilot bearing to the flywheel using the special tool.
Note
Drive in the pilot bearing outer race using a hammer.
SST: 5-8522-0024-0 - pilot bearing installer
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2) Temporarily tighten the following parts to the crankshaft in the order shown in the diagram.
Washer
Flexible plate
Flywheel
Caution
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Tightening Angle : 120 ° 2nd time
Caution
The total rotation angle should be 150 to 180°.
3. CKP sensor installation
2) Install the CKP sensor to the flywheel housing.
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Legend
1. O-ring
2. CKP sensor
3) Connect the connector to the CKP sensor.
4. Clutch installation
Refer to "5.Transmission, Transaxle 5E.Clutch System(MVL) Clutch installation".
5. Transmission installation
Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission installation".

Flywheel housing removal (RZ4E-TC)
1. Component views
Flywheel housing
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Part name
1. Bolt
2. CKP sensor
3. Flywheel housing
5. Flywheel
6. Bearing
7. Washer
8. Bolt
9. Nut
10. Bolt
11. Plug
12. O-ring
Tightening torque
1: 5.0 N・m { 0.51 kgf・m / 44.3 lb・in }
8-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
8-2: 60 to 90 °
9: 52 N・m { 5.3 kgf・m / 38 lb・ft }
10: 52 N・m { 5.3 kgf・m / 38 lb・ft }
11: 63 N・m { 6.4 kgf・m / 46 lb・ft }
2. Engine removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Engine removal".
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4. Engine oil drain
1) Remove the drain plug from the oil pan, and drain the engine oil to a pan.
2) Install the drain plug to the oil pan.
Caution
Wipe off any oil attached to the drain plug hole.
Do not forget to tighten the drain plug.
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Legend

Legend
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2. Gasket

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Caution
12. Generator bracket removal
1) Remove the generator bracket from the cylinder block.
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13. Intake air duct removal
1) Disconnect the connector from the boost pressure and CAC temperature sensor.
2) Remove the intake air duct from the intake throttle valve.
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14. Intake throttle valve removal
1) Disconnect the connector from the intake throttle valve.
2) Remove the intake throttle valve and gasket from the inlet manifold.
Legend
1. Intake throttle valve
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2. Gasket
15. Oil level gauge guide tube removal
1) Remove the oil level gauge from the oil level gauge guide tube.
2) Remove the oil level gauge guide tube from the crankcase.
16. Water pipe removal
1. Except Euro4 specifications (Specifications for models with heaters)
2) Remove the vacuum pipe from the air duct bracket.
Legend
1. Vacuum pipe
2. Vacuum hose
3. Bracket
3) Disconnect the heater hose from the water pipe.
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4) Remove the water pipe from the air duct bracket.
5) Remove the pipe clip from the water pipe.

6) Remove the water pipe from the inlet cover.
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2. Except Euro4 specifications (Specifications for models without heaters)

Legend
1. Vacuum pipe
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2. Vacuum hose
3. Bracket
3) Remove the water hose from the water pipe.

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17. EGR cooler water hose disconnect
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1) Disconnect the EGR cooler water feed hose from the EGR cooler.
Legend
1. EGR cooler water return hose

2. EGR cooler water feed hose
2) Disconnect the heater hoses from the EGR cooler.
3) Disconnect the heater hose from the EGR cooler water return pipe.
4) Disconnect the EGR cooler water hose from EGR cooler water pipe A.
5) Remove EGR cooler water pipe A from the inlet cover.
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Legend
1. EGR cooler water pipe A

18. Glow plug removal
1) Remove the glow plug terminal and glow plug connector from the glow plug.
Legend
1. Glow plug terminal
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2. Glow plug connector
2) Remove the glow plug from the cylinder head.
19. EGR removal
1) Remove the air duct bracket from the inlet cover.

2) Remove the harness bracket from the inlet cover.
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3) Remove the following parts as a set from the cylinder head and inlet cover.
EGR pipe
EGR valve
EGR duct
Gasket
Legend
1. EGR duct
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2. EGR pipe
3. EGR valve
4. Gasket
4) Remove the following parts from the EGR pipe.
EGR valve
EGR duct
Gasket
Caution
Seal to prevent foreign material from entering.
2) Remove the vacuum pipe from the bracket.

Legend
1. Vacuum pipe
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2. Vacuum hose
3. Bracket

EGR cooler
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EGR valve
EGR duct
Gasket
Legend
1. EGR duct
2. EGR cooler
3. EGR valve
4. Gasket
6) Remove the following parts from the EGR cooler.
EGR valve
EGR duct
Gasket
Caution
1) Remove the inlet cover from the cylinder head.
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Caution
Legend
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Caution
Legend
1. Fuel feed pipe

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Caution

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Note
Fixing position
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Legend

2. Gasket
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Legend
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Caution
Caution
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Legend
1. O-ring
2. CKP sensor
29. Flywheel removal

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Note
Caution
Legend
1. CKP sensor
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3. Ring gear
Washer
Flexible plate
Flywheel
Note
Caution
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Legend
1. CKP sensor
3. Ring gear
Caution
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31. Flywheel housing removal
1) Remove the flywheel housing from the cylinder block.
Caution
2) Remove the timing chain from the idle gear A sprocket.

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Flywheel housing installation (RZ4E-TC)
1. Component views
Flywheel housing
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Part name
1. Bolt
2. CKP sensor
3. Flywheel housing
5. Flywheel
6. Bearing
7. Washer
8. Bolt
9. Nut
10. Bolt
11. Plug
12. O-ring
Tightening torque
1: 5.0 N・m { 0.51 kgf・m / 44.3 lb・in }
8-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
8-2: 60 to 90 °
9: 52 N・m { 5.3 kgf・m / 38 lb・ft }
10: 52 N・m { 5.3 kgf・m / 38 lb・ft }
11: 63 N・m { 6.4 kgf・m / 46 lb・ft }
2. Flywheel housing installation
Measure the protrusion amount of the piston head in order to select the gasket grade.
1) Measure the protrusion amount of the piston head using a dial gauge.
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Caution
The measurement point should be as close to the cylinder block as possible.
The difference between the protruding amount of each piston must be within the specified range.
Standard: 0.05 mm { 0.0020 in }

Legend
1. Measurement point
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Legend
2) Turn the crankshaft in the forward direction (clockwise) to align the idle gear A alignment mark.
Note
Align the alignment marks at the same time at the two locations: the alignment mark of idle gear A
and the crank gear, the alignment mark of idle gear A and the supply pump gear.
Caution
After the alignment marks are aligned, do not rotate the crankshaft until the camshaft carrier is
installed.
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Legend
1. Idle gear A
2. Crank gear
Legend
1. Supply pump gear

2. Idle gear A
3) Install the timing chain to the idle gear A sprocket.
Note
Align the timing chain yellow paint section with the flange timing mark, and install.
Check whether the idle gear A sprocket white paint teeth section and flange timing mark are aligned.
Legend
1. Timing chain yellow paint section
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2. Flange timing mark
4) Apply ThreeBond 1207B or equivalent to the position on the flywheel housing shown in the diagram.
Standard value
5) Apply ThreeBond 1207B or equivalent to the positions on the cylinder block and crankcase shown in the
diagram.
Standard value
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6) Install the flywheel housing to the cylinder block in the order shown in the diagram.
Caution
Carefully wipe away any gasket that has leaked out from between the aligning surfaces of the
flywheel housing and cylinder block.
Caution
Note
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SST: 5-8840-3221-0 - sleeve
Sleeve dimension
Legend
1. Sleeve (5-8840-3178-0)
2. Sleeve (5-8840-3221-0/5-8840-3225-0)
3. 39 mm {1.54 in}
4. 35 mm {1.38 in}
Legend
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2. Flywheel housing
3. Standard value
5. Crankshaft
Note
Legend
1. Flywheel
2. Washer
3. Bolt
Caution
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Note

Washer
Flexible plate
Flywheel
Caution
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Caution
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Legend
1. O-ring
2. CKP sensor
Caution
cylinder head.
2) Select the cylinder head gasket grade based on the average piston head protrusion amount.
Caution
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Caution
Standard value
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Caution

Washer
Note

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Note
marks.
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1. Alignment mark
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2. Notch
Caution
Standard value
Note
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10) Install the timing chain to the camshaft sprocket.
Note
Align the timing chain yellow paint section with the camshaft sprocket marking, and install.
Legend
1. Yellow paint section
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2. Mark
Caution
Note

Fixing position
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Caution
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Note
Legend
1. Detent

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Legend
1. Fuel feed pipe
Legend

13. EGR installation
Caution
If the procedures or methods for assembling the EGR device are mistaken, it can lead to cracks in the
pipe or gas leaks. Always follow the procedures.
Even when disassembling only a portion of the EGR-related parts, loosen all the EGR-related parts
once, replace the gaskets with new ones, and then temporarily tighten in the following order before
performing final tightening.
1) Temporarily tighten the following parts to the EGR pipe in the order shown in the diagram.
EGR valve
EGR duct
Gasket
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2) Temporarily tighten the EGR to the inlet cover.
3) Final tighten the following parts to the EGR pipe in the order shown in the diagram.
EGR valve
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EGR duct
Gasket
4) Final tighten the EGR to the inlet cover.

Caution
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1) Temporarily tighten the following parts to the EGR cooler in the order shown in the diagram.
EGR valve
EGR duct
Gasket
2) Temporarily tighten the EGR to the inlet cover in the order shown in the diagram.
3) Final tighten the following parts to the EGR cooler in the order shown in the diagram.
EGR valve
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EGR duct
Gasket
4) Final tighten the EGR to the inlet cover in the order shown in the diagram.

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1) Install the inlet cover and EGR to the cylinder head in the order shown in the diagram.
2) Install the harness bracket to the inlet cover.
Note
Install the harness bracket so that the detent makes full contact with the inlet cover.

Legend
1. Inlet cover
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2. Detent
3) Install the air duct bracket to the inlet cover.
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Note

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1. Inlet cover
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2. Detent
4) Install the vacuum pipe to the air duct bracket.

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1. Vacuum pipe
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2. Vacuum hose
3. Air duct bracket
15. EGR cooler water hose connect
1) Install EGR cooler water pipe A to the inlet cover.
2) Connect the EGR cooler water hose to EGR cooler water pipe A.
Legend

3) Connect the heater hose to EGR cooler water pipe A.
4) Connect the heater hoses to the EGR cooler.
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5) Connect the EGR cooler water feed hose to the EGR cooler.
Legend
1. Heater hose
16. Water pipe installation
1) Install the water pipe to the inlet cover.

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3) Install the water pipe to the air duct bracket.

4) Connect the heater hose to the water pipe.
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1. Vacuum pipe
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2. Vacuum hose
3. Bracket

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4) Install the water hose to the water pipe.
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Legend
1. Vacuum pipe
2. Vacuum hose
3. Bracket
17. Oil level gauge guide tube installation
1) Apply engine oil to the O-ring.
2) Install the oil level gauge guide tube to the crankcase.
3) Install the oil level gauge to the oil level gauge guide tube.
18. Glow plug installation
1) Install the glow plug to the cylinder head.
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2) Install the glow plug terminal and glow plug connector to the glow plug.
Legend

19. Intake throttle valve installation
1) Install the intake throttle valve and gasket to the inlet manifold.
Caution
Legend
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2. Gasket
2) Connect the connector to the intake throttle valve.
20. Intake air duct installation
1) Install the intake duct to the intake throttle valve.
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt
Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Clamp (Intake throttle side)
Clamp installation direction

Standard value
a: 45 °
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2) Connect the connector to the boost pressure and CAC temperature sensor.
21. Generator bracket installation
1) Install the generator bracket to the cylinder block.

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Note
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1. Protrusion
Caution

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1. Stud bolt
2. Washer
3. Nut

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1. Stud bolt
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2. Spacer
3. Washer
4. Nut
Note
Caution

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Caution
Caution

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diagram.

1) Install the gasket to the turbocharger oil pipe.
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Caution

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1. Turbocharger
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2. Gasket
Caution
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2. Bolt
3. Eyebolt
Legend
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1. Turbocharger oil pipe (return side)
2. Bolt
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30. Engine oil filling
1) Replenish the engine with the engine oil.
2) Check the tightening of the oil pan drain plug.
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Engine installation".

Front cover removal (RZ4E-TC)
1. Component views
Front cover
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Part name
1. Bolt
2. Washer
4. Bolt
5. Nut
6. Water pump
7. Water inlet pipe
8. O-ring
9. Front cover
10. Gasket
11. Bolt
12. Bolt
13. Oil seal cover
14. Nut
15. Bolt
Tightening torque
1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
1-2: 60 to 90 °
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Crankcase removal
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Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Crankcase removal".
3. Water pump removal
1) Remove the water pump from the front cover.
2) Remove the crankshaft pulley from the crankshaft.
Caution
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5. Crankshaft front oil seal removal
1) Remove the oil seal cover from the front cover.
2) Remove the crankshaft front oil seal and slinger as a set from the crankshaft using the special tool.
Caution
Do not damage the oil seal installation surface of the crankshaft and front cover.
6. Front cover removal
1) Remove the water inlet pipe from the front cover.
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2) Remove the bypass pipe from the front cover.
3) Remove the front cover from the cylinder block.

Legend
1. Front cover
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2. Gasket
Front cover installation (RZ4E-TC)
1. Component views
Front cover
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Part name
1. Bolt
2. Washer
4. Bolt
5. Nut
6. Water pump
7. Water inlet pipe
8. O-ring
9. Front cover
10. Gasket
11. Bolt
12. Bolt
13. Oil seal cover
14. Nut
15. Bolt
Tightening torque
1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
1-2: 60 to 90 °
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Front cover installation
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1) Install the gasket to the front cover.
2) Referring to the diagram, apply ThreeBond 1207B to the front cover.
Caution
Install the front cover within 5 minutes of applying the liquid gasket.
Standard value
3) Install the front cover to the cylinder block.
Caution
Carefully wipe away any liquid gasket that has leaked out from between the aligning surfaces of the
front cover and cylinder block.
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Legend
1. Front cover
2. Gasket
5) Install the bypass pipe to the front cover.
6) Install the water inlet pipe to the front cover.

3. Crankshaft front oil seal installation
1) Install the crankshaft front oil seal and slinger to the crankshaft using the special tool.
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Caution
Do not reuse the crankshaft front oil seal.
2) Check the dimension of the crankshaft end face and crankshaft front oil seal end face.
Legend
1. Stud bolt
2. Washer
3. Sleeve
4. Bolt
5. Front cover
7. Crankshaft
8. Crankshaft front slinger
9. Adapter
Standard value
a: 44.9 to 45.5 mm { 1.768 to 1.791 in }
3) Install the oil seal cover to the front cover.
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2) Install the crankshaft pulley to the crankshaft in the order shown in the diagram.
Note
Secure the ring gear to prevent the crankshaft from turning when tightening the crankshaft pulley
bolt.
Caution

5. Water pump installation
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1) Install the water pump to the front cover.
6. Crankcase installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Crankcase installation".

Idle gear removal (RZ4E-TC)
1. Component views
Idle gear
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Part name

3. Bolt
4. Bolt
5. Timing chain
8. Bolt
9. Timing chain guide
10. Bolt
11. Crank gear
12. Oil pump
13. Bolt
14. Idle gear A
15. Supply pump gear
16. Bolt
19. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 64 N・m { 6.5 kgf・m / 47 lb・ft }
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17: 70 N・m { 7.1 kgf・m / 52 lb・ft }
19: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Timing chain removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Timing chain removal".
3. Idle gear removal
1) Remove the timing chain guide from the cylinder block.
2) Apply the dial gauge to the idle gear tooth to be measured, and gently move the gear left and right to measure
the fluctuation of the dial gauge.
Note
If the measured value exceeds the limit, replace the idle gear.
Limit: 0.30 mm { 0.0118 in }
3) Measure the idle gear axial direction clearance using a feeler gauge.
Note
Replace the idle gear or thrust collar if the measured value exceeds the limit.
Limit: 0.20 mm { 0.0079 in }
4) Install the M5 bolts for securing the sub gear to idle gear A.
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Legend
1. M5 bolt
5) Remove the flange from idle gear A.
6) Remove idle gear A from the idle gear A shaft.
7) Remove the idle gear A shaft from the cylinder block.

Legend
1. Front mark
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Idle gear inspection (RZ4E-TC)
1. Idle gear inspection
1) Measure the idle gear shaft outer diameter using a micrometer.
Note
If the measured value exceeds the limit, replace the idle gear shaft.
Limit: 43.345 mm { 1.7065 in }
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2) Measure the inner diameter of the idle gear bushing using a dial gauge.
3) Calculate the clearance between the idle gear and idle gear shaft.
Note
If the measured value exceeds the limit, replace the idle gear or idle gear shaft.
Limit: 0.20 mm { 0.0079 in }
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Idle gear installation (RZ4E-TC)
1. Component views
Idle gear
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Part name

3. Bolt
4. Bolt
5. Timing chain
8. Bolt
10. Bolt
11. Crank gear
12. Oil pump
13. Bolt
14. Idle gear A
16. Bolt
19. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 64 N・m { 6.5 kgf・m / 47 lb・ft }
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17: 70 N・m { 7.1 kgf・m / 52 lb・ft }
19: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. In case of disassembled idle gear A
1) Secure the sub gear and idle gear to the vise.
2) Turn the sub gear right using the special tool until the M5 bolt holes are aligned between idle gear A and the
sub gear.
3) Tighten the M5 bolt and check that the sub gear does not move.

1) Apply engine oil to the idle gear A shaft.
2) Install the idle gear A shaft to the cylinder block by aligning the cylinder block and idle gear A shaft oil holes.
3) Install idle gear A to the idle gear A shaft by aligning the mark on idle gear A.
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Legend
1. Idle gear A
2. Crank gear
Legend
1. Supply pump gear

2. Idle gear A
4) Install the flange to idle gear A with the front mark facing toward the front.
5) Apply engine oil to the threaded portions and seating surfaces of the idle gear A bolts.
6) Temporarily tighten idle gear A to the idle gear A shaft and cylinder block.
Legend
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1. Front mark
7) Final tighten idle gear A to the cylinder block.
8) Remove the M5 bolts for securing the sub gear from idle gear A.
Legend
1. M5 bolt
9) Install the timing chain guide to the cylinder block.

3. Timing chain installation
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Timing chain installation".
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Inlet cover removal (RZ4E-TC)
1. Component views
Inlet cover (Euro4 specifications)
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Part name
1. Gasket
2. Inlet cover
3. Nut
4. Bolt
5. EGR valve
6. Gasket
7. Gasket
8. EGR cooler
9. Gasket
10. EGR duct
11. Bolt
12. Bolt
13. Bolt
14. Nut
15. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Inlet cover (Except Euro4 specifications)
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Part name
1. Gasket
2. Inlet cover
3. Nut
4. Bolt
5. EGR valve
6. Gasket
7. Gasket
8. EGR pipe
9. Gasket
10. EGR duct
11. Bolt
12. Bolt
13. Bolt
14. Nut
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Generator removal
Refer to "1.Engine 1J.Electrical(RZ4E-TC) generator removal".
3. Engine oil drain
Caution
4. A/C compressor disconnect
1) Disconnect the pipe clip from the air duct bracket.
2) Disconnect the A/C compressor from the generator bracket.
Note

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Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Intake throttle valve removal".

Legend
1. Vacuum pipe
2. Vacuum hose
3. Bracket
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1. Vacuum pipe
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2. Vacuum hose
3. Bracket

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Legend

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Legend

10. EGR removal

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EGR pipe
EGR valve
EGR duct
Gasket
Legend
1. EGR duct
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2. EGR pipe
3. EGR valve
4. Gasket
EGR valve
EGR duct
Gasket
Caution

Legend
1. Vacuum pipe
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2. Vacuum hose
3. Bracket

EGR cooler
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EGR valve
EGR duct
Gasket
Legend
1. EGR duct
2. EGR cooler
3. EGR valve
4. Gasket
EGR valve
EGR duct
Gasket
Caution
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Inlet cover installation (RZ4E-TC)
1. Component views
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Part name
1. Gasket
2. Inlet cover
3. Nut
4. Bolt
5. EGR valve
6. Gasket
7. Gasket
8. EGR cooler
9. Gasket
10. EGR duct
11. Bolt
12. Bolt
13. Bolt
14. Nut
15. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Gasket
2. Inlet cover
3. Nut
4. Bolt
5. EGR valve
6. Gasket
7. Gasket
8. EGR pipe
9. Gasket
10. EGR duct
11. Bolt
12. Bolt
13. Bolt
14. Nut
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. EGR installation
Caution
EGR valve
EGR duct
Gasket
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EGR valve
EGR duct
Gasket

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Caution
EGR valve
EGR duct
Gasket
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EGR valve
EGR duct
Gasket

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Note
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Legend
1. Inlet cover
2. Detent

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Note
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Legend
1. Inlet cover
2. Detent

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Legend
1. Vacuum pipe
2. Vacuum hose
3. Air duct bracket
Legend
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Legend
1. Heater hose
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Legend
1. Vacuum pipe
2. Vacuum hose
3. Bracket

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Legend
1. Vacuum pipe
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2. Vacuum hose
3. Bracket
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Intake throttle valve installation".

9. A/C compressor connect
1) Connect the A/C compressor to the generator bracket.
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2) Connect the pipe clip to the air duct bracket.
11. Generator installation
Refer to "1.Engine 1J.Electrical(RZ4E-TC) generator installation".

Intake throttle valve removal (RZ4E-TC)
Caution
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negative terminal.

2. Intake hose removal
1) Remove the intake hose from the intake air duct and air pipe.
Legend
1. Air pipe
2. Intake hose
3. Intake air duct

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Legend
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2. Gasket
Intake throttle valve installation (RZ4E-TC)
Caution
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Legend

2. Gasket
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Standard value
a: 45 °
3. Intake hose installation
1) Install the intake hose to the intake air duct and air pipe.
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Caution
Legend
1. Air pipe
2. Intake hose
3. Intake air duct
1. Post procedures

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Piston removal (RZ4E-TC)
1. Oil pump removal
Refer to "1.Engine 1E.Lubrication(RZ4E-TC) oil pump removal".
2. Piston removal
1) Remove any carbon from the top of the cylinder bore using a scraper.
2) Turn the crankshaft to align it to bottom dead center.
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4) Remove the connecting rod bearing from the connecting rod bearing cap.
Note
5) Turn the crankshaft to align it to top dead center.
6) Remove the piston and connecting rod from the cylinder block.
Note
Pull out the piston and connecting rod from the cylinder head side.
Push out from the lower end of the connecting rod by using the handle of a hammer, etc., so as not to
damage the bearing.
Caution
When pushing out the connecting rod, do not damage the oil jet and cylinder inner surface.
7) Remove the connecting rod bearing from the connecting rod.

Note
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Piston disassembly (RZ4E-TC)
1. Component views
Piston
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Part name
1. Piston ring
2. Snap ring
3. Piston pin
4. Piston
5. Connecting rod
6. Connecting rod upper bearing
7. Connecting rod lower bearing
8. Connecting rod cap
9. Connecting rod bolt
Tightening torque
9-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
9-2: 90 to 105 °
2. Piston disassembly
1) Remove the piston ring from the piston using ring pliers.
Caution
When reusing the piston rings, organize them according to the order of the cylinders so that other
cylinder pistons and piston rings do not get mistaken.
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2) Remove the snap ring from the piston.
Caution
Do not reuse the snap ring.
3) Remove the piston pin from the piston and connecting rod.
Caution
Organize the disassembled piston pins, pistons, and connecting rods in the same order as the
cylinders.
Piston inspection (RZ4E-TC)
1. Piston inspection
1. Cleaning
1) Remove any carbon from the following parts.
Piston head
Piston ring groove
Piston ring end gap
Caution
Do not use a wire brush.
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1) Inspect the piston for the following.
Cracking
Wear
Seizing
2) Inspect the connecting rod bearing for the following.
Wear
Damage
Spalling
Note
Replace the bearings as an assembly if there are abnormal conditions.
3) Inspect the piston pin for the following.
Crack
Wear
Damage
3. Measurement of clearance between cylinder bore and piston
1) Measure the inner diameter of the cylinder bore in the thrust direction and radial direction at the specified
positions using a cylinder gauge.
Legend
a. Thrust direction
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b. Radial direction
Measurement position
c: 12 mm { 0.47 in } Measurement position from the upper surface of the cylinder block
d: 55 mm { 2.17 in } Measurement position from the upper surface of the cylinder block
e: 95 mm { 3.74 in } Measurement position from the upper surface of the cylinder block
2) Calculate the average measured value excluding the maximum and minimum values.
3) Measure the piston outer diameter at the measurement position in the diagram, perpendicular to the piston pin.
Legend
a: 14.5 mm { 0.571 in }
4) Calculate the clearance between the piston and the cylinder bore inner diameter.
Note
If the measured value is outside the standard range, replace the piston.
5) Select a piston so that the clearance is the specified value.
Note
Grades A, B, and C are marked on the top of the piston when shipped from the factory.
Grade Outer diameter

79.950 to 79.979 mm {
A
3.1476 to 3.1488 in }
79.960 to 79.989 mm {
B
3.1480 to 3.1492 in }
79.970 to 79.999 mm {
C
3.1484 to 3.1496 in }
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Legend
1. Grade marking
2. Front mark
4. Measurement of piston ring joint
1) Insert the piston ring into the cylinder bore.
Note
Push the piston ring into the cylinder using the piston until the cylinder bore is at the position where
it is smallest.
Push in a right angle to the cylinder wall.
Caution
Do not decline the piston ring in either direction.
2) Measure the clearance of the ring joint using a feeler gauge.
Note
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If the measured value is outside the standard range, replace the piston ring.
Piston ring joint clearance

Piston ring Standard value
0.20 to 0.34 mm {
Top ring
0.0079 to 0.0134 in }
0.70 to 0.94 mm {
2nd ring
0.0276 to 0.0370 in }
0.20 to 0.49 mm {
Oil ring
0.0079 to 0.0193 in }
5. Measurement of clearance between piston ring and piston ring groove
1) Remove all carbon from the piston ring grooves.
2) Install the piston ring to the piston.
3) Measure the clearance between the piston ring groove and the piston ring using a feeler gauge.
Note
Top ring cannot be measured, because of its shape.
Replace the piston or piston ring if the measured value exceeds the limit.
Clearance between piston ring

and piston ring groove
Standard
Piston ring Limit
value
Top ring - -
0.05 to 0.09
mm { 0.15 mm {
2nd ring
0.0020 to 0.0059 in }
0.0035 in }
0.03 to 0.07
mm { 0.15 mm {
Oil ring
0.0012 to 0.0059 in }
0.0028 in }
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6. Measurement of clearance between piston and piston pin
1) Apply the engine oil to the piston pin.
2) Insert the piston pin to the piston.
3) Inspect whether a certain amount of resistance exists in the piston when the piston pin is lightly pushed.
Note
Inspect with the piston at room temperature.
If there is looseness, measure the clearance of the piston and piston pin.
4) Measure the outer diameter of the piston pin using a micrometer.
Note
If the measured value is outside the standard range, replace the piston pin.
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5) Calculate the clearance from the piston pin hole inner diameter and piston pin outer diameter.
Note
Replace the piston or piston pin if the measured value exceeds the standard value.
6) Measure the connecting rod small end bushing inner diameter using a dial gauge.
7) Calculate the clearance between the inner diameter of the connecting rod small end bushing and the outer
diameter of the piston pin.
Note
Replace the connecting rod or piston pin if the measured value exceeds the limit.

7. Connecting rod measurement
1) Measure the twisting and degree of parallelization of the connecting rod using a connecting rod aligner.
Note
For a connecting rod alignment of 100 mm {3.94 in}, measure the twist and the degree of
parallelization of the large end hole and the small end hole.
Replace the connecting rod if the measured value exceeds the standard value.
Standard: 0.05 mm { 0.0020 in } Twisting
Standard: 0.05 mm { 0.0020 in } Degree of parallelization
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8. Connecting rod oil clearance measurement
Note
The removed caps should be lined up in the order of the cylinder number.
2) Clean the bearing and crankshaft pin.
3) Place the PLASTIGAUGE on the crankshaft pin.

4) Apply engine oil to the threaded portions and seating surfaces of the tightening bolts.
5) Temporarily tighten the connecting rod bearing caps and connecting rods to the crankshaft.
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6) Final tighten the tightening bolts in the order shown in the diagram using the special tool.
Caution
Do not rotate the crankshaft.
Tightening torque: 30.0 N・m { 3.1 kgf・m / 22 lb・ft } 1st time

8) Measure the widest point of the flattened PLASTIGAUGE, and measure the oil clearance of the crank pin
section.
Note
Replace the bearing as a set if the measured value exceeds the standard value.
9) Remove any PLASTIGAUGE adhering to the following parts.
Connecting rod bearing

Crank pin
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Piston reassembly (RZ4E-TC)
1. Component views
Piston
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Part name
1. Piston ring
2. Snap ring
3. Piston pin
4. Piston
5. Connecting rod
Tightening torque
9-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
9-2: 90 to 105 °
2. Piston reassembly
1) Sufficiently apply engine oil to the piston pin.
2) Install the snap ring for one side to the piston.
Caution
3) Align the piston to the connecting rod.
Caution
Install so that the piston head front mark and the connecting rod convex mark face the same
direction.
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Legend
1. Front mark
2. Convex mark
4) Install the piston pin to the piston and connecting rod.
5) Install the snap ring to the piston.
Caution
Confirm that the snap ring securely fits into the piston groove and that both the piston and
connecting rod move smoothly.
Check that the snap ring is installed in the ring groove.
6) Install the oil ring to the piston.
Note
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There is no top or bottom direction for the oil ring.
Caution
The oil ring joint and coil expander joint should be 180° opposite from each other.
Install so that there is no opening at the coil expander joint section.
7) Install the 2nd ring to the piston using ring pliers.
Note
Install the 2nd ring with the laser mark facing upwards.
Caution
When reusing the piston ring, do not insert it upside down.
8) Install the top ring to the piston using ring pliers.
Note
Install the top ring with the laser mark facing upwards.
Caution
When reusing the piston ring, do not insert it upside down.
Legend
1. Top ring joint
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2. 2nd ring joint
3. Oil ring joint
4. Coil expander joint
Piston installation (RZ4E-TC)
1) Install the connecting rod bearing to the connecting rod.
Caution
bearing.
3) Sufficiently apply the engine oil to the following locations.
Piston ring
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Piston ring groove
Piston side surface
Cylinder bore surface
4) Turn the crankshaft in the forward direction and align to top dead center.
5) Install the piston to the cylinder block using the special tool.
Note
Face the piston front mark towards the front.
Use the piston ring compressor to insert the piston into the cylinder block.
SST: 5-8840-9018-0 - piston setting tool
Caution
When pushing the piston, do not allow the connecting rod to interfere with the oil jet.
If the crank pin is at bottom dead center, the connecting rod may hit and damage the oil jet.
Do not damage the cylinder block inner surface.
6) Install the connecting rod bearing to the bearing cap.
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Caution
bearing.
9) Temporarily tighten the bearing caps to the connecting rods after matching their cylinder numbers.
Caution
Do not reuse the connecting rod bolts.
10) Final tighten the bearing cap bolts to the connecting rod in the order shown in the diagram, using a torque
wrench and the special tool.
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11) Turn the crankshaft and check that it turns smoothly without interference.
Caution
Check that there is no oil jet deformation and that there is no interference with other parts.
2. Oil pump installation
Refer to "1.Engine 1E.Lubrication(RZ4E-TC) oil pump installation".

Timing chain removal (RZ4E-TC)
1. Component views
Timing chain
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Part name

3. Bolt
4. Bolt
5. Timing chain
8. Bolt
10. Bolt
11. Crank gear
12. Oil pump
13. Bolt
14. Idle gear A
16. Bolt
19. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 64 N・m { 6.5 kgf・m / 47 lb・ft }
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17: 70 N・m { 7.1 kgf・m / 52 lb・ft }
19: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Engine removal
Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Engine removal".
4. Engine oil drain
Caution
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Legend

Legend
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2. Gasket

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Caution
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Legend
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2. Gasket
Legend
1. Vacuum pipe
2. Vacuum hose
3. Bracket
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Legend
1. Vacuum pipe
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2. Vacuum hose
3. Bracket

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Legend

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Legend

18. Glow plug removal
1) Remove the glow plug terminal and glow plug connector from the glow plug.
Legend
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2) Remove the glow plug from the cylinder head.
19. EGR removal

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EGR pipe
EGR valve
EGR duct
Gasket
Legend
1. EGR duct
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2. EGR pipe
3. EGR valve
4. Gasket
EGR valve
EGR duct
Gasket
Caution

Legend
1. Vacuum pipe
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2. Vacuum hose
3. Bracket

EGR cooler
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EGR valve
EGR duct
Gasket
Legend
1. EGR duct
2. EGR cooler
3. EGR valve
4. Gasket
EGR valve
EGR duct
Gasket
Caution
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Caution
Legend
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Caution
Legend
1. Fuel feed pipe

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Caution

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Note
Fixing position
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Legend

2. Gasket
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Legend
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Caution
Caution
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Legend
1. O-ring
2. CKP sensor
29. Flywheel removal

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Note
Caution
Legend
1. CKP sensor
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3. Ring gear
Washer
Flexible plate
Flywheel
Note
Caution
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Legend
1. CKP sensor
3. Ring gear
Caution
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31. Flywheel housing removal
1) Remove the flywheel housing from the cylinder block.
Caution
2) Remove the timing chain from the idle gear A sprocket.

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Timing chain installation (RZ4E-TC)
1. Component views
Timing chain
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Part name

3. Bolt
4. Bolt
5. Timing chain
8. Bolt
10. Bolt
11. Crank gear
12. Oil pump
13. Bolt
14. Idle gear A
16. Bolt
19. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 64 N・m { 6.5 kgf・m / 47 lb・ft }
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17: 70 N・m { 7.1 kgf・m / 52 lb・ft }
19: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2. Flywheel housing installation
Measure the protrusion amount of the piston head in order to select the gasket grade.
1) Measure the protrusion amount of the piston head using a dial gauge.
Caution
The measurement point should be as close to the cylinder block as possible.
The difference between the protruding amount of each piston must be within the specified range.
Standard: 0.05 mm { 0.0020 in }

Legend
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Legend
2) Turn the crankshaft in the forward direction (clockwise) to align the idle gear A alignment mark.
Note
Align the alignment marks at the same time at the two locations: the alignment mark of idle gear A
and the crank gear, the alignment mark of idle gear A and the supply pump gear.
Caution
After the alignment marks are aligned, do not rotate the crankshaft until the camshaft carrier is
installed.
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Legend
1. Idle gear A
2. Crank gear
Legend
1. Supply pump gear

2. Idle gear A
3) Install the timing chain to the idle gear A sprocket.
Note
Align the timing chain yellow paint section with the flange timing mark, and install.
Check whether the idle gear A sprocket white paint teeth section and flange timing mark are aligned.
Legend
1. Timing chain yellow paint section
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2. Flange timing mark
4) Apply ThreeBond 1207B or equivalent to the position on the flywheel housing shown in the diagram.
Standard value
5) Apply ThreeBond 1207B or equivalent to the positions on the cylinder block and crankcase shown in the
diagram.
Standard value
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6) Install the flywheel housing to the cylinder block in the order shown in the diagram.
Caution
Carefully wipe away any gasket that has leaked out from between the aligning surfaces of the
flywheel housing and cylinder block.
Caution
Note
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SST: 5-8840-3221-0 - sleeve
Sleeve dimension
Legend
1. Sleeve (5-8840-3178-0)
2. Sleeve (5-8840-3221-0/5-8840-3225-0)
3. 39 mm {1.54 in}
4. 35 mm {1.38 in}
Legend
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2. Flywheel housing
3. Standard value
5. Crankshaft
Note
Legend
1. Flywheel
2. Washer
3. Bolt
Caution
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Note

Washer
Flexible plate
Flywheel
Caution
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Caution
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Legend
1. O-ring
2. CKP sensor
Caution
cylinder head.
2) Select the cylinder head gasket grade based on the average piston head protrusion amount.
Caution
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Caution
Standard value
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Caution

Washer
Note

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Legend
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Note
marks.
Legend
1. Alignment mark
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2. Notch
Caution
Standard value
Note
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10) Install the timing chain to the camshaft sprocket.
Note
Align the timing chain yellow paint section with the camshaft sprocket marking, and install.
Legend
1. Yellow paint section
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2. Mark
Caution
Note

Fixing position
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Caution
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Note
Legend
1. Detent

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Legend
1. Fuel feed pipe
Legend

13. EGR installation
Caution
EGR valve
EGR duct
Gasket
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EGR valve
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EGR duct
Gasket

Caution
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EGR valve
EGR duct
Gasket
EGR valve
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EGR duct
Gasket

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Note

Legend
1. Inlet cover
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2. Detent
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Note

Legend
1. Inlet cover
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2. Detent

Legend
1. Vacuum pipe
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2. Vacuum hose
3. Air duct bracket
Legend

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Legend
1. Heater hose

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Legend
1. Vacuum pipe
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2. Vacuum hose
3. Bracket

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Legend
1. Vacuum pipe
2. Vacuum hose
3. Bracket
18. Glow plug installation
1) Install the glow plug to the cylinder head.
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2) Install the glow plug terminal and glow plug connector to the glow plug.
Legend

Caution
Legend
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2. Gasket

Standard value
a: 45 °
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Note
Legend
1. Protrusion
Caution

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Legend
1. Stud bolt
2. Washer
3. Nut

Legend
1. Stud bolt
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2. Spacer
3. Washer
4. Nut
Note
Caution

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Caution
Caution

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diagram.

1) Install the gasket to the turbocharger oil pipe.
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Caution

Legend
1. Turbocharger
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2. Gasket
Caution
Legend

2. Bolt
3. Eyebolt
Legend
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1. Turbocharger oil pipe (return side)
2. Bolt
Legend


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Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Engine installation".

Supplementary Information (RZ4E-TC)
1. Component views
Engine mounting
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Part name
1. Bolt
3. Bolt
4. Bolt
6. Bolt
8. Bolt
9. Bolt
Tightening torque
1: 131 N・m { 13.4 kgf・m / 97 lb・ft }
3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
4: 116 N・m { 11.8 kgf・m / 86 lb・ft }
6: 131 N・m { 13.4 kgf・m / 97 lb・ft }
8: 52 N・m { 5.3 kgf・m / 38 lb・ft }
9: 116 N・m { 11.8 kgf・m / 86 lb・ft }
Cylinder head cover
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Part name
1. Oil filler cap

3. Oil seal
4. Nut
6. Gasket
7. O-ring
8. Gasket
9. Gasket
10. Bolt
Tightening torque
4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
Cylinder head
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Part name

2. Split collar
4. Valve spring
7. Valve
9. Bolt
10. Cylinder head
12. HLA
13. Rocker arm
Tightening torque
8-1: 115 N・m { 11.7 kgf・m / 85 lb・ft }
8-2: 115 N・m { 11.7 kgf・m / 85 lb・ft }
8-3: 90 to 120 °
8-4: 90 to 120 °
9: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Camshaft
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Part name
1. Camshaft cap
2. Bolt
4. Bolt
6. Bolt
7. Inlet camshaft
8. Bolt
9. Gasket
10. Cylinder head
11. Bolt
12. Vacuum pump
13. Bolt
Tightening torque
2: 7.0 N・m { 0.7 kgf・m / 62 lb・in }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
6: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 7.0 N・m { 0.7 kgf・m / 62 lb・in }
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11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Timing chain
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Part name

3. Bolt
4. Bolt
5. Timing chain
8. Bolt
10. Bolt
11. Crank gear
12. Oil pump
13. Bolt
14. Idle gear A
16. Bolt
19. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 64 N・m { 6.5 kgf・m / 47 lb・ft }
17: 70 N・m { 7.1 kgf・m / 52 lb・ft }
19: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Idle gear
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Part name

3. Bolt
4. Bolt
5. Timing chain
8. Bolt
10. Bolt
11. Crank gear
12. Oil pump
13. Bolt
14. Idle gear A
16. Bolt
19. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 32 N・m { 3.3 kgf・m / 24 lb・ft }
16: 64 N・m { 6.5 kgf・m / 47 lb・ft }
17: 70 N・m { 7.1 kgf・m / 52 lb・ft }
19: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Crankshaft pulley
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Part name
1. Bolt
2. Washer
Tightening torque
1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
1-2: 60 to 90 °
Piston
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Part name
1. Piston ring
2. Snap ring
3. Piston pin
4. Piston
5. Connecting rod
Tightening torque
9-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
9-2: 90 to 105 °
Flywheel
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Part name
1. Bolt
2. CKP sensor
3. Flywheel housing
5. Bearing
6. Flywheel washer
7. Bolt
9. Flexible plate
11. Bolt
Tightening torque
1: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
7-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
7-2: 60 to 90 °
11-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
11-2: 120 °
11-3: 30 to 60 °
Flywheel housing
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Part name
1. Bolt
2. CKP sensor
3. Flywheel housing
5. Flywheel
6. Bearing
7. Washer
8. Bolt
9. Nut
10. Bolt
11. Plug
12. O-ring
Tightening torque
1: 5.0 N・m { 0.51 kgf・m / 44.3 lb・in }
8-1: 40 N・m { 4.1 kgf・m / 30 lb・ft }
8-2: 60 to 90 °
9: 52 N・m { 5.3 kgf・m / 38 lb・ft }
10: 52 N・m { 5.3 kgf・m / 38 lb・ft }
11: 63 N・m { 6.4 kgf・m / 46 lb・ft }
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Part name
1. Bolt
2. Oil seal cover
Tightening torque
1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

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Part name
Crankshaft
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Part name
1. Bolt
2. Bearing cap
3. Thrust bearing
5. Crankshaft
7. Thrust bearing
Tightening torque
1-1: 50 N・m { 5.1 kgf・m / 36.9 lb・ft }
1-2: 60 to 90 °

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Part name
1. Gasket
2. Inlet cover
3. Nut
4. Bolt
5. EGR valve
6. Gasket
7. Gasket
8. EGR cooler
9. Gasket
10. EGR duct
11. Bolt
12. Bolt
13. Bolt
14. Nut
15. Bolt
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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Part name
1. Gasket
2. Inlet cover
3. Nut
4. Bolt
5. EGR valve
6. Gasket
7. Gasket
8. EGR pipe
9. Gasket
10. EGR duct
11. Bolt
12. Bolt
13. Bolt
14. Nut
Tightening torque
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
13: 25 N・m { 2.5 kgf・m / 18 lb・ft }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Exhaust manifold
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Part name
1. Gasket
2. Bolt
3. Heat protector
4. Exhaust manifold
5. Nut
6. Bolt
7. Heat protector
8. Bolt
Tightening torque
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
5-2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5-3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
6: 25 N・m { 2.5 kgf・m / 18 lb・ft }
8-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
8-2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
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8-3: 52 N・m { 5.3 kgf・m / 38 lb・ft }
Front cover
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Part name
1. Bolt
2. Washer
4. Bolt
5. Nut
6. Water pump
7. Water inlet pipe
8. O-ring
9. Front cover
10. Gasket
11. Bolt
12. Bolt
13. Oil seal cover
14. Nut
15. Bolt
Tightening torque
1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
1-2: 60 to 90 °
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 25 N・m { 2.5 kgf・m / 18 lb・ft }
12: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
14: 25 N・m { 2.5 kgf・m / 18 lb・ft }
15: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Crankcase
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Part name
1. Bolt
3. Bolt
5. Crankcase
6. Oil pan
7. Bolt
8. Nut
9. Gasket
10. Drain bolt
Tightening torque
1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
7: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
8: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 83.3 N・m { 8.5 kgf・m / 61 lb・ft }
Cylinder block
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Part name
1. Cylinder block

1B Engine Mechanical Rz4e

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1B Engine Mechanical Rz4e

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Available Formats

Camshaft removal (RZ4E-TC)

2: 7.0 N・m { 0.7 kgf・m / 62 lb・in }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 7.0 N・m { 0.7 kgf・m / 62 lb・in }

11: 25 N・m { 2.5 kgf・m / 18 lb・ft }

13: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Cylinder head cover removal

3. Camshaft carrier removal

1. Timing chain tensioner

5) Remove the timing chain from the camshaft sprocket.

6) Disconnect the vacuum hose from the vacuum pump.

1) Remove the vacuum pump from the camshaft carrier.

Standard: 0.050 to 0.130 mm { 0.0020 to 0.0051 in }

Limit: 0.250 mm { 0.0098 in }

2) Use the M5 lock bolt to secure the inlet camshaft gear.

5) Remove the camshaft sprocket from the exhaust camshaft.

1. Camshaft gear disassembly

1. Inlet camshaft sub gear disassembly

1) Remove the M5 lock bolt from the inlet camshaft gear.

2) Secure the camshaft in a vise using an aluminum clasp, etc.

1. Inlet camshaft sub gear

2. Camshaft runout measurement

1) Put the camshaft on the V-block.

2) Slowly turn the camshaft to measure runout of the dial gauge.

Limit: 0.05 mm { 0.0020 in }

1) Measure the height of the cam lobe using a micrometer.

Cam lobe height

1) Measure the diameter of the camshaft journal using a micrometer.

Camshaft journal diameter

1. Camshaft gear reassembly

1. Inlet camshaft sub gear assembly

1) Secure the camshaft in a vise using an aluminum clasp, etc.

1. Inlet camshaft sub gear

SST: 5-8840-3179-0 - scissors gear spring wrench

2: 7.0 N・m { 0.7 kgf・m / 62 lb・in }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 7.0 N・m { 0.7 kgf・m / 62 lb・in }

11: 25 N・m { 2.5 kgf・m / 18 lb・ft }

13: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1. Exhaust camshaft gear

4) Apply engine oil to the following parts.

Camshaft cap sliding surface

5) Install the camshaft cap to the camshaft carrier.

Tightening torque: 7.0 N・m { 0.7 kgf・m / 62 lb・in }

3. Vacuum pump installation

1) Install the vacuum pump to the camshaft carrier.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4. Camshaft carrier installation

1) Install the dowel pin to the cylinder head.

4) Referring to the diagram, apply ThreeBond 1207B to the cylinder head.

a: 4.0 to 5.0 mm { 0.157 to 0.197 in } Bead width

Tightening torque: 7.0 N・m { 0.7 kgf・m / 62 lb・in }

Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }

1. Timing chain tensioner

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) cylinder head cover installation".

1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

7: 10.0 N・m { 1.0 kgf・m / 89 lb・in }