Part 1

3MZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL SPARK PLUG TUBE GASKET

(a) Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST: 09950-60010
09951-00430
SST: 09950-70010
09951-07100
(b) Return the ventilation plate tab to its original position.
(c) Apply a light coat of MP grease to the gasket lip.
2. INSTALL REAR ENGINE OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST: 09223-15030
SST: 09950-70010
09951-07100

NOTE:
- Do not tap the oil seal at an angle.
- Keep the lip free of foreign objects.

(b) Apply MP grease to the oil seal lip.
3. INSTALL REAR ENGINE OIL SEAL RETAINER
(a) Remove any old packing material from the contact surface.

(b) Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE:
- Remove any oil from the contact surface.
- Install the oil seal retainer within 3 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

(c) Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
4. INSTALL OIL PUMP SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST: 09223-00010

NOTE:
- Do not tap the oil seal at an angle.
- Keep the lip free of foreign objects.

(b) Apply MP grease to the oil seal lip.
5. INSTALL OIL PUMP ASSEMBLY
(a) Remove any old packing material from the contact surface.

(b) Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.

(c) Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE:
- Remove any oil from contact surface.
- Apply seal packing to the inner side of the bolt holes.
- Install the oil pump within 3 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

(d) Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.

(e) Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Bolt A - Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
Bolt B - Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Bolt C - Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
6. INSTALL NO. 1 OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
7. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old seal packing from the contact surface.

(b) Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE:
- Remove any oil from the contact surface.
- Apply seal packing to the outer side of the bolt holes in the region "X".
- Apply seal packing to the inner side of the bolt holes in the region "Y".
- Install the oil pan within 3 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

(c) Install the oil pan No. 1 with the 17 bolts. Tighten the bolts uniformly in several steps.
10 mm Bolt A - Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
12 mm Bolt B - Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
8. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove any old seal packing from the contact surface.

(b) Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE:
- Remove any oil from the contact surface.
- Apply seal packing to the inner side of the bolt holes.
- Install the oil pan within 3 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

(c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
10. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft-lbf)
11. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
(b) Check and clean the oil filter installation surface.
(c) Apply clean engine oil to the gasket of a new oil filter.
(d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

(e) Using SST, tighten it an additional 3/4 turn.
SST: 09228-07501
12. INSTALL INLET WATER HOUSING
(a) Remove any old packing material from the contact surface.

(b) Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

NOTE:
- Remove any oil from the contact surface.
- Install the inlet water housing within 3 minutes after applying seal packing.
- Do not expose the seal to coolant within 2 hours after installing.

(c) Install the inlet water housing with the 8 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
13. INSTALL CYLINDER HEAD GASKET

(a) Place a new cylinder head gasket on the cylinder block with the R mark upward.

NOTE:
- Remove any oil from the contact surface.
- Be sure to install the gasket in the correct direction.
- Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

14. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.

Bank 1:

(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft-lbf)
NOTE: The cylinder head bolts are tightened in 2 successive steps.

(d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90° in the same sequence as step (c).
(f) Check that each painted mark is now at a 90° angle to the front.

(g) Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
15. INSTALL NO. 2 CYLINDER HEAD GASKET

(a) Place a new cylinder head gasket on the cylinder block with the L mark upward.

NOTE:
- Remove any oil from the contact surface.
- Be sure to install the gasket in the correct direction.
- Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

16. INSTALL CYLINDER HEAD LH
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washers to the cylinder head bolts.

Bank 2:

(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTE: The cylinder head bolts are tightened in 2 successive steps.

(g) Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft-lbf)
17. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign objects are on the mesh part of the filter.
(b) Assemble the valve filter and the plug.

(a) Install the rear cover and a new gasket with the 12 bolts and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
19. INSTALL NO. 2 ENGINE HANGER
(a) Install the 2 bolts and No. 2 engine hanger.
Torque: 20 Nm (214 kgf-cm, 15 ft-lbf)
20. INSTALL CAMSHAFT SUB GEAR

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

(b) Install the camshaft gear bolt washer and the camshaft sub-gear.
HINT: Attach the pins on the gears to the gear bolt washer ends.

(c) Install the wave washer.

(d) Using snap ring pliers, install the snap ring.

(e) Using SST, align the holes of the camshaft main gear and sub-gear by turning the camshaft sub-gear counterclockwise, and temporarily install a service bolt.
SST: 09960-10010
09962-01000
09963-00500
(f) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
NOTE: Do not damage the camshaft journals.
HINT: When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

21. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Align the alignment pin with the groove and install VVT-i on the camshaft.
NOTE: Install it with the lock-pin engaged and locked at the most retard angle position.

(b) Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.
NOTICE:
- Be sure to apply the oil, otherwise the specified torque cannot be obtained.
- New nuts must be used when replacing the VVT-i unit.

(c) Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
Torque: 150 Nm (1530 kgf-cm, 111 ft-lbf)

NOTE:
- The lock nut has left-hand threads.
- Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.

22. INSTALL NO. 2 CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. 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) Apply new engine oil to the thrust portion and journal of the camshaft.

(b) Place the No. 2 camshaft at a 90° angle of the timing mark (2-dot mark) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.

(d) Install the oil seal to the camshaft.

NOTE:
- Do not turn over the oil seal lip.
- Insert the oil seal until it stops.

(e) Remove any old packing material from the contact surface.

(f) Apply seal packing to the No. 1 bearing cap as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE:
- Install the No. 1 bearing cap within 5 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(i) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
23. INSTALL CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. 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) Apply new engine oil to the thrust portion and journal of the camshaft.

(b) Align the timing marks (2-dot mark) of the camshaft drive gear with the mark on the driven gear.
(c) Place the camshaft on the cylinder head.

(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(f) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
(g) Remove the service bolt.
24. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. 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) Apply new engine oil to the thrust portion and journal of the camshaft.

(b) Place the No. 4 camshaft at a 90° angle of the timing mark (1-dot mark) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.

(d) Install the oil seal to the camshaft.

NOTE:
- Do not turn over the oil seal lip.
- Insert the oil seal until it stops.

(e) Remove any old packing material from the contact surface.

(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(i) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)