Installation
3MZ-FE ENGINE MECHANICAL: CYLINDER HEAD:
INSTALLATION
1. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter:
8.95 to 9.05 mm (0.3524 to 0.3563 in.)
Minimum outside diameter:
8.75 mm (0.3445 in.)
If the diameter is less than the minimum, replace the bolt.
2. INSTALL CYLINDER HEAD GASKET NO.2
(a) Place a new cylinder head gasket on the cylinder block with the L mark upward.
- Remove any oil from the contact surface.
- Be careful 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.
3. INSTALL CYLINDER HEAD LH
NOTE: The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
SST: 09011-38121
Torque: 54 Nm (550 kgf-cm, 40 ft-lbf)
(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 90° angle to the front.
(g) Using a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft-lbf)
(h) Using several steps, install and tighten the 2 bolts and intake air connector bracket No.2 uniformly in the sequence shown in the illustration.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
(i) Connect the ground cable with the 2 bolts.
Nut A - Torque: 8.4 Nm (85 kgf-cm, 74 in-lbf)
Nut B - Torque: 11 Nm (112 kgf-cm, 97 in-lbf)
4. INSTALL NO.4 CAMSHAFT SUB-ASSEMBLY Installation
5. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY Installation
6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Adjustments
7. INSTALL WATER INLET PIPE Installation
8. INSTALL OIL LEVEL GAUGE GUIDE
(a) Install a new O-ring to the oil level gauge guide.
(b) Apply soapy water to the O-ring.
(c) Push in the oil level gauge guide end into the guide hole of the cylinder block.
(d) Install the oil level gauge guide with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Install the oil level gauge.
9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
(a) Install a new gasket as shown in the illustration.
(b) Install the exhaust manifold converter No.2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Nut - Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
Bolt - Torque: 58 Nm (591 kgf-cm, 43 ft-lbf)
(c) Retighten nuts 1 and 2 shown in the illustration.
10. CONNECT COOLING FAN ECU
(a) Connect the 2 bolts and cooling fan ECU.
Torque: 2.6 Nm (26 kgf-cm, 23 in-lbf)
11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
(a) Install the 2 bolts and exhaust manifold heat insulator No.2.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
12. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
(a) Install the bolt, nut and manifold converter insulator No.3.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
13. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block with the R mark upward.
- Remove any oil from the contact surface.
- Be careful 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
NOTE: The cylinder head bolts are tightened in 2 successive steps.
(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.
(c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
SST: 09011-38121
Torque: 54 Nm (550 kgf-cm, 40 ft-lbf)
(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 90° angle to the front.
(g) Using a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft-lbf)
(h) Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 in-lbf)
15. INSTALL NO.2 CAMSHAFT Installation
16. INSTALL CAMSHAFT Installation
17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Adjustments
18. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (80 kgf-cm, 71 in-lbf)
19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket as shown in the illustration.
(b) Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
(c) Retighten nuts 1 and 2 shown in the illustration.
20. INSTALL MANIFOLD STAY
(a) Temporarily install the manifold stay to the exhaust manifold and transaxle.
(b) Fully tighten the 2 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
21. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
(a) Install the 3 bolts and exhaust manifold heat insulator No.1.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
22. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3 Installation
23. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation
24. INSTALL TIMING BELT NO.3 COVER Installation
25. INSTALL CAMSHAFT TIMING PULLEY Installation
26. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2 Installation
27. INSPECT TIMING BELT Installation
28. INSTALL TIMING BELT Installation
29. INSTALL CHAIN TENSIONER ASSEMBLY NO.1 Installation
30. INSTALL TIMING BELT GUIDE NO.2 Installation
31. INSTALL ENGINE MOUNTING BRACKET RH Installation
32. INSTALL TIMING BELT NO.2 COVER Installation
33. INSTALL TIMING BELT NO.1 COVER Installation
34. INSTALL CRANKSHAFT PULLEY Installation
35. INSTALL ENGINE MOUNTING STAY NO.2 RH Installation
36. INSTALL ENGINE MOVING CONTROL ROD Installation
37. INSTALL AIR CLEANER BRACKET Installation
38. INSTALL RESERVOIR BRACKET Installation
39. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Installation
40. INSTALL WATER OUTLET
(a) Install 2 new gaskets to the 2 cylinder heads.
(b) Install the water outlet together with water by-pass hose No.1 and unlock the hose clamp.
(c) Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
(d) Install the clamp.
(e) Connect the engine coolant temperature sensor connector.
(f) Connect the radiator hose inlet.
41. CONNECT RADIATOR HOSE INLET
42. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
(b) Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
(c) Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(d) Connect the heater inlet water hose.
43. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1 Installation
44. INSTALL INTAKE AIR SURGE TANK Installation
45. INSTALL EMISSION CONTROL VALVE SET Installation
46. INSTALL W/ CONVERTER INVERTER ASSEMBLY
Installation
47. INSTALL AIR CLEANER CASE W/ RESONATOR Installation
48. INSTALL AIR CLEANER CAP W/ INLET Installation
49. INSTALL COOL AIR INTAKE DUCT SEAL Installation
50. INSTALL BATTERY CARRIER SUB-ASSEMBLY Installation
51. INSTALL BATTERY Installation
52. INSTALL SERVICE PLUG GRIP Installation
53. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER Installation
54. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
55. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
56. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
57. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
58. INSTALL ENGINE UNDER COVER NO.2 Installation
59. INSTALL FRONT FENDER APRON SEAL RH Installation
60. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH Installation
61. INSTALL ENGINE UNDER COVER NO.1 Installation
62. INSTALL FRONT WHEEL RH
63. ADD ENGINE OIL
64. ADD COOLANT (for Inverter) Coolant (for Inverter)
65. ADD COOLANT (for Engine) Testing and Inspection
66. INSPECT FOR OIL LEAK
67. INSPECT FOR COOLANT LEAK (for Inverter)
68. INSPECT FOR COOLANT LEAK (for Engine) Testing and Inspection
69. INSPECT FOR FUEL LEAK Testing and Inspection
70. INSPECT FOR EXHAUST GAS LEAK
71. INSPECT IGNITION TIMING Testing and Inspection
72. INSPECT ENGINE IDLE SPEED Testing and Inspection
73. INSPECT COMPRESSION Testing and Inspection
74. INSPECT CO/HC Testing and Inspection
75. PERFORM INITIALIZATION
(a) Some system need initialization when reconnecting the cable from the battery terminal. Repair Instruction - Initialization
76. INSTALL ENGINE ROOM COVER SIDE Installation
77. INSTALL ENGINE ROOM SIDE LH COVER NO.2 Installation