Disassembly

3MZ-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

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 NO. 2 CYLINDER HEAD COVER GASKET
(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 DIPSTICK SUB-ASSEMBLY
(a) Remove the oil level dipstick sub-assembly from the oil level dipstick guide.
12. REMOVE OIL LEVEL DIPSTICK GUIDE
(a) Remove the bolt and oil level dipstick guide.
(b) Remove the O-ring from the oil level dipstick 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 NO. 1 TIMING BELT COVER

(a) Remove the 4 bolts and No. 1 timing belt cover.
15. REMOVE NO. 2 TIMING BELT COVER

(a) Remove the 5 bolts and No. 2 timing belt 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 NO. 2 TIMING BELT GUIDE

(a) Remove the No. 2 timing belt guide from the crankshaft.
18. REMOVE TIMING BELT
(a) Set the 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 the 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 NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
(a) Using a 10 mm socket hexagon wrench, remove the pivot bolt, timing belt idler No. 1 and distributor drive gear plate washer.
20. REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY
(a) Remove the bolt and No. 2 timing belt idler sub-assembly.
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 NO. 3 TIMING BELT COVER

(a) Remove the 6 bolts and No. 3 timing belt cover.
(b) Remove the 6 collars and 6 bushings from the No. 3 timing belt 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

NOTE:
- 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.

NOTE:
- 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.

NOTE:
- 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.

NOTE:
- Do not pry out the camshaft.
- Do not damage the portion of the cylinder head which receives the shaft thrust.

30. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

(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. 4 camshaft.

NOTE:
- 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. 4 camshaft.
31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Clamp the camshaft in a vise on the hexagonal lobe.
(b) Check that the VVT-i does not turn.

(c) Cover all the oil ports with vinyl tape except the port on the advance angle side (nearest to the convex portion) shown in the illustration.
(d) Apply about 100 kPa (1 kgf/cm2, 14 psi) of air pressure to the port on the advance angle side.
NOTE: Cover the ports with a shop rag or piece of cloth when applying pressure to keep oil from splashing.
HINT: This operation releases the lock pin for the most retard angle lock.

(e) Turn the VVT-i to the advance angle side (the white arrow marked direction in the illustration) by hand.
Standard:
The VVT-i turns.
HINT: Depending on the air pressure, the VVT-i will turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, it might be difficult to get the lock-pin to release.

(f) Check that the VVT-i moves freely within about 30° range. Do not move the VVT-i unit to the most retard angle position as the lock-pin will be engaged again.
Standard:
Smooth movable range is about 30°
(g) Turn the VVT-i by hand and lock it at the most retard angle position.
32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
NOTE: Do not remove or install the camshaft timing gear (VVT-i) unless the VVT-i or the camshaft needs to be replaced.

(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTE: Do not damage the camshaft.

(b) Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.

NOTE:
- Remove it with the lock-pin engaged and locked at the most retard angle position.
- The lock nut has left-hand threads.
- Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.

(c) Remove the camshaft VVT-i.
NOTE: Never remove the 3 bolts on the gear.
If it is difficult to remove the VVT-i, tap it lightly using a plastic-faced hammer and then remove it.
33. REMOVE CAMSHAFT SUB GEAR

(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTE: Do not damage the camshaft.

(b) Using SST, turn the sub-gear counterclockwise, and remove the service bolt.
SST: 09960-10010
09962-01000
09963-00500

(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, camshaft sub-gear and camshaft gear bolt washer.
HINT: Arrange the camshaft sub-gears and gear bolt washers (RH and LH sides) so that they can be returned to the original locations when re-assembling.

34. REMOVE NO. 2 ENGINE HANGER
(a) Remove the 2 bolts and No. 2 engine hanger from the cylinder head.
35. REMOVE REAR CYLINDER HEAD COVER

(a) Remove the 12 bolts, nut and rear cylinder head cover from the cylinder head.
36. REMOVE OIL CONTROL VALVE FILTER

(a) Remove the plug, gasket and valve filter.
37. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Using an 8 mm socket hexagon wrench, remove the hexagon bolt.

(b) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTE:
- Do not drop the washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.

38. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head gasket from the cylinder block.
39. REMOVE CYLINDER HEAD LH

(a) Using an 8 mm socket hexagon wrench, remove the hexagon bolt.

(b) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTE:
- Do not drop the washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.

40. REMOVE NO. 2 CYLINDER HEAD GASKET
(a) Remove the No. 2 cylinder head gasket from the cylinder block.
41. REMOVE INLET WATER HOUSING

(a) Remove the 8 bolts and 2 nuts, then remove the inlet water housing.
42. REMOVE OIL FILTER SUB-ASSEMBLY

(a) Using SST, remove the oil filter.
SST: 09228-07501
(b) Using a 12 mm socket hexagon wrench, remove the oil filter union.
43. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket.
44. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

(b) Insert the oil pan seal cutter blade between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTE: Be careful not to damage the contact surfaces of the oil pans.

45. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the bolt and 2 nuts, then remove the oil strainer and the gasket.
46. REMOVE OIL PAN SUB-ASSEMBLY

(a) Loosen and remove the 17 bolts uniformly.

(b) Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.
NOTE: Do not damage the contact surfaces of the oil pan and cylinder block.

47. REMOVE NO. 1 OIL PAN BAFFLE PLATE
(a) Remove the 6 bolts and the No. 1 oil pan baffle plate from the oil pan.
48. REMOVE REAR ENGINE OIL SEAL RETAINER
(a) Remove the 6 bolts.

(b) Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and the main bearing cap.
49. REMOVE REAR ENGINE OIL SEAL

(a) Using a screwdriver and a hammer, tap out the oil seal.
50. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 9 bolts.
(b) Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
(c) Remove the O-ring.
51. REMOVE OIL PUMP SEAL

(a) Using a screwdriver, pry out the oil seal.
52. REMOVE SPARK PLUG TUBE GASKET

(a) Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.
NOTE: Do not damage the baffle plate of the cylinder head cover.

(b) Using a screwdriver and a hammer, tap out the gasket.