Мануал для двигателя 2az fe - Большая энциклопедия инструкций и руководств

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rzbor

Я езжу на Toyota Camry (XV40)

Как ни странно, не выходит найти распиновку 2azfe Camry 40. Поделитесь пожалуйста.

1 год

Hairat111

Я езжу на Lexus RX (2G)

Можно ссылку пожалуйста на руководство по ремонту 2AZFE?

2 года

trufan3500

Я езжу на Toyota Vitz (130)

Привет. Ссылка не работает, поделитесь?

4 года

sshturman

Я езжу на Toyota Camry (XV40)

Спасибо за ссылку!

7 лет

PACCOXA

Автор

Без машины

Рад что пригодилась.

7 лет

somebody

Несуществующий пользователь

Без машины

ого! весЧ!

7 лет

mit178

Я езжу на Mercedes-Benz E-class (W124)

Спасибо друг, надеюсь не пригодиться)))))

7 лет

PACCOXA

Автор

Без машины

))))

7 лет

Maxim0808

Я езжу на УАЗ 315195 Hunter

класс спасибо

7 лет

PACCOXA

Автор

Без машины

Рад что пригодилась.

7 лет

Источник

2AZ-FE ENGINE MECHANICAL – ENGINE	EM–1

ENGINE

INSPECTION

1.INSPECT ENGINE COOLANT

(a)Inspect the engine coolant (See page CO-1).

2.INSPECT ENGINE OIL

(a)Inspect the engine oil (See page LU-1).

3.INSPECT BATTERY

(a)Inspect the battery (See page CH-4).

4.INSPECT SPARK PLUGS

(a)Inspect the spark plugs (See page IG-5).

5.INSPECT AIR CLEANER FILTER ELEMENT SUBASSEMBLY

(a)Remove the air cleaner filter element sub-assembly. EM

(b)Visually check that there is no dirt, blockage, and/or damage to the air cleaner filter element.

HINT:

•If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air.

•If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it.

6.INSPECT IGNITION TIMING

(a)Warm up the engine.

	Intelligent Tester	(b) When using the intelligent tester:
	Check the ignition timing.

		(1) Connect the intelligent tester to the DLC3.
		(2) Enter DATA LIST MODE on the intelligent
		tester.
		Ignition timing:
		8 to 12° BTDC at idle
	CAN VIM	HINT:
	Refer to the intelligent tester operator’s manual
	DLC3
	C110200E02	for help when selecting the DATA LIST.

									(c) When not using the intelligent tester:

									Check the ignition timing.
DLC3			CG				(1) Using SST, connect terminals 13 (TC) and 4
									(CG) of the DLC3.
									SST 09843-18040
1	2	3	4	5	6	7 8			NOTICE:
									• Confirm the terminal numbers before
9 10 111213141516			connecting them. Connection with a
									wrong terminal can damage the engine.
					TC			• Turn off all electrical systems before
					A082779E69
									connecting the terminals.

									• Perform this inspection after the cooling
									fan motor is turned off.

2AZ-FE ENGINE MECHANICAL – ENGINE

(2)Remove the No. 1 engine cover.

(3)Pull out the wire harness as shown in the illustration. Connect the clip of the timing light to the wire harness.

NOTICE:

•Use a timing light which can detect the first signal.

•After checking, be sure to tape the wire

harness.

A052004 (4) Check the ignition timing at idle.

Ignition timing:

8 to 12° BTDC at idle

NOTICE:

When checking the ignition timing, the transmission should be in neutral.

HINT:

After engine rpm is kept at 1,000 to 1,300 rpm for 5 seconds, check that it returns to idle speed.

(5)Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

(6)Check the ignition timing at idle.

Ignition timing:

5 to 15° BTDC at idle

(7)Confirm that the ignition timing moves to the advanced angle side when the engine rpm is increased.

(8)Remove the timing light.

Intelligent Tester

CAN VIM

DLC3

C110200E02

7. INSPECT ENGINE IDLE SPEED

(a) Warm up the engine.

(b) When using the intelligent tester: Check the idle speed.

(1) Connect the intelligent tester to the DLC3.

	HINT:
	Refer to the intelligent tester operator’s manual
	for further details.
(2) Enter DATA LIST MODE on the intelligent
	tester.
	Idle speed

Item		Specified Condition

M/T		650 to 750 rpm

A/T		610 to 710 rpm

NOTICE:

• When checking the idle speed, the transmission should be in neutral.

• Check the idle speed with the cooling fan off.

• Switch off all accessories and air conditioning before connecting the intelligent tester.

2AZ-FE ENGINE MECHANICAL – ENGINE	EM–3

(c)When not using the intelligent tester: Check the idle speed.

	DLC3				(1)	Using SST, connect the tachometer tester
							probe to terminal 9 (TAC) of the DLC3.
							SST 09843-18030
1 2 3 4 5 6	7 8			(2)	Check the idle speed.
9 10 11121314	15 16					Idle speed

			Item		Specified Condition


TAC					M/T		650 to 750 rpm
		A082779E70
					A/T		610 to 710 rpm

8. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coils.
(d) Remove the spark plugs.	EM
(e) Check the cylinder compression pressure.

(1)Insert a compression gauge into the spark plug hole.

(2)Fully open the throttle.

(3)While cranking the engine, measure the compression pressure.

Compression pressure:

			1.360 MPa (13.9 kgf/ cm2, 198 psi)
			Minimum pressure:
			0.98 MPa (10 kgf/ cm2, 142 psi)
	A001037

			Difference between each cylinder:

100 kPa (1.0 kgf/ cm2, 14 psi) NOTICE:

•Always use a fully charged battery to obtain an engine speed of 250 rpm or more.

•Check the other cylinders’ compression pressure in the same way.

•This measurement must be done as quickly as possible.

(4)If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again.

HINT:

•If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.

•If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.

9.INSPECT CO/HC

(a)Start the engine.

(b)Run the engine at 2,500 rpm for approximately 180 seconds.

(c)Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.

EM–4	2AZ-FE ENGINE MECHANICAL – ENGINE

(d) Immediately check CO/HC concentration at idle and/or 2,500 rpm.

HINT:

• Complete the measuring within 3 minutes.

• Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm).

(e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

(1) Check A/F sensor and heated oxygen sensor operation (See page EC-21).

(2) See the table below for possible causes, and then inspect and repair.

		CO	HC	Problems			Causes

					1.	Faulty ignitions:
EM
					–	Incorrect timing
	Normal	High	Rough idle		– Fouled, shorted or improperly gapped plugs

		2.	Incorrect valve clearance

					3.	Leaky intake and exhaust valves
					4.	Leaky cylinders

					1.	Vacuum leaks:
						–	PCV hoses
		Low	High	Rough idle		–	Intake manifold
		(fluctuating HC reading)		–	Throttle body

						–	Brake booster line
					2.	Lean mixture causing misfire

					1.	Restricted air filter
					2.	Plugged PCV valve
					3.	Faulty SFI system:
				Rough idle		–	Faulty pressure regulator
		High	High		–	Defective ECT
		(black smoke from exhaust)
					–	Defective MAF meter

						–	Faulty ECM
						–	Faulty injectors
						– Faulty throttle position sensor

2AZ-FE ENGINE MECHANICAL – DRIVE BELT	EM–5

DRIVE BELT

COMPONENTS

V-RIBBED BELT

FRONT FENDER APRON SEAL RH

ENGINE UNDER COVER RH

A134946E01

EM–6	2AZ-FE ENGINE MECHANICAL – DRIVE BELT

	REMOVAL
	1.	REMOVE FRONT WHEEL RH
	2.	REMOVE ENGINE UNDER COVER RH
	3.	REMOVE FRONT FENDER APRON SEAL RH
19 mm	4.	REMOVE V-RIBBED BELT
	(a) Using SST and 19 mm socket wrench, loosen the V-
Socket		ribbed belt tensioner arm clockwise, then remove
Wrench		the V-ribbed belt.
		SST	09216-42010
		NOTICE:
		• Be sure to connect SST and the tools so that
		they are in line during use.
SST		• When retracting the tensioner, turn it
A114351E03		clockwise slowly for 3 seconds or more. Do
EM		not apply force rapidly.
	• After the tensioner is fully retracted, do not
		apply force any more than necessary.

INSPECTION

REPLACE

1. INSPECT V-RIBBED BELT

(a) Visually check the V-ribbed belt for excessive wear, frayed cords, etc. If any defect has been found, replace the V-ribbed belt.

HINT:

• Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.

• A «new belt» is a belt which has been used for less than 5 minutes with the engine running.

• A «used belt» is a belt which has been used for 5 minutes or more with the engine running.

CORRECT	INCORRECT
	A131418E01
	19 mm	INSTALLATION
	1.	INSTALL V-RIBBED BELT
	Socket
	Wrench		(a) Using SST and 19 mm socket wrench, loosen the V-
			ribbed belt tensioner arm clockwise, then install the
			V-ribbed belt.
			SST	09216-42010
			NOTICE:
SST			• Be sure to connect SST and the tools so that
	A114351E03		they are in line during use.
		• When retracting the tensioner, turn it

			clockwise slowly for 3 seconds or more. Do
			not apply force rapidly.

2AZ-FE ENGINE MECHANICAL – DRIVE BELT	EM–7

•After the tensioner is fully retracted, do not apply force any more than necessary.

(b)After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Check to confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

2.INSTALL FRONT FENDER APRON SEAL RH

3.INSTALL ENGINE UNDER COVER RH

4.INSTALL FRONT WHEEL RH

Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

EM–8	2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

	VALVE CLEARANCE

Timing Mark

Groove

A098345E09

No. 1 Cylinder TDC/Compression

A098170E04

ADJUSTMENT

1.	REMOVE FRONT WHEEL RH
2.	REMOVE ENGINE UNDER COVER LH
3.	REMOVE ENGINE UNDER COVER RH
4.	REMOVE FRONT FENDER APRON SUB-ASSEMBLY
	RH
5.	REMOVE NO. 1 ENGINE COVER (See page EM-94)
6.	REMOVE IGNITION COIL ASSEMBLY (See page EM-
	106)
7.	REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
	(See page EM-21)
8.	SET NO. 1 CYLINDER TO TDC/COMPRESSION
	(a) Turn the crankshaft pulley until its groove and the
		timing mark «0» of the timing chain cover are
		aligned.
	(b) Check that each timing mark of the camshaft timing
		gear and sprocket is aligned with each timing mark
		located on the No. 1 and No. 2 bearing caps as
		shown in the illustration. If not, turn the crankshaft
		by 1 revolution (360°) to align the timing marks as
		above.
9.	CHECK VALVE CLEARANCE
	(a) Check only the valves indicated.
		(1) Using a feeler gauge, measure the clearance
		between the valve lifter and camshaft.
		Standard valve clearance (cold)

Item			Standard Condition

Intake		0.19 to 0.29 mm (0.0075 to 0.0114 in.)

Exhaust		0.38 to 0.48 mm (0.0150 to 0.0189 in.)

(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters.

(b) Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression.

2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE	EM–9

No. 4 Cylinder TDC/Compression

A098171E04

A001082E01

	(1) Using a feeler gauge, measure the clearance
	between the valve lifter and camshaft.
	Standard valve clearance (cold)

Item		Standard Condition

Intake		0.19 to 0.29 mm (0.0075 to 0.0114 in.)

Exhaust		0.38 to 0.48 mm (0.0150 to 0.0189 in.)

	(2) Record any out-of-specification valve clearance
	measurements. They will be used later to
	determine the required replacement valve
	lifters.
10. ADJUST VALVE CLEARANCE
(a) Remove the No. 2 camshaft (see page EM-38).
(b) Remove the camshaft (see page EM-38).
(c) Remove the valve lifters.
EM
(d)	Using a micrometer, measure the thickness of the

removed valve lifters.

(e)Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.

New lifter thickness

Item	Specification

Intake	A = B + (C — 0.24 mm (0.0095 in.))
Exhaust	A = B + (C — 0.43 mm (0.0169 in.))


A	New lifter thickness

B	Used lifter thickness

C	Measured valve clearance

CALCULATION EXAMPLE (Intake):

1.Measured intake valve clearance = 0.40 mm (0.0158 in.)

(Measured — Specification = Excess clearance) (a)0.40 mm (0.0158 in.) — 0.24 mm (0.0095 in.) =

0.16 mm (0.0063 in.)

2.Measured used lifter measurement = 5.250 mm (0.2067 in.)

3.New lifter thickness = 5.410 mm (0.2130 in.) (Excess clearance + Used lifter thickness = Ideal new lifter)

(a)0.16 mm (0.0063 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.)

4.Closest new lifter = 5.420 mm (0.2134 in.)

– Select No. 42 lifter

EM–10	2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

	(f) Select a new lifter with a thickness as close as
	possible to the calculated values.
	HINT:
	• Lifters are available in 35 sizes in increments of
42	0.020 mm (0.0008 in.), from 5.060 to 5.740 mm
(0.1992 to 0.2260 in.).
	• The identification number inside the valve lifters
	shows the value to 2 decimal places. (The
	illustration shows 5.420 mm (0.2134 in.)
	A126901E01

2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE	EM–11

(g) Valve lifter selection chart (intake).

	Measured clearance	0.0012)-(0.0000	0.0020)-(0.0012	0.0028)-(0.0020	0.0035)-(0.0028	0.0043)-(0.0036	0.0051)-(0.0044	0.0059)-(0.0052	0.0067)-(0.0059	0.0074)-(0.0067	0.0114)-(0.0075	0.0122)-(0.0115	0.0130)-(0.0122	0.0138)-(0.0130	0.0146)-(0.0138	0.0154)-(0.0146	0.0161)-(0.0154	0.0169)-(0.0162	0.0177)-(0.0170	0.0185)-(0.0178	0.0193)-(0.0185	0.0201)-(0.0193	0.0209)-(0.0201	0.0217)-(0.0209	0.0224)-(0.0217	0.0232)-(0.0225	0.0240)-(0.0233	0.0248)-(0.0241	0.0256)-(0.0248	0.0264)-(0.0256	0.0272)-(0.0264	0.0280)-(0.0272	0.0287)-(0.0280	0.0295)-(0.0288	0.0303)-(0.0296	0.0311)-(0.0304	0.0319)-(0.0311	0.0327)-(0.0319	0.0335)-(0.0327	0.0343)-(0.0335	0.0350)-(0.0343	0.0358)-(0.0351	0.0366)-(0.0359

		mm (in.)
	Installed lifter	mm (in.)	0.030-0.000	0.050-0.031	0.070-0.051	0.090-0.071	0.110-0.091	0.130-0.111	0.150-0.131	0.170-0.151	0.189-0.171	0.290-0.190	0.310-0.291	0.330-0.311	0.350-0.331	0.370-0.351	0.390-0.371	0.410-0.391	0.430-0.411	0.450-0.431	0.470-0.451	0.490-0.471	0.510-0.491	0.530-0.511	0.550-0.531	0.570-0.551	0.590-0.571	0.610-0.591	0.630-0.611	0.650-0.631	0.670-0.651	0.690-0.671	0.710-0.691	0.730-0.711	0.750-0.731	0.770-0.751	0.790-0.771	0.810-0.791	0.830-0.811	0.850-0.831	0.870-0.851	0.890-0.871	0.910-0.891	0.930-0.911
	thickness

	5.060	(0.1992)											12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
	5.080	(0.2000)									06		14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
	5.100	(0.2008)								06 08		16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
	5.120	(0.2016)							06 08 10		18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
	5.140	(0.2024)						06 08 10 12		20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
	5.160	(0.2031)					06 08 10 12 14		22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74					EM
	5.180	(0.2039)				06 08 10 12 14 16		24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72	74

	5.200	(0.2047)			06 08 10 12 14 16 18		26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74
	5.210	(0.2051)		06 08 10 12 14 16 18 20		28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.220	(0.2055)		06 08 10 12 14 16 18 20		28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.230	(0.2059)		06 08 10 12 14 16 18 20		30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.240	(0.2063)		08 10 12 14 16 18 20 22		30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.250	(0.2067)	06 08 10 12 14 16 18 20 22		32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.260	(0.2071)	06 10 12 14 16 18 20 22 24		32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.270	(0.2075)	08 10 12 14 16 18 20 22 24		34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.280	(0.2079)	08 12 14 16 18 20 22 24 26		34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.290	(0.2083)	10 12 14 16 18 20 22 24 26		36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.300	(0.2087)	10 14 16 18 20 22 24 26 28		36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.310	(0.2091)	12 14 16 18 20 22 24 26 28		38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.320	(0.2094)	12 16 18 20 22 24 26 28 30		38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.330	(0.2098)	14 16 18 20 22 24 26 28 30		40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.340	(0.2102)	14 18 20 22 24 26 28 30 32		40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.350	(0.2106)	16 18 20 22 24 26 28 30 32		42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.360	(0.2110)	16 20 22 24 26 28 30 32 34		42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.370	(0.2114)	18 20 22 24 26 28 30 32 34		44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.380	(0.2118)	18 22 24 26 28 30 32 34 36		44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.390	(0.2122)	20 22 24 26 28 30 32 34 36		46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.400	(0.2126)	20 24 26 28 30 32 34 36 38		46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.410	(0.2130)	22 24 26 28 30 32 34 36 38		48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.420	(0.2134)	22 26 28 30 32 34 36 38 40		48 50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.430	(0.2138)	24 26 28 30 32 34 36 38 40		50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.440	(0.2142)	24 28 30 32 34 36 38 40 42		50 52 54 56 58 60 62 64 66 68 70 72 74 74
	5.450	(0.2146)	26 28 30 32 34 36 38 40 42		52 54 56 58 60 62 64 66 68 70 72 74 74
	5.460	(0.2150)	26 30 32 34 36 38 40 42 44		52 54 56 58 60 62 64 66 68 70 72 74 74
	5.470	(0.2154)	28 30 32 34 36 38 40 42 44		54 56 58 60 62 64 66 68 70 72 74 74
	5.480	(0.2157)	28 32 34 36 38 40 42 44 46		54 56 58 60 62 64 66 68 70 72 74 74
	5.490	(0.2161)	30 32 34 36 38 40 42 44 46		56 58 60 62 64 66 68 70 72 74 74
	5.500	(0.2165)	30 34 36 38 40 42 44 46 48		56 58 60 62 64 66 68 70 72 74 74
	5.510	(0.2169)	32 34 36 38 40 42 44 46 48		58 60 62 64 66 68 70 72 74 74
	5.520	(0.2173)	32 36 38 40 42 44 46 48 50		58 60 62 64 66 68 70 72 74 74
	5.530	(0.2177)	34 36 38 40 42 44 46 48 50		60 62 64 66 68 70 72 74 74
	5.540	(0.2181)	34 38 40 42 44 46 48 50 52		60 62 64 66 68 70 72 74 74
	5.550	(0.2185)	36 38 40 42 44 46 48 50 52		62 64 66 68 70 72 74 74
	5.560	(0.2189)	36 40 42 44 46 48 50 52 54		62 64 66 68 70 72 74 74
	5.570	(0.2193)	38 40 42 44 46 48 50 52 54		64 66 68 70 72 74 74
	5.580	(0.2197)	38 42 44 46 48 50 52 54 56		64 66 68 70 72 74 74
	5.590	(0.2201)	40 42 44 46 48 50 52 54 56		66 68 70 72 74 74
	5.600	(0.2205)	40 44 46 48 50 52 54 56 58		66 68 70 72 74 74
	5.620	(0.2213)	42 46 48 50 52 54 56 58 60		68 70 72 74 74
	5.640	(0.2220)	44 48 50 52 54 56 58 60 62		70 72 74 74 74
	5.660	(0.2228)	46 50 52 54 56 58 60 62 64		72 74 74 74
	5.680	(0.2236)	48 52 54 56 58 60 62 64 66		74 74 74
	5.700	(0.2244)	50 54 56 58 60 62 64 66 68		74 74
	5.720	(0.2252)	52 56 58 60 62 64 66 68 70		74
)	5.740	(0.2260)	54 58 60 62 64 66 68 70 72																																	A126931E02

New lifter thickness

Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
	mm (in.)		mm (in.)		mm (in.)

06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)

EM–12	2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE


Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
	mm (in.)		mm (in.)		mm (in.)

08	5.080 (0.2000)	32	5.320	(0.2094)	56	5.560 (0.2189)

10	5.100 (0.2008)	34	5.340	(0.2102)	58	5.580 (0.2197)

12	5.120 (0.2016)	36	5.360	(0.2110)	60	5.600 (0.2205)

14	5.140 (0.2024)	38	5.380	(0.2118)	62	5.620 (0.2213)

16	5.160 (0.2031)	40	5.400	(0.2126)	64	5.640 (0.2220)

18	5.180 (0.2039)	42	5.420	(0.2134)	66	5.660 (0.2228)

20	5.200 (0.2047)	44	5.440	(0.2142)	68	5.680 (0.2236)

22	5.220 (0.2055)	46	5.460	(0.2150)	70	5.700 (0.2244)

24	5.240 (0.2063)	48	5.480	(0.2157)	72	5.720 (0.2252)

26	5.260 (0.2071)	50	5.500	(0.2165)	74	5.740 (0.2260)

28	5.280 (0.2079)	52	5.520	(0.2173)	—	—

Standard intake valve clearance (cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.)

EXAMPLE:

The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter.

2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE	EM–13

(h) Valve lifter selection chart (exhaust).

Installed lifter		-(0.00000.0012)	-(0.00120.0020)	-(0.00200.0028)	-(0.00280.0035)	-(0.00360.0043)	-(0.00440.0051)	-(0.00520.0059)	-(0.00590.0067)	-(0.00670.0075)	-(0.00750.0083)	-(0.00830.0091)	-(0.00910.0098)	-(0.00990.0106)	-(0.01070.0114)	-(0.01150.0118)	-(0.01180.0157)	-(0.01580.0165)	-(0.01660.0173)	-(0.01740.0181)	-(0.01810.0189)	-(0.01890.0197)	-(0.01970.0205)	-(0.02050.0213)	-(0.02130.0220)	-(0.02210.0228)	-(0.02290.0236)	-(0.02370.0244)	-(0.02440.0252)	-(0.02520.0260)	-(0.02600.0268)	-(0.02680.0276)	-(0.02760.0283)	-(0.02840.0291)	-(0.02920.0299)	-(0.03000.0307)	-(0.03070.0315)	-(0.03150.0323)	-(0.03230.0331)	-(0.03310.0339)	-(0.03390.0346)	-(0.03470.0354)	-(0.03550.0362)	-(0.03630.0370)	-(0.03700.0378)	-(0.03780.0386)	-(0.03860.0394)	-(0.03940.0402)	-(0.04020.0409)	-(0.04100.0417)	-(0.04180.0425)
Measured clearance
Measured clearance
	mm (in.)
	mm (in.)
thickness		0.030-	0.050-	0.070-	0.090-	0.110-	0.130-	0.150-	0.170-	0.190-	0.210-	0.230-	0.250-	0.270-	0.290-	0.299-	0.400-	0.420-	0.440-	0.460-	0.480-	0.500-	0.520-	0.540-	0.560-	0.580-	0.600-	0.620-	0.640-	0.660-	0.680-	0.700-	0.720-	0.740-	0.760-	0.780-	0.800-	0.820-	0.840-	0.860-	0.880-	0.900-	0.920-	0.940-	0.960-	0.980-	1.000-	1.020-	1.040-	1.060-	1.080-

Installed lifter thickness	0.000	0.031	0.051	0.071	0.091	0.111	0.131	0.151	0.171	0.191	0.211	0.231	0.251	0.271	0.291	0.300	0.401	0.421	0.441	0.461	0.481	0.501	0.521	0.541	0.561	0.581	0.601	0.621	0.641	0.661	0.681	0.701	0.721	0.741	0.761	0.781	0.801	0.821	0.841	0.861	0.881	0.901	0.921	0.941	0.961	0.981	1.001	1.021	1.041	1.061
mm (in.)mm (in.)
5.060	(0.1992)																									28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.080	(0.2000)															06		14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.100	(0.2008)														06 08		16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.120	(0.2016)													06 08 10		18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.140	(0.2024)												06 08 10 12		20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.160	(0.2031)											06 08 10 12 14		22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.180	(0.2039)										06 08 10 12 14 16		24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74						EM
5.200	(0.2047)									06 08 10 12 14 16 18		26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74

5.210	(0.2051)								06 08 10 12 14 16 18 20		26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.220	(0.2055)								06 08 10 12 14 16 18 20		28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.230	(0.2059)							06 08 10 12 14 16 18 20 22		28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.240	(0.2063)							06 08 10 12 14 16 18 20 22		30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.250	(0.2067)						06 08 10 12 14 16 18 20 22 24		30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.260	(0.2071)						06 08 10 12 14 16 18 20 22 24		32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.270	(0.2075)					06 08 10 12 14 16 18 20 22 24 26		32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.280	(0.2079)					06 08 10 12 14 16 18 20 22 24 26		34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.290	(0.2083)				06 08 10 12 14 16 18 20 22 24 26 28		34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.300	(0.2087)				06 08 10 12 14 16 18 20 22 24 26 28		36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.310	(0.2091)			06 08 10 12 14 16 18 20 22 24 26 28 30		36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.320	(0.2094)			06 08 10 12 14 16 18 20 22 24 26 28 30		38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.330	(0.2098)		06 08 10 12 14 16 18 20 22 24 26 28 30 32		38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.340	(0.2102)		06 08 10 12 14 16 18 20 22 24 26 28 30 32		40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.350	(0.2106)	06 08 10 12 14 16 18 20 22 24 26 28 30 32 34		40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.360	(0.2110)	06 08 10 12 14 16 18 20 22 24 26 28 30 32 34		42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.370	(0.2114)	08 10 12 14 16 18 20 22 24 26 28 30 32 34 36		42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.380	(0.2118)	08 10 12 14 16 18 20 22 24 26 28 30 32 34 36		44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.390	(0.2122)	10 12 14 16 18 20 22 24 26 28 30 32 34 36 38		44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.400	(0.2126)	10 12 14 16 18 20 22 24 26 28 30 32 34 36 38		46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.410	(0.2130)	12 14 16 18 20 22 24 26 28 30 32 34 36 38 40		46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.420	(0.2134)	12 14 16 18 20 22 24 26 28 30 32 34 36 38 40		48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.430	(0.2138)	14 16 18 20 22 24 26 28 30 32 34 36 38 40 42		48 50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.440	(0.2142)	14 16 18 20 22 24 26 28 30 32 34 36 38 40 42		50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.450	(0.2146)	16 18 20 22 24 26 28 30 32 34 36 38 40 42 44		50 52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.460	(0.2150)	16 18 20 22 24 26 28 30 32 34 36 38 40 42 44		52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.470	(0.2154)	18 20 22 24 26 28 30 32 34 36 38 40 42 44 46		52 54 56 58 60 62 64 66 68 70 72 74 74 74
5.480	(0.2157)	18 20 22 24 26 28 30 32 34 36 38 40 42 44 46		54 56 58 60 62 64 66 68 70 72 74 74 74
5.490	(0.2161)	20 22 24 26 28 30 32 34 36 38 40 42 44 46 48		54 56 58 60 62 64 66 68 70 72 74 74 74
5.500	(0.2165)	20 22 24 26 28 30 32 34 36 38 40 42 44 46 48		56 58 60 62 64 66 68 70 72 74 74 74
5.510	(0.2169)	22 24 26 28 30 32 34 36 38 40 42 44 46 48 50		56 58 60 62 64 66 68 70 72 74 74 74
5.520	(0.2173)	22 24 26 28 30 32 34 36 38 40 42 44 46 48 50		58 60 62 64 66 68 70 72 74 74 74
5.530	(0.2177)	24 26 28 30 32 34 36 38 40 42 44 46 48 50 52		58 60 62 64 66 68 70 72 74 74 74
5.540	(0.2181)	24 26 28 30 32 34 36 38 40 42 44 46 48 50 52		60 62 64 66 68 70 72 74 74 74
5.550	(0.2185)	26 28 30 32 34 36 38 40 42 44 46 48 50 52 54		60 62 64 66 68 70 72 74 74 74
5.560	(0.2189)	26 28 30 32 34 36 38 40 42 44 46 48 50 52 54		62 64 66 68 70 72 74 74 74
5.570	(0.2193)	28 30 32 34 36 38 40 42 44 46 48 50 52 54 56		62 64 66 68 70 72 74 74 74
5.580	(0.2197)	28 30 32 34 36 38 40 42 44 46 48 50 52 54 56		64 66 68 70 72 74 74 74
5.590	(0.2201)	30 32 34 36 38 40 42 44 46 48 50 52 54 56 58		64 66 68 70 72 74 74 74
5.600	(0.2205)	30 32 34 36 38 40 42 44 46 48 50 52 54 56 58		66 68 70 72 74 74 74
5.620	(0.2213)	32 34 36 38 40 42 44 46 48 50 52 54 56 58 60		68 70 72 74 74 74
5.640	(0.2220)	34 36 38 40 42 44 46 48 50 52 54 56 58 60 62		70 72 74 74 74
5.660	(0.2228)	36 38 40 42 44 46 48 50 52 54 56 58 60 62 64		72 74 74 74
5.680	(0.2236)	38 40 42 44 46 48 50 52 54 56 58 60 62 64 66		74 74 74
5.700	(0.2244)	40 42 44 46 48 50 52 54 56 58 60 62 64 66 68		74 74
5.720	(0.2252)	42 44 46 48 50 52 54 56 58 60 62 64 66 68 70		74
5.740	(0.2260)	44 46 48 50 52 54 56 58 60 62 64 66 68 70 72
)																																																	A114356E01

New lifter thickness

Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
	mm (in.)		mm (in.)		mm (in.)

06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)

EM–14	2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE


Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
	mm (in.)		mm (in.)		mm (in.)

08	5.080 (0.2000)	32	5.320	(0.2094)	56	5.560 (0.2189)

10	5.100 (0.2008)	34	5.340	(0.2102)	58	5.580 (0.2197)

12	5.120 (0.2016)	36	5.360	(0.2110)	60	5.600 (0.2205)

14	5.140 (0.2024)	38	5.380	(0.2118)	62	5.620 (0.2213)

16	5.160 (0.2031)	40	5.400	(0.2126)	64	5.640 (0.2220)

18	5.180 (0.2039)	42	5.420	(0.2134)	66	5.660 (0.2228)

20	5.200 (0.2047)	44	5.440	(0.2142)	68	5.680 (0.2236)

22	5.220 (0.2055)	46	5.460	(0.2150)	70	5.700 (0.2244)

24	5.240 (0.2063)	48	5.480	(0.2157)	72	5.720 (0.2252)

26	5.260 (0.2071)	50	5.500	(0.2165)	74	5.740 (0.2260)

28	5.280 (0.2079)	52	5.520	(0.2173)	—	—

Standard exhaust valve clearance (cold): 0.38 to 0.48 mm (0.0150 to 0.0189 in.)

EXAMPLE:

The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.430 mm (0.0169 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 42 lifter.

(i)Install the selected valve lifter.

11.INSTALL CAMSHAFT

(a)Apply a light coat of engine oil to the journal portion of the camshaft.

(b)Install the timing chain onto the camshaft timing

Paint Mark	gear with the paint mark aligned with the timing
	mark on the camshaft timing gear as shown in the
	illustration.

Timing Mark

A098176E04

(c)Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.

(d)Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

A098177E03

2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE	EM–15

No. 1

4 2 6 10

A098177E06

Paint Mark

(e)Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque: No. 1 bearing cap

30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 bearing cap

9.0N*m (92 kgf*cm, 80 in.*lbf)

12.INSTALL NO. 2 CAMSHAFT

(a)Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b)Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.

Timing Mark

A098178E03

(c)While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.

A086659

(d)Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

(e)Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

A098174E05

7
8	4	2	6	10

No. 2

A098174E07

(f)Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque: No. 2 bearing cap

30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 bearing cap

9.0N*m (92 kgf*cm, 80 in.*lbf)

EM–16	2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

(g)While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

Tighten	Torque: 54 Nm (551 kgfcm, 40 ft.*lbf)
	NOTICE:
	Be careful not to damage the valve lifter.

Hold

A098173E04

	7 Links
Paint Mark	Paint Mark

Timing Mark	Timing Mark
		Groove


			A098180E04

(h)Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark «0» of the timing chain cover.

13.INSTALL NO. 1 CHAIN TENSIONER (See page EM-32)

14.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-33)

15.INSTALL IGNITION COIL ASSEMBLY (See page EM33)

16.CHECK FOR ENGINE OIL LEAKS

17.INSTALL NO. 1 ENGINE COVER (See page EM-121)

18.INSTALL FRONT FENDER APRON RH

19.INSTALL ENGINE UNDER COVER LH

20.INSTALL ENGINE UNDER COVER RH

21.INSTALL FRONT WHEEL RH

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–17

TIMING CHAIN

COMPONENTS

	ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
64 (653, 47)	NO. 2 ENGINE MOUNTING BRACKET RH
	9.0 (92, 80 in.*lbf)

52 (531, 38)

64 (653, 47)

NO. 1 ENGINE COVER SUB-ASSEMBLY

NO. 2 ENGINE MOUNTING STAY RH

V-RIBBED BELT

9.8 (100, 87 in.*lbf) 52 (531, 38)

21 (214, 15)

GENERATOR ASSEMBLY

FRONT FENDER APRON SEAL RH

N*m (kgf*cm, ft.*lbf) : Specified torque

A134948E01

EM–18	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

43 (439, 32)

VANE PUMP ASSEMBLY

			FRONT EXHAUST
			PIPE ASSEMBLY
	EXHAUST PIPE GASKET
			56 (571, 41)
			EXHAUST PIPE GASKET
62 (633, 46)			REAR EXHAUST PIPE NO. 1
			SUPPORT BRACKET
FRONT EXHAUST PIPE NO. 1
SUPPORT BRACKET	33 (337, 24)	33 (337, 24)


	ENGINE UNDER COVER RH

ENGINE UNDER COVER LH

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

A134947E01

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–19

				9.0 (92, 80 in.*lbf)
				IGNITION COIL ASSEMBLY
				14 (143, 10)
		14 (143, 10)
11 (110,			11 (110,
x6		x2

CYLINDER HEAD COVER SUB-ASSEMBLY			EM
CYLINDER HEAD COVER GASKET
				CRANK POSITION
				SENSOR
			9.0 (92, 80 in.*lbf)
TMMK: 170 (1,733, 125)
TMC: 180 (1,835, 133)
CRANKSHAFT PULLEY		OIL PAN SUB-ASSEMBLY

25 (255, 18)
OIL PAN DRAIN PLUG	GASKET		9.0 (92, 80 in.*lbf)
		x2	x12

				9.0 (92, 80 in.*lbf)
Nm (kgfcm, ft.*lbf) : Specified torque	Non-reusable part
				A134922E01

EM–20	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

CHAIN SUB-ASSEMBLY	NO. 1 CHAIN VIBRATION DAMPER
	CRANKSHAFT TIMING SPROCKET

CHAIN TENSIONER

SLIPPER

NO. 2 CHAIN SUB-ASSEMBLY

OIL PUMP DRIVE SPROCKET

EM	19 (194, 14)
	SPRING

	NO. 1 CRANKSHAFT	CHAIN TENSIONER

	POSITION SENSOR	12 (122, 9.0)
	PLATE	30 (301, 22)
	9.0 (92, 80 in.*lbf)
	OIL PUMP DRIVEN SPROCKET

	TIMING CHAIN GUIDE	NO. 1 CHAIN TENSIONER
		ASSEMBLY

9.0 (92, 80 in.*lbf)

11 (112,

V-RIBBED BELT

TENSIONER

ASSEMBLY

GASKET

55 (561, 41)

22 (220, 16)	x4
STUD BOLT
9.0 (92, 80 in.*lbf)
60 (607, 44)
TIMING CHAIN CASE OIL SEAL	x8

	25 (255, 18)
Nm (kgfcm, ft.*lbf) : Specified torque	TIMING CHAIN COVER SUB-ASSEMBLY
Non-reusable part

A134923E01

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–21

REMOVAL

1.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2.REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94)

3.REMOVE FRONT WHEEL RH

4.REMOVE ENGINE UNDER COVER LH

5.REMOVE ENGINE UNDER COVER RH

6.REMOVE FRONT FENDER APRON SEAL RH

7.DRAIN ENGINE OIL (See page LU-4)

8.REMOVE FRONT EXHAUST PIPE ASSEMBLY

HINT:

		See page EX-2.
		EM
	9.	REMOVE NO. 2 ENGINE MOUNTING STAY RH (See

		page EM-95)
	10.	REMOVE ENGINE MOVING CONTROL ROD SUB-
		ASSEMBLY (See page EM-95)
	11.	REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
		(See page EM-96)
	12.	REMOVE V-RIBBED BELT (See page EM-6)
	13.	REMOVE GENERATOR ASSEMBLY (See page CH-11)
	14.	REMOVE VANE PUMP ASSEMBLY (See page EM-
		101)
	15.	REMOVE IGNITION COIL ASSEMBLY (See page EM-
		106)
	16.	DISCONNECT VENTILATION HOSE
	17.	DISCONNECT NO. 2 VENTILATION HOSE
	18.	REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
		(a) Remove the 2 bolts and disconnect the 2 engine
		wires.

EM–22	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

(b)Remove the 8 bolts, 2 nuts, and the cylinder head cover.

19.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page EM-8)

20.REMOVE CRANKSHAFT PULLEY (See page EM-75)

21.REMOVE CRANK POSITION SENSOR (See page ES411)

22. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 12 bolts and 2 nuts.

A114333

SST

A000019E05

(b)Insert the blade of SST between the crankcase and oil pan. Cut through the sealer and remove the oil pan.

SST 09032-00100 NOTICE:

Be careful not to damage the contact surfaces of the crankcase, chain cover and oil pan.

23.REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a)Remove the 2 nuts, tensioner and gasket.

NOTICE:

Do not turn the crankshaft without the chain tensioner.

A098348E01







		No. 1 Engine Hanger			No. 2 Engine Hanger

A052507E05

24. INSTALL ENGINE HANGERS

(a) Install the No. 1 engine hanger and No. 2 engine hanger with the bolts as shown in the illustration. Parts No.:

No. 1 Engine hanger	12281-28010

No. 2 Engine hanger	12282-28010

Bolt	91512-61020

Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)

(b) Attach the sling device to the engine hangers and chain block.

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–23

25.REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a)Lift the engine upward using the chain block.

NOTICE:

Do not lift the engine more than necessary.

(b) Remove the bolt, nut and V-ribbed belt tensioner.

26.REMOVE ENGINE MOUNTING INSULATOR

(a)Attach the engine chain hoist to the engine hangers. EM

CAUTION:

Do not attempt to hang the engine by hooking the chain to any other part.

(b)Remove the bolt and disconnect the engine mounting insulator FR.

A059880

(c)M/T:

Remove the bolt and disconnect the engine lateral control rod.

(d)Remove the 2 bolts and disconnect the steering gear return tube clamps from the frame.

EM–24	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

		(e)	Remove the 4 nuts from the engine mounting

			insulator RH.
		(f)	Raise the engine and remove the engine mounting
			insulator RH.

A059900

27.REMOVE ENGINE MOUNTING BRACKET RH

(a)Remove the 3 bolts and engine mounting bracket.

28.REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See page LU-11)

29.REMOVE TIMING CHAIN CASE OIL SEAL (See page LU-12)

30.REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a)Remove the crankshaft position sensor plate.

31.REMOVE CHAIN TENSIONER SLIPPER

(a)Remove the bolt and chain tensioner slipper.

A125372

32.REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a)Remove the 2 bolts and chain vibration damper.

A125371

	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–25

		33. REMOVE TIMING CHAIN GUIDE

		(a) Remove the bolt and timing chain guide.

A125373

34. REMOVE CHAIN SUB-ASSEMBLY

(a) Remove the chain sub-assembly.

A128185

35.REMOVE CRANKSHAFT TIMING SPROCKET

(a)Remove the crankshaft timing sprocket.

	A125374
			36. REMOVE NO. 2 CHAIN SUB-ASSEMBLY



90°		(a) Turn the crankshaft by 90° counterclockwise to align
			the adjusting hole of the oil pump drive shaft
			sprocket with the groove of the oil pump.

Groove

A098351E01

EM–26	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

		(b) Insert a 4 mm diameter bar into the adjusting hole of

		the oil pump drive shaft sprocket to lock the gear in
		position, and then remove the nut.

Groove

A098352E01

Bolt

Spring

Chain Tensioner Plate

B011415E03

(d)Remove the chain tensioner, oil pump driven sprocket and chain.

A063847

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–27

INSPECTION

	1.	INSPECT CHAIN SUB-ASSEMBLY (See page EM-138)
	2.	INSPECT NO. 2 CHAIN SUB-ASSEMBLY (See page
		EM-138)
	3.	INSPECT OIL PUMP DRIVE SPROCKET (See page
		EM-138)
	4.	INSPECT OIL PUMP DRIVE SHAFT SPROCKET (See
		page EM-139)
	5.	INSPECT CHAIN TENSIONER SLIPPER (See page
		EM-140)
	6.	INSPECT NO. 1 CHAIN VIBRATION DAMPER (See
		page EM-140)
	7.	INSPECT CHAIN TENSIONER PLATE (See page EM-
	EM
		140)

8.INSPECT NO. 1 CHAIN TENSIONER (See page EM140)

INSTALLATION

1.INSTALL NO. 2 CHAIN SUB-ASSEMBLY

(a)Set the crankshaft key into the left horizontal position.

(b)Turn the drive shaft so that the cutout faces upward.

B011424

Mark Link

Timing Mark

Oil Pump Drive	Oil	Pump
Shaft Sprocket	Drive Sprocket

(c)Align the yellow mark links with the timing marks of each gear as shown in the illustration.

(d)Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.

(e)Temporarily tighten the oil pump drive shaft sprocket with the nut.

Timing Mark

Mark Link

A094198E06

EM–28	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

			(f) Insert the damper spring into the adjusting hole, and

			then install the chain tensioner plate with the bolt.
			Torque: 12 Nm (122 kgfcm, 9 ft.*lbf)

		Bolt

Spring

Chain Tensioner Plate

A090851E03

(g)Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

(h)Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf)

(i)Rotate the crankshaft clockwise by 90°, and align the crankshaft key to the top.

A036525

2.INSTALL CRANKSHAFT TIMING SPROCKET

(a)Install the crankshaft timing sprocket.

A125374

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–29

3.INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a)Install the chain vibration damper with the 2 bolts.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

			4. INSTALL CHAIN SUB-ASSEMBLY

			(a) Set the No. 1 cylinder to TDC/compression.
			(1) Turn the camshafts with a wrench (using the
			hexagonal lobe) to align the timing marks of the
			camshaft timing gear with each timing mark
	Timing Marks		located on the No. 1 and No. 2 bearing caps as
	EM
			shown in the illustration.

Timing Marks

A053018E05

(2)Using the crankshaft pulley bolt, turn the crankshaft to position with the key on the crankshaft upward.

(b)Install the chain onto the crankshaft timing sprocket with the gold or pink mark link aligned with the timing mark on the crankshaft.

EM–30	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

		(c) Using SST and a hammer, tap in the crankshaft

	SST	timing sprocket.
		SST 09309-37010

A098369E01

(d) Align the gold or yellow link with each timing mark Mark Link located on the camshaft timing gear and sprocket,

then install the chain.

	A098370E01
	5. INSTALL CHAIN TENSIONER SLIPPER
Hold	(a) Install the chain tensioner slipper with the bolt.
	Torque: 19 Nm (194 kgfcm, 14 ft.*lbf)
	A124787E01

6.INSTALL TIMING CHAIN GUIDE

(a)Install the timing chain guide with the bolt.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

7.INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a)Install the sensor plate with the «F» mark facing forward.

8.INSTALL TIMING CHAIN CASE OIL SEAL (See page LU-15)

9.INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See page LU-15)

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–31

10.INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a)Install the V-ribbed belt tensioner with the bolt and nut.

Torque: 60 N*m (607 kgf*cm, 44 ft.*lbf) NOTICE:

Do not lift the engine more than necessary.

11.INSTALL ENGINE MOUNTING BRACKET RH

(a)Install the engine mounting bracket with the 3 bolts.

Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)

A052481

12. INSTALL ENGINE MOUNTING INSULATOR

A (a) Raise the engine and install the engine mounting insulator RH.

		(b) Install the engine mounting insulator RH with the 4
		nuts.
		Torque: Nut A
B		95 Nm (969 kgfcm, 70 ft.*lbf)
	Nut B

B	B	87 Nm (888 kgfcm, 64 ft.*lbf)
A059900E02
		(c) Install the steering gear return tube clamps to the
		frame with the 2 bolts.
		Torque: 8.0 Nm (80 kgfcm, 69 in.*lbf)
		A138332

(d)Install the engine mounting insulator FR with the bolt.

Torque: 87 N*m (888 kgf*cm, 64 ft.*lbf)

A059880

EM–32			2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

M/T					(e) M/T:
				Install the engine lateral control rod with the bolt.
					Torque: 89 Nm (910 kgfcm, 66 ft.*lbf)
				A060825E01
					13. INSTALL OIL PAN SUB-ASSEMBLY
					(a) Remove any old packing material and be careful not
					to drop any oil on the contact surfaces of the
					cylinder block and oil pan.
					(b) Apply a continuous bead of seal packing (Diameter
EM					3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the
				illustration.
					Seal packing:
					Toyota Genuine Seal Packing Block, Three
					Bond 1207B or Equivalent
					NOTICE:
					• Remove any oil from the contact surfaces.
					• Install the oil pan within 3 minutes after
			Seal Packing	applying seal packing.
					• Do not start the engine for at least 2 hours
6.0 mm (0.236 in.)				after installing.
			(c) Install the oil pan to the cylinder block.
Seal Diameter: 3.0 to 4.0 mm
				A114332E01
	9		10		(d) Uniformly tighten the 12 bolts and 2 nuts in the
		11	sequence shown in the illustration.
	1, 15
8			12	Torque: 9.0 Nm (92 kgfcm, 80 in.*lbf)

7					14. INSTALL CRANK POSITION SENSOR (See page ES-
			13	411)
				15. INSTALL CRANKSHAFT PULLEY (See page EM-76)
6

5	4	3	2	14
A114333E01

16.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a)Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

A098376E03

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–33

(b)Install a new gasket and the chain tensioner with the 2 nuts.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE:

If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

	Engine Front
	A098377E03
	(c) Turn the crankshaft counterclockwise, then	EM
	disconnect the plunger knock pin from the hook.
	Disconnect
Hook	Turn
	Pin
	A112204E02

	Plunger
Push	Turn

	A112205E02

(d)Turn the crankshaft clockwise, then check that the plunger is extended.

17.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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

EM–34	2AZ-FE ENGINE MECHANICAL – TIMING CHAIN

				(b) Apply seal packing to the 2 locations shown in the
				illustration.
				Seal packing:
				Toyota Genuine Seal Packing Block, Three
				Bond 1207B or Equivalent
				NOTICE:
				• Remove any oil from the contact surface.
				• Install the cylinder head cover within 3
				minutes of applying seal packing.
			A094205E01	• Do not add engine oil for at least 2 hours after
				installing the cylinder head cover.
A	A	A	A	(c) Install the cylinder head cover with the 8 bolts and 2
nuts.

	B			Torque: Bolt A
		B	11 Nm (112 kgfcm, 8 ft.*lbf)
EM				Bolt B
			14 Nm (143 kgfcm, 10 ft.*lbf)
				Nut
				11 Nm (112 kgfcm, 8 ft.*lbf)
		A	Nut
A	Nut	A127550E01

(d)Install the 2 engine wires with the 2 bolts.

Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)

18.INSTALL NO. 2 VENTILATION HOSE

19.INSTALL VENTILATION HOSE

20.INSTALL IGNITION COIL ASSEMBLY

(a)Install the 4 ignition coils with the 4 bolts.

Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

21.INSTALL VANE PUMP ASSEMBLY (See page EM-113)

22.INSTALL GENERATOR ASSEMBLY (See page CH-19)

23.INSTALL V-RIBBED BELT (See page EM-6)

24.INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118)

25.INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119)

26.INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119)

27.INSTALL FRONT EXHAUST PIPE ASSEMBLY

HINT:

See page EX-3.

28.ADD ENGINE OIL

29.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120)

30.CHECK FOR ENGINE OIL LEAKS

31.CHECK FOR EXHAUST GAS LEAKS

32.CHECK IGNITION TIMING (See page EM-1)

2AZ-FE ENGINE MECHANICAL – TIMING CHAIN	EM–35

33.INSTALL FRONT FENDER APRON SEAL RH

34.INSTALL ENGINE UNDER COVER LH

35.INSTALL ENGINE UNDER COVER RH

36.INSTALL FRONT WHEEL RH

37.INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121)

2AZ-FE ENGINE MECHANICAL – CAMSHAFT	EM–35

CAMSHAFT
COMPONENTS
V-RIBBED BELT
9.0 (92, 80 in.*lbf)
NO. 1 ENGINE COVER SUB-ASSEMBLY	EM

FRONT FENDER APRON SEAL RH
ENGINE UNDER COVER RH
ENGINE UNDER COVER LH
Nm (kgfcm, ft.*lbf) : Specified torque
	A134949E01

EM–36	2AZ-FE ENGINE MECHANICAL – CAMSHAFT

9.0 (92, 80 in.*lbf)

IGNITION COIL ASSEMBLY

11 (112,

VENTILATION HOSE

CYLINDER HEAD COVER

SUB-ASSEMBLY

GASKET

N*m (kgf*cm, ft.*lbf) : Specified torque

A134919E01

2AZ-FE ENGINE MECHANICAL – CAMSHAFT	EM–37

	9.0 (92, 80 in.*lbf)
	NO. 3 CAMSHAFT BEARING CAP
30 (301, 22)	x16

x4
NO. 1 CAMSHAFT BEARING CAP	NO. 3 CAMSHAFT BEARING CAP

NO. 2 CAMSHAFT BEARING CAP	CAMSHAFT
	EM
	NO. 2 CAMSHAFT
54 (551, 40)
CAMSHAFT TIMING GEAR ASSEMBLY	NO. 2 CAMSHAFT TIMING SPROCKET

	54 (551, 40)
9.0 (92, 80 in.*lbf)
NO. 1 CHAIN TENSIONER ASSEMBLY
GASKET
Nm (kgfcm, ft.*lbf) : Specified torque
Non-reusable part
	A134921E01

EM–38	2AZ-FE ENGINE MECHANICAL – CAMSHAFT

	REMOVAL

1.REMOVE FRONT WHEEL RH

2.REMOVE ENGINE UNDER COVER LH

3.REMOVE ENGINE UNDER COVER RH

4.REMOVE FRONT FENDER APRON SEAL RH

5.REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94)

6.REMOVE IGNITION COIL ASSEMBLY (See page EM106)

7.REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-21)

8.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page EM-8)

9.REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-22)

10.REMOVE NO. 2 CAMSHAFT

Loosen	(a) While holding the camshaft with a wrench, loosen
	the camshaft timing set bolt.

Hold

A098173E03

(b)Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

(c)Remove the 5 bearing caps.

(d)While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.

(e)Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket.

(f)Remove the camshaft timing sprocket from the timing chain.

A086659

2AZ-FE ENGINE MECHANICAL – CAMSHAFT	EM–39

									11. REMOVE CAMSHAFT

									(a) Using several steps, uniformly loosen and remove
									the 10 bearing cap bolts in the sequence shown in
									the illustration.
						9
1			5	7	3

2									(b) Remove the 5 bearing caps.

								(c) Remove the camshaft and camshaft timing gear

									while holding the timing chain by hand.

							4
6	10	8
		A098175E04
									(d) Tie the timing chain with a string as shown in the


									illustration.
									NOTICE:
									Be careful not to drop anything inside the timing
									chain cover.

A052474

		12. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

		(a) Clamp the camshaft in a vise, and make sure that
	Advance Side Port	the camshaft timing gear does not rotate.
	(b) Cover all the oil ports except the advance side port

		shown in the illustration with vinyl tape.

A090848E03

(c)Apply air pressure of 100 kPa (1.0 kgf/cm2, 14 psi) to the oil path, then turn the camshaft timing gear in the advance direction (counterclockwise) by hand.

CAUTION:

Cover the paths with a shop rag or piece of cloth to avoid oil splashes.

HINT:

Depending on the air pressure, the camshaft timing

gear will turn to the advance angle side without A031032 applying force by hand. Also, if the pressure is difficult to apply because of air leakage from the

port, the lock may be difficult to release.

EM–40	2AZ-FE ENGINE MECHANICAL – CAMSHAFT

		(d) Remove the flange bolt of the camshaft timing gear.

		NOTICE:
		• Be sure not to remove the other 4 bolts.
		• If planning to reuse the gear, be sure to
		release the straight pin lock before installing
		the gear.

A032639

INSPECTION

1.INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a)Check the lock of the camshaft timing gear.

(1)Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.

NOTICE:

Be careful not to damage the camshaft.

(b)Release the lock pin.

(1)Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT:

The 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

(2)Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.

A062190E02

Retard	Advance
Side Path	Side Path

A062191E03

(3)Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the two broken paths.

CAUTION:

Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

(4)Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure of the retard side path.

OK:

Gear rotates in the advance direction.

HINT:

This operation releases the lock pin for the most retarded position.

2AZ-FE ENGINE MECHANICAL – CAMSHAFT	EM–41

(5)When the camshaft timing gear reaches the most advanced position, remove the air gun from the retard side path and advance side path, in that order.

NOTICE:

Do not remove the air gun from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

(c)Check for smooth rotation.

(1)Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.

OK:

Gear rotates smoothly.

NOTICE: EM

Do not use an air gun to check for smooth operation.

(d)Check the lock in the most retarded position.

(1)Confirm that the camshaft timing gear is locked at the most retarded position.

2.INSPECT CAMSHAFT

(a)Inspect the camshaft for runout.

(1)Place the camshaft on V-blocks.

(2)Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout: 0.03 mm (0.0012 in.)

If the circle runout is greater than the maximum, replace the camshaft.

EM01628E01

(b)Inspect the cam lobes.

(1)Using a micrometer, measure the cam lobe height.

Standard cam lobe height:

47.306 to 47.406 mm (1.8624 to 1.8664 in.) Minimum cam lobe height:

47.196 mm (1.8581 in.)

If the cam lobe height is less than the minimum, replace the camshaft.

A036687E01

(c)Inspect the camshaft journals.

(1)Using a micrometer, measure the journal diameter.

Standard journal diameter

Journal Position	Specified Condition

No. 1	35.971 to 35.985 mm (1.4162 to
	1.4167 in.)
Other	22.959 to 22.975 mm (0.9039 to
	0.9045 in.)

A036688E01

EM–42	2AZ-FE ENGINE MECHANICAL – CAMSHAFT

If the journal diameter is not as specified, check the oil clearance.

3.INSPECT NO. 2 CAMSHAFT

(a)Inspect the camshaft for runout.

(1)Place the camshaft on V-blocks.

(2)Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout:

0.03 mm (0.0012 in.)

If the circle runout is greater than the

maximum, replace the No. 2 camshaft.

EM01628E01

(b) Inspect the cam lobes.

(1) Using a micrometer, measure the cam lobe

height.

Standard cam lobe height:

45.983 to 46.083 mm (1.8104 to 1.8143 in.)

Minimum cam lobe height:

45.873 mm (1.8060 in.)

If the cam lobe height is less than the minimum,

replace the No. 2 camshaft.

A036687E01

(1) Using a micrometer, measure the journal

diameter.

Standard journal diameter

Journal Position

Specified Condition

No. 1

35.971 to 35.985 mm (1.4162 to

1.4167 in.)

Other

22.959 to 22.975 mm (0.9039 to

0.9045 in.)

A036688E01

If the journal diameter is not as specified, check

the oil clearance.

INSTALLATION

Straight Pin

1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Put the camshaft timing gear and camshaft together

with the straight pin and key groove misaligned, as

shown in the illustration.

(b) Turn the camshaft timing gear as shown in the

illustration while pushing it gently against the

camshaft. Push further at the position where the pin

Key Groove

fits into the groove.

A098365E02

NOTICE:

Be sure not to turn the camshaft timing gear to

the retard angle side (the right angle).

and camshaft.

(d) Tighten the flange bolt with the camshaft timing gear

fixed in place.

Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)

2AZ-FE ENGINE MECHANICAL – CAMSHAFT	EM–43

Paint Mark

Timing Mark

A098176E03

(e)Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.

2.INSTALL CAMSHAFT

(a)Apply a light coat of engine oil to the journal portion of the camshaft.

(b)Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark in the camshaft timing gear as shown in the illustration.

(c)Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.

(d)Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

A098177E03

No. 1

4 2 6 10

A098177E06

Paint Mark

(e)Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque: No. 1 Bearing cap

30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 Bearing cap

9.0N*m (92 kgf*cm, 80 in.*lbf)

3.INSTALL NO. 2 CAMSHAFT

(a)Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b)Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.

EM–44	2AZ-FE ENGINE MECHANICAL – CAMSHAFT

		(c) While holding the No. 2 camshaft by hand,

		temporarily tighten the camshaft timing sprocket set
		bolt.

A086659

A098174E05

7
8	4	2	6	10

No. 2

A098174E07

Tighten

(d)Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

(e)Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(f)Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque: No. 2 Bearing cap

30 N*m (301 kgf*cm, 22 ft.*lbf) No. 3 Bearing cap

9.0N*m (92 kgf*cm, 80 in.*lbf)

(g)While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)

2AZ-FE ENGINE MECHANICAL – CAMSHAFT	EM–45

Paint Mark
7 Links	Paint Mark

	Timing Marks
Timing Mark


		Groove

		A052460E05

	(h) Check that the paint marks on the chain are aligned
	with the timing marks on the camshaft timing gear
	and camshaft timing sprocket. Also, check that the
	crankshaft pulley groove is aligned with the timing
	mark «0» of the timing chain cover.
4.	INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See
	page EM-32)
5.	CHECK VALVE CLEARANCE (See page EM-8)
6.	INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
	(See page EM-33)
7.	INSTALL IGNITION COIL ASSEMBLY (See page EM-
	33)
8.	INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
	(See page EM-121)
9.	INSTALL FRONT FENDER APRON SEAL RH	EM

10.INSTALL ENGINE UNDER COVER LH

11.INSTALL ENGINE UNDER COVER RH

12.INSTALL FRONT WHEEL RH

13.CHECK FOR ENGINE OIL LEAKS

EM–46	2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD

CYLINDER HEAD

	COMPONENTS
	FRONT WIPER ARM AND	20 (204, 15)
	BLADE ASSEMBLY RH
	FRONT FENDER TO
	COWL SIDE SEAL RH
	FRONT WIPER ARM AND
EM	BLADE ASSEMBLY LH
COWL TOP VENTILATOR
LOUVER SUB-ASSEMBLY
	7.5 (77, 66 in.*lbf)
	85 (867, 63)
	5.0 (51, 44 in.*lbf)	FRONT FENDER TO
	COWL SIDE SEAL LH

	WINDSHIELD WIPER
	LINK ASSEMBLY
	COWL TOP PANEL OUTER SUB-ASSEMBLY
	Nm (kgfcm, ft.*lbf) : Specified torque
		A136912E01

2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD	EM–47

	ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
64 (653, 47)	NO. 2 ENGINE MOUNTING BRACKET RH
	9.0 (92, 80 in.*lbf)

52 (531, 38)

64 (653, 47)

NO. 1 ENGINE COVER SUB-ASSEMBLY

NO. 2 ENGINE MOUNTING STAY RH

V-RIBBED BELT

9.8 (100, 87 in.*lbf) 52 (531, 38)

21 (214, 15)

GENERATOR ASSEMBLY

FRONT FENDER APRON SEAL RH

N*m (kgf*cm, ft.*lbf) : Specified torque

A134948E01

EM–48	2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD

	AIR CLEANER CAP SUB-ASSEMBLY
	AIR CLEANER CASE SUB-ASSEMBLY
	5.0 (51, 44 in.*lbf)
EM	5.0 (51, 44 in.*lbf)

	9.0 (92, 80 in.*lbf)
	3.5 (36, 31 in.*lbf)
	AIR CLEANER INLET ASSEMBLY
	BATTERY
	BATTERY TRAY
	Nm (kgfcm, ft.*lbf) : Specified torque
	A134950E01

2AZ-FE ENGINE MECHANICAL – CYLINDER HEAD	EM–49

43 (439, 32)

VANE PUMP ASSEMBLY

			FRONT EXHAUST
			PIPE ASSEMBLY
	EXHAUST PIPE GASKET
			56 (571, 41)
			EXHAUST PIPE GASKET
62 (633, 46)			REAR EXHAUST PIPE NO. 1
			SUPPORT BRACKET
FRONT EXHAUST PIPE NO. 1
SUPPORT BRACKET	33 (337, 24)	33 (337, 24)


	ENGINE UNDER COVER RH

ENGINE UNDER COVER LH

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

A134947E01

Loading…

Источник

2.0 Двигатель

2. Двигатель

Бензиновые двигатели модели 1AZ-FE и 2AZ-FE

Общие сведения

Механизм привода клапанов

Система смазки

Система охлаждения

Система впуска и выспуска

Топливная система

Система зажигания

Система пуска

Стартер

Система привода вспомогательных агрегатов двигателя

Система управления двигателем

Механическая часть двигателей моделей 1AZ-FE и 2AZ-FE

Общие сведения и техника безопасности по снятию силового агрегата

Удаление герметика

Спецификация типов применяемых гаек и болтов

Обслуживание механической части двигателя

Общие ремонтные операции

Разборка, проверка и сборка головки блока цилиндров

Разборка, проверка и сборка блока цилиндров

Общая сборка

Бензиновый двигатель модели 1МZ-FE

Общие сведения

Механизм привода клапанов

Система смазки

Система охлаждения

Система впуска и выспуска

Топливная система

Система зажигания

Система управления двигателем

Основные элементы системы управления двигателем

Механическая часть двигателя модели 1MZ-FE

Обслуживание механической части двигателя

Проверка и регулировка тепловых зазоров в клапанах

Снятие, проверка и установка ремня привода механизма газораспределения (ГРМ)

Снятие головки блока цилиндров

Разборка головки блока цилиндров

Сборка головки блока цилиндров

Установка головки блока цилиндров

Разборка, проверка и сборка блока цилиндров

Приложение

Диагностические коды неисправностей системы управления двигателем моделей 1AZ-FE – 2AZ-FE, 1MZ-FE

Таблицы

Таблица 2.1 Технические характеристики двигателя 1AZ-FE

Таблица 2.2 Технические характеристики двигателя 2AZ-FE

Таблица 2.3 Конструктивные и эксплуатационные особенности двигателей 1AZ-FE и 2AZ-FE

Таблица 2.4 Данные для обслуживания системы смазки

Таблица 2.5 Данные для обслуживания системы охлаждения

Таблица 2.6 Моменты затяжки

Таблица 2.7 Данные для обслуживания топливной системы

Таблица 2.8 Технические характеристики свечей зажигания

Таблица 2.9 Технические характеристики стартера

Таблица 2.10 Структура системы управления двигателей 1AZ-FE и 2AZ-FE

Таблица 2.11 Данные для обслуживания системы управления двигателем

Таблица 2.12 Данные для регулировок и контроля

Таблица 2.13 Основные элементы системы управления двигателем

Таблица 2.14 Работа системы управления надежностью

Таблица 2.15 Типы применяемых болтов

Таблица 2.16 Спецификация размеров и моментов затяжки применяемых болтов

Таблица 2.17 Типы применяемых гаек

Таблица 2.18 Данные для обслуживания механической части двигателя

Таблица 2.19 Технические характеристики двигателя 1МZ-FE

Таблица 2.20 Конструктивные и эксплуатационные особенности двигателей 1MZ-FE

Таблица 2.21 Данные для обслуживания системы смазки двигателя 1MZ-FE

Таблица 2.22 Данные для обслуживания системы охлаждения двигателя 1MZ-FE

Таблица 2.23 Данные для обслуживания топливной системы

Таблица 2.24 Технические характеристики свечей зажигания

Таблица 2.25 Структура системы управления двигателей 1МZ-FE

Таблица 2.26 Данные для обслуживания системы управления двигателем 1МZ-FE

Таблица 2.27 Основные элементы системы управления двигателем 1МZ-FE

Таблица 2.28 Добавленные коды неисправности (DTC)

Таблица 2.29 Не используемые коды неисправности (DTC)

Таблица 2.30 Новшества, примененные в работе системы управления надежностью

Таблица 2.31 Данные для обслуживания механической части двигателя 1МZ-FE

Таблица 2.32 Операции по техническому обслуживанию

Таблица 2.33 Размерные группы вкладышей коренных подшипников

Таблица 2.34 Диагностические коды неисправностей системы управления двигателем

Таблица 2.35 Отдельные технические данные, считываемые при помощи тестера

Таблица 2.36 Диагностические коды неисправностей системы управления двигателем

Источник

4Runner Allex Allion Alphard Altezza Aristo Auris Avalon Avanza Avensis Avensis Verso Aygo bB Belta Blade Brevis Caldina Cami Camry Carina Carina E Carina ED Celica Chaser Corolla Corolla Ceres Corolla II Corolla Levin Corolla Rumion Corolla Spacio Corolla Verso Corona Corona Exiv Corona Premio Corsa Cresta Crown Curren Duet Dyna Echo Estima FJ Cruiser Fortuner Fun Cargo Gaia Grand Hiace Granvia Harrier Hiace Highlander Hilux Hilux Surf Ipsum Isis Ist Kluger Land Cruiser Land Cruiser Prado Lite Ace Mark II Mark II Qualis Mark X Master Ace Matrix Model F MR2 Nadia Noah Opa Paseo Passo Pick-Up Picnic Platz Porte Premio Previa Prius Probox Progres Ractis Raum RAV4 Regius Regius Ace Rush Sequoia Sienna Sienta Soarer Solara Sprinter Sprinter Carib Sprinter Marino Sprinter Trueno Starlet Succeed Supra T100 Tacoma Tercel Touring Hiace Town Ace Toyoace Tundra Vanguard Venza Verossa Verso Vigo Vista Vitz Voltz Voxy WiLL Cypha WiLL VS Windom Wish Yaris Yaris Verso ДВС и КПП Прочее

Сборник руководств на английском языке по техническому обслуживанию и ремонту двигателей Toyota моделей 1AZ-FE/1AZ-FSE/2AZ-FE.

Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: —
Формат: PDF
Размер: 9,7 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: —
Формат: JPG
Размер: 81,4 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: —
Формат: PDF
Размер: 7,6 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: 1990
Страниц: —
Формат: PDF
Размер: 79,6 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: 599
Формат: PDF
Размер: 21,2 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: 1987
Страниц: —
Формат: PDF
Размер: 82,3 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: —
Формат: PDF
Размер: 22,2 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: —
Формат: PDF
Размер: 5,2 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: 1980
Страниц: 138
Формат: PDF
Размер: 15,3 Mb

Руководство на английском языке по техническому обслуживанию и ремонту двигателей Toyota моделей 2H/12H-T.

Автор: —
Издательство: Toyota Motor Company
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Страниц: 338
Формат: PDF
Размер: 478,7 Mb

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Автор: —
Издательство: Toyota Motor Company
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Формат: PDF
Размер: 27,4 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: 1987
Страниц: —
Формат: PDF
Размер: 22,7 Mb

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Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: —
Формат: PDF
Размер: 386,1 Mb

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Автор: —
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Размер: —

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Автор: —
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Страниц: 320
Формат: PDF
Размер: —

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Автор: —
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Автор: —
Издательство: Toyota Motor Company
Год издания: —
Страниц: 209
Формат: PDF
Размер: 23,0 Mb

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Автор: —
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Страниц: —
Формат: PDF
Размер: 29,6 Mb

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Автор: —
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Размер: 581,8 Mb

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Автор: —
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Страниц: 228/-
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Издательство: —
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Автор: —
Издательство: Легион-Автодата
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Размер: —

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Размер: —

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Издательство: Легион-Автодата
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Источник

Toyota: двигатели 1AZ-FE, 2AZ-FE, 2AD-FTV. Руководство — страница 2

— 1AZ-FE И 2AZ-FE

01NEG54Y

: Угол открытия впускного клапана

: Угол открытия выпускного клапана

Диапазон

регулирования

фаз

системой VVT-i

Диапазон

регулирования

фаз

системой VVT-i

ВМТ

НМТ

ВМТ

НМТ

ДВИГАТЕЛЬ 1AZ-FE

ДВИГАТЕЛЬ 2AZ-FE

EG — 3

Технические данные

Двигатель

1AZ-FE

2AZ-FE

Кол-во и расположение цилиндров

4-цилиндровый, рядный

Клапанный механизм

16-клапанный, с двумя верхними

валами (DOHC),

с цепным приводом (с VVT-i)

Камера сгорания

Шатрового типа

Коллекторы

С поперечным газообменом

Топливная система

Впрыск топлива с электронным

управлением (EFI)

Система зажигания

DIS (Система зажигания с

раздельными катушками)

Рабочий объем

см

(куб. дюйм)

1998 (121,9)

2362 (144,2)

Диаметр цилиндра и ход поршня,

мм (дюймов)

86,0 x 86,0 (3,39 x 3,39)

88,5 x 96,0 (3,48 x 3,78)

Степень сжатия

9,8 : 1

Максимальная мощность

[по стандарту EEC]

112 кВт при 6000 мин-1

125 кВт при 6000 мин-1

Максимальный крутящий момент

[по стандарту EEC]

194 Н

м при 4000 об/мин

224 Н

м при 4000 об/мин

Впускной

Открытие

— 43

до ВМТ

Фазы

газораспределе

Впускной

Закрытие

— 20

после НМТ

— 25

после НМТ

газораспределе

ния

Выпуск-

Открытие

до НМТ

ния

Выпуск-

ной

Закрытие

после ВМТ

Порядок работы цилиндров

1 — 3 — 4 — 2

Октановое число по исследовательскому

методу

не менее 95

не менее 91

Класс масла

API SL, EC или ILSAC

Норма токсичности ОГ

EURO IV

Эксплуатационная

масса

двигателя*

(для справки)

кг

(фунт)

131 (288,8)

138 (304.2)

*: Указана масса двигателя, полностью заправленного моторным маслом и охлаждающей жидкостью.

Фазы газораспределения

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2.0 Двигатель

2. Двигатель

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