Toyota Camry 2007-2009 Service Manual - Service_Specifications

SERVICE SPECIFICATIONS – STANDARD BOLT

STANDARD BOLT

HOW TO DETERMINE BOLT STRENGTH

Bolt Type

Hexagon Head Bolt Stud Bolt Weld Bolt Class Normal Recess Bolt Deep Recess Bolt

No Mark No Mark No Mark 4T

w/ Washer w/ Washer 6T

SS–1

10T

11T

SS–2

SERVICE SPECIFICATIONS – ST ANDARD BOLT

SPECIFIED TORQUE FOR STANDARD BOLTS

Class Diameter

(mm)

4T 6 1 5 55 48 in.*lbf 6 60 52 in.*lbf

8 1.25 12.5 130 9 14 145 10 10 1.25 26 260 19 29 290 21 12 1.25 47 480 35 53 540 39 14 1.5 74 760 55 84 850 61 16 1.5 115 1,150 83 - - -

5T 6 1 6.5 65 56 in.*lbf 7.5 75 65 in.*lbf

8 1.25 15.5 160 12 17.5 175 13 10 1.25 32 330 24 36 360 26 12 1.25 59 600 43 65 670 48 14 1.5 91 930 67 100 1,050 76 16 1.5 140 1,400 101 - - -

6T 6 1 8 80 69 in.*lbf 9 90 78 in.*lbf

8 1.25 19 195 14 21 210 15 10 1.25 39 400 29 44 440 32 12 1.25 71 730 53 80 810 59 14 1.5 110 1,100 80 125 1,250 90 16 1.5 170 1,750 127 - - -

7T 6 1 10.5 110 8 12 120 9

8 1.25 25 260 19 28 290 21 10 1.25 52 530 38 58 590 43 12 1.25 95 970 70 105 1,050 76 14 1.5 145 1,500 108 165 1,700 123 16 1.5 230 2,300 166 - - -

8T 8 1.25 29 300 22 33 330 24

10 1.25 61 620 45 68 690 50 12 1.25 110 1,100 80 120 1,250 90

9T 8 1.25 34 340 25 37 380 27

10 1.25 70 710 51 78 790 57 12 1.25 125 1,300 94 140 1,450 105

10T 8 1.25 38 390 28 42 430 31

10 1.25 78 800 58 88 890 64 12 1.25 140 1,450 105 155 1,600 116

11T 8 1.25 42 430 31 47 480 35

10 1.25 87 890 64 97 990 72 12 1.25 155 1,600 116 175 1,800 130

Pitch (mm)

Specified torque Hexagon head bolt Hexagon flange bolt N*m kgf*cm ft.*lbf N*m kgf*cm ft.*lbf

SERVICE SPECIFICATIONS – STANDARD BOLT

HOW TO DETERMINE NUT STRENGTH

Nut Type

Present Standard Hexagon Nut Old Standard Hexagon Nut Class

Cold Forging Nut Cutting Processed Nut

No Mark 4N

SS–3

No Mark (w/ Washer) No Mark (w/ Washer) No Mark 5N (4T)

7N (5T)

No Mark 10N (7T)

11N

12N

HINT:

• *: Nut with 1 or more marks on one side surface of the nut.

• Use the nut with the same number of the nut strength classification or greater than the bolt strength classification number when tightening parts with a bolt and nut.

Example:

• Bolt = 4T

• Nut = 4N or more

SS–4

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE CONTROL SYSTEM

2AZ-FE ENGINE CONTROL SYSTEM

SERVICE DATA

Camshaft timing oil control valve assembly Resistance at 20°C (68°F) 6.9 to 7.9 Ω Camshaft position sensor Standard resistance 1 (G+) - 2(G-) 835 to 1,400 Ω at Cold

1 (G+) - 2(G-) 1,060 to 1,645 Ω at Hot Crankshaft position sensor Standard resistance Cold 985 to 1,600 Ω

Hot 1,265 to 1,890 Ω Throttle body assembly Resistance at 20°C (68°F)

2 (M+) - 1 (M-) 0.3 to 100 kΩ E.F.I. engine coolant temperature sensor Resistance Approx. 20°C (68°F) 2.32 to 2.59 kΩ

Approx. 80°C (176°F) 0.310 to 0.326 kΩ Knock sensor Resistance at 20°C (68°F) 120 to 280 kΩ Circuit opening relay (engine room R/B Unit D) Specified condition 1E-8 - 1E-12 Below 1 Ω

1E-7 - 1E-13 10 kΩ or higher 1E-7 - 1E-13 Below 1 Ω (when battery voltage is applied to terminals 1G-5

EFI relay (engine room R/B Unit D) Specified condition 1E-9 - 1E-10 Below 1 Ω

1E-7 - 1E-12 10 kΩ or higher 1E-7 - 1E-12 Below 1 Ω (when battery voltage is applied to terminals 1H-10

A/F relay (engine room R/B Unit D) Specified condition 1E-7 - 1E-10 Below 1 Ω

1A-3 - 1A-4 10 kΩ or higher 1A-3 - 1A-4 Below 1 Ω (w hen battery voltage is applied to terminals 1D-5

Accelerator pedal rod Standard voltage (ACCEL POS #1) Released 0.5 to 1.1 V

Depressed 2.5 to 4.5 V

Standard voltage (ACCEL POS #2) Released 1.2 to 2.0 V

Depressed 3.4 to 5.0 V

and 1H-9)

and 1H-2)

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE CONTROL SYSTEM

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Throttle body assembly x Intake manifold 30 305 22 Knock sensor x Cylinder block sub-assembly 20 204 15 ECM x ECM bracket 3.0 30 27 ECM x Body 6.5 66 57 Accelerator pedal rod assembly x Body 5.4 55 48 in.*lbf Camshaft timing oil control valve assembly x Cylinder head sub-

assembly Vacuum hose clamp x Intake manifold 5.0 51 44 in.*lbf Camshaft position sensor x Cylinder head sub-assembly 9.0 92 80 in.*lbf Crankshaft position sensor x Timing chain cover sub-assembly 9.0 92 80 in.*lbf Engine coolant temperature sensor x Cylinder head sub-assembly 20 204 15 Intake manifold x Cylinder head sub-assembly 30 306 22 Intake manifold x Cylinder block sub-assembly 30 306 22 Cowl top panel outer sub-assembly x Body 5.0 51 44 in.*lbf

9.0 92 80 in.*lbf

SS–5

SS–6

SERVICE SPECIFICATIONS – 2GR-FE ENGINE CONTROL SYSTEM

2GR-FE ENGINE CONTROL SYSTEM

SERVICE DATA

Throttle body

Standard throttle valve opening

percentage Camshaft timing oil control valve assembly Resistance at 20°C (68°F) 6.9 to 7.9 Ω Crankshaft position sensor

-10 to 50 °C (14 to 122 °F) 1,630 to 2,740 Ω

50 to 100 °C (122 to 212 °F) 2,065 to 3,225 Ω Throttle body Resistance at 20°C (68°F)

2 (M+) - 1 (M-) 0.3 to 100 kΩ

5 (VC) - 3 (E2) 1.2 to 3.2 kΩ E.F.I. engine coolant temperature sensor Resistance Approx. 20°C (68°F) 2.32 to 2.59 kΩ

Approx. 80°C (176°F) 0.310 to 0.326 kΩ Knock sensor Resistance at 20°C (68°F) 120 to 280 kΩ Circuit opening relay (engine room R/B Unit D) Specified condition 1E-8 - 1E-12 Below 1 Ω

1E-7 - 1E-13 10 kΩ or higher 1E-7 - 1E-13

EFI relay (engine room R/B Unit D) Specified condition 1E-9 - 1E-10 Below 1 Ω

1E-7 - 1E-12 10 kΩ or higher 1E-7 - 1E-12

A/F relay (engine room R/B Unit D) Specified condition 1E-7 - 1E-10 Below 1 Ω

1A-3 - 1A-4 10 kΩ or higher 1A-3 - 1A-4

IG2 Relay Standard resistance 3 - 5 10 kΩ or higher

Acceleration pedal rod Standard voltage (ACCEL POS #1) Released 0.5 to 1.1 V

Depressed 2.5 to 4.5 V

Standard voltage (ACCEL POS #2) Released 1.2 to 2.0 V

Depressed 3.4 to 5.0 V

60% or more

Below 1 Ω (when battery voltage is applied to terminals 1G-5 and 1H-9)

Below 1 Ω (when battery voltage is applied to terminals 1H-10 and 1H-2)

Below 1 Ω (when battery voltage is applied to terminals 1D-5 and 1H-2)

3 - 5 Below 1 Ω (Battery voltage applied between terminals 1 and 2)

SERVICE SPECIFICATIONS – 2GR-FE ENGINE CONTROL SYSTEM

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Throttle body assembly x Intake air surge tank 10 102 7 Knock sensor x Cylinder block sub-assembly 20 199 14 Water outlet x Cylinder head sub-assembly 15 153 11 ECM x Instrument panel reinforcement 5.5 56 49 in.*lbf ECM x Blower assembly 5.5 56 49 in.*lbf Accelerator pedal rod assembly x Body 5.4 55 48 in.*lbf Camshaft timing oil control valve assembly x Cylinder head cover sub-

assembly VVT sensor x Cylinder head cover sub-assembly 10 102 7 Crankshaft position sensor x Cylinder block sub-assembly 10 102 7 Engine coolant temperature sensor x Cylinder head sub-assembly 20 204 15

10 102 7

SS–7

SS–8

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

2AZ-FE ENGINE MECHANICAL

SERVICE DATA

with Terminals TC and CG of DLC3

Ignition timing

Idle speed

Compression

Valve clearance (cold)

Balanceshaft Standard thrust clearance 0.050 to 0.090 mm (0.0020 to 0.0035 in.) Maximum thrust clearance 0.09 mm (0.0035 in.) Standard oil clearance 0.004 to 0.049 mm (0.0002 to 0.0019 in.) Maximum oil clearance 0.049 mm (0.0019 in.)

Housing journal bore diameter

Journal diameter

Bearing center wall thickness

Oil pump drive sprocket Minimum sprocket diameter (with chain) 48.2 mm (1.898 in.) Oil pump drive shaft sprocket Minimum sprocket diameter (with chain) 48.2 mm (1.898 in.) Crankshaft timing sprocket Minimum sprocket diameter (with chain) 51.6 mm (2.031 in.) Chain tensioner slipper Maximum wear 1.0 mm (0.039 in.) Chain vibration damper No. 1 Maximum wear 1.0 mm (0.039 in.) Chain tensioner plate Maximum wear 0.5 mm (0.020 in.)

Cylinder head set bolt

Chain sub-assembly Maximum chain elongation 114.5 mm (4.508 in.) No. 2 Chain sub-assembly Maximum chain elongation 102.2 mm (4.024 in.)

Camshaft timing gear assembly

Camshaft timing sprocket Camshaft (Intake)

Maximum circle runout 0.03 mm (0.0012 in.) Standard cam lobe height 47.306 to 47.406 mm (1.8624 to 1.8664 in.) Maximum cam lobe height 47.196 mm (1.8581 in.) No. 1 journal diameter 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Outer journal diameter 22.959 to 22.975 mm (0.9039 to 0.9045 in.)

connected with Terminals TC and CG of DLC3

disconnected M/T 650 to 750 rpm A/T 610 to 710 rpm

Compression pressure Minimum pressure Difference between each cylinder

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.)

Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.) Mark 1 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Mark 2 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Mark 3 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Standard bolt length 58.3 to 59.7 mm (2.295 to 2.350 in.) Maximum bolt length 60.3 mm (2.374 in.) Mark 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.) Mark 2 1.490 to 1.492 mm (0.0586 to 0.0587 in.) Mark 3 1.493 to 1.495 mm (0.0587 to 0.0589 in.)

Standard bolt length 141.3 to 142.7 mm (5.563 to 5.618 in.) Maximum bolt length 144.2 mm (5.677 in.)

Minimum gear or sprocket diameter (with chain)

8 to 12°BTC at idle

5 to 15°BTC at idle

1.360 MPa (13.9 kgf/cm

0.98 MPa (10 kgf/cm 100 kPa (1.0 kgf/cm

97.3 mm (3.831 in.)

, 14 psi)

, 198 psi)

, 142 psi)

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

SS–9

Standard thrust clearance Maximum thrust clearance 0.110 mm (0.0043 in.)

Standard oil clearance

Maximum oil clearance 0.070 mm (0.0028 in.)

Cylinder head journal bore diameter

Standard bearing center wall thickness

Camshaft journal diameter

Camshaft No. 2 (Exhaust) Maximum circle runout 0.03 mm (0.0012 in.) 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.) No. 1 journal diameter 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter 22.959 to 22.975 mm (0.9039 to 0.9045 in.) Standard thrust clearance Maximum thrust clearance 0.150 mm (0.0059 in.)

Standard oil clearance

Maximum oil clearance 0.100 mm (0.0039 in.)

Cylinder head journal bore diameter

Standard bearing center wall thickness

Camshaft journal diameter

Intake manifold Maximum warpage 0.20 mm (0.0079 in.) Exhaust manifold Maximum warpage 0.70 mm (0.0276 in.) Cylinder head

Maximum warpage

Inner compression spring

Intake valve

Intake

No. 1 journal bearing mark 1 0.007 to 0.038 mm (0.0003 to 0.0015 in.) No. 1 journal bearing mark 2 0.008 to 0.038 mm (0.0003 to 0.0015 in.) No. 1 journal bearing mark 3 0.008 to 0.038 mm (0.0003 to 0.0015 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Mark 1 40.000 to 40.008 mm (1.5748 to 1.5752 in.) Mark 2 40.009 to 40.017 mm (1.5752 to 1.5755 in.) Mark 3 40.018 to 40.025 mm (1.5755 to 1.5758 in.) Mark 1 2.000 to 2.004 mm (0.0787 to 0.0789 in.) Mark 2 2.005 to 2.008 mm (0.0789 to 0.0791 in.) Mark 3 2.009 to 2.012 mm (0.0791 to 0.0792 in.) Mark 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 2 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 3 35.971 to 35.985 mm (1.4162 to 1.4167 in.)

Exhaust

No. 1 journal 0.015 to 0.054 mm (0.0006 to 0.0021 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Mark 1 40.000 to 40.008 mm (1.5748 to 1.5752 in.) Mark 2 40.009 to 40.017 mm (1.5752 to 1.5755 in.) Mark 3 40.018 to 40.025 mm (1.5755 to 1.5758 in.) Mark 1 2.000 to 2.004 mm (0.00787 to 0.0789 in.) Mark 2 2.005 to 2.008 mm (0.0789 to 0.0791 in.) Mark 3 2.009 to 2.012 mm (0.0791 to 0.0792 in.) Mark 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 2 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Mark 3 35.971 to 35.985 mm (1.4162 to 1.4167 in.)

Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.08 mm (0.0031 in.) Exhaust manifold side 0.08 mm (0.0031 in.) Free length 47.43 mm (1.867 in.) Maximum deviation 1.6 mm (0.063 in.) Standard overall length 101.71 mm (4.0043 in.) Minimum overall length 101.21 mm (3.9846 in.) Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Standard margin thickness 1.05 to 1.45 mm (0.0413 to 0.0571 in.) Minimum margin thickness 0.50 mm (0.0197 in.)

0.040 to 0.095 mm (0.0016 to 0.0037 in.)

0.080 to 0.135 mm (0.0032 to 0.0053 in.)

SS–10

Exhaust valve

Intake valve guide bush

Bush bore diameter

Protrusion height 9.6 to 10.0 mm (0.3779 to 0.3937 in.) Standard oil clearance 0.025 to 0.060 mm (0.0010 to 0.0024 in.)

Exhaust valve guide bush

Bush bore diameter

Protrusion height 9.6 to 10.0 mm (0.3779 to 0.3937 in.) Standard oil clearance 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Valve lifter

Connecting rod Standard thrust clearance 0.160 to 0.362 mm (0.0063 to 0.0143 in.) Maximum thrust clearance 0.362 mm (0.0143 in.) Standard oil clearance 0.032 to 0.063 mm (0.0013 to 0.0025 in.) Maximum oil clearance 0.063 mm (0.0025 in.)

Connecting rod bearing center wall thickness (Reference)

Connecting rod small end bore diameter 22.005 to 22.014 mm (0.8663 to 0.8667 in.)

Connecting rod small end bore diameter (Reference)

Standard oil clearance 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance 0.011 mm (0.0004 in.) Maximum rod out-of alignment per 100 mm (3.94 in.) 0.05 mm (0.0020 in.) Maximum rod twist per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)

Cylinder block

Piston Standard piston diameter 88.469 to 88.479 mm (3.4830 to 3.4834 in.) Standard piston oil clearance 0.021 to 0.044 mm (0.0008 to 0.0017 in.) Maximum piston oil clearance 0.10 mm (0.0039 in.) Piston pin bore diameter 22.001 to 22.010 mm (0.8662 to 0.8665 in.)

Piston pin bore diameter (Reference)

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

Standard overall length 101.15 mm (3.9823 in.) Minimum overall length 100.70 mm (3.9646 in.) Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Standard margin thickness 1.20 to 1.60 mm (0.0472 to 0.0630 in.) Minimum margin thickness 0.50 mm (0.0197 in.) Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard bush oil clearance 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Minimum bush oil clearance 0.080 mm (0.0031 in.) Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)

Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard oil clearance 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Minimum oil clearance 0.100 mm (0.0039 in.) Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)

Lifter diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.) Lifter bore diameter 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard oil clearance 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance 0.070 mm (0.0028 in.)

Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586 in.) Mark 2 1.489 to 1.491 mm (0.0586 to 0.0587 in.) Mark 3 1.492 to 1.494 mm (0.0587 to 0.0588 in.)

Mark A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) Mark B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) Mark C 22.012 to 22.014 mm (0.8666 to 0.8667 in.)

Maximum warpage 0.05 mm (0.0020 in.) Standard cylinder bore diameter 88.500 to 88.513 mm (3.4843 to 3.4847 in.) Maximum cylinder bore diameter 88.633 mm (3.4894 in.)

Mark A 22.001 to 22.004 mm (0.8662 to 0.8663 in.) Mark B 22.005 to 22.007 mm (0.8663 to 0.8664 in.) Mark C 22.008 to 22.010 mm (0.8664 to 0.8665 in.)

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

Piston ring

No. 1 Ring 0.020 to 0.070 mm (0.0008 to 0.0028 in.)

Ring groove clearance

Standard end gap

Maximum end gap

Piston pin Standard piston pin diameter 21.997 to 22.006 mm (0.8660 to 0.8664 in.)

Piston pin diameter (Reference)

Standard oil clearance 0.001 to 0.007 mm (0.0004 to 0.0003 in.) Maximum oil clearance 0.010 mm (0.0004 in.)

Connecting rod bolt

Crankshaft Standard thrust clearance 0.040 to 0.240 mm (0.0016 to 0.0095 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) Thrust washer thickness 1.930 to 1.980 mm (0.0760 to 0.0780 in.)

Cylinder block main journal bore diameter (Reference)

Main journal diameter 54.988 to 55.000 mm (2.1648 to 2.1654 in.)

Main journal diameter (Reference)

Standard main bearing center wall thickness (Reference)

Maximum circle runout 0.03 mm (0.0012 in.) Standard oil clearance 0.017 to 0.040 mm (0.0007 to 0.0016 in.) Maximum oil clearance 0.060 mm (0.0024 in.) Maximum main journal taper and out-of-round 0.003 mm (0.0001 in.) Maximum crank pin taper and out-of round 0.003 mm (0.0001 in.) Crank pin diameter 47.990 to 48.000 mm (1.8894 to 1.8898 in.)

No. 2 Ring 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil Ring 0.020 to 0.070 mm (0.0008 to 0.00 28 in.) No. 1 Ring 0.24 to 0.31 mm (0.0094 to 0.0122 in.) No. 2 Ring 0.33 to 0.43 mm (0.0130 to 0.0169 in.) Oil Ring 0.10 to 0.30 mm (0.0040 to 0.0119 in.) No. 1 Ring 0.89 mm (0.0350 in.) No. 2 Ring 1.37 mm (0.0539 in.) Oil Ring 0.73 mm (0.0287 in.)

Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) Mark B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) Mark C 22.004 to 22.006 mm (0.8663 to 0.8664 in.) Mark A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) Mark B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) Mark C 22.004 to 22.006 mm (0.8663 to 0.8664 in.)

Standard diameter 7.0 to 7.3 mm (0.276 to 0.287 in.) Maximum diameter 7.0 mm (0.276 in.)

Mark 0 59.000 to 59.002 mm (2.3228 to 2.3229 in.) Mark 1 59.003 to 59.004 mm (2.3230 to 2.3230 in.) Mark 2 59.005 to 59.006 mm (2.3230 to 2.3231 in.) Mark 3 59.007 to 59.009 mm (2.3231 to 2.3232 in.) Mark 4 59.010 to 59.011 mm (2.3232 to 2.3233 in.) Mark 5 59.012 to 59.013 mm (2.3233 to 2.3234 in.) Mark 6 59.014 to 59.016 mm (2.3234 to 2.3235 in.)

Mark 0 54.999 to 55.000 mm (2.1653 to 2.1654 in.) Mark 1 54.997 to 54.998 mm (2.1652 to 2.1653 in.) Mark 2 54.995 to 54.996 mm (2.1652 to 2.1652 in.) Mark 3 54.993 to 54.994 mm (2.1651 to 2.1651 in.) Mark 4 54.991 to 54.992 mm (2.1650 to 2.1650 in.) Mark 5 54.988 to 54.990 mm (2.1649 to 2.1650 in.) Mark 1 1.993 to 1.996 mm (0.0785 to 0.0786 in.) Mark 2 1.997 to 1.999 mm (0.0786 to 0.0787 in.) Mark 3 2.000 to 2.002 mm (0.0787 to 0.0788 in.) Mark 4 2.003 to 2.005 mm (0.0789 to 0.0789 in.)

SS–11

SS–12

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

Crankshaft bearing cap set bolt

Standard diameter 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter 7.2 mm (0.284 in.)

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Engine mounting bracket No. 2 RH x Timing chain cover 52 531 38 Engine mounting bracket RH x Cylinder block 54 551 40 Engine moving control rod with bracket x Engine mounting bracket No. 2 RH 64 653 47 Engine moving control rod with bracket x Fender apron RH 64 653 47 Engine mounting stay No. 2 RH x Cylinder head 64 653 47 Engine mounting stay No. 2 RH x Engine mounting bracket No. 2 RH 64 653 47 Engine hanger No. 1 x Cylinder head 38 387 28 Engine hanger No. 2 x Cylinder head 38 387 28 ECT sensor x Cylinder head 20 204 15 Knock sensor x Cylinder block 20 204 15 Engine oil pressure switch assembly x Cylinder head 15 153 11 Water by-pass pipe No. 1 x Cylinder block 9.0 92 80 in.*lbf Oil cooler pipe x Cylinder block 9.0 92 80 in.*lbf Transverse engine engine mounting bracket x Cylinder block 54 551 40 Drive shaft bearing bracket x Cylinder block 64 653 47 V-ribbed belt tensioner assembly x Timing chain cover 60 607 44 Ignition coil assembly x Cylinder head 9.0 92 80 in.*lbf Engine cover x Cylinder head cover 7.0 71 62 in.*lbf

Except

Exhaust manifold converter x Cylinder head

Exhaust manifold stay x Exhaust manifold converter 44 449 32 Manifold converter insulator No. 1 x Exhaust manifold converter 12 122 9 Oil level gauge guide x Water by-pass pipe No. 1 9.0 92 80 in.*lbf Intake manifold x Cylinder head 30 306 22 Drive plate and ring gear (A/T) x Crankshaft 98 1,000 72 Flywheel sub-assembly (M/T) x Crankshaft 130 1,330 96 Engine mounting insulator LH x Automatic transaxle assembly 95 969 70 Engine mounting insulator LH x Manual transaxle assembly 143 1,459 105 Engine mounting insulator RH x Engine mounting bracket RH Nut A 95 969 70 Engine mounting insulator RH x Frame Nut B 87 888 64 Engine mounting insulator FR x Engine mounting bracket FR 87 888 64 Engine mounting bracket rear No. 2 x Engine lateral control rod (M/T) 89 910 66 Vane pump assembly x Timing chain cover 43 439 32 Frame side plate x Front frame assembly Bolt A 85 867 63 Frame side plate x Body Bolt B 32 326 24 Front suspension member brace rear x Front frame assembly Bolt C 85 867 63 Front suspension member brace rear x Body Bolt D 32 326 24 Steering return tube clamp x Frame 8.0 80 69 in.*lbf Compressor and magnetic clutch x Cylinder block 25 250 18

Battery clamp x Body

Speed sensor front LH (with ABS) x Steering knuckle 8.0 82 71 in.*lbf Speed sensor front RH (with ABS) x Steering knuckle 8.0 82 71 in.*lbf Air cleaner assembly x Body 5.0 51 44 in.*lbf Air cleaner inlet assembly x Body 5.0 51 44 in.*lbf

Balanceshaft housing x Stiffening crankcase assembly

PZEV For PZEV 37 378 27

Bolt 9.0 92 80 in.*lbf Nut 3.5 36 31 in.*lbf

1st 22 220 16 2nd Turn 90° Turn 90° Turn 90°

37 378 27

SS–13

SS–14

Stiffening crankcase assembly x Cylinder block 24 245 18 with head taper screw plug No. 1 x Cylinder block 26 265 19 No. 1 oil nozzle sub-assembly x Cylinder block 7.0 71 62 in.*lbf Oil control valve filter x Cylinder block 30 306 22

Cylinder block water drain cock x Stiffening crankcase assembly

Cylinder head x Cylinder block

Camshaft timing gear assembly x Camshaft 54 551 40 Camshaft timing sprocket x Camshaft 54 551 40 Camshaft bearing cap No. 1 x Cylinder head 30 301 22 Camshaft bearing cap No. 2 x Cylinder head 30 301 22 Camshaft bearing cap No. 3 x Cylinder head 9.0 92 80 in.*lbf Oil pump assembly x Stiffening crankcase assembly 19 194 14 Chain tensioner plate x Stiffening crankcase assembly 12 122 9 Oil pump drive sprocket x Oil pump 30 301 22 Chain vibration damper No. 1 x Cylinder head 9.0 92 80 in.*lbf Chain vibration damper No. 1 x Cylinder block 9.0 92 80 in.*lbf Chain tensioner slipper x Cylinder block 19 194 14 Timing chain guide x Crankshaft bearing cap No. 1 9.0 92 80 in.*lbf Oil pan x Stiffening crankcase assembly 9.0 92 80 in.*lbf Oil pan drain plug x Oil pan 25 255 18 Timing chain cover x Cylinder block, Cylinder head Bolt A 9.0 92 80 in.*lbf

Crankshaft position sensor x Timing chain cover 9.0 92 80 in.*lbf

Crankshaft pulley x Crankshaft

Chain tensioner assembly No. 1 x Timing chain cover 9.0 92 80 in.*lbf Camshaft position sensor x Cylinder head 9.0 92 80 in.*lbf Radio setting condenser x Cylinder head 10 102 7

Cylinder head cover x Cylinder head

Cylinder head cover x Engine wire 8.4 86 74 in.*lbf Oil filter union x Stiffening crankcase assembly 30 306 22

Oil filter union x Stiffening crankcase assembly (with Oil cooler)

Oil filter x Oil filter union 13 133 10 Spark plug x Cylinder head 19 194 14 Ventilation valve x Cylinder head cover 19 194 14 No. 1 exhaust pipe support bracket x Body 19 194 14

Stud bolt

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

Part Tightened N*m kgf*cm ft.*lbf

13 1st 79 806 58 2nd Turn 90° Turn 90° Turn 90°

Bolt B 25 255 18 Bolt C 55 561 41 Nut 11 112 8

TMMK made

TMC made 180 1,835 133

Bolt A 11 112 8 Bolt B 14 143 10 Nut 11 112 8

Oil filter union

Nut 9.0 92 80 in.*lbf Union bolt 25 255 18

Bolt A 5 51 44 in.*lbf Bolt B 5 51 44 in.*lbf Bolt C 9.5 97 84 in.*lbf Bolt D 9.5 97 84 in.*lbf

170 1,733 125

79 806 58

255 130

18 9

SERVICE SPECIFICATIONS – 2AZ-FE ENGINE MECHANICAL

Part Tightened N*m kgf*cm ft.*lbf

Stud bolt

Crankshaft bearing cap x Cylinder block

Connecting rod cap x Connecting rod

Bolt A 5.0 51 44 in.*lbf Bolt B 22 220 16 Bolt C 9.5 97 84 in.*lbf Bolt D 5.0 51 44 in.*lbf 1st 20 204 15 2nd 40 408 29 3rd Turn 90° Turn 90° Turn 90° 1st 25 250 18 2nd Turn 90° Turn 90° Turn 90°

SS–15

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL

2GR-FE ENGINE MECHANICAL

SERVICE DATA

SS–15

Ignition timing Terminals TC and CG of DLC3

connected

Terminals TC and CG of DLC3

disconnected Idle speed 600 to 700 rpm (Transmission in neutral) Compression

Difference between each cylinder

Cylinder head set bolt Outside diameter Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.)

Chain Elongation Maximum 136.9 mm (5.390 in.) No. 2 chain Elongation Maximum 137.6 mm (5.417 in.) Crankshaft timing gear Diameter (w/ chain) Minimum 61.4 mm (2.417 in.) Idle sprocket Diameter (w/ chain) Minimum 61.4 mm (2.417 in.) Idle gear shaft Idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.) Idle gear inside diameter 23.020 to 30.030 mm (0.9063 to 0.9067 in.) Oil clearance Standard 0.020 to 0.043 mm (0.0008 to 0.0017 in.)

Chain tensioner assembly No. 2 Worn depth Maximum 0.9 mm (0.035 in.) Chain tensioner assembly No. 3 Worn depth Maximum 0.9 mm (0.035 in.) Chain tensioner slipper Worn depth Maximum 1.0 mm (0.039 in.) Chain vibration damper No. 1 Worn depth Maximum 1.0 mm (0.039 in.) Chain vibration damper No. 2 Worn depth Maximum 1.0 mm (0.039 in.) Cylinder head sub-assembly

Warpage Maximum 0.10 mm (0.0039 in.) Intake valve Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Margin thickness Standard 1.0 mm (0.039 in.)

Overall length Standard 105.85 mm (4.1673 in.)

Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2158 in.)

Compression pressure

Minimum pressure

Minimum 10.70 mm (0.4213 in.)

Maximum 0.093 mm (0.0037 in.)

Cylinder head lower 0.05 mm (0.0020 in.)

Exhaust 0.08 mm (0.0031 in.)

Maximum 0.5 mm (0.0197 in.)

Maximum 105.35 mm (4.1476 in.)

8 to 12° BTDC at idle (Transmission in neutral)

5 to 15° BTDC at idle (Transmission in neutral)

1.4 MPa (14 kgf/cm

0.98 MPa (10 kgf/cm

0.1 MPa (1.0 kgf/cm

Intake 0.08 mm (0.0031 in.)

, 199 psi) or more

, 142 psi)

, 15 psi) or less

SS–16

Margin thickness Standard 1.0 mm (0.0394 in.)

Overall length Standard 111.40 mm (4.3858 in.)

Inner compression spring Free length 45.46 mm (1.7898 in.) Deviation Maximum 1.0 mm (0.039 in.) Angle (reference) Maximum 2° Intake valve guide bush Inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Oil clearance Standard 0.025 to 0.060 mm (0.0010 to 0.0024 in.)

Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Protrusion height 9.3 to 9.7 mm (0.3661 to 0.3819 in.) Exhaust valve guide bush Inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Oil clearance Standard 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Bush bore diameter Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Protrusion height 9.30 to 9.70 mm (0.3661 to 0.3819 in.) No. 1 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)

Circuit runout Maximum 0.04 mm (0.0016 in.) Cam lobe height Standard 44.316 to 44.416 mm (1.7447 to 1.7487 in.)

Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

No. 2 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)

Circuit runout Maximum 0.04 mm (0.0016 in.) Cam lobe height Standard 44.262 to 44.362 mm (1.7426 to 1.7465 in.)

Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

No. 3 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)

Circuit runout Maximum 0.04 mm (0.0016 in.)

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL

Maximum 0.5 mm (0.0197 in.)

Maximum 109.90 mm (4.3268 in.)

Maximum 0.08 mm (0.0031 in.)

Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)

Maximum 0.10 mm (0.0039 in.)

Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)

Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)

Maximum 44.166 mm (1.7388 in.)

Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum No. 1 journal 0.10 mm (0.0039 in.)

Other journals 0.09 mm (0.0035 in.)

Maximum 0.15 mm

Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)

Maximum 44.112 mm (1.7367 in.)

Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum No. 1 journal 0.10 mm (0.0039 in.)

Other journals 0.09 mm (0.0035 in.)

Maximum 0.15 mm

Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL

Cam lobe height Standard 44.316 to 44.416 mm (1.7447 to 1.7487 in.)

Maximum 44.166 mm (1.7388 in.)

Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum No. 1 journal 0.10 mm (0.0039 in.)

Other journals 0.09 mm (0.0035 in.)

Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

Maximum 0.15 mm No. 4 camshaft Journal diameter No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)

Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.) Circuit runout Maximum 0.04 mm (0.0016 in.) Cam lobe height Standard 44.262 to 44.362 mm (1.7426 to 1.7465 in.)

Maximum 44.112 mm (1.7367 in.)

Oil clearance Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)

Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum No. 1 journal 0.10 mm (0.0039 in.)

Other journals 0.09 mm (0.0035 in.) Thrust clearance Standard 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

Maximum 0.15 mm Ring pin for cylinder head sub-assembly Protrusion height 2.5 to 3.5 mm (0.098 to 0.138 in.) Straight pin for cylinder head sub-assembly Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.) Connecting rod thrust clearance Standard 0.15 to 0.40 mm (0.0059 to 0.0157 in.)

Maximum 0.50 mm (0.020 in.) Connecting rod oil clearance Standard 0.045 to 0.067 mm (0.0018 to 0.0026 in.)

Maximum 0.070 mm (0.0028 in.) Crankshaft thrust clearance Standard 0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Maximum 0.30 mm (0.0118 in.)

Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.) Cylinder block warpage Maximum 0.07 mm (0.0028 in.) Cylinder bore diameter Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in.)

Maximum 94.200 mm (3.7087 in.)

Piston diameter

Distance 9.8 mm (0.3858 in.)

Standard 93.960 to 93.980 mm (3.6992 to 3.7000 in.)

Maximum 93.830 mm (3.6941 in.)

Oil clearance Standard 0.02 to 0.052 mm (0.0008 to 0.0020 in.)

Maximum 0.06 mm Connecting rod out-of alignment Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) Connecting rod twist Maximum 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) Piston pin hole inside diameter 22.001 to 22.010 mm (0.8662 to 0.8665 in.) Piston pin diameter 21.997 to 22.006 mm (0.8660 to 0.8664 in.) Oil clearance Standard 0.001 to 0.007 mm (0.00004 to 0.00028 in.)

Maximum 0.015 mm (0.0006 in.) Connecting rod bushing inside diameter 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Oil clearance Standard 0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum 0.03 mm (0.0012 in.)

SS–17

SS–18

Piston ring groove clearance No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.)

Piston ring end gap Standard No. 1 0.25 to 0.35 mm (0.0098 to 0.0138 in.)

Connecting rod bolt diameter Standard 7.2 to 7.3 mm (0.283 to 0.287 in.)

Crankshaft bearing cap set bolt diameter Standard 10.8 to 11.0 mm (0.4252 to 0.4331 in.)

Crankshaft circle runout Maximum 0.06 mm (0.0024 in.) Main journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.) Main journal taper and out-of-round Maximum 0.02 mm (0.0008 in.) Crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) Crank pin taper and out-of-round Maximum 0.02 mm (0.0008 in.) Crankshaft oil clearance Standard 0.026 to 0.047 mm (0.0010 to 0.0019 in.)

Straight pin for cylinder block sub-assembly Protrusion height Pin A 23 mm (0.906 in.)

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL

No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)

Oil 0.070 to 0.150 mm (0.0028 to 0.0059 in.)

No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.)

Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Maximum No. 1 0.50 mm (0.0197 in.)

No. 2 0.85 mm (0.0335 in.)

Oil (Side rail) 0.60 mm (0.0236 in.)

Maximum 7.0 mm (0.276 in.)

Maximum 10.7 mm (0.4213 in.)

Maximum 0.050 mm (0.0020 in.)

Pin B 6 mm (0.236 in.) Pin C 11 mm (0.433 in.) Pin D 9 mm (0.354 in.)

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Ignition coil assembly x Cylinder head cover sub-assembly 10 102 7 Engine hanger No. 1 x Cylinder head sub-assembly RH 33 337 24 Engine hanger No. 2 x Cylinder head sub-assembly LH 33 337 24 Engine mounting bracket RH x Cylinder block sub-assembly 54 551 40 Oil level gauge guide x Cylinder head sub-assembly 21 214 15 Idler pulley sub-assembly No. 2 x Timing chain cover sub-assembly 43 438 32 V-ribbed belt tensioner assembly x Cylinder block sub-assembly 43 438 32 Intake manifold x Cylinder head sub-assembly 21 214 15 Exhaust manifold sub-assembly RH x Cylinder head sub-assembly

RH Exhaust manifold sub-assembly LH x Cylinder head sub-assembly LH 21 214 15 Drive plate & ring gear sub-assembly x Crankshaft 83 850 61 Air cleaner case x Body 5.0 51 44 in.*lbf E.F.I engine coolant temperature x water by-pass joint RR 20 200 14 Engine assembly w/ Transaxle x Body Bolt A 85 867 63

Bolt B 32 329 24 Bolt C 85 867 63

Bolt D 32 329 24 Manifold stay No. 2 x Exhaust manifold sub-assembly LH 34 347 25 Air cleaner inlet No. 1 x Body 5.0 51 44 in.*lbf Air cleaner inlet assembly x Body 5.0 51 44 in.*lbf Battery clamp x Body Bolt 9.0 92 80 in.*lbf

Nut 3.5 36 31 Steering intermediate shaft x Steering gear 35 360 26 Stabilizer link x Shock absorber 74 755 55 Tie rod assembly x Steering gear 49 500 36 Speed sensor front x Front axle 8.0 82 71 in.*lbf Front axle hub nut x Front drive shaft 294 2,998 217 Cooler compressor x V-ribbed belt tensioner 25 250 18 Engine mounting control bracket x Engine

mounting bracket front No. 1 LH

Engine assembly w/ Transaxle x Front frame assembly

Drive shaft bearing bracket x Cylinder block sub-assembly 64 650 47 Exhaust manifold heat insulator No. 2 x Exhaust manifold sub-

assembly LH Oil pressure switch x Oil pan sub-assembly 21 210 15 Engine mounting stay No. 2 RH x Intake manifold 21 214 15 Timing gear cover No. 2 x Chain cover sub-assembly 6.0 61 53 in.*lbf Engine mounting bracket front No. 1 LH x Chain cover 54 551 40 Camshaft bearing cap x Camshaft housing 1st 10 102 7

Camshaft housing x Cylinder head sub-assembly 28 286 21 Chain tensioner No. 1 x Cylinder head sub-assembly 10 102 7 Chain tensioner No. 2 x Cylinder head sub-assembly 21 214 15 Chain tensioner No. 3 x Cylinder head sub-assembly 21 214 15

Bolt A 44 450 32 Bolt B 38 387 28

Nut 23 235 17 Bolt 87 887 64 Nut 95 969 70

2nd 16 163 12

21 214 15

8.5 87 75 in.*lbf

SS–19

SS–20

Camshaft timing gear assembly x Camshaft 100 1,020 74 Camshaft timing exhaust gear assembly x Camshaft 100 1,020 74 Engine rear oil seal retainer x Cylinder block sub-assembly 10 102 7 Knock sensor x Cylinder block sub-assembly 20 204 15 Water inlet pipe x Cylinder block sub-assembly 10 102 7 Cylinder head RH x Cylinder block sub-

assembly

Cylinder head sub-assembly LH x Cylinder block sub-assembly

Chain vibration damper No. 1 x Cylinder block sub-assembly 23 230 17 Idle gear No. 1 x Cylinder block sub-assembly 60 612 44 Timing chain cover plate x Timing chain cover sub-assembly 9.1 93 81 in.*lbf Timing chain cover sub-assembly x Cylinder

head and block

Water pump assembly x Timing chain cover sub-assembly 9.1 93 81 in.*lbf Oil pan baffle plate x Cylinder block sub-assembly 10 102 7 Oil pan stud bolt x Cylinder block and timing chain cover sub-

assembly Oil pan stud bolt x No. 2 oil pan sub-assembly 4.0 41 35 in.*lbf Oil strainer stud bolt x Timing chain cover sub-assembly 4.0 41 35 in.*lbf Oil strainer sub-assembly x Cylinder block and timing chain cover sub-

assembly Oil pan sub-assembly x Cylinder block and

timing chain cover sub-assembly

Oil pan sub-assembly No. 2 x Oil pan sub-assembly 10 102 7 Oil pan drain plug x Oil pan sub-assembly No. 2 40 408 30 Crankshaft pulley x Crankshaft 250 2,550 184 Cylinder head cover sub-assembly x Cylinder

head sub-assembly RH

Cylinder head cover sub-assembly LH x Cylinder head sub-assembly LH

Water outlet x Cylinder head sub-assembly bolt 10 102 7

Water inlet housing set nut 10 102 7 Water inlet set bolt and nut 10 102 7 Oil filter cap x Oil pan 25 255 18 Camshaft position sensor 10 102 7

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL

Part Tightened N*m kgf*cm ft.*lbf

1st 36 367 27 2nd Turn 90° Turn 90° Turn 90° 3nd Turn 90° Turn 90° Turn 90°

Recessed head 1st 36 367 27

2nd Turn 90° Turn 90° Turn 90° 3nd Turn 90° Turn 90° Turn 90°

14 mm (0.55 in.)

head

Areas 1: Bolt 21 214 15 Areas 2: Bolt 21 214 15

Areas 3: Bolt and

Nut

Areas 4: Bolt A 43 438 32

Areas 4: Except

Bolt A

bolt A 10 102 7

except bolt A 21 214 15

bolt A 21 214 15

except bolt A 10 102 7

bolt A 21 214 15

except bolt A 10 102 7

nut 10 104 8

30 306 22

21 214 15

10 102 7

SERVICE SPECIFICATIONS – 2GR-FE ENGINE MECHANICAL

Part Tightened N*m kgf*cm ft.*lbf

Ventilation valve x Cylinder head cover sub-assembly LH 27 275 20 Oil pipe union x Cylinder block sub-assembly 65 663 48 Oil pipe union x Cylinder head cover sub-assembly 65 663 48 Oil pipe x Cylinder head sub-assembly 10 102 7 Crankshaft position sensor x Cylinder block sub-assembly 10 102 7 Camshaft timing oil control valve assembly x Cylinder head cover 10 102 7 Cylinder block water drain cock sub-assembly x Cylinder block sub-

assembly Drain cock sub-assembly x Water inlet housing 30 306 22 Water drain cock plug x Water drain cock sub-assembly 13 130 9 Drain cock plug x Drain cock sub-assembly 13 130 9 Spark plug x Cylinder head sub-assembly 25 254 18 Stud bolt x Cylinder head sub-assembly For A and B bolts 10 102 7

For C bolts 4.0 41 35 in.*lbf W/ head screw plug x Cylinder head sub-assembly 44 449 32 W/ head screw plug No. 2 x Cylinder head sub-assembly 80 816 59 Main bearing cap x Cylinder block sub-assembly 16 pointed head

1st

2nd Turn 90° Turn 90° Turn 90°

14 mm head 52 525 38

Connecting rod cap x Connecting rod 1st 25 255 18

2nd Turn 90° Turn 90° Turn 90°

Stud bolt x Cylinder block sub-assembly bolt A 10 102 7

bolt B 17 173 13

Sub-assembly oil nozzle No. 1 x Cylinder block sub-assembly 9.0 92 80 in.*lbf

25 255 18

61 622 45

SS–21

SERVICE SPECIFICATIONS – 2AZ-FE FUEL

2AZ-FE FUEL

SERVICE DATA

SS–21

Fuel pressure Fuel pressure : at fuel pressure remains for 5 minutes after engine has

stopped Fuel injector Resistance at 20°C (68°F) 11.6 to 12.4 Ω

Injection volume Difference between each injector

Fuel drop 1 drop or less per 12 minutes Fuel pump Resistance at 20°C (68°F) 0.2 to 3.0 Ω

304 to 343 kPa (3.1 to 3.5 kgf/cm

147 kPa (1.5 kgf/cm

76 to 92 cm 16 cm

(0.98 cu in.) or less

, 21 psi) or more

(4.6 to 5.6 cu in.) per 15 seconds

, 44.1 to 49.7 psi)

SS–22

SERVICE SPECIFICATIONS – 2AZ-FE FUEL

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Fuel delivery pipe x Cylinder head 20 204 15 Fuel pressure pulsation damper x Fuel delivery pipe 9.0 90 80 in.*lbf Fuel tank bent tube set plate x Fuel tank assembly 5.9 60 52 in.*lbf Fuel main tube support x Fuel tank assembly 5.4 55 48 in.*lbf Fuel tank band sub-assembly No. 1 x Body 39 400 29 Fuel tank protector lower center x Fuel tank assembly 5.4 55 48 in.*lbf Parking brake cable assembly No. 2 x Body Bolt 6.0 61 53 in.*lbf

Nut 8.5 87 75 in.*lbf

Parking brake cable assembly No. 3 x Body Bolt 6.0 61 53 in.*lbf

Nut 8.5 87 75 in.*lbf

Stabilizer bar bracket x Suspension member 31 316 23

SS–22

SERVICE SPECIFICATIONS – 2GR-FE FUEL

2GR-FE FUEL

SERVICE DATA

Fuel pressure Fuel pressure : at fuel pressure remains for 5 minutes after engine has

stopped Fuel injector Resistance at 20°C (68°F) 11.6 to 12.4 Ω

Injection volume Difference between each injector

Fuel drop 1 drop or less per 16 minutes Fuel pump Resistance at 20°C (68°F) 0.2 to 3.0 Ω

304 to 343 kPa (3.1 to 3.5 kgf/cm

147 kPa (1.5 kgf/cm

84 to 100 cm

16 cm

(0.98 cu in.) or less

, 21 psi) or more

(5.1 to 6.0 cu in.) per 15 seconds

, 44.1 to 49.7 psi)

SERVICE SPECIFICATIONS – 2GR-FE FUEL

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Fuel delivery pipe sub-assembly x Intake manifold 21 214 15 Intake air surge tank x Intake manifold Bolt 18 184 13

Nut 16 163 12 Intake air surge tank x Cylinder head 21 214 15 Vacuum hose clamp set bolt 5.4 55 48 in.*lbf Fuel tank bent tube set plate x Fuel tank assembly 5.9 60 52 in.*lbf Fuel main tube support x Fuel tank assembly 5.4 55 48 in.*lbf Fuel tank band sub-assembly No. 1 x Body 39 400 29 Fuel tank protector lower center x Fuel tank assembly 5.4 55 48 in.*lbf Parking brake cable assembly No. 2 x Body Bolt 6.0 61 53 in.*lbf

Nut 8.5 87 75 in.*lbf Parking brake cable assembly No. 3 x Body Bolt 6.0 61 53 in.*lbf

Nut 8.5 87 75 in.*lbf Stabilizer bar bracket x Suspension member 31 316 23

SS–23

SERVICE SPECIFICATIONS – 2AZ-FE EMISSION CONTROL

2AZ-FE EMISSION CONTROL

SERVICE DATA

VSV for EVAP Resistance 1 - 2 26 to 30 Ω at 20°C (68°F)

1 - Body ground 10 MΩ or higher

2 - Body ground 10 MΩ or higher Air fuel ratio sensor Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) Oxygen sensor Resistance 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F)

SS–23

SS–24

SERVICE SPECIFICATIONS – 2AZ-FE EMISSION CONTROL

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Charcoal canister assembly x Body 39 398 29 Air fuel ratio sensor x Front pipe assembly 44 449 32 Oxygen sensor x Front pipe assembly 44 449 32

SS–24

SERVICE SPECIFICATIONS – 2GR-FE EMISSION CONTROL

2GR-FE EMISSION CONTROL

SERVICE DATA

VSV for EVAP Resistance 1 - 2 26 to 30 Ω at 20°C (68°F)

1 - Body ground 10 MΩ or higher

2 - Body ground 10 MΩ or higher Air fuel ratio sensor Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) Oxygen sensor Resistance 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F)

SERVICE SPECIFICATIONS – 2GR-FE EMISSION CONTROL

TORQUE SPECIFICATIONS

Part Tightened N*m kgf*cm ft.*lbf

Charcoal canister assembly x Body 39 398 29 No. 1 Vacuum switching valve x Head cover 5.0 51 44 in.*lbf Air fuel ratio sensor x Front pipe assembly 44 449 32 Oxygen sensor x Front pipe assembly 44 449 32

SS–25

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Toyota Camry 2007-2009 Service Manual - Service_Specifications

Specifications and Main Features

Frequently Asked Questions

User Manual