16–1 COOLING – WATER PUMP ASSY (1ZZ–FE/3ZZ–FE) WATER PUMP ASSY (1ZZ–FE/3ZZ–FE) 160AO–01 INSPECTION 1. (a) INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage. Hole B10233 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–38 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 140KO–01 COMPONENTS Compression Ring No. 1 Compression Ring No. 2 Oil Ring (Side Rail) Oil Ring (Expander) Piston z Snap Ring z Bush z Snap Ring Piston Pin Connecting Rod Connecting Rod Bearing 5. 0 (51, 44 in. Vlbf) Ring Pin Straight Pin Straight Pin Cylinder Block Sub–assy 1 (112, 8) Ring Pin Crankshaft Bearing Crankshaft Thrust Washer Upper Key Crankshaft Connecting Rod Bearing See page 14–39 1st 20 (204, 15) 2nd Turn 90_ 5. 0 (51, 44 in. Vlbf) Straight Pin Crankshaft Thrust Washer Upper Crankshaft Bearing Connecting Rod Bearing Cap Crankshaft Bearing Cap Sub–assy Straight Pin Ring Pin 5. 0 (51, 44 in. Vlbf) 19 (194, 14) See page 14–39 1st 44 (449, 33) 2nd Turn 90_ 5. 0 (51, 44 in. Vlbf) A62767 N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–39 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 140KP–01 OVERHAUL . (a) INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0. 160 – 0. 342 mm (0. 063 – 0. 0135 in. ) Maximum thrust clearance: 0. 342 mm (0. 0135 in. ) A01155 2. A01156 INSPECT CONNECTING ROD BEARING OIL CLEARANCE NOTICE: Do not turn the crankshaft. (a) Using marking paint, write the matched cylinder number on each connecting rod and cap. HINT: The match marks on the connecting rods and caps are for ensuring correct reassembly. (b) Using SST, remove the 2 connecting rod cap bolts.

SST 09205–16010 (c) Clean the crank pin and bearing. (d) Check the crank pin and bearing for pitting and scratches. Plastigage (e) Lay a strip of Plastigage across the crank pin. A01159 (f) Front Check that the protrusion of the connecting rod cap is facing in the correct direction. A62797 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–40 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) (g) (h) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using SST, tighten the bolts in several passes by the specified torque. SST 09205–16010 Torque: 20 NVm (204 kgfVcm, 15 ftVlbf)

A01163 90_ Front Paint Mark (i) (j) (k) (l) Mark the front of the connecting cap bolts with paint. Retighten the cap bolts by 90_ as shown in the illustration. Check that the crankshaft turns smoothly. Remove the 2 bolts, connecting rod cap and lower bearing. A62798 (m) Measure the Plastigage at its widest point. Standard oil clearance: 0. 028 – 0. 060 mm (0. 0011 – 0. 0024 in. ) Maximum oil clearance: 0. 080 mm (0. 0031 in. ) NOTICE: Remove the Plastigage completely after the measurement. A01160 (n) Mark 1, 2 or 3 If replacing a bearing, select a new one having the same number as marked on the connecting rod.

There are 3 sizes of standard bearings, marked ”1”, ”2” and ”3” accordingly. Reference: Standard bearing center wall thickness Mark 1 2 3 mm (in. ) 1. 486 – 1. 490 (0. 0585 – 0. 0587) 1. 490 – 1. 494 (0. 0587 – 0. 0588) 1. 494 – 1. 498 (0. 0588 – 0. 0590) A62799 3. (a) (b) HINT: S S A01166 REMOVE PISTON SUB–ASSY W/CONNECTING ROD Using a ride reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–41 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 4. (a) REMOVE CONNECTING ROD BEARING Remove the connecting rod bearing from the connecting rod and crankshaft. 5. REMOVE PISTON RING SET HINT: Take care not to misplace the piston rings on both the match with the piston and the direction of the rings. (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and oil ring by hand. A01175 6. (a) REMOVE PISTON PIN HOLE SNAP RING Using a small screwdriver, pry out the 2 snap rings. A01192 7. (a) (b) HINT: S S A01179

REMOVE W/PIN PISTON SUB–ASSY Gradually heat the piston to 80 – 90_C (176 – 194_F). Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. The piston and pin are a matched set. Arrange the piston, pins, ring, connecting rod and bearings in the correct order. REMOVE CONNECTING ROD SMALL END BUSH Using SST and a press, press out the bushing. SST 09222–30010 8. SST (a) A62800 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–42 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 3 7 9 5 1 9. (a) (b) REMOVE CRANKSHAFT BEARING CAP SUB ASSY Remove the 10 bearing cap bolts.

Uniformly loosen the 10 bearing cap sub–assy bolts, in several passes, in the sequence shown in the illustration. SST 09011–38121 4 8 10 6 2 A62801 (c) Using a screwdriver, remove the bearing cap sub–assembly by prying the indicated portions between the cylinder block and bearing cap sub–assembly. Remove the 5 lower main bearings. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap sub–assembly. A01195 10. (a) (b) A32142 INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0. 4 – 0. 24 mm (0. 0016 – 0. 0094 in. ) Maximum thrust clearance: 0. 30 mm (0. 0118 in. ) If the thrust clearance is greater than maximum, measure the thrust washer thickness. If the thickness is not specified, replace the thrust washer. Thrust washer thickness: 2. 430 – 2. 480 mm (0. 0957 – 0. 0976 in. ) 11. (a) 12. REMOVE CRANKSHAFT THRUST WASHER UPPER Remove the crankshaft thrust washer from the cylinder block. REMOVE CRANKSHAFT (a) Lift out the crankshaft. (b) Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. NOTICE: Arrange the main bearings and thrust washers in the correct order. 3. REMOVE CRANKSHAFT BEARING (a) 14. (a) Remove the crankshaft bearing from the cylinder block. REMOVE STUD BOLT Remove the 9 stud bolts from the cylinder block. 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–43 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 15. (a) INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0. 05 mm (0. 0020 in. ) A01169 16. (a) INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

Standard diameter: 79. 000 – 79. 013 mm (3. 1102 – 3. 1108 in. ) Maximum diameter: 79. 013 mm (3. 1108 in. ) If the diameter is greater than the maximum, replace the cylinder block. Thrust Direction Axial Direction A B C 10 mm A62802 10 mm 17. (a) INSPECT PISTON DIAMETER Using a micrometer, measure the piston diameter at a right angle to the piston pin hole, and at the piston of 29. 8 mm (1. 173 in. ) from the piston head. Piston diameter: 1ZZ–FE 78. 925 – 78. 935 mm (3. 1073 – 3. 1077 in. ) 3ZZ–FE 78. 955 – 78. 965 mm (3. 1085 – 3. 1089 in. ) 29. 8 mm A62803 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–44

ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 18. (a) INSPECT PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 1ZZ–FE 0. 065 – 0. 088 mm (0. 0026 – 0. 0035 in. ) 3ZZ–FE 0. 035 – 0. 058 mm (0. 0014 – 0. 0023 in. ) Maximum oil clearance: 1ZZ–FE 0. 088 mm (0. 0035 in. ) 3ZZ–FE 0. 058 mm (0. 0023 in. ) If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block. 19. (a) INSPECT CONNECTING ROD SUB–ASSY A62804 Using a connecting rod aligner and feeler gauge, check the connecting rod alignment. 1) Check for out–of–alignment. Maximum out–of alignment: 0. 05 mm (0. 0020 in. ) per 100 mm (3. 94 in. ) If out–of alignment is greater than maximum, replace the connecting rod assembly. (2) Check for twist. Maximum twist: 0. 05mm (0. 0020 in. ) per 100 mm (3. 94 in. ) If twist is greater than maximum, replace the connecting rod assembly. A62805 20. (a) INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove. Ring groove clearance: No. 1 0. 020 – 0. 070 mm (0. 0008 – 0. 0028 in. ) No. 2 0. 030 – 0. 070 mm (0. 0012 – 0. 0028 in. ) A01171 1. (a) INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, that means 100 mm (3. 94 in. ) from the top of the cylinder block. A01170 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–45 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) (b) Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0. 25 – 0. 35 mm (0. 0098 – 0. 0138 in. ) No. 2 0. 35 – 0. 50 mm (0. 0138 – 0. 0197 in. ) Maximum end gap: No. 1 0. 74 mm (0. 029 in. ) No. 2 0. 89 mm (0. 035 in. ) EM7639 22. (a) INSPECT PISTON PIN Using a micrometer, measure the piston pin diameter.

Piston pin diameter: 20. 004 – 20. 013 mm (0. 7876 – 0. 7879 in. ) NOTICE: Push the piston pin into the matched piston. EM0227 23. (a) INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolts. Standard diameter: 6. 6 – 6. 7 mm (0. 260 – 0. 264 in. ) Maximum diameter: 6. 4 mm (0. 252 in. ) If the diameter is less than minimum, replace the bolt. (b) A01470 24. (a) INSPECT CRANKSHAFT Using a dial indicator and V–blocks, measure the circle runout, as shown in the illustration. Maximum circle runout: 0. 03 mm (0. 0012 in. ) A11783 (b) (c)

Using a micrometer, measure the diameter of each main journal at the points shown in the illustration. Diameter: 47. 988 – 48. 000 mm (1. 8893 – 1. 8898 in. ) Check each main journal for taper and out–of–round as shown. Maximum taper and out–of–round: 0. 02 mm (0. 0008 in. ) ZF6927 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–46 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) (d) (e) Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration. Diameter: 43. 992 – 44. 000 mm (1. 7320 – 1. 7323 in. ) Check each crank pin for taper and out–of–round as shown. Maximum taper and out–of–round: 0. 2 mm (0. 0008 in. ) ZF6928 25. (a) INSPECT CRANKSHAFT BEARING CAP SET BOLT Using vernier caliper, measure the tension portion diameter of the bolts. Standard diameter: 7. 3 – 7. 5 mm (0. 287 – 0. 295 in. ) Minimum diameter: 7. 2 mm (0. 283 in. ) A01194 Plastigage 26. (a) (b) (c) INSPECT CRANKSHAFT OIL CLEARANCE Clean each main journal and bearing. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. A11780 (d) 8 4 2 6 10 Using SST, tighten the bolts in several passes, in the sequence shown, by the specified torque. SST 09011–38121 Torque: 44 NVm (449 kgfVcm, 33 ftVlbf) 7 3 1 5 9 A62801 e) 90_ Front Paint Mark A62806 Mark the front of the bearing cap sub–assembly bolts with paint. (f) Retighten the bearing cap sub–assy bolts by 90_ as shown in the illustration. (g) Check that the painted mark is now at a 90_ angle to the front. NOTICE: Do not turn the crankshaft. (h) Remove the bearing cap sub–assy. 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–47 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) (i) Measure the Plastigage at its widest point. Standard oil clearance: 0. 013 – 0. 030 mm (0. 0005 – 0. 0012 in. ) Minimum oil clearance: 0. 05 mm (0. 0020 in. ) NOTICE: Completely remove the plastigage

A11781 No. 2 No. 1 No. 3 (j) Mark 0, 1, 2, 3, 4, 5 or 6 No. 6 No. 5 No. 2 Mark 0, 1, 2, 3, 4 or 5 No. 5 No. 1 No. 3 No. 4 If replacing a bearing, select a new one having the same number. If the number of the bearing cannot be determined, calculate the correct use bearing number by adding together the numbers imprinted on the cylinder block and crankshaft, then select a new bearing having the calculated number. There are 4 sizes of standard bearings, marked ”1”, ”2”, ”3” and ”4” accordingly. Cylinder block (A) + Crankshaft (B) Use bearing 0–2 ”1” 3–5 ”2” 6–8 ”3” 9–11 ”4” Mark 0, 1, 2, 3, or 4

HINT: EXAMPLE: Cylinder block ”4” (A) + Crankshaft ”3” (B) = Total number 7 (Use bearing ”3”) A62807 Item Mark ”0” ”1” ”2” ”3” ”4” ”5” ”6” ”0” ”1” ”2” ”3” ”4” ”5” ”1” ”2” ”3” ”4” mm (in. ) 52. 000 – 52. 003 (2. 0472 – 2. 0473) 52. 003 – 52. 005 (2. 0473 – 2. 0474) 52. 005 – 52. 007 (2. 0474 – 2. 0475) 52. 007 – 52. 010 (2. 0475 – 2. 0476) 52. 010 – 52. 012 (2. 0476 – 2. 0477) 52. 012 – 52. 014 (2. 0477 – 2. 0478) 52. 014 – 52. 016 (2. 0478 – 2. 0479) 47. 998 – 48. 000 (1. 8897 – 1. 8898) 47. 996 – 47. 998 (1. 8896 – 1. 8897) 47. 994 – 47. 996 (1. 8895 – 1. 8896) 47. 992 – 47. 994 (1. 8894 – 1. 8895) 47. 990 – 47. 992 (1. 8893 – 1. 8894) 47. 88 – 47. 990 (1. 8892 – 1. 8893) 1. 994 – 1. 997 (0. 0785 – 0. 0786) 1. 997 – 2. 000 (0. 0786 – 0. 0787) 2. 000 – 2. 003 (0. 0787 – 0. 0789) 2. 003 – 2. 006 (0. 0789 – 0. 0790) Cylinder block main journal bore diameter (A) Crankshaft main journal diameter (B) Standard bearing center wall thickness 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–48 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 27. (a) INSTALL STUD BOLT Install the 9 stud bolt to the cylinder block. Torque: Stud bolt A, B and C 5. 0 NVm (51 kgfVcm, 44 in. Vlbf) Stud bolt D 11 NVm (112 kgfVcm, 8 ftVlbf) Upper side: Lower side: Intake side: C A A B D 16 16. 5 27. 9 A B 18. 5 13 22. 5 8 C 9 D 31. 5 10 48 [mm] A62883 28. (a) INSTALL RING PIN Using a plastic hammer, install the 5 ring pins to the cylinder block. Standard protrusion: Ring pin A 6 mm (0. 24 in. ) Ring pin B 10 mm (0. 39 in. ) RIng pin C 7 mm (0. 28 in. ) Front side: Upper side: C A C B 6 10 7 A 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) B C [mm] A62884 14–49 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 29. (a) INSTALL STRAIGHT PIN Using a plastic hammer, install the 9 straight pins to the cylinder block. Standard protrusion: Straight pin A 5 mm (0. 20 in. ) Straight pin B 7. 5 mm (0. 30 in. ) Straight pin C 8 mm (0. 31 in. Straight pin D 12 mm (0. 47 in. ) Lower side: Front side: A Exhaust side: C B Rear side: 5 7. 5 8 12 A D B C D [mm] A62885 30. (a) INSTALL CONNECTING ROD SMALL END BUSH Align the oil hole of a new bushing with the one of the connecting rod. Oil Hole A62809 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–50 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) (b) SST (c) Using SST and a press, press into the small end bushing. SST 09222–30010 After installing the bushing, check that the oil hole of the connecting rod is aligned with the hole of the small end bushing and that the oil clearance measured on both sides of connecting rod are equal.

A62800 (d) Horn the connecting rod end bushing to obtain the standard specified oil clearance. Oil clearance: 0. 005 – 0. 011 mm (0. 0002 – 0. 0004 in. ) HINT: When pushing the piston pin with engine oil applied into the connecting rod with thumb, the piston pin is supposed to have a little resistance to insert at normal room temperature. A36991 31. (a) INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that end gap of the snap ring is aligned with the pin hole cutout portion of the piston. A01193 32. Cavity) Front Mark (Protrusion) INSTALL W/PIN PISTON SUB–ASSY Gradually heat the piston to 80 – 90_C (176–194_F). Align the front marks on the piston with connecting rod, and push in the piston with your thumb. (a) (b) A62810 33. (a) INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. HINT: Be sure that end gap of the snap ring is aligned with the pin hole cutout portion of the piston. A01192 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–51 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Cord Mark 34. INSTALL PISTON RING SET

A62811 HINT: In case of reusing the piston rings, install them to the matched pistons with the surfaces faced correctly. (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark (No. 2 only): T or 2R (c) Position the piston rings so that the ring ends are as shown. Upper Side Rail Compression No. 2 Front Compression No. 1 or Expander Lower Side Rail A62812 35. (a) INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod and let not stick the oils and fats. A01188 36. (a) INSTALL CRANKSHAFT Install the upper bearing with an oil groove on cylinder block. NOTICE: Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats. A01190 (b) Install the lower bearing on the bearing cap sub–assy. NOTICE: Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats. A01189 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–52

ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) (c) (d) (e) Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward. Apply engine oil to upper bearing and install the crankshaft on the cylinder block. Apply a light coat of engine oil on the bolt threads, the bolt seats, and the bearings of the bearing cap sub–assy. A01191 Seal Packing (f) Apply seal packing in the shape of bead (Diameter 2. 5 – 3. 5 mm (0. 08 – 0. 12 in. ) consequently as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent NOTICE: S Remove any oil from the contact surface.

S Install the bearing cap sub–assembly within 3 minutes after applying seal packing. S Do not put into engine oil within 2 hours after the installation. A01038 (g) 8 4 2 6 10 Using SST, tighten the bolts in several passes, in the sequence shown, by the specified torque. SST 09011–38121 Torque: 44 NVm (449 kgfVcm, 33 ftVlbf) 7 3 1 5 9 A62801 (h) 90_ Front Paint Mark (i) (j) (k) A62806 Mark the front of the bearing cap sub–assy bolts with paint. Retighten the bearing cap sub–assy bolts by 90_ as shown in the illustration. Check that the painted mark is now at a 90_ angle to the front. Tighten 10 other bolts for the bearing cap.

Torque: 19 NVm (194 kgfVcm, 14 ftVlbf) 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–53 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Front Mark 37. (a) INSTALL CONNECTING ROD SUB–ASSY A62813 Front Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. (b) Check the position of the piston ring ends. (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. (d) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.

NOTICE: S Clean the backside and the surface of the connecting rod cap bearing and let not stick the oils and fats. S Match the numbered connecting rod cap with the same numbered connecting rod. (e) Check that the protrusion of the connecting rod cap is facing in the correct direction. A62797 (f) (g) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using SST, tighten the bolts in several passes by the specified torque. SST 09205–16010 Torque: 20 NVm (204 kgfVcm, 15 ftVlbf) A01163 90_ Front Paint Mark (h) (i) (j) Mark the front of the connecting cap bolts with paint.

Retighten the cap bolts by 90_ as shown in the illustration. Check that the crankshaft turns smoothly. A62798 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–27 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 140KM–01 COMPONENTS Valve Lifter Valve Spring Retainer Lock Valve Spring Retainer Inner Compression Spring z Valve Stem Oil O Seal or Ring Valve Spring Seat z Exhaust Valve Guide Bush Valve Lifter Valve Spring Retainer Lock Valve Spring Retainer Inner Compression Spring z Valve Stem Oil O Seal or Ring Valve Spring Seat z Intake Valve Guide Bush W/ Head Taper Screw Plug No. 44 (449, 33) z Gasket Ring Pin 9. 5 (97, 84 in. Vlbf) 5. 0 (51, 44 in. Vlbf) Union Union 9. 5 (97, 84 in. Vlbf) Union 5. 0 (51, 44 in. Vlbf) Cylinder Head Sub–assy 9. 5 (97, 84 in. Vlbf) Intake Valve Exhaust Valve N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A62766 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–28 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 140KN–01 OVERHAUL 1. (a) 2. (a) REMOVE W/HEAD TAPER SCREW PLUG NO. 2 Using a socket hexagon wench 10, remove the taper screw plug and gasket. REMOVE VALVE LIFTER Remove the 16 valve lifters from the cylinder head. 3. (a)

REMOVE INNER COMPRESSION SPRING Using SST, compress the valve spring and remove the 2 keepers, the retainer, and the spring seat. SST 09202–70020 (09202–00010) SST A62780 4. (a) 5. (a) 6. (a) 7. (a) REMOVE INTAKE VALVE Remove the 8 intake valves from the cylinder head. REMOVE EXHAUST VALVE Remove the 8 exhaust valves from the cylinder head. REMOVE VALVE STEM OIL O SEAL OR RING Remove the 16 valve stem oil seals from the valve guide bush. REMOVE VALVE SPRING SEAT Remove the 16 valve spring seats from the cylinder head. SST 8. (a) (b) REMOVE VALVE GUIDE BUSH Heat the cylinder head to 80 – 100_C (176 – 212_F).

Using SST, tap out the valve guide bush. SST 09201–10000, 09201–01055, 09950–70010 (09951–07100) A62781 9. (a) REMOVE STUD BOLT Remove the 11 stud bolts from the cylinder head. 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–29 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 10. (a) INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Cylinder block side Intake manifold side Exhaust manifold side 0. 05 mm (0. 0020 in. ) 0. 10 mm (0. 0040 in. ) 0. 10 mm (0. 0040 in. ) A01075 1. (a) INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. A01071 12. (a) INSPECT VALVE GUIDE BUSHING OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Busing inside diameter: 5. 510 – 5. 530 mm (0. 2169 – 0. 2177 in. ) A62782 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5. 470 – 5. 485 mm (0. 2154 – 0. 2159 in. ) Exhaust 5. 465 – 5. 480 mm (0. 2152 – 0. 2158 in. ) A62783 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–30

ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0. 025 – 0. 060 mm (0. 0010 – 0. 0024 in. ) Exhaust 0. 030 – 0. 065 mm (0. 0012 – 0. 0026 in. ) Maximum oil clearance: Intake 0. 08 mm (0. 0031 in. ) Exhaust 0. 01 mm (0. 0039 in. ) 13. (a) (b) INSPECT VALVE GUIDE BUSH Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Diameter: 10. 285 – 10. 306 mm (0. 4049 – 0. 4057 in. ) If the bushing bore diameter of the cylinder head is greater than 10. 06 mm (0. 4057 in. ), machine the bushing bore to the dimension of 10. 335 – 10. 356 mm (0. 4068 – 0. 4077 in. ) to install a over size bushing. A01445 HINT: bushing bore diameter mm (in. ) 10. 285 – 10. 306 (0. 4049 – 0. 4057) 10. 335 – 10. 356 (0. 4068 – 0. 4077) Bushing size Use STD Use O/S 0. 05 14. (a) INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the valve spring. Free length: 43. 40 mm (1. 7087 in. ) EM0801 Deviation (b) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2. 0 mm (0. 078 in. ) Maximum angle (reference): 2_ A62784 ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–31 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 15. (a) INSPECT INTAKE VALVE Using a vernier calipers, check the valve overall length. Standard overall length: 88. 65 mm (3. 4902 in. ) Minimum overall length: 88. 35 mm (3. 4784 in. ) EM2534 (b) Using a vernier calipers, check the valve head margin thickness. Standard margin thickness: 1. 0 mm (0. 039 in. ) Minimum margin thickness: 0. 7 mm (0. 028 in. ) Margin Thickness A62785 16. (a) INSPECT EXHAUST VALVE Using a vernier calipers, check the valve overall length. Standard overall length: 88. 69 mm (3. 4917 in. Minimum overall length: 88. 39 mm (3. 4799 in. ) EM2534 (b) Using a vernier calipers, check the valve head margin thickness. Standard margin thickness: 1. 0 mm (0. 039 in. ) Minimum margin thickness: 0. 7 mm (0. 028 in. ) Margin Thickness A62785 17. (a) (b) (c) Width INSPECT VALVE SEATS Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Check the valve face and seat according to the following procedure. (1) If blue appears 360_ around the face, the valve is concentric. If not, replace the valve. A62786 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–32

ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) (2) (3) If blue appears 360_ around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with the width between 1. 0 – 1. 4 mm (0. 039 – 0. 055 in. ). 45_ 30_ 18. REPAIR VALVE SEATS NOTICE: Take off a cutter gradually to make smooth valve seats. (a) If the seating is too high on the valve face, use 30_ and 45 _ cutters to correct the seat. 1. 0 – 1. 4 mm A62787 (b) 60_ 45_ (c) (d) If the seating is too low on the valve face, use 75_ and 45_ cutters to correct the seat.

Hand–lap the valve and valve seat with an abrasive compound. Check the valve seating position. 1. 0 – 1. 4 mm A62788 19. (a) INSPECT VALVE LIFTER Using a micrometer, measure the lifter diameter. Lifter diameter: 30. 966 – 30. 976 mm (1. 2191 –1. 2195 in. ) P16860 20. (a) (b) A01080 INSPECT VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31. 000 – 31. 025 mm (1. 2205 – 1. 2215 in. ) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0. 024 – 0. 059 mm (0. 0009 – 0. 0023 in. ) Maximum oil clearance: 0. mm (0. 0039 in. ) 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–33 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 21. (a) (b) (c) A01455 Plastigage 22. (a) (b) (c) INSPECT CAMSHAFT THRUST CLEARANCE Install the 2 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0. 040 – 0. 095 mm (0. 0016 – 0. 0037 in. ) Maximum thrust clearance: 0. 110 mm (0. 0043 in. ) If the thrust clearance is greater than maximum, replace the cylinder head. If damages are found on the camshaft thrust surfaces, the camshaft also has to be replaced.

INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. A62789 (d) Install the bearing caps (See page 14–4). Torque: No. 1 23 NVm (235 kgfVcm, 17 ftVlbf) No. 3 13 NVm (132 kgfVcm, 10 ftVlbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. A01454 (f) Measure the plastigage at its widest point. Standard oil clearance: 0. 035 – 0. 072 mm (0. 0014 – 0. 0028 in. ) Maximum oil clearance: 0. 10 mm (0. 0039 in. ) NOTICE: Completely remove the Plastigage after the measuring.

If the oil clearance is greater than maximum, replace the cylinder head. A01453 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–34 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 23. (a) (b) INSTALL STUD BOLT AND RING PIN Install the 11 stud bolts to cylinder head, Torque: Stud bolt A, D and E 9. 5 NVm (97, 84 in. Vlbf) Stud bolt B and C 5. 0 NVm (51, 44 in. Vlbf) Using a plastic hammer, install the new 2 ring pins to the cylinder head. Standard protrusion: 5 mm (0. 020 in. ) Upper side: Front side: B F A Exhaust side: C C Intake side: D E 34. 5 16. 5 53. 5 24. 5 9 B 89 21. 5 38. 5 C 12 D 38. 5 22. 5 48. 5 12 5 16 A E 12 F [mm] ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) A62790 14–35 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 14 mm 25 mm A B 9 mm 24. (a) INSTALL UNION Mark the standard position away from the edge, onto the water hose union as shown in the illustration. C A62791 Adhesive (b) Apply adhesive to the water hose union hole of the cylinder head. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent. A62792 (c) B A C A62793 Using a press, press in a new water hose union until the standard marks come to the level of the cylinder head surface. Standard protrusion: A 29 mm (1. 14 in. ) B 66. 5 mm (2. 62 in. ) C 24 mm (0. 5 in. ) NOTICE: S Install the water hose union within 3 minutes after applying adhesive. S Do not put into coolant within an hour after installing. SST 25. (a) (b) INSTALL VALVE GUIDE BUSH Gradually heat the cylinder head to 80 – 100_C (176 – 212_F). Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201–10000, 09201–01055, 09950–70010 (09951–07100) Protrusion height: 8. 7 – 9. 1 mm (0. 342 – 0. 358 in. ) A62794 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–36 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 26. Intake Mark ”NOK” Exhaust INSTALL VALVE STEM OIL O SEAL OR RING

Black Surface Gray Surface A62795 (a) Apply a light coat of engine oil on the valve stem oil seals. NOTICE: Be very careful to assemble the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. HINT: The intake valve stem oil seal is gray and the exhaust valve stem oil seal is black. (b) Using SST, push in a new valve stem oil seal. SST 09201–41020 SST A62796 27. (a) INSTALL INNER COMPRESSION SPRING Install the valve, spring seat, valve spring, and spring retainer. A01065 (b) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202–70020 (09202–00010) SST A62780 c) Using a plastic hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. A07307 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–37 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 28. (a) INSTALL W/HEAD TAPER SCREW PLUG NO. 2 Using a socket hexagon wrench 10, install the taper screw plug with a new gasket. Torque: 44 NVm (449 kgfVcm, 33 ftVlbf) 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–1 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 140KJ–01 COMPONENTS

Oil Filler Cap Sub–assy Gasket 11 (112, 8) 9. 0 (92, 80 in. Vlbf) Seal Washer 9. 0 (92, 80 in. Vlbf) Ventilation Valve Sub–assy 9. 0 (92, 80 in. Vlbf) Cylinder Head Cover Sub–assy Gasket Spark Plug 25 (255, 18) Crankshaft Pulley 138 (1,407, 102) 11 (112, 8) 9. 0 (92, 80 in. Vlbf) z O–ring Water Pump Assy N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A62768 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–2 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 13 (133, 10) 23 (235, 17) Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 1 Camshaft Timing Gear or Sprocket 54 (551, 40) 54 (551, 40) Camshaft No. Camshaft Camshaft Timing Gear Assy Chain Sub–assy Chain Tensioner Slipper 19 (194, 14) Crankshaft Timing Gear Chain Vibration Damper No. 1 9. 0 (92, 80 in. Vlbf) Crankshaft Position Sensor Plate No. 1 9. 0 (92, 80 in. Vlbf) Chain Tensioner Assy No. 1 13 (133, 10) 19 (194, 14) z Oil Seal N·m (kgf·cm, ft·lbf) : Specified torque Timing Chain or Belt Cover Sub–assy z Non–reusable part 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) A62769 14–3 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) See page 14–4 1st 49 (500, 36) 2nd Turn 90_ Plate Washer Cylinder Head Sub–assy z O–ring Oil Control Valve Filter z Gasket 30 (306, 22)

Camshaft Timing Oil Control Valve Assy 9. 0 (92, 80 in. Vlbf) z Gasket Cylinder Block Water Drain Cock Sub–assy 20 (204, 15) Cylinder Block Sub–assy z Oil Seal z Gasket Oil Pump Assy Oil Filter Union 9. 0 (92, 80 in. Vlbf) 30 (306, 22) z Gasket Oil Strainer Sub–assy 9. 0 (92, 80 in. Vlbf) Oil Filter Sub–assy 9. 0 (92, 80 in. Vlbf) Oil Pan Sub–assy z Gasket 37 (377, 27) Oil Pan Drain Plug N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 9. 0 (92, 80 in. Vlbf) A62770 14–4 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 140KL–01 OVERHAUL 1. (a) 2. a) 3. (a) 4. (a) 5. (a) 6. (a) REMOVE OIL FILLER CAP SUB–ASSY Remove the oil filler cap from the cylinder head cover. REMOVE OIL FILLER CAP GASKET Remove the gasket from the oil filler cap. REMOVE VENTILATION VALVE SUB–ASSY Remove the ventilation valve from the cylinder head cover. REMOVE SPARK PLUG Using a spark plug wrench, remove the 4 spark plugs. REMOVE CYLINDER HEAD COVER SUB–ASSY Remove the 9 bolts, 2 seal washer, 2 nuts and cylinder head cover. REMOVE CYLINDER HEAD COVER GASKET Remove the gasket from the cylinder head cover. 7. (a) REMOVE WATER PUMP ASSY Remove the 6 bolts, water pump and O–ring.

A62179 8. Mark Mark REMOVE CRANKSHAFT PULLEY Set No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley, and align its groove with timing mark ”0” of the timing chain cover. (2) Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration. (a) Mark Timing Chain Cover Surface HINT: If not, turn the crankshaft 1 revolution (360_) and align the marks as above. Groove A62185 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–5 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) (b) (c)

Using SST, remove the pulley bolt. SST 09960–10010 (09962–01000, 09963–01000) Remove the crankshaft pulley from the crankshaft. SST A62837 9. REMOVE CHAIN TENSIONER ASSY NO. 1 (a) Remove the 2 nuts and chain tensioner. NOTICE: Be sure not to revolve the crank shaft without the chain tensioner. 10. REMOVE TIMING CHAIN OR BELT COVER SUB–ASSY (a) (b) Remove the 11 bolts and nuts. Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screw– driver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block. 11.

REMOVE TIMING GEAR COVER OIL SEAL (a) Using a screwdriver remove the oil seal. A10076 A30848 12. (a) 13. (a) 14. (a) REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1 Remove the crankshaft position sensor plate from the crankshaft. REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and chain tensioner slipper. REMOVE CHAIN VIBRATION DAMPER NO. 1 Remove the 2 bolts and chain vibration damper. 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–6 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 15. (a) REMOVE CHAIN SUB–ASSY A30857 Using screwdrivers, ply out the timing chain with the crankshaft timing gear as shown in the illustration.

NOTICE: S Put shop rag to protect the engine. S In case of revolving the camshafts with the chain off the sprockets, turn the crankshaft 1/4 revolution for valves not to touch the pistons. 16. (a) REMOVE CAMSHAFT Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts. 2 4 5 3 1 A62814 17. (a) REMOVE CAMSHAFT TIMING GEAR OR SPROCKET Grip the camshaft with a vice, and remove the bolt and camshaft timing gear. NOTICE: Be careful not to damage the camshaft. A32167 18. Retard Side Path INSPECT CAMSHAFT TIMING GEAR ASSY a) Advance Side Path Close Open Open Close Check the lock of camshaft timing gear. (1) Grip the camshaft with a vice, and confirm the camshaft timing gear is locked. NOTICE: Be careful not to damage the camshaft. (b) Release lock pin. (1) Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration. HINT: Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece. (2) Break through the tapes of the advance side path and the retard side path on the opposite side of the groove. Vinyl Tape Rubber A62190 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 4–7 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Retard Side Path Advanced Side Path (3) Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1. 5 kgfVcm}. CAUTION: Cover the pathes with shop rag to avoid oil splashing. A62191 Retard Side Path Advanced Side Path (4) Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path. Decompress Hold Pressure A62192 HINT: The lock pin is released, and camshaft timing gear, revolves in the advance direction. 5) When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, take out that of timing advance side path. CAUTION: Camshaft timing assembly gear occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side path. It often causes the breakage of the lock pin. (c) Check smooth revolution (1) Revolve the camshaft timing gear assembly within the movable range except for the most retarded position several times, and check the smooth revolution.

CAUTION: Be sure to perform this check by hand, instead of air pressure. (d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked at the most retarded position. 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–8 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 19. Retard Side Path REMOVE CAMSHAFT TIMING GEAR ASSY (a) Advance Side Path Close Open Open Grip the camshaft with a vice, and confirm that the gear is locked. CAUTION: Be careful not to damage the camshaft. (b) Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.

HINT: Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece. (c) Break through the tapes of the advance side path and the retard side path on the opposite side of the groove. Close Vinyl Tape Rubber A62190 Retard Side Path Advanced Side Path Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1. 5 kgf/ cm2}. CAUTION: Cover the pathes with shop rag to avoid oil splashing. (d) A62191 Retard Side Path Advanced Side Path (e)

Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path. Decompress Hold Pressure A62192 HINT: The lock pin is released, and camshaft timing gear revolves in the advance direction. (f) When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, takeout that of timing advance side path. CAUTION: Camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side paths.

It often causes the breakage of the lock pin. 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–9 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Fringe Bolt (g) Remove the fringe bolt of camshaft timing gear assembly. NOTICE: S Be sure not to remove the other 4 bolts. S In case of reusing the camshaft timing gear, release the strait pin locking first, and then install the gear. Straight Pin A62193 20. (a) REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY Remove the bolt and camshaft timing oil control valve. 21. (a) REMOVE OIL CONTROL VALVE FILTER Remove the bolt, gasket and oil control valve filter.

Mesh A62815 3 7 9 6 2 22. (a) REMOVE CYLINDER HEAD SUB–ASSY 23. (a) Using a bi–hexagon wrench 10, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. NOTICE: S Be careful not to drop washers into the cylinder head. 1 5 10 8 4 S Head warpage or cracking could result from removA62816 ing bolts in an incorrect order. REMOVE CYLINDER HEAD GASKET Remove the gasket from the cylinder block. 24. (a) REMOVE OIL PUMP ASSY Remove the 5 bolts, oil pump and gasket. B08737 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–10

ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 25. (a) REMOVE OIL FILTER SUB–ASSY Using SST, remove the oil filter. SST 09228–06501 SST A62817 26. (a) REMOVE OIL FILTER UNION Using a socket hexagon wrench 12, remove the oil filter union. 27. Cut Position REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver with its tip taped, pry out the oil seal. NOTICE: After the removal, check if the crankshaft is not damaged. If there is, mend it with a sandpaper (# 400). A62202 28. (a) REMOVE OIL PAN DRAIN PLUG Remove the oil pan drain plug and gasket from the oil pan. 29. (a)

REMOVE OIL PAN SUB–ASSY Remove the 14 bolts and 2 nuts. A01153 (b) Insert the blade of SST between the bearing cap sub–assembly and oil pan, and cut off applied sealer and remove the oil pan. SST 09032–00100 NOTICE: Be careful not to damage the oil pan contact surface of the bearing cap sub–assembly and the oil pan flange. A01456 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) 14–11 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 30. (a) 31. (a) REMOVE OIL STRAINER SUB–ASSY Remove the bolt, 2 nuts, oil strainer and gasket. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB–ASSY Remove the cylinder block water drain cock from the cylinder block. 2. Raise Move Lock INSPECT CHAIN TENSIONER ASSY NO. 1 Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. (a) (b) A62818 33. (a) INSPECT CHAIN SUB–ASSY Using a spring tension gauge and vernier calipers, pull the timing chain with 140 N (4. 3 kgf, 315 lb) and measure the length of it. Maximum chain elongation : 112. 6 mm (4. 433 in. ) Measuring Area 0 12 34 5 16 A62819 HINT: Make the same measurements pulling at 3 or more places selected at