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EM2378
A32118
A32119
A62820
Overall Length
14±12
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
35. INSPECT C RANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di- ameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.
Minimum sprocket diameter (w / chain):
51.6mm (2.032 in.)
36. INSPECT CHAIN TENSIONER SLIPPER
(a) Using a vernier calipers, measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 in.)
37. INSPECT CHAIN VIBRATION DAMPER NO.1
(a) Using a vernier calipers, measure the vibration damper wears.
Maximum wear: 1.0 mm (0.039 in.)
38. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length:
156.0 ± 159.0 mm (6.142±6.260 in.)
Maximum bolt length: 159.5 mm (6.280 in.)
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EM1628
EM2011
EM2538
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±13
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
39. INSPECT CAMSHAFT
(a) Inspect camshaft for runout.
(1) Place the camshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
(b) Inspect cam lobes. (1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.333 ± 44.433 mm (1.7454 ± 1.7493 in.)
Exhaust 43.761 ± 43.861 mm (1.7229 ± 1.7268 in.)
Minimum cam lobe height:
Intake 44.18 mm (1.7394 in.)
Exhaust 43.61 mm (1.7169 in.)
(c) Inspect camshaft journals. (1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
34.449 ± 34.465 mm (1.3563 ± 1.3569 in.)
Others journal diameter:
22.949 ± 22.965 mm (0.9035 ± 0.9041 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
40. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Apply two or three threads of adhesive to the drain union, and install i\
t within 3 minutes. Torque: 20 N m (204 kgf cm15 ftlbf)
(b) After applying the specified torque, rotate the drain union clockwise until i\
ts drain port faces downward.
NOTICE:
Do not put into coolant in an hour after the installation.
Do not rotate the drain union more than 360 in (b), and never loosen it after setting the union
correctly.
41. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 nuts and a bolt. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
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A62821
Seal Width 4 ± 5 mm
6 mm Seal Packing
A62822
SST
A62817SST
14±14
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
42. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing material from the contact sur- face.
(b) Apply seal packing in the shape of bead (Diameter 3.5 mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal
packing.
Do not put into engine oil within 2 hours after instal-
ling.
(c) Install the oil pan with the 14 bolts and 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
43. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install it. Torque: 37 N m (377 kgf cm, 27 ftlbf)
44. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crank shaft.
45. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter union. Torque: 30 N m (306 kgf cm, 22 ftlbf)
46. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501
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A30890
A62826
Lot No.
A62816
84 2 59731610
A62823
Paint Mark
90
Front
A62815
Mesh
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±15
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
47. INSTALL OIL PUMP ASSY
(a) Engage the spline teeth of the oil pump drive rotor with the
large teeth of the crankshaft, and side the oil pump.
(b) Install the oil pump with the 5 bolts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
48. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE:
Pay attention to the installation direction.
Place the cylinder head quietly in order not to damage
the gasket with the bottom part of the head.
49. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Using a bi±hexagon wrench 10, install and uniformly tight- en the 10 cylinder head bolts with plate washers, in sever-
al passes, in the sequence shown.
Torque: 49 N m (500 kgf cm, 36 ftlbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90 in the numerical or-
der shown.
(e) Check that the point marked bolts are moved at 90
angle.
50. INSTALL OIL CONTROL VALVE FILTER
(a) Confirm that the filter is clear.
(b) Install the oil control valve filter to the cylinder head.
(c) Place a new gasket on the bolt, and install it. Torque: 30 N m (306 kgf cm, 22 ftlbf)
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A62824
Straight Pin
Key Groove
A32167
A62150
14±16
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Install a new O±ring to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
52. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc- tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N m (551 kgfcm 40 ftlbf)
(e) Check that the camshaft timing gear assembly can move to the retard angle side (the right angle), and is locked at
the most retarded position.
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and install the camshaft tim- ing gear.
Torque: 54 N m (551 kgf cm 40 ftlbf)
NOTICE:
Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT
(a) Apply light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.
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A62825
62 4 8
51 3 7
11
10 9
A10079
Mark
A62170
Set KeyUpward
A62171
Yellow
Color Line
Timing Mark
A62172
SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±17
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(c) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 23 N m (235 kgf cm, 17 ftlbf)
Bearing cap No. 3 13 N m (133 kgf cm, 10 ftlbf)
55. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression. (1) Turn the hexagonal wrench head portion of thecamshafts, and align the point marks of the cam-
shaft timing gears.
(2) Using a crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
(b) Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
(c) Using a SST, install the sprocket. SST 09223±22010
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A62173
Yellow Color MarkTiming Mark
A30867
A62174
SST
A62175
Seal Width
4 ± 5 mm
Seal Packing
14±18
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
56. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
57. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N m (194 kgf cm, 14 ftlbf)
58. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
59. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to the oil seal lip.
(b) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip off foreign materials.
60. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material from the contact sur- face.
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A62176
Chain Cover
Groove
Cylinder Head
Groove Seal Width
4 ± 5 mm
A B
7 mm 4.5 mm 3 mm
6 mm
12 mm
B
A
A ± A B ± B A
A
A62177
Raise
Push
Hook
Pin
A62178
Push
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Apply seal packing in the shape of bead (Diameter 3.5
mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent
(c) Install the timing chain cover, with the 12 bolts and nut.
Torque:
M6 13 N m (133 kgf cm, 10 ftlbf)
M8 19 N m (194 kgf cm, 14 ftlbf)
NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal
packing.
Do not put into engine oil within 2 hours after instal-
ling.
61. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check the O±ring is clean, and set the hook as shown in the illustration.
(b) Apply engine oil to the chain tensioner and install it with the 2 nuts..
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
NOTICE:
When installing the tensioner, set the hook again if the
hook releases the plunger.
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