Part 2

3MZ-FE ENGINE UNIT

COMPONENTS:

DISASSEMBLY (STEPS 37-72)

37. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Using a socket hexagon wrench 8 mm, 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.

NOTICE:
^ 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 a socket hexagon wrench 8 mm, 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.

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

40. REMOVE CYLINDER HEAD GASKET NO. 2
a. Remove the cylinder head gasket No. 2 from the cylinder block.

41. REMOVE WATER INLET HOUSING
a. Remove the 8 bolts and 2 nuts, then remove the water inlet housing.

42. REMOVE OIL FILTER SUB-ASSEMBLY
a. Using SST, remove the oil filter.
SST 09228-07501
b. Using a socket hexagon wrench 12 mm, remove the oil filter union.
43. REMOVE OIL PAN DRAIN PLUG
a. Remove the oil pan drain plug and gasket.

44. REMOVE OIL PAN SUB-ASSEMBLY NO. 2
a. Remove the 10 bolts and 2 nuts.

b. Insert the blade of SST between oil pan and oil pan No. 2, cut off the sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
^ Do not damage the contact surfaces of oil pan and oil pan No. 2.
^ Do not damage the flange portion of oil pan No. 2 when removing.

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.

NOTICE: Do not damage the contact surfaces of the oil pan and cylinder block.

47. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 6 bolts and the oil pan baffle plate from the oil pan.
48. REMOVE ENGINE REAR 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 ENGINE REAR 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.

NOTICE: Do not 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.

NOTICE: Do not damage the cylinder head cover.

53. INSPECT TIMING BELT

NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.
^ Check the belt for any defects, as shown in the illustration. Also, check these points.

a. If there is premature parting:
^ Check for proper installation.
^ Check the timing cover gasket for damage and proper installation.
b. If the belt teeth are cracked or damaged, check if either camshaft is locked.
c. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.
d. If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.
e. If there is noticeable wear on the belt teeth:
^ Check the timing cover for damage.
^ Check that the gasket has been installed correctly.
^ Check for foreign object on the pulley teeth. If there is any trouble in the belt condition, replace the timing belt.

54. INSPECT CAMSHAFT
a. Inspect camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the runout is greater than the maximum, replace the camshaft.

b. Inspect cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake: 43.132 to 43.232 mm (1.6981 to 1.7020 inch)
Exhaust: 43.010 to 43.110 mm (1.6933 to 1.6972 inch)
Minimum cam lobe height:
Intake: 42.98 mm (1.6921 inch)
Exhaust: 42.86 mm (1.6874 inch)
If the cam lobe height is less than the minimum, replace the camshaft.

c. Inspect camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 to 26.975 mm (1.0614 to 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.

55. 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 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than the minimum, replace the bolt.
56. REMOVE W/HEAD STRAIGHT SCREW PLUG NO. 1 (RH CYLINDER)
a. Using a hexagon wrench 14 mm, remove the 2 straight screw plugs and 2 gaskets.
57. REMOVE W/HEAD STRAIGHT SCREW PLUG NO. 2 (LH CYLINDER)
a. Using a hexagon wrench 14 mm, remove the 2 straight screw plugs and 2 gaskets.
58. REMOVE VALVE LIFTER

HINT: Store the lifters in the correct order so that they can be returned to the original locations when reassembling.

59. REMOVE INTAKE VALVE
a. Using SST, compress the valve spring and remove the 2 retainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)

HINT: Store the valves, valve springs and spring retainers in the correct order so that they can be returned to the original locations when reassembling.

60. REMOVE EXHAUST VALVE
a. Using SST, compress the valve spring and remove the 2 retainer locks, retainer, spring and valve.
SST 09202-70020 (09202-00010)

HINT: Store the valves, valve springs and spring retainers in the correct order so that they can be returned to the original locations when reassembling.

61. REMOVE VALVE STEM OIL SEAL OR RING
a. Using needle-nose pliers, remove the oil seals.
62. REMOVE VALVE SPRING SEAT
a. Remove the valve spring seats from the cylinder head.
63. REMOVE SEMICIRCULAR PLUG
a. Remove the semicircular plug from the cylinder head.

64. INSPECT CYLINDER HEAD FOR FLATNESS
a. Using a precision straight edge and a feeler gauge, measure the warpage of the contacting surface between the cylinder block and the manifolds.
Maximum warpage:
Cylinder block surface: 0.05 mm (0.0020 inch)
Intake manifold surface: 0.10 mm (0.0039 inch)
Exhaust manifold surface: 0.10 mm (0.0039 inch)
If warpage is greater than the maximum, replace the cylinder head.

65. INSPECT CYLINDER HEAD FOR CRACKS
a. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.

66. INSPECT INTAKE VALVE
a. Check the valve overall length.
Standard overall length: 95.45 mm (3.7579 inch)
Minimum overall length: 94.95 mm (3.7382 inch)

b. Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 inch)

c. Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 inch)
Minimum margin thickness: 0.5 mm (0.020 inch)

67. INSPECT EXHAUST VALVE
a. Check the valve overall length.
Standard overall length: 95.40 mm (3.7559 inch)
Minimum overall length: 94.90 mm (3.7362 inch)

b. Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 inch)

c. Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 inch)
Minimum margin thickness: 0.5 mm (0.020 inch)

68. INSPECT INNER COMPRESSION SPRING
a. Using vernier calipers, measure the free length of the valve spring.
Free length: 45.50 mm (1.7913 inch)

b. Using a steel square, measure the deviation of the valve spring.
Maximum deviation: 2.0 mm (0.079 inch)

c. Using a spring tester, measure the tension of the valve spring at the specified installed length.
Installed tension: 186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbs) at 33.8 mm (1.331 inch)
If the installed tension is not as specified, replace the valve spring.

69. INSPECT VALVE GUIDE BUSHING OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the guide bushing.
Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 inch)
b. Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.
Standard oil clearance:
Intake: 0.025 to 0.060 mm (0.0010 to 0.0024 inch)
Exhaust: 0.030 to 0.065 mm (0.0012 to 0.0026 inch)
Maximum oil clearance:
Intake: 0.08 mm (0.0031 inch)
Exhaust: 0.10 mm (0.0039 inch)

70. REMOVE VALVE GUIDE BUSH
a. Heat the cylinder head to 80 to 100°C (176 to 212°F).

b. Using SST and a hammer, tap out the guide bush.
SST 09201-10000 (09201-01055), 09950-70010 (09951-07100)

71. INSTALL VALVE GUIDE BUSH
a. Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 inch)
If the bush bore diameter of the cylinder head is greater than 10.313 mm (0.4060 inch), machine the bush bore to the dimension of 10.345 to 10.363 mm (0.4073 to 0.4080 inch).

HINT: Using a caliper gauge, measure of the cylinder head.

Bush Diameter:

b. Using vernier calipers, measure the new bush length.

HINT: Using vernier calipers, measure of the bush.

Bush Length:

c. Heat the cylinder head to 80 to 100°C (176 to 212°F).

d. Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-10000 (09201-01055), 09950-70010 (09951-07100)
Protrusion height:
Intake: 11.1 to 11.5 mm (0.437 to 0.453 inch)
Exhaust: 8.9 to 9.3 mm (0.350 to 0.366 inch)

e. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and the valve stem.
Standard oil clearance:
Intake: 0.025 to 0.060 mm (0.0010 to 0.0024 inch)
Exhaust: 0.030 to 0.065 mm (0.0012 to 0.0026 inch)
72. INSPECT VALVE SEATS
a. Apply a light coat of Prussian blue (or white lead) to the valve face.
b. Lightly press the valve against the seat.

NOTICE: Do not rotate the valve.

c. Check the valve face and seat according to the following procedure.
(1) If Prussian blue appears around the entire face, the valve is concentric. If not, replace the valve.
(2) If Prussian blue appears around the entire valve seat, the guide and face are concentric. If not, resurface the seat.
(3) Check that the seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 inch).