P12697
P25743
Painted Mark
Front90°
90°
P12911
Seal Width
2 ± 3 mm A
BA
B
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
EM±107
1393 Author: Date:
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque: 24.5 N´m (250 kgf´cm, 18 ft´lbf)
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolts with paint.
(d) Retighten the cap bolts by 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
14. CHECK CONNECTING ROD THRUST
CLEARANCE (See page EM±83)
15. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.
Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.
Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 6 bolts Uniformly tight-
en the bolt in several passes, in the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL EGR COOLER
Install a new gasket and the EGR cooler with the 3 bolts and 2
nuts.
Torque: 9 N´m (90 kgf´cm, 78 in.´lbf)
P12477
Seal Packing
Z09223
Seal Width
3 ± 5 mmA
BA
B EM±108
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
1394 Author: Date:
17. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826±00100 or equivalent
(b) Install the drain union.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing downward.
18. INSTALL WATER SEAL PLATE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the seal plate
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the seal plate as shown in the il-
lustration.
Seal packing: Part No. 08826±00100 or equivalent
Install a nozzle that has been cut to a 3 ± 5 mm (0.12
± 0.20 in.) opening.
Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
19. INSTALL OIL FILTER UNION
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
20. INSTALL OIL FILTER (See page LU±15)
21. INSTALL OIL PUMP (See page LU±15)
22. INSTALL NO.1 OIL PAN (See page LU±15)
23. INSTALL OIL STRAINER (See page LU±15)
24. INSTALL NO.2 OIL PAN (See page LU±15)
25. INSTALL WATER PUMP (See page CO±8)
26. INSTALL WATER INLET HOUSING
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water in-
let housing and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
P00601
Adhesive
A05416
1
2 34 5
67
8
EM±110
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
1396 Author: Date:
30. INSTALL OIL PRESSURE SWITCH
(See page LU±1)
31. INSTALL GENERATOR, BRACKET AND
ADJUSTING BAR ASSEMBLY
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
32. INSTALL CYLINDER HEAD (See page EM±57)
33. INSTALL TIMING PULLEYS AND BELT
(See page EM±21)
34. REMOVE ENGINE STAND
35. A/T:
INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent
(b) Install the front spacer, drive plate and rear plate on the
crankshaft.
(c) Install and uniformly tighten the 8 bolts, in several passes,
in the sequence shown.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
36. M/T:
INSTALL FLYWHEEL (See step 35)
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
IG0DB±01
SPARK TEST
CHECK CONNECTION OF IGNITION COIL WITH
CHECK RESISTANCE OF HIGH±TENSION CORDS
CHECK POWER SUPPLY TO IGNITION COILS WITH
1. Turn ignition switch to ON.
2. Check that there is battery positive voltage at ignition
CHECK RESISTANCE OF IGNITION COILS
Resistance:
SecondaryCold Hot
9.7 ± 16.7 kW12.4 ± 19.6 kW
CHECK RESISTANCE OF SENSORS
Resistance: Cold Hot
Camshaft position sensor
Crankshaft position sensor835 ± 1,400 W
985 ± 1,600 W1,060 ± 1,645 W
1,265 ± 1,890 W
CHECK IGT SIGNAL FROM ECM
TRY ANOTHER IGNITERIGNITER CONNECTORS
(See step 2)
Maximum resistance: 25 kW per cord
IGNITERS
coil positive (+) terminal.
(See step 4)
(See steps 5 and 6)
(See page DI±22) NO
OK
OK
OK
OK
OK
BAD
BAD
BAD
BAD
BAD
BAD
Connect securely.
Replace cord(s).
Check wiring between ignition switch to ignition
Replace ignition coil(s) with igniter(s).
Replace sensor(s).
Check wiring between ECM and igniters, and coils with igniters.
then try another ECM.
± IGNITION (5S±FE)IGNITION SYSTEM
IG±1
1683 Author: Date:
IGNITION SYSTEM
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in these sentences express the temperature of the coils themselves. ºColdº is from
±10°C (14°F) to 50°C (122°F) and ºHotº is from 50°C (122°F) to 100°C (212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high±tension cord from the spark plug.
(2) Remove the spark plug.
(3) Install the spark plug to the high±tension cord.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors during this test, crank the engine for no more
than 5 ± 10 seconds at time.
If the spark does not occur, do the test as follows:
IG0DF±01
CHECK POWER SUPPLY OF HIGH±TENSION COIL AND IGNITER
SPARK TEST
CHECK RESISTANCE OF HIGH±TENSION CORD
Maximum resistance: 25 kW per cord
CHECK RESISTANCE OF IGNITION COIL 1. Turn ignition switch to ON.
2. Check that there is battery voltage at ignition
coil positive (+) terminal. CHECK CONNECTION OF IGNITION COIL AND IGNITER
Resistance:
Cold Hot
Secondary
10.8 ± 14.9 kW13.1 ± 17.5 kWReplace the ignition coil (s). Connect securely.
Replace the cord(s).
Check wiring between ignition switch to
ignition coil and igniter.
NO
OK OK
OKBAD
BAD
BAD
BAD
CONNECTORS
Primary
0.70 ± 0.94 W0.85 ± 1.10 W AISAN made:
Secondary
6.8 ± 11.7 kW8.6 ± 13.7 kW Primary
0.70 ± 0.94 W0.85 ± 1.10 W Diamond made:
OK
Continue to the next page
± IGNITION (1MZ±FE)IGNITION SYSTEM
IG±1
1695 Author: Date:
IGNITION SYSTEM
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in these sentences express the tempera-
ture of the coils themselves. ºColdº is from ±10°C (14°F) to
50°C (122°F) and ºHotº is from 50°C (122°F) to 100°C
(212°F).
1. INSPECT IGNITER AND SPARK TEST
Check that the spark occurs.
(1) Remove the ignition coil.
(2) Remove the spark plug.
(3) Install the spark plug to the ignition coil, and connect
the ignition coil connector.
(4) Ground the spark plug.
(5) Check if spark occurs while engine is being
cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more 5 ± 10 se-
conds at a time.
If the spark does not occur, do the test as follows:
Replace the camshaft position sensor.CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR
Resistance: Cold Hot
835 ± 1,400 W1,060 ± 1,645 W
CHECK IGT SIGNAL FROM ECM
CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR
Resistance: Cold Hot
1,630 ± 2,740 W2,065 ± 3,225 W
TRY ANOTHER IGNITERReplace the crankshaft position sensor.
Check wiring between ECM and igniter, and
then try another ECM.
OK
OK
OKBAD
BAD
BAD
OK
Continued from the previous page
DENSO made:
Wabash made:1,690 ± 2,560 W2,145 ± 3,010 W
B00848
P24453
WRONG
CORRECT
P24457
IG±2
± IGNITION (1MZ±FE)IGNITION SYSTEM
1696 Author: Date:
2. INSPECT HIGH±TENSION CORDS
(a) Remove the V±bank cover.
(b) Disconnect the high±tension cords from the spark plugs.
(1) Using needle±nose pliers, disconnect the cord
clamp from the engine wire protector.
(2) Disconnect the high±tension cords from the spark
plugs.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(3) Disconnect the high±tension cords from the clamp.
(c) Disconnect the high±tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high±tension cord at the grommet.
NOTICE:
Pulling on or bending the cords may damage the con-
ductor inside.
Do not wipe any of the oil from the grommet after the
high±tension cord is disconnected.
P24458HolderGrommet
S00813
CORRECT WRONG
Clearance
IG0147
Megger
Ground
S03776
IG±4
± IGNITION (1MZ±FE)IGNITION SYSTEM
1698 Author: Date:
(g) Connect the high±tension cords to the ignition coils.
(1) Assemble the holder and grommet.
(2) Align the spline of the ignition coil with the spline of
the holder, and push in the cord.
NOTICE:
Check that the holder is correctly installed to the grommet
and ignition coil as shown in the illustration.
(3) Check that the lock claw of the holder is engaged by
lightly pulling the holder.
(h) Connect the high±tension cords to the spark plugs.
(i) Install the V±bank cover.
3. INSPECT SPARK PLUGS
NOTICE:
Never use a wire brush for cleaning.
Never attempt to adjust the electrode gap on a used
spark plug.
Spark plugs should be replaced every 100,000 km
(60,000 miles).
(a) Remove the high±tension cords set. (See step 2)
(b) Remove the ignition coils.
(c) Inspect the electrode.
Using a megger (insulation resistance meter), measure
the insulation resistance.
Standard correct insulation resistance:
10 MW or more
If the resistance is less than specified, proceed to step (e).
HINT:
If a megger is not available, the following simple method of in-
spection provides fairly accurate results.
(d) Simple Method:
(1) Quickly race the engine to 4,000 rpm 5 times.
(2) Remove the spark plug. (See step (e))
(3) Visually check the spark plug.
If the electrode is dry ... OK
If the electrode is wet ... Proceed to step (f)
(4) Install the spark plug. (See step (i))
± INTRODUCTIONFOR ALL OF VEHICLES
IN±17
17 Author: Date:
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two±way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle's electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.