Disassembly
3MZ-FE ENGINE MECHANICAL: ENGINE UNIT:
DISASSEMBLY
1. REMOVE SPARK PLUG
2. REMOVE VENTILATION VALVE SUB-ASSEMBLY
3. REMOVE OIL FILTER CAP SUB-ASSEMBLY
4. REMOVE OIL FILLER CAP GASKET
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
6. REMOVE CYLINDER HEAD COVER GASKET NO.2
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
8. REMOVE CYLINDER HEAD COVER GASKET
9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
10. REMOVE VVT SENSOR
(a) Remove the sensor.
(b) Remove the O-ring from the sensor.
11. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
12. REMOVE 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 center bolt 150.
14. REMOVE TIMING BELT NO.1 COVER
15. REMOVE TIMING BELT NO.2 COVER
16. REMOVE ENGINE MOUNTING BRACKET RH
17. REMOVE TIMING BELT GUIDE NO.2
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 mark 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. 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°.
NOTE: With timing belt removed: The crankshaft pulley must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and incur damage.
(d) Remove the timing belt tensioner.
NOTE: Do not reinstall the tensioner with its plunger extended.
(e) Remove the timing belt in this order.
19. REMOVE NO.1 TIMING BELT IDLER SUB-ASSEMBLY
(a) Using a 10 socket hexagon wrench, remove the pivot bolt, timing belt idler No. 1 and plate washer.
20. REMOVE NO.2 TIMING BELT IDLER SUB-ASSEMBLY
21. REMOVE CRANKSHAFT POSITION SENSOR
22. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the bolt and RH timing pulley.
SST: 09960-10010
09962-01000
09963-01000
(b) Using SST, remove the bolt and LH timing pulley.
SST: 09960-10010
09962-01000
09963-01000
HINT: Be sure to return the RH and LH camshaft timing pulleys to their original locations when reassembling.
23. REMOVE TIMING BELT NO.3 COVER
24. REMOVE 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
NOTICE:
- Do not scratch the sensor part of the crankshaft timing pulley.
- Before using SST, apply lubricating oil on the threads and tip of the center bolt 150.
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 camshaft drive and driven gear's timing marks (2 dot marks each) by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear with a service bolt.
Recommended service bolt:
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
(c) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft.
- Do not pry out the camshaft.
- Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
28. REMOVE NO.2 CAMSHAFT
(a) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 2 camshaft.
- Do not pry out the camshaft.
- Be careful not to damage the portion of the cylinder head receiving 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 camshaft drive and driven gear's timing marks (1 dot mark each) by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub gear to the main gear with a service bolt.
Recommended service bolt:
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
(c) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 3 camshaft.
- Do not pry out the camshaft.
- Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
30. REMOVE NO.4 CAMSHAFT SUB-ASSEMBLY
(a) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 4 camshaft.
- Do not pry out the camshaft.
- Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
(b) Remove the oil seal from the No. 4 camshaft.
31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
NOTE: Do not remove or install the timing gear (VVT-i) unless you are replacing the VVT-i or the camshaft.
(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.
- Remove it with the lock-pin engaged and locked at the extreme retarded angle position.
- The lock nut has LH threads.
- Only use the socket wrench. Other tools will deform the cam angle rotor.
(c) Remove the timing gear (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.
32. REMOVE CAMSHAFT SUB GEAR
(a) Clamp the camshaft in a vise on the hexagonal lobe.
NOTE: Be careful not to 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 location when reassembling.
33. REMOVE ENGINE HANGER NO.2
34. REMOVE CYLINDER HEAD COVER REAR
35. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the plug, gasket and valve filter.
36. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Using an 8 mm socket hexagon wrench, remove the hexagon bolt.
(b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.
37. REMOVE CYLINDER HEAD GASKET
38. REMOVE CYLINDER HEAD LH
(a) Using an 8 mm socket hexagon wrench, remove the hexagon bolt.
(b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.
39. REMOVE CYLINDER HEAD GASKET NO.2
40. REMOVE WATER INLET HOUSING
(a) Uniformly loosen and remove the 8 bolts and 2 nuts in the sequence shown in the illustration. Remove the water inlet housing.
41. 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.
42. REMOVE OIL PAN DRAIN PLUG
43. REMOVE NO.2 OIL PAN SUB-ASSEMBLY
(a) Remove the 10 bolts and 2 nuts.
(b) Insert the blade of oil pan seal cutter between oil pan No. 1 and oil pan No. 2. Cut through the sealer and remove the oil pan No. 2.
- Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
- Do not damage the flange portion of oil pan No. 2 during removal.
44. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
45. REMOVE OIL PAN SUB-ASSEMBLY
(a) Uniformly loosen and remove the 15 bolts and 2 nuts in the sequence shown in the illustration.
(b) Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.
NOTE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.
46. REMOVE OIL PAN BAFFLE PLATE
47. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Uniformly loosen and 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.
48. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
49. 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.
50. REMOVE OIL PUMP SEAL
(a) Using a screwdriver, pry out the oil seal.
51. REMOVE SPARK PLUG TUBE GASKET
(a) Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.
NOTE: Be careful not to damage the baffle plate of the cylinder head cover.
(b) Using a screwdriver and a hammer, tap out the gasket.
(c) Using needle-nose pliers, pry out the gasket.
NOTE: Be careful not to damage the cylinder head cover.
52. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
53. REMOVE WATER SEAL PLATE
54. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
(a) Using a 10 mm socket hexagon wrench, remove the screw plug.
55. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
(a) Using a 10 mm socket hexagon wrench, remove the screw plug.
56. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
(a) Using a 10 mm socket hexagon wrench, remove the screw plug.
57. REMOVE PISTON AND CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push out the piston and the connecting rod assembly from the top of the cylinder block.
HINT:
- Keep the bearings, the connecting rod and the cap together.
- Arrange the piston and the connecting rod assemblies in correct order so they can be returned to the original locations when reassembling.
58. REMOVE CONNECTING ROD BEARING
59. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the 2 side rails and oil ring by hand.
60. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
61. REMOVE W/PIN PISTON SUB-ASSEMBLY
(a) Gradually heat the piston to approximately 80°C (176°F).
(b) Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod.
- The piston and pin are a matched set.
- The pistons, the pins, the rings, the connecting rods and the bearings must be returned to their original locations when reassembling.
62. REMOVE CRANKSHAFT
(a) Lift the crankshaft.
(b) Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block.
HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order.
63. REMOVE CRANKSHAFT THRUST WASHER SET
64. REMOVE CRANKSHAFT BEARING
65. CLEAN CYLINDER BLOCK
NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.
66. REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bushing.
SST: 09222-30010