Part 2

3MZ-FE ENGINE MECHANICAL: 3MZ-FE ENGINE UNIT: REASSEMBLY - Continued

25. INSTALL EXHAUST VALVE

(a) Install the valve, spring seat, valve spring, and spring retainer.
NOTE: Install the same parts in the same combination to the original locations.

(b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem.
SST: 09202-70020
09202-00010

(c) Using a plastic hammer and a discarded valve (the tip is wrapped with tape), lightly tap the installed valve to fit into place.
NOTE: Do not damage the installed valve stem tip.

26. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil to the valve lifter.
NOTE: Install the same parts in the same combination to the original locations.

(b) Install the valve lifter.
(c) Check that the valve lifter rotates smoothly by hand.
27. INSTALL SEMICIRCULAR PLUG
(a) Remove any old seal packing (FIPG) material.

(b) Apply seal packing to the semi-circular plug grooves.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(c) Install the 2 semi-circular plugs to the cylinder heads.
- Install the plugs so that it is flush with the top of the cylinder head.
- Install the semi-circular plugs within 3 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

28. INSTALL W/ HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER)
(a) Using a hexagon wrench 14 mm, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
29. INSTALL W/ HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER)
(a) Using a hexagon wrench 14 mm, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
30. 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.
31. INSTALL ENGINE REAR 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
- 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.
32. INSTALL ENGINE REAR 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
- 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)
33. 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
- 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.
34. 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
- 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)
35. INSTALL OIL PAN BAFFLE PLATE NO.1
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
36. 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
- 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 15 bolts and 2 nuts. 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)
37. 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)
38. INSTALL OIL PAN SUB-ASSEMBLY NO.2
(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
- 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)
39. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft-lbf)
40. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Using a socket hexagon wrench 12 mm, 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
41. INSTALL WATER INLET 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
- Remove any oil from the contact surface.
- Install the water inlet housing within 3 minutes after applying seal packing.
- Do not expose the seal to coolant within 2 hours after installing.

(c) Install the water inlet 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)
42. 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.

43. 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.

(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 a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
44. 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.

45. 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.

(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 a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft-lbf)
46. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign object is 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)
48. INSTALL ENGINE HANGER NO.2
(a) Install the 2 bolts and engine hanger No.2.
Torque: 20 Nm (214 kgf-cm, 15 ft-lbf)
49. 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 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.