Part 1
3MZ-FE ENGINE MECHANICAL: 3MZ-FE ENGINE UNIT:
DISASSEMBLY
1. REMOVE SPARK PLUG
(a) Remove the 6 spark plugs.
2. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(a) Remove the ventilation valve sub-assembly.
3. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap sub-assembly.
4. REMOVE OIL FILLER CAP GASKET
(a) Remove the oil filler cap gasket.
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 9 bolts and cylinder head cover sub-assembly.
6. REMOVE CYLINDER HEAD COVER GASKET
(a) Remove the cylinder head cover gasket.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove the 9 bolts and cylinder head cover sub-assembly LH.
8. REMOVE CYLINDER HEAD COVER GASKET NO.2
(a) Remove the cylinder head cover gasket No.2.
9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Remove the 2 bolts and 2 camshaft timing oil control valve assemblies from the cylinder heads.
(b) Remove the O-ring from each camshaft timing oil control valve assembly.
10. REMOVE VVT SENSOR
(a) Remove the 2 bolts and 2 VVT sensors.
11. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
(a) Remove the oil level gage sub-assembly from the oil level gage guide.
12. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt and oil level gage guide.
(b) Remove the O-ring from the oil level gage guide.
13. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the pulley bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
(b) Using SST and the pulley bolt, remove the pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05031
NOTE: Before using SST, apply lubricating oil on the threads and tip of the SST center bolt.
14. REMOVE TIMING BELT NO.1 COVER
(a) Remove the 4 bolts and timing belt No.1 cover.
15. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 5 bolts and timing belt No.2 cover.
16. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 2 bolts, 2 nuts, and engine mounting bracket RH from the water pump assembly.
17. REMOVE TIMING BELT GUIDE NO.2
(a) Remove the timing belt guide No.2 from the crankshaft.
18. REMOVE TIMING BELT
(a) Set No.1 cylinder to TDC/compression.
(1) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
(2) Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley with the oil pump body.
(3) Check that timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned.
HINT: If not, turn the crankshaft 1 revolution (360°).
(4) Remove the crankshaft pulley bolt.
(b) If reusing the timing belt, check that there are 4 installation marks on the timing belt as shown in the illustration.
(1) If the installation marks have disappeared, put new installation marks on the timing belt before removing.
(c) Set No.1 cylinder to approximately 60° BTDC/ compression.
(1) Turn the crankshaft counterclockwise by approximately 60°.
NOTICE:
- Be sure to set the timing pulley at the correct angle in order to prevent it from being damaged when the timing belt is removed.
- If the timing belt is removed when the crankshaft timing pulley is not installed at the correct angle, the piston head or valve head may come into contact with the pulley and damage it. Make sure that the timing pulley is installed at the correct angle.
(d) Remove the timing belt tensioner.
NOTE: Do not reinstall the tensioner with its plunger extended.
(e) Remove the timing belt in the following order.
NOTE: Do not turn the crankshaft or camshaft timing pulley with the timing belt removed. If turned, the piston head or valve head may come into contact with the crankshaft or timing pulley and damage them.
19. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.1
(a) Using a socket hexagon wrench 10 mm, remove the pivot bolt, timing belt idler No.1 and distributor drive gear plate washer.
20. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2
(a) Remove the bolt and timing belt idler sub-assembly No.2.
21. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
22. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the bolt and the RH timing pulley.
SST: 09960-10010
09962-01000
09963-01000
(b) Using SST, remove the bolt and the LH timing pulley.
SST: 09960-10010
09962-01000
09963-01000
HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.
23. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 6 bolts and timing belt No.3 cover.
(b) Remove the 6 collars and 6 bushings from the timing belt No.3 cover.
24. REMOVE TIMING BELT IDLER BRACKET
(a) Remove the 2 bolts and timing belt idler bracket.
25. REMOVE CRANKSHAFT TIMING PULLEY
(a) Remove the bolt and the timing belt plate.
(b) Install the pulley bolt to the crankshaft.
(c) Using SST, remove the crankshaft timing pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05011
- Do not scratch the sensor part of the crankshaft timing pulley.
- Before using SST, apply lubricating oil to the threads and tip of the SST center bolt.
26. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 3 bolts and 3 nuts, then remove the water pump and the gasket.
27. REMOVE CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
(a) Align the timing marks (2-dot mark) of the camshaft drive and the driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub-gear to the main gear with a service bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.
(c) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft.
- Do not pry out the camshaft.
- Do not damage the portion of the cylinder head which receives the shaft thrust.
28. REMOVE NO.2 CAMSHAFT
(a) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No.2 camshaft.
- Do not pry out the camshaft.
- Do not damage the portion of the cylinder head which receives the shaft thrust.
(b) Remove the oil seal from the No.2 camshaft.
29. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
(a) Align the timing marks (1-dot mark) of the camshaft drive and the driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub-gear to the main gear with a service bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.
(c) Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No.3 camshaft.
- Do not pry out the camshaft.
- Do not damage the portion of the cylinder head which receives the shaft thrust.