Part 3

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

50. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Align the alignment pin with the groove and install VVT-i on the camshaft.
NOTE: Install it with the lock-pin engaged and locked at the most retard angle position.

(b) Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.
NOTICE:
- Be sure to apply the oil, otherwise the specified torque cannot be obtained.
- New nuts must be used when replacing the VVT-i unit.

(c) Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
Torque: 150 Nm (1,530 kgf-cm, 111 ft-lbf)
- The lock nut has left-hand threads.
- Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.

51. INSTALL NO.2 CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. 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) Apply new engine oil to the thrust portion and journal of the camshaft.

(b) Place the No.2 camshaft at a 90° angle of the timing mark (2-dot mark) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.

(d) Install the oil seal to the camshaft.
- Do not turn over the oil seal lip.
- Insert the oil seal until it stops.

(e) Remove any old packing material from the contact surface.

(f) Apply seal packing to the No.1 bearing cap as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Install the No.1 bearing cap within 5 minutes after applying seal packing.
- Do not expose the seal to engine oil within 2 hours after installing.

(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(i) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
52. INSTALL CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. 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) Apply new engine oil to the thrust portion and journal of the camshaft.

(b) Align the timing marks (2-dot mark) of the camshaft drive gear with the mark on the driven gear.
(c) Place the camshaft on the cylinder head.

(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(f) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
(g) Remove the service bolt.
53. INSTALL NO.4 CAMSHAFT SUB-ASSEMBLY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. 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) Apply new engine oil to the thrust portion and journal of the camshaft.

(b) Place the No.4 camshaft at a 90° angle of the timing mark (1-dot mark) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.

(d) Install the oil seal to the camshaft.
- Do not turn over the oil seal lip.
- Insert the oil seal until it stops.

(e) Remove any old packing material from the contact surface.

(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(i) Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
54. INSTALL 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 installed. 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) Apply new engine oil to the thrust portion and journal of the camshaft.

(b) Align the timing marks (1-dot mark) of the camshaft drive gear with the mark on the driven gear.
(c) Place the camshaft on the cylinder head.

(d) Install the 5 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(a) Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
56. INSTALL CRANKSHAFT TIMING PULLEY

(a) Align the keyway of the timing pulley with the key located on the crankshaft and slide the timing pulley into place.
NOTE: Do not scratch the sensor area of the crankshaft timing pulley.

(b) Install the timing belt plate with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
57. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to a new O-ring and install it to the level gage guide.
(b) Install the level gage guide.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
58. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
(a) Install the oil level gage sub-assembly.
59. INSTALL TIMING BELT IDLER BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
60. INSTALL TIMING BELT NO.3 COVER
(a) Visually check for cracks and breaks on the gasket of the timing belt cover.
HINT: If a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.

(b) If the timing belt cover gasket is needed to repair, follow the procedure below.
(1) Repair the cracks and breaks by applying the seal packing to the damaged area.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTE: When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.

(c) If the timing belt cover gasket is needed to replace, follow the procedure below.
(1) Using a screwdriver and gasket scraper, remove the remaining gasket.
NOTE: Do not damage the timing belt cover.

(2) Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.
- Affix the gasket in the center of the groove.
- At the corners, try to keep the gasket thickness uniform.

(3) If there is a gap on the joint of the gasket, apply seal packing to close the gap.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTE: When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.

(d) Install the timing belt cover with the 6 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
61. INSTALL CAMSHAFT TIMING PULLEY

(a) Paying attention to the direction of the belt guide, install the camshaft timing pulley and tighten the bolt temporally.
- Face the belt guide of the RH timing pulley toward front of the engine.
- Face the belt guide of the LH timing pulley toward rear of the engine.

(b) Using SST, tighten the RH pulley bolt.
SST: 09960-10010
09962-01000
09963-01000
Torque: 125 Nm (1,275 kgf-cm, 92 ft-lbf)

(c) Using SST, tighten the LH pulley bolt.
SST: 09960-10010
09962-01000
09963-01000
Torque: 125 Nm (1,275 kgf-cm, 92 ft-lbf)
62. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
63. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
64. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1
(a) Using a socket hexagon wrench 10 mm, install the plate washer and timing belt idler No.1 with the pivot bolt.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)