Page 3608 of 4770
S06043
Front Mark MAHLE Made
RH Piston
LH Piston(1 Cavity)
Front Mark
(Mold Mark)
Front Mark
(1 Cavity)
Front Mark
(Mold Mark)
Z09179
Code Mark
Code Mark No.1
No.2
S06058
RH Piston
Lower Side Rail
No.2
Compression
Front Mark
Expander
Upper Side Rail
No.1
Compression
Lower Side Rail
Upper Side RailFront Mark LH PistonNo.2
Compression
Expander
No.1
CompressionFront Markor EM±102
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
1388 Author: Date:
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
No.11R, T or G1
No.22R, 2T or G2
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
Page 3609 of 4770

P12402
Z09177
No.1 and No.4 No.2 and No.3
Upper
Lower
22.4 mm 19.0 mm
P12599
A05263
Mark
1, 2, 3 or 4
P12600
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
EM±103
1389 Author: Date:
3. INSTALL CONNECTING ROD BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:
Main bearings come in widths of 19.0 mm (0.748 in.) and
22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bear-
ings in the No.1 and No.4 cylinder block journal positions
with the main bearing cap. Install the 19.0 mm (0.748 in.)
bearings in the No.2 and No.3 positions.
Upper bearings have an oil groove and oil holes; lower
bearings do not.
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Install the bearing with the oil hole in the cylinder block.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.2 journal position of
the cylinder block with the oil grooves facing outward.
Page 3610 of 4770

P12495
A05264
A05265
A05266
Less than 6 mm
A05267
EM±104
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
1390 Author: Date:
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. PLACE MAIN BEARING CAPS AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the 2 thrust washers on the No.2 bearing cap with
the grooves facing outward.
(b) Temporarily place the 4 main bearing caps level and let
them in their proper locations.
(c) Apply a light coat of engine oil on the threads and under
the main bearing cap bolts for the 12 pointed head.
(d) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
(e) Insert the main bearing cap with your hand until the clear-
ance between the main bearing cap and the cylinder
block will become less than 6 mm (0.23 in.) by making the
2 internal main bearing cap bolts as a guide.
(f) Using a plastic±faced hammer, lightly tap the bearing cap
to ensure a proper fit.
8. INSTALL 12 POINTED HEAD MAIN BEARING CAP
BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any of the main bearing cap bolts is broken or deformed,
replace it.
Page 3611 of 4770

P12753
10 11
12 13
14
151
162
3
45
6
7
89
P25741
Painted Mark
Front90°
90°
P12586
1
2
34
567
8
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
EM±105
1391 Author: Date:
(a) Apply a light coat of engine oil on the threads and under
the main bearing cap bolts.
(b) Install and uniformly tighten the 16 main bearing cap
bolts, in several passes, in the sequence shown.
Torque: 22 N´m (225 kgf´cm, 16 ft´lbf)
If any of the main bearing cap bolts does not meet the torque
specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolts with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
9. INSTALL HEXAGON HEAD MAIN BEARING CAP
BOLTS
(a) Install a new seal washer to the main bearing cap bolt.
(b) Install and uniformly tighten the 8 main bearing cap bolts,
in several passes, in the sequence shown.
Torque: 27 N´m (275 kgf´cm, 20 ft´lbf)
(c) Check that the crankshaft turns smoothly.
10. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM±83)
Page 3613 of 4770

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)
Page 3614 of 4770

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.
Page 3616 of 4770
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)
Page 3648 of 4770

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: