EG2–50

3VZ–E ENGINE – ENGINE MECHANICAL

CYLINDER HEAD
COMPONENTS FOR REMOVAL AND
INSTALLATION
 EG2–51
3VZ–E ENGINE – ENGINE MECHANICAL
EG2–52
3VZ–E ENGINE – ENGINE MECHANICAL

CYLINDER HEADS REMOVAL

1. REMOVE AIR CLEANER AND HOSE
2. DRAIN ENGINE COOLANT

3. REMOVE RADIATOR
(a) Disconnect the reservoir hose.
(b) A/T only:
Disconnect the oil cooler hoses.
(c) Remove the radiator hoses.

(d) Remove the 2 clips and No.2 fan shroud.

(e) Remove the 4 bolts and No.1 fan shroud.
(f) Remove the 4 bolts and radiator.

4. M/T only:
DISCONNECT CLUTCH RELEASE CYLINDER HOSE

5. REMOVE PS DRIVE BELT AND PUMP PULLEY

6. DISCONNECT PS PUMP FROM ENGINE
7. REMOVE A/C DRIVE BELT
 EG2–53
3VZ–E ENGINE – ENGINE MECHANICAL

8. REMOVE COOLING FAN

Remove the 4 nuts and cooling fan.
9. REMOVE GENERATOR DRIVE BELT

10. DISCONNECT STRAP, WIRES, CONNECTORS,

HOSES AND CABLES
(a) Disconnect the strap, wires and connectors:
• Ground strap from LH fender apron
• Generator connector and wire
• Igniter connector
• Oil pressure sender gauge connector
• Ground strap from engine rear side
• ECM connectors
• VSV connectors
• A/C compressor connector
• M/T only:
• Starter relay connector
• Solenoid resister connector
w/ ADD:
ADD switch connector
(b) Disconnect these hoses:
PS air hoses from gas filter and air pipe
Brake booster hose
w/ Cruise Control System:
Cruise control vacuum hose
• Charcoal canister hose from canister
VSV vacuum hoses
(c) Disconnect these cables:
Accelerator cable
A/T only:
Throttle cable
w/ Cruise Control System:
Cruise control cable
11. DISCONNECT HEATER HOSES
12. DISCONNECT FUEL INLET AND OUTLET HOSES
EG2–54
3VZ–E ENGINE – ENGINE MECHANICAL

13. REMOVE FRONT EXHAUST PIPE

(a) Disconnect the heated oxygen sensor connector.
(b) Loosen the pipe clamp bolt.
(c) Remove the 2 bolts and pipe bracket.

(d) Remove the 3 nuts, and disconnect the exhaust pipe from
the exhaust manifold. Remove the gasket.
(e) Remove the 2 bolts, joint retainer, exhaust pipe and gasket
from the catalytic converter.

14. DISCONNECT HIGH–TENSION CORDS FROM

SPARK PLUGS
Disconnect the high – tension cords at the rubber boot. Do
not pull on the cords.
NOTICE: Pulling on or bending the cords may damage the
conductor Inside.
15. REMOVE DISTRIBUTOR
16. REMOVE TIMING BELT
(See steps 4 to6, 12 to 19 and 24 in timing belt
removal in timing belt)
17. REMOVE AIR INTAKE CHAMBER
(a) Disconnect the throttle position sensor connector.
(b) Disconnect the charcoal canister vacuum hose from the throttle
body.
(c) Disconnect the vacuum and fuel hoses from the pressure regu-
lator.

(d) Disconnect the PCV hose from the union.

 EG2–55
3VZ–E ENGINE – ENGINE MECHANICAL

(e) Disconnect the No.4 water bypass hose from the union of
intake manifold.

(f) Remove the No.5 water bypass hose from the water bypass
pipe.

(g) Disconnect the cold start injector connector.

(h) Disconnect the vacuum hose from the gas filter.
(i) Remove the union bolt, 2 gaskets and cold start injector
tube.
(j) Disconnect the EGR gas temperature sensor connector.
(k) Disconnect the EGR vacuum hoses from the air pipe and
EGR vacuum modulator.

(I) Remove the nut. 2 bolts, intake chamber stay and

throttle cable bracket.

(m) Remove the 2 bolts and No.1 engine hanger.

EG2–56
3VZ–E ENGINE – ENGINE MECHANICAL

(n) Remove the nut, bolt and PS pump bracket.

(o) Remove the 5 nuts, the EGR valve and pipes assembly
and 2 gaskets.

(p) Disconnect the No.1 air hose from the PAIR reed
valve.

(q) Disconnect the 4 vacuum hoses from the air pipes.

(r) Remove the 2 bolts and accelerator cable bracket.

(s) Remove the 6 bolts, 2 nuts, intake chamber and gasket.

 EG2–57
3VZ–E ENGINE – ENGINE MECHANICAL

18. REMOVE ENGINE WIRE

(a) Disconnect these connectors and wire:
• Knock sensor connector
• Cold start injector time switch connector
• ECT sensor connector
• ECT sender gauge connector
• No.1 ECT switch connector
• RH ground strap from No.3 camshaft bearing cap
• Injector connectors

(b) Remove the 2 bolts and engine wire.

19. REMOVE NO.2 AND NO.3 FUEL PIPES

(a) Disconnect the vacuum hose from the TVV.
(b) Remove the 4 union bolts, 8 gaskets, No.2 and No.3
fuel pipes.

20. REMOVE NO.4 TIMING BELT COVER

Remove the 4 bolts and timing belt cover.

21. REMOVE NO.2 IDLER PULLEY

Remove the 4 bolts and idler pulley.
EG2–58
3VZ–E ENGINE – ENGINE MECHANICAL

22. REMOVE NO.3 TIMING BELT COVER

Remove the 6 bolts and timing belt cover.

23. REMOVE VSV BRACKET AND VSV PROM PAIR

REED VALVE
24. REMOVE PAIR REED VALVE AND NO.1 AIR
INJECTION MANIFOLD
Remove the 2 bolts, 2 nuts, the PAIR reed valve, injec-
tion manifold assembly and gasket.

25. REMOVE DELIVERY PIPES AND INJECTORS

(a) Remove the 4 nuts holding the delivery pipes to the intake
manifold.
(b) Remove the 2 delivery pipes and 6 injectors assemblies.
NOTICE: Be careful not to drop the injectors when re-
moving the delivery pipes.
(c) Remove the 4 insulators, 10 spacers and 4 0 –rings
from the cylinder head.
(d) Pull out the 6 injectors from the delivery pipes.
(e) Remove the O–ring and grommet from each injector.
26. REMOVE WATER BYPASS OUTLET
(a) Disconnect the No.3 water hose from the No. 1 water
bypass pipe.
(b) Remove the 2 nuts, water bypass outlet and gasket.

27. REMOVE INTAKE MANIFOLD

Remove the 12 bolts, 4 nuts, intake manifold and 2
gaskets.
28. REMOVE KNOCK SENSOR WIRE
 EG2–59
3VZ–E ENGINE – ENGINE MECHANICAL

29. REMOVE EXHAUST CROSSOVER PIPE

Remove the 6 nuts, crossover pipe and 2 gaskets.

30. DISCONNECT WATER BYPASS PIPE FROM RH

CYLINDER HEAD
Remove the bolt, and disconnect the water bypass
pipe from the RH cylinder head.
31. REMOVE GENERATOR

32. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK

(a) Remove the oil dipstick.
(b) Remove the bolt and oil dipstick guide.

33. REMOVE NO.2 ENGINE HANGER FROM LH

CYLINDER HEAD
Remove the 2 bolts and engine hanger.

34. REMOVE CYLINDER HEAD COVERS

Remove the 11 bolts, engine wire bracket, cylinder
head cover and gasket. Remove the 2 cylinder head
covers.
EG2–60
3VZ–E ENGINE – ENGINE MECHANICAL

35. REMOVE CAMSHAFTS

(a) Uniformly loosen and remove the 12 bearing cap bolts on
each cylinder head, in several passes, in the sequence
shown, then repeat for the other side, as shown.
(b) Remove the 10 camshaft bearing caps, 2 oil seals and
2 camshafts.

HINT: Arrange the bearing caps in correct order.

36. REMOVE CYLINDER HEADS

(a) Remove the cylinder head (6 pointed head) bolt from each
cylinder head.
 EG2–61
3VZ–E ENGINE – ENGINE MECHANICAL

(b) Uniformly loosen the 8 cylinder head bolts on each cylinder

head in several passes, in the sequence shown, then re-
peat for the other side, as shown.
Remove the 18 cylinder head bolts and plate washers.
NOTICE: Head warpage or cracking could result from
removing bolts in Incorrect order.

(c) Lift the cylinder head from the dowels on the cylinder block,
and place the 2 cylinder heads on wooden blocks on a
bench.
If the cylinder head is off, pry between the cylinder head
and cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact sur-
faces of the cylinder head and cylinder block.

37. REMOVE GENERATOR BRACKET

Remove the 3 bolts and brackets.

38. REMOVE EXHAUST MANIFOLD FROM RH

CYLINDER HEAD
(a) Remove the bolt, nut and exhaust manifold heat insulator.
(b) Remove the 6 nuts, exhaust manifold and gasket.
EG2–62
3VZ–E ENGINE – ENGINE MECHANICAL

39. REMOVE EXHAUST MANIFOLD FROM LH

CYLINDER HEAD
(e) Remove the 3 nuts and exhaust manifold heat insulator.
(b) Remove the 6 nuts, exhaust manifold and gasket.

CYLINDER HEADS DISASSEMBLY

(See Components for Removal and Installation)
1. REMOVE CAMSHAFT HOUSING PLUGS
(a) Remove the 2 bolts and housing rear cover.
(b) Remove the housing plug.

2. REMOVE VALVE LIFTERS AND SHIMS

Pull out the valve lifter and shim by hand.

HINT: Arrange the valve lifters and shims in cor-

rect order.

3. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the
2 keepers.
SST 09202–43013
 EG2–63
3VZ–E ENGINE – ENGINE MECHANICAL

(b) Remove these parts:

(1) Spring retainer
(2) Valve spring
(3) Valve
(4) Spring seat

HINT: Arrange the valves, valve springs, spring

seats and spring retainers in correct order.

(c) Using needle–nose pliers, remove the oil seal.

CYLINDER HEAD COMPONENTS

INSPECTION AND REPAIR
1. CLEAN TOP SURFACES OF PISTONS AND
CYLINDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead cen-
ter (TDC). Using a gasket scraper, remove all the carbon
from the piston top surface.

(b) Using a gasket scraper, remove all the gasket material from
the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION: Protect your eyes when using high–pres-
sure compressed sir.
EG2–64
3VZ–E ENGINE – ENGINE MECHANICAL

2. CLEAN CYLINDER HEAD

A. Remove gasket material
Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE: Be careful not to scratch the cylinder block
contact surface.

B. Clean combustion chambers

Using a wire brush, remove all the carbon from the
combustion chambers.
NOTICE: Be careful not to scratch the cylinder block
contact surface.

C. Clean valve guide bushings

Using a valve guide bushing brush and solvent, clean
all the guide bushings.

D. Clean cylinder head

Using a soft brush and solvent, thoroughly clean the
cylinder head.
 EG2–65
3VZ–E ENGINE – ENGINE MECHANICAL

3. INSPECT CYLINDER HEAD

A. Inspect for flatness
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
40.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylin-
der head.

B. Inspect for cracks

Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface
for cracks.
If cracked, replace the cylinder head.

4. CLEAN VALVES
(a) Using a gasket scraper, chip oft any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

5. INSPECT VALVE STEMS AND GUIDE BUSHINGS

(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
8.0 10 – 8.030 mm (0.3154 – 0.3.16 1 in.)
EG2–66
3VZ–E ENGINE – ENGINE MECHANICAL

(b) Using a micrometer, measure the diameter of the valve

stem.
Valve stem diameter:
Intake
7.970 – 7.985 mm (0.3138 – 0.3144 in.)
Exhaust
7.965 – 7.980 mm (0.3138 – 0.3142 in.)

(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
0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the
valve and guide bushing.

6. IF NECESSARY, REPLACE VALVE GUIDE

BUSHINGS
(a) Insert an old valve wrapped with tape into the valve guide
bushing, and break oft the valve guide bushing by hitting
it with a hammer. Remove the snap ring.
HINT: Wrap the tape approx. 12 mm (0.47 in.) from the
valve stem end.
NOTICE: Be careful not to damage the valve lifter
hole.

(b) Gradually heat the cylinder head to 80 – 100°C (176

– 212° F).
 EG2–67
3VZ–E ENGINE – ENGINE MECHANICAL

(c) Using SST and a hammer, tap out the guide bushing.
SST 09201–10000, 09608–35014(09608–06020)

(d) Using a caliper gauge, measure the bushing bore diameter

of the cylinder head.

(e) Select a new guide bushing (STD or O/S 0.05).

Both intake and exhaust If the bushing bore diameter of the cylinder head is
Bushing bore mm (in.) Bushing size greater than 13.027 mm (0.5129 in.), machine the bush-
ing bore to the following dimension:
13.050 – 13.077 mm (0.5138 – 0.5148 in.)
If the bushing bore diameter of the cylinder head is great-
er than 13.077 mm (0.5148 in.), replace the cylinder
head.

(f) Gradually heat the cylinder head to 80 – 100°C (1176

– 212° F).

(g) Using SST and a hammer, tap in a new guide bushing until
the snap ring makes contact with the cylinder
head.
SST 09201–60011
EG2–68
3VZ–E ENGINE – ENGINE MECHANICAL

(h) Using a sharp 8 mm reamer, ream the guide bushing to the

obtain standard specified clearance (See step 5
above) between the guide bushing and valve stem.

7. INSPECT AND GRIND VALVES

(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle:
44.50

(c) Check the valve head margin thickness.

Standard margin thickness:
1.3 – 1.7 mm (0.051 – 0.067 in.)
Minimum margin thickness:
1.0 mm l0.039 in.)
If the margin thickness is less than minimum, replace
the valve.

(d) Check the valve overall length.

Standard overall length:
104.3 mm (4.106 in.)
Minimum overall length:
103.8 mm (4.087 in.)
if the overall length is less than minimum, replace the
valve.

(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder
or replace the valve.
NOTICE: Do not grind off more than minimum.
 EG2–69
3VZ–E ENGINE – ENGINE MECHANICAL

8. INSPECT AND CLEAN VALVE SEATS

(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.

(b) Check the valve seating position.

Apply a light coat of prussian blue (or white lead) to
the valve face. Lightly press the valve against the seat.
Do not rotate valve.
(c) Check the valve face and seat for the following:
• If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
• 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 following width:
1.2 – 1.6 mm (0.047 – 0.063 In.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use
30° and 45° cutters to correct the seat.

(2) If the seating is too low on the valve face, use

60° and 45° cutters to correct the seat.

(d) Hand–lap the valve and valve seat with an abrasive com-
pound.
(e) After hand–lapping, clean the valve and valve seat.
EG2–70
3VZ–E ENGINE – ENGINE MECHANICAL

9. INSPECT VALVE SPRINGS

(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation:
1.23 mm (0.0484 in.)
If the deviation is greater than maximum, replace the
valve spring.

(b) Using a vernier caliper, measure the free length of the valve
spring.
Free length:
White painted mark: 46.50 mm (1.8307 in.)
Green painted mark: 47.01 mm (1.8508 In.)
If the free length is not as specified, replace the valve
spring.

(c) Using a spring tester, measure the tension of the valve

spring at the specified installed length.
Installed tension:
At 40.0 mm (1.575 In.)
242 – 268 N (24.7 – 27.3 kgf, 54.5 – 60.2 lbf)
If the installed tension is not as specified, replace the
valve spring.

10. INSPECT CAMSHAFTS AND BEARINGS

A. Inspect camshaft for runout
(a) Place the camshaft on V–blocks.
(b) Using a dial indicator, measure the circle runout at the cen-
ter journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace
the camshaft.

B. Inspect cam lobes

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
47.830 – 47.930 mm (1.8830 – 1.8870 in.)
Minimum cam lobe height:
47.50 mm (1.8701 In.)
If the cam lobe height is less than minimum, replace
the camshaft.
 EG2–71
3VZ–E ENGINE – ENGINE MECHANICAL

C. Inspect camshaft journals

Using a micrometer, measure the journal diameter.
Journal diameter:
33.959 – 33.975 mm (1.3370 – 1.3376 in.)
If the journal diameter is not as specified, check the oil
clearance.

D. Inspect camshaft bearings

Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps
and cylinder head as a set.

E. Inspect camshaft journal oil clearance

(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft
journals.
(d) Install the bearing caps.
(See step 5 in cylinder heads installation)
Torque: 16 N–m (160 kgf–cm, 12 ft–lbf)
NOTICE: Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 – 0.066 mm (0.0010 – 0.0026 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace
the camshaft. If necessary, replace the bearing caps
and cylinder head as a set.
(g) Completely remove the Plastigage.
(h) Remove the camshafts.
F. Inspect camshaft thrust clearance
(a) Install the camshaft.
(See step 5 in cylinder heads installation)
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.080 – 0.190 mm (0.0031 – 0.0075 in.)
Maximum thrust clearance:
0.25 mm (0.0098 in.)
EG2–72
3VZ–E ENGINE – ENGINE MECHANICAL

If the thrust clearance is greater than maximum, re-

place the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
(c) Remove the camshafts.

11. INSPECT VALVE LIFTERS AND LIFTER BORES

(a) Using a caliper gauge, measure the lifter bore diameter of
the cylinder head.
Lifter bore diameter:
37.960 – 37.975 mm (1.4945 – 1.4951 in.)

(b) Using a micrometer, measure the lifter diameter.

Lifter diameter:
37.922 – 37.932 mm (1.4930 – 1.4934 in.)

(c) Subtract the lifter diameter measurement from the lifter

bore diameter measurement.
Standard oil clearance:
0.028 – 0.053 mm (0.0011 – 0.0021 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace
the lifter. If necessary, replace the cylinder head.

12. INSPECT AIR INTAKE CHAMBER

Using a precision straight edge and feeler gauge,
measure the surface contacting the intake manifold for
warpage.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the
chamber.
 EG2–73
3VZ–E ENGINE – ENGINE MECHANICAL

13. INSPECT INTAKE MANIFOLD

Using a precision straight edge and feeler gauge,
measure the surface contacting the cylinder head and
air intake chamber for warpage.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the man-
ifold.

14. INSPECT EXHAUST MANIFOLD

Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head for warp-
age.
Maximum warpage:
0.70 mm (0.0276 in.)
If warpage is greater than maximum, replace the man-
ifold.

CYLINDER HEADS ASSEMBLY

(See Components for Removal and Installation)
HINT:
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil
to all sliding and rotating surfaces.
• Replace all gaskets and oil seals with new ones.
EG2–74
3VZ–E ENGINE – ENGINE MECHANICAL

1. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201–41020

HINT: The intake valve oil seal is gray and the ex-
haust valve oil seal is brown.

(b) Install these parts:

(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer

(c) Using SST, compress the valvespring and place the 2

keepers around the valve stem.
SST 09202–43013

(d) Using a plastic–faced hammer, lightly tap the valve stem tip
to assure proper fit.
 EG2–75
3VZ–E ENGINE – ENGINE MECHANICAL

2. INSTALL VALVE LIFTERS AND SHIMS

(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

3. INSTALL CAMSHAFT HOUSING PLUGS

(a) Place a new housing plug in position on the cylinder head,
facing the cup side inward.

(b) Install the housing rear plate with the 2 bolts.

Torque: 4.9 N–m (50 kgf–cm, 43in.–bf)

CYLINDER HEADS INSTALLATION

(See Components for Removal and Installation)
1. INSTALL RH EXHAUST MANIFOLD TO RH
CYLINDER HEAD
(a) Install a new gasket and the exhaust manifold with the
6 nuts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)
(b) Install the exhaust manifold heat insulator with the
bolt and nut.
2. INSTALL RH EXHAUST MANIFOLD TO LH
CYLINDER HEAD
(a) Install a new gasket and the exhaust manifold with the 6
nuts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)
(b) Install the exhaust manifold heat insulator with the 3
bolts.
EG2–76
3VZ–E ENGINE – ENGINE MECHANICAL

3. INSTALL GENERATOR BRACKET

Install the bracket with the 3 bolts.
Torque: 37 N–m (380 kgf–cm. 27 ft–lbf)

4. INSTALL CYLINDER HEADS

A. Place cylinder head on cylinder block
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
NOTICE: Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder
head gasket.

B. Install cylinder head (12 pointed head) bolts

HINT:
• The cylinder head bolts are tightened in 3 progres-
sive steps (steps (c), (e) and (f)).
• If any bolts is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under the
heads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c) Install and uniformly tighten the 8 cylinder head bolts
on each the cylinder head, in several passes, in the
sequence shown, then repeat for the other side, as
shown.
Torque: 44 N–m (450 kgf–cm, 33 ft–lbf)
If any of the bolts do not meet the torque specification,
replace the bolt(s).
 EG2–77
3VZ–E ENGINE – ENGINE MECHANICAL

(d) Mark the front of the cylinder head bolt head with paint.

(e) Retighten the cylinder head bolts by 90° in the numerical

order shown.

(f) Retighten cylinder head bolts by an additional 90°.

(g) Check that the painted mark is now facing rearward.

C. Install cylinder head (6 pointed head) bolts

(a) Apply a light coat of engine oil on the threads and under the
heads of the cylinder head bolts.
(b) Install the cylinder head bolt to each cylinder head.
Torque: 41 N–m (420 kgf–cm, 30 ft–lbf)
EG2–78
3VZ–E ENGINE – ENGINE MECHANICAL

5. INSTALL CAMSHAFTS
(a) Place the camshaft on the cylinder head.
(b) Apply seal packing to the No. 1 and No.5 bearing caps as
shown.
Seal packing:
Part No. 08826–00080 or equivalent

(c) Install the bearing caps in their proper locations.

(d) Apply a light coat of engine oil on the threads and under the
heads of the bearing cap bolts.
(e) Install and uniformly tighten the 12 bearing cap bolts on
each cylinder head, in several passes, in the sequence
shown, then repeat for the other side, as shown.
Torque: 16 N–m (160 kgf–em, 12 ft–lbf)
 EG2–79
3VZ–E ENGINE – ENGINE MECHANICAL

(f) Apply MP grease to a new oil seal lip.

(g) Using SST, tap in the 2 camshaft oil seals.

SST 09214 – 60010
6. CHECK AND ADJUST VALVE CLEARANCE
(See steps 7 and 8 in valve clearance inspection
and adjustment in tune – up)
Turn the camshaft and position the cam lobe upward,
check and adjust the valve clearance.
Valve clearance (Cold):
Intake
0.18 – 0.28 mm (0.007 – 0.011 in.)
Exhaust
0.22 – 0.32 mm (0.009 – 0.013 in.)

7. INSTALL CYLINDER HEAD COVERS

(a) Remove the old packing (FIPG) material.
(b) Apply seal packing to the cylinder head, as shown in the
illustration.
Seal packing:
Part No. 08826–00080 or equivalent
EG2–80
3VZ–E ENGINE – ENGINE MECHANICAL

(c) Install the gasket to the head cover.

(d) Install the cylinder head cover with the 11 bolts.
Uniformly tighten the bolts one each cylinder head cover,
in several passes, in the sequence shown, then
repeat for the other side, as shown. Install the 2
cylinder head covers.
Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf)

8. INSTALL WATER BYPASS PIPE TO RH CYLINDER

HEAD
Install the water bypass pipe with the bolt.

9. INSTALL No.2 ENGINE HANGER

Install the engine hanger with the 2 bolts.
Torque: 40 N–m (410 kgf–cm, 30 ft–lbf)

10. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK

(a) Install a new 0–ring on the oil dipstick.
(b) Install the oil dipstick guide with the bolt.
Torque: 37 N–m (380 kgf–cm, 27 ft–lbf)
(c) Install the oil dipstick.
11. INSTALL GENERATOR
 EG2–81
3VZ–E ENGINE – ENGINE MECHANICAL

12. INSTALL EXHAUST CROSSOVER PIPE

Install 2 new gaskets and the crossover pipe with the
6 nuts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)
13. INSTALL KNOCK SENSOR WIRE

14. INSTALL INTAKE MANIFOLD

install 2 new gaskets and the intake manifold with the
12 bolts and 4 nuts.
Torque: 18 N–m (185 kgf–cm, 13 ft–lbf)

15. INSTALL WATER BYPASS OUTLET

(a) Install a new gasket and the water bypass outlet with the
2 nuts.
Torque: 18 N–m (185 kgf–cm, 13 ft–lbf)
(b) Connect the No.3 water bypass hose to the No.1
water bypass pipe.

16. INSTALL INJECTORS AND DELIVERY PIPE

(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new O–ring, and install
it to the injector.

(c) While turning the injector clockwise and counter–

clockwise, push it to the delivery pipe. Install the 6
injectors.
(d) Position the injector connector outward.
EG2–82
3VZ–E ENGINE – ENGINE MECHANICAL

(e) Install a O–ring to the spacer.

(f) Place the 6 spacers and insulators into the injector
holes.
(g) Place the 4 spacers on the stud bolts.

(h) Place the 2 delivery pipes together with the 6 injectors in

position on the intake manifold.
(i) Temporarily install the 4 spacers and nuts.
(j) Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable
cause is incorrect installation of O –rings. Replace the
O–rings.
(k) Position the injector connector upward.

(I) Tighten the 4 nuts holding the delivery pipes to the intake
manifold.
Torque: 13 N–m (130 kgf–cm. 9 ft–lbf)
(m) Install the No. 1 fuel pipe to the No.3 bearing cap with the
bolt.

17. INSTALL PAIR REED VALVE AND NO.1 INJECTION

MANIFOLD
(a) Position a new gasket on the RH exhaust manifold.
(b) Install the PAIR reed valve and injection manifold assem-
bly with the 2 nuts and 2 bolts.
Torque:
Bolt: 37 N–m (380 kgf –cm, 27 ft–lbf)
Nut: 29 N–m (300 kgf–cm, 22 ft–lbf)
18. INSTALL VSV BRACKET AND VSV TO PAIR REED
VALVE
19. INSTALL NO.3 TIMING BELT COVER
Install the timing belt cover with the6 bolts.
Torque: 8.3 N–m (85 kgf–cm, 74 in.–lbf)
 EG2–83
3VZ–E ENGINE – ENGINE MECHANICAL

20. INSTALL NO.2 IDLER PULLEY

(a) Remove any old packing (FIPG) material and be careful not
to drop any oil on the contact surfaces of the water outlet
housing on the No.2 idler pulley and the intake manifold.
• Using a razor blade and gasket scraper, remove all the
old packing (FIPG) material from the gasket surfaces
and sealing groove.
• Thoroughly clean all components to remove all
the loose material.
• Using a non–residue solvent, clean both sealing sur-
faces.
(b) Apply seal packing to the sealing groove of the water outlet
housing on the idler pulley as shown in the illustration.
Seal packing:
Part No. 08826–00100 or equivalent
• Install a nozzle that has been cut to a 2 – 3 mm
(0.08 – 0.12 in.) opening.
• Parts must be assembled within 5 minutes of applica-
tion. Otherwise the material must be removed and
reapplied.
• Immediately remove nozzle from the tube and
reinstall cap.
(c) Install the idler pulley with the 4 bolts. Uniformly tighten the
bolts in several passes.
Torque: 18 N–m (185 kgf–cm, 13 ft–lbf)

21. INSTALL NO.4 TIMING BELT COVER

Install the timing belt cover with the 4 bolts.
Torque: 8.3 N–m (85 kgf–cm 74 in.–lbf)

22. INSTALL NO.2 AND NO.3 FUEL PIPES

(a) Install the No.2 fuel pipe with 4 new gaskets and 2
union bolts.
Torque: 34 N–m (350 kgf–cm, 25 ft–lbf)
(b) Install the No.3 fuel pipe with 4 new gaskets and 2
union bolts.
Torque: 34 N–m (350 kgf–cm. 25 ft–lbf)
EG2–84
3VZ–E ENGINE – ENGINE MECHANICAL

23. INSTALL ENGINE WIRE

(a) Install the engine wire with the 2 bolts.

(b) Connect these connectors and strap:

• Injector connectors
• RH ground strap
• ECT sender gauge connector
• ECT sensor connector
• No.2 ECT switch connector
• Cold start injector time switch connector
• Knock sensor connector

24. INSTALL AIR INTAKE CHAMBER

(a) Install a new gasket and the intake chamber with the
6 bolts and 2 nuts.
Torque: 18 N–m (185 kgf–cm, 13 ft–lbf)

(b) Install the accelerator cable bracket with the 2 bolts.

(c) Connect the 4 vacuum hoses to the air pipes.

(d) Connect the No. 1 air hose to the reed valve.

 EG2–85
3VZ–E ENGINE – ENGINE MECHANICAL

(e) Install 2 new gaskets, the EGR valve, pipes assembly, air
intake chamber stay and throttle cable bracket with the6
nuts and 2 bolts.
Torque:
(A): 29 N–m (300 kgf–cm, 22 ft–lbf)
(B): 18 N–m (185 kgf.cm, 13 ft–lbf)

(f) Connect the EGR hoses to the air pipe and EGR
vacuum modulator.
(g) Connect the EGR gas temperature sensor connector.

(h) Install the PS pump bracket with the bolt and nut.

(i) Install No.1 engine hanger.

Torque: 40 N–m (410 kgf–cm, 30 ft–lbf)

(j) Connect the cold start injector tube with 2 new gaskets and
the union bolt.
Torque: 15 N–m (150 kgf–cm. 11 ft–lbf)
(k) Connect the vacuum hose to the gas filter.
(1) Connect the cold start injector connector.
EG2–86
3VZ–E ENGINE – ENGINE MECHANICAL

(m) Install the No. 5 water bypass hose to the water bypass
pipe.

(n) Connect the No.4 water bypass hose to the union of

intake manifold.

(o) Connect the PCV hose to the union.

(p) Connect the vacuum and fuel hoses to the pressure

regulator.
(q) Connect the charcoal canister vacuum hose to the throttle
body.
(r) Connect the throttle position sensor connector.

26. INSTALL TIMING BELT

(See timing belt installation in timing belt)
26. INSTALL DISTRIBUTOR
(See steps 1 and 2 in distributor installation ”in
distributor in Ignition System (3VZ–E))
27. CONNECT HIGH–TENSION CORDS TO SPARK
PLUGS
 EG2–87
3VZ–E ENGINE – ENGINE. MECHANICAL

28. INSTALL FRONT EXHAUST PIPE

(a) Connect the exhaust pipe to the LH exhaust manifold with
new gasket and 3 new nuts.
Torque: 62 N–m (630 kgf–cm, 46 ft–lbf)
(b) Connect the exhaust pipe to the catalytic converter with
new gasket and the 2 bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)

(c) Install the pipe bracket to the transmission with the 2

bolts.
(d) Install the pipe bracket to the exhaust pipe with the pipe
clamp.
(e) Connect the heated oxygen sensor connector.

29. CONNECT FUEL INLET AND OUTLET HOSES

30. CONNECT HEATER HOSES

31. CONNECT CABLES, HOSES, CONNECTORS, STRAP

AND WIRES
(a) Connect these cables:
• Accelerator cable
• A/T only:
Throttle cable
• w/ Cruise Control System:
Cruise control cable
(b) Connect these hoses:
• PS air hoses to gas filter and air pipe
• Brake booster hose
• w/ Cruise Control System:
Cruise control vacuum hose
• Charcoal canister hose from canister
• VSV vacuum hoses
(c) Connect the strap, wires and connectors:
• Ground strap to LH fender apron
• Generator connector and wire
• Igniter connector
EG2–88
3VZ–E ENGINE – ENGINE MECHANICAL

• Oil pressure sender gauge connector

• Ground strap to engine rear side
• ECM connectors
• VSV connectors
• A/C compressor connector
• M/T only:
Starter relay connector
• Solenoid resister connector
• DLC1
• w/ ADD:
ADD switch connector

32. INSTALL GENERATOR DRIVE BELT

33. INSTALL COOLING FAN
Install the cooling fan with the 4 nuts.
Torque: 5.4 N–m (55 kgf.cm, 48 in.–lbf)
34. INSTALL A/C DRIVE BELT

35. INSTALL PS PUMP

36. INSTALL PS PUMP PULLEY AND DRIVE BELT

37. M/T only:

CONNECT CLUTCH RELEASE CYLINDER HOSE
 EG2–89
3VZ–E ENGINE – ENGINE MECHANICAL

38. INSTALL RADIATOR

(a) Install the radiator with the 4 bolts.
(b) Install the No. 1 fan shroud with the 4 bolts.
(c) Install the No.2 fan shroud with the 2 clips.

(d) Install the radiator hoses.

(e) A/T only:
Connect the oil cooler hoses.
(f) Connect the reservoir hose.

39. INSTALL AIR CLEANER AND HOSE

40. FILL WITH ENGINE COOLANT
41. START ENGINE AND CHECK FOR LEAKS
42. PERFORM ENGINE ADJUSTMENT
(See tune–up)
43. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
44. RECHECK ENGINE COOLANT LEVEL AND OIL
LEVEL