Engine Mechanical - 1MZ-FE: Other Toyota Highlander I

FUEL PRESSURE RELEASE

Disconnect fuel pump connector. Start engine and run until it stops, then turn ignition off. Place a container under high-pressure fuel line connection. Slowly loosen and disconnect connection. Plug open end of fuel line. Reconnect fuel pump connector. Once fuel pressure is released, fuel system components may be serviced.

Note. Remove engine and transaxle as an assembly.

CYLINDER HEAD & MANIFOLDS

CAMSHAFT

Note. When servicing camshafts, reference to right and left components are as viewed from rear of engine.

WATER PUMP

OIL PAN

Valve Train

1. With caliper gauge, measure inside diameter of valve stem guide bushings. Use a micrometer to measure diameter of corresponding valve stem. Difference between these 2 measurements is oil clearance. If clearance exceeds specifications, replace valve and guide bushing. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS.
2. After grinding valves enough to remove pits and carbon, check that valve is ground to correct valve face angle. Check valve head margin thickness. If face angle cannot be properly ground or in margin thickness is less than minimum, replace valve. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS.
3. Check overall valve length. If length is less than minimum, replace valve. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS. Check surface of valve stem tip for wear. Resurface tip with grinder or replace valve.
4. With a 45 degree carbide cutter, resurface valve seats, removing only enough metal to clean seats. Apply light coat of Prussian Blue to valve face and lightly press valve against seat (DO NOT rotate valve). If Blue appears evenly around entire valve face, valve is okay. If not, resurface or replace valve.
5. Ensure seat contact width in middle of valve face is within specification. If not, recut valve face and hand-lap valve and seat. Replace valves and seats as necessary. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS.
6. Place valve spring next to steel square and measure deviation of spring. If spring deviation exceeds specifications, replace valve spring. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS.
7. With calipers, measure free length of valve spring. If free length is not within specification, replace spring. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS.
8. With spring tester, apply specified tension to press spring to indicated length. If installed tension is not as specified, replace spring. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS.
9. Measure valve guide bushing diameter. Replace guide, after heating cylinder head to 176-212°F (80-100°C), if not within specifications. See «VALVES & VALVE SPRINGS»(ref-159178-S19507481352003111700000) table under ENGINE SPECIFICATIONS.

Camshafts

1. Place camshaft on "V" blocks and use a dial indicator to measure circle runout at center journal. If runout exceeds specifications, replace camshaft. See «CAMSHAFT»(ref-159178-S10449220792003111700000) table under GENERAL SPECIFICATIONS.
2. Use a micrometer to measure cam lobe height. If height is less than specified, replace camshaft. See «CAMSHAFT»(ref-159178-S10449220792003111700000) table under GENERAL SPECIFICATIONS.
3. With micrometer, measure camshaft journal diameter. If diameter is not within specification, check camshaft oil clearance. Go to step 5 .
4. Check camshaft bearings for flaking or scoring. Replace bearing and cylinder head as a set if bearings are damaged.
5. To check camshaft oil clearance using Plastigage, install camshaft in cylinder head using proper procedure. See «CAMSHAFT»(ref-159178-S06751180662003111700000) under REMOVAL & INSTALLATION. Replace camshaft and/or cylinder head if oil clearance is not within specification.
6. Check camshaft end play with camshafts installed. Attach a dial indicator to end of camshaft and measure end play while moving camshaft back and forth. If clearance is greater than specifications, remove camshaft, or replace bearing caps and cylinder head as an assembly.
7. Install camshafts without installing exhaust sub-gear. With a dial indicator, measure camshaft gear backlash. If backlash exceeds specifications, replace camshafts.
8. With camshaft removed, use calipers to measure free distance of camshaft gear spring. Measure between open ends of spring. If free distance is not within specifications, replace camshaft gear spring.

Cylinder Head

1. Use calipers to measure valve lifter bore diameter in cylinder head. Use a micrometer to measure lifter diameter. Difference in these 2 measurements represents valve lifter oil clearance. If oil clearance in not within specification, replace lifter or cylinder head. See «VALVE LIFTERS»(ref-159178-S37711582602003111700000) table under ENGINE SPECIFICATIONS.
2. If installing spark plug tubes in NEW cylinder head, apply sealant on cylinder head end of spark plug tube. Using press, install spark plug tube until distance between top surface of spark plug tube and camshaft bearing cap surface of cylinder head is 1.669-1.709 in. (42.39-43.40 mm).
3. If installing PCV pipe in NEW cylinder head, use hammer and wooden block to install PCV pipe. The PCV pipes are installed between exhaust camshaft and outer edge of cylinder head. see scheme 13 Install PCV pipe until top of PCV pipe is even with valve cover gasket surface on cylinder head.

Connecting Rod Bearings

1. Before removing piston and connecting rod, use a dial indicator to measure thrust clearance while moving connecting rod back and forth on crankshaft. See «PISTONS, PINS & RINGS»(ref-159178-S18050586182003111700000) table under ENGINE SPECIFICATIONS. If thrust clearance exceeds maximum, replace connecting rod assembly(s). If necessary, replace crankshaft.
2. Check match marks on connecting rod and cap to ensure correct reassembly of sets. Remove both cap bolts. In their loosened position, use bolts to wiggle connecting rod cap and lower bearings (keep bearing inserted in cap).
3. Clean crank pin and bearing and check for any pitting or scratches. If crank pin or bearing is damaged, replace bearings. Replace crankshaft, if necessary.
4. Lay strip of Plastigage across crank pin and install connecting rod cap with 2 bolts. Tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000) . Remove cap bolts, cap and lower bearing. Check Plastigage at widest point to determine if oil clearance is within specifications. See «PISTONS, PINS & RINGS»(ref-159178-S18050586182003111700000) table under ENGINE SPECIFICATIONS. If clearance exceeds maximum, replace bearings. If necessary, grind or replace crankshaft. NOTE: If bearing is replaced, use a replacement having the same number as marked on connecting rod. Replacement bearings are available in 4 sizes. See «ROD BEARING SPECIFICATIONS»(ref-159178-S20631984322003111700000) table. ROD BEARING SPECIFICATIONS Bearing Size Mark Thickness - In. (mm) 1 .0584-.0585 (1.484-1.487) 2 .0585-.0587 (1.487-1.490) 3 .0587-.0588 (1.490-1.493) 4 .0588-.0589 (1.493-1.496)

Piston Rings

1. Position edge of piston ring into appropriate ring groove. With feeler gauge, measure clearance between ring and piston groove. If ring groove clearance exceeds specifications, replace piston. See «PISTONS, PINS & RINGS»(ref-159178-S18050586182003111700000) table under ENGINE SPECIFICATIONS.
2. Insert piston ring into cylinder bore. Use piston to evenly push ring to position slightly below bottom of ring travel in bore, about 4.13 in. (105 mm) from top of cylinder block. Remove piston and use feeler gauge to measure ring end gap. See «PISTONS, PINS & RINGS»(ref-159178-S18050586182003111700000) table under ENGINE SPECIFICATIONS. If gap exceeds specification, replace piston ring. If gap exceeds specification with NEW piston ring, replace cylinder block.
3. Position piston rings with ring end gaps in proper areas and with identification mark on piston ring toward top of piston. (Scheme 37) No. 1 compression ring may contain a "1R", "T" or "G1" identification mark. No. 2 compression ring may contain a "2R", "2T" or "G2" identification mark. Ensure proper ring is installed in correct location.

Scheme 37

Piston Fitting

1. To reassemble, install piston on connecting rod with front mark on top of piston aligned with front mark on connecting rod. (Scheme 38)or (Scheme 39). Install NEW snap ring in piston. Ensure ends of snap ring are not aligned with piston pin cutout area of piston.
2. Heat piston to 140°F (60°C) in water. Coat piston pin with engine oil. Install piston pin and remaining NEW snap ring. Ensure ends of snap ring are not aligned with piston pin cutout area of piston.
3. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference. Piston and connecting rod must be installed in cylinder block with front mark facing timing belt end of engine. (Scheme 37)
4. Connecting rod and rod bearing are stamped with size mark ("1", "2", "3" or "4"). (Scheme 40) Size marks on connecting rod and rod bearing must be the same.
5. Rod bearing thickness is determined by size mark. See «ROD BEARING SPECIFICATIONS»(ref-159178-S20631984322003111700000) table. If replacing rod bearing, ensure size mark on replacement rod bearing is same as size mark on original rod bearing. Size mark must also be same as that stamped on connecting rod.
6. Ensure piston and connecting rod are installed in cylinder block with front mark facing timing belt end of engine. Ensure protrusion on connecting rod cap is facing timing belt end of engine.
7. Coat connecting rod bolt threads and bolt head contact surface. Alternately tighten bolts, in several steps, to specification. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).
8. Ensure bearing oil clearance and connecting rod side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159178-S11547755112003111700000) table and «CONNECTING RODS»(ref-159178-S41674513772003111700000) table under ENGINE SPECIFICATIONS.

Scheme 38

Scheme 39

Scheme 40

Crankshaft & Main Bearings

1. Remove 8 main bearing cap side bolts (hexagon bolts) and seal washers from side of cylinder block in alternating sequence in several steps.
2. Remove 16 main bearing caps bolts in several steps, in sequence shown. (Scheme 41) Remove main bearing caps. Remove crankshaft. Keep upper main bearings together with cylinder block.
3. Clean each main journal and bearing. Check all areas for pitting or scratching. If journal or bearing is damaged, replace bearings. If necessary, replace crankshaft.
4. Place crankshaft into position. Lay strip of Plastigage across each journal. Install 4 main bearing caps. Install and tighten bolts 16 main cap bolts and 8 side bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).
5. Remove main bearing caps without turning crankshaft. Measure Plastigage at widest point. This represents crankshaft journal oil clearance. If clearance exceeds maximum specification, replace bearings. If necessary, replace crankshaft. NOTE: If identification number of bearing cannot be determined, find and add together numbers imprinted on cylinder block and crankshaft, then refer to appropriate table for replacement bearing selection. Journal bearings No. 1 and No. 4 have 5 standard bearing sizes marked "3", "4", "5", "6" and "7". Journal bearings No. 2 and No. 3 have 5 standard bearing sizes marked "1", "2", "3", "4" and "5". (Scheme 42)or (Scheme 43).
6. Measure main journals for proper diameter, taper and out-of-round. If diameter is out of specification, check journal oil clearance. If taper and out-of-round exceed specifications, replace crankshaft. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159178-S11547755112003111700000) table under ENGINE SPECIFICATIONS.
7. Main bearing size mark is located on side of main bearing. (Scheme 44) If replacing main bearing, ensure size mark on replacement main bearing is the same as size mark on original main bearing. If size mark on original main bearing cannot be obtained, use size marks on cylinder block and crankshaft to determine size mark of main bearing to be used. Main bearing thickness is determined by size mark. See «MAIN BEARING SPECIFICATIONS»(ref-159178-S41867377212003111700000) table. MAIN BEARING SPECIFICATIONS Size Mark Bearing Thickness - In. (mm) TMC Made 1.0979-.0980 (2.486-2.489) 2.0980-.0981 (2.489-2.491) 3.0981-.0982 (2.491-2.494) 4.0982-.0983 (2.494-2.496) 5.0983-.0985 (2.496-2.501) 6.0985-.0986 (2.501-2.504) 7.0986-.0987 (2.504-2.506) TMMK Made 1.0978-.0980 (2.484-2.489) 2.0980-.0981 (2.489-2.491) 3.0981-.0982 (2.491-2.494) 4.0982-.0983 (2.494-2.496) 5.0983-.0984 (2.496-2.499) 6.0984-.0985 (2.499-2.501) 7.0985-.0987 (2.501-2.506)
8. Coat threads of all main bearing bolts and bolt head-to-main bearing cap area with engine oil. Temporarily install 8 main bearing cap bolts to inside positions. Insert main bearing cap by hand until clearance between main bearing cap and cylinder block is less than.23 in. (5.8 mm), using internal cap bolts as a guide.
9. Use soft-face hammer and lightly tap bearing cap to ensure proper fit. Install and tighten 12-point head main bearing cap bolts in progressive steps. Follow tightening sequence shown. see scheme 38 Tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).
10. NEW seal washers must be installed on main bearing cap side bolts (hexagon bolts) during final assembly. Install and tighten main bearing cap side bolts (hexagon bolts) to specification in sequence using several steps. see scheme 38 See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Thrust Bearings

Install thrust bearing on No. 2 main bearing with grooves facing toward crankshaft. Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck warpage exceeds specification. See «CYLINDER BLOCK»(ref-159178-S21641732652003111700000) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore diameter at.39 in. (9.9 mm) from top and bottom of cylinder bore and at middle of cylinder bore. Replace cylinder block if cylinder bore diameter is not within specification. See «CYLINDER BLOCK»(ref-159178-S21641732652003111700000) table under ENGINE SPECIFICATIONS.
3. If wear is less than.008 in. (.02 mm), use a ridge reamer to grind top of cylinder bore.
4. Ensure main bearing bore inside diameter is within specification with main bearing caps installed and bolts tightened to specification. See «CYLINDER BLOCK»(ref-159178-S21641732652003111700000) table under ENGINE SPECIFICATIONS. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000). Main bearing bore inside diameter is determined by size mark stamped on front of cylinder block. (Scheme 44)

Oil Pump

Oil pump provides pressurized engine lubrication. see scheme 34

Oil Pressure

With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm 2 ) at idle and 43-78 psi (3.0-5.5 kg/cm 2 ) at 3000 RPM.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS

CONNECTING RODS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

CYLINDER BLOCK

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

CYLINDER HEAD

CAMSHAFT

VALVE LIFTERS

VALVE LIFTERS