Toyota Camry 2007-2009 Service Manual - 2AZ-FE_Engine_Mechanical
2AZ-FE ENGINE MECHANICAL – ENGINE
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.
(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.
EM–1
EM
DLC3
Intelligent Tester
CAN VIM
DLC3
12345678
91011
12
CG
14 16
13
15
TC
C110200E02
A082779E69
6. INSPECT IGNITION TIMING
(a) Warm up the engine.
(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
HINT:
Refer to the intelligent tester operator's manual
for help when selecting the DATA LIST.
(c) When not using the intelligent tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4
(CG) of the DLC3.
SST 09843-18040
NOTICE:
• Confirm the terminal numbers before
connecting them. Connection with a
wrong terminal can damage the engine.
• Turn off all electrical systems before
connecting the terminals.
• Perform this inspection after the cooling
fan motor is turned off.
EM
EM–2
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.
DLC3
Intelligent Tester
CAN VIM
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.
DLC3
345678
2
1
9101112
TAC
1314
15
2AZ-FE ENGINE MECHANICAL – ENGINE
(c) When not using the intelligent tester:
Check the idle speed.
(1) Using SST, connect the tachometer tester
probe to terminal 9 (TAC) of the DLC3.
SST 09843-18030
(2) Check the idle speed.
Idle speed
16
A082779E70
Item Specified Condition
M/T 650 to 750 rpm
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–3
A001037
(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/ cm
2
, 198 psi)
Minimum pressure:
2
0.98 MPa (10 kgf/ cm
, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/ cm
2
, 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.
EM
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
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:
– Incorrect timing
Normal High Rough idle
Low High
High High
Rough idle
(fluctuating HC reading)
Rough idle
(black smoke from exhaust)
– Fouled, shorted or improperly g apped plugs
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
1. Vacuum leaks:
– PCV hoses
– Intake manifold
– Throttle body
– Brake booster line
2. Lean mixture causing misfire
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
– Faulty pressure regulator
– Defective ECT
– Defective MAF meter
–Faulty ECM
– Faulty injectors
– Faulty throttle po sition sensor
ENGINE2AZ-FE ENGINE MECHANICAL
DRIVE BELT
COMPONENTS
2AZ-FE ENGINE MECHANICAL – DRIVE BELT
V-RIBBED BELT
FRONT FENDER APRON SEAL RH
EM–5
EM
ENGINE UNDER COVER RH
A134946E01
EM
EM–6
SST
REPLACE
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
4. REMOVE V-RIBBED BELT
19 mm
Socket
Wrench
(a) Using SST and 19 mm socket wrench, loosen the V -
ribbed belt tensioner arm clockwise, then remove
the V-ribbed belt.
SST 09216-42010
NOTICE:
• Be sure to connect SST and the tools so that
they are in line during use.
• When retracting the tensioner, turn it
A114351E03
clockwise slowly for 3 seconds or more. Do
not apply force rapidly.
• After the tensioner is fully retracted, do not
apply force any more than necessary.
INSPECTION
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
19 mm
Socket
Wrench
SST
A131418E01
A114351E03
INSTALLATION
1. INSTALL V-RIBBED BELT
(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:
• Be sure to connect SST and the tools so that
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
• 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–7
EM
EM
EM–8
Timing Mark
Timing Mark
2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE
VALVE CLEARANCE
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.
No. 1 Cylinder TDC/Compression
IN
EX
Groove
A098345E09
A098170E04
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
IN
EX
A098171E04
(c) 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
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.
(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.))
EM
A001082E01
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
EM–10
42
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
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
Measured clearance
Installed lifter
thickness
2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE
(g) Valve lifter selection chart (intake).
mm (in.)
EM–11
mm (in.)
5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.210 (0.2051)
5.220 (0.2055)
5.230 (0.2059)
5.240 (0.2063)
5.250 (0.2067)
5.260 (0.2071)
5.270 (0.2075)
5.280 (0.2079)
5.290 (0.2083)
5.300 (0.2087)
5.310 (0.2091)
5.320 (0.2094)
5.330 (0.2098)
5.340 (0.2102)
5.350 (0.2106)
5.360 (0.2110)
5.370 (0.2114)
5.380 (0.2118)
5.390 (0.2122)
5.400 (0.2126)
5.410 (0.2130)
5.420 (0.2134)
5.430 (0.2138)
5.440 (0.2142)
5.450 (0.2146)
5.460 (0.2150)
5.470 (0.2154)
5.480 (0.2157)
5.490 (0.2161)
5.500 (0.2165)
5.510 (0.2169)
5.520 (0.2173)
5.530 (0.2177)
5.540 (0.2181)
5.550 (0.2185)
5.560 (0.2189)
5.570 (0.2193)
5.580 (0.2197)
5.590 (0.2201)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
)
5.740 (0.2260)
0.000 - 0.030 (0.0000 - 0.0012)
0.031 - 0.050 (0.0012 - 0.0020)
18 20 22 24 26 28 3016
12
18 20 22 24 26 28 30
1614
20
1814
16
182022 24 26 28 30 32
2016
22 24 26 28 30 32 34
2018
22 24 26 28 30 32 34
2218 24 26 28 30 32 34 36
2220 24 26 28 30 32 34 36
2420 26 28 30 32 34 36 38
2422 26 28 30 32 34 36 38
2622 28 30 32 34 36 38 40
2624 28 30 32 34 36 38 40
2824 30 32 34 36 38 40 42
2826 30 32 34 36 38 40 42
3026 32 34 36 38 40 42 44
3028 32 34 36 38 40 42 44
3228 34 36 38 40 42 44 46
3230 34 36 38 40 42 44 46
3430 36 38 40 42 44 46 48
3432 36 38 40 42 44 46 48
3632 38 40 42 44 46 48 50
3634 38 40 42 44 46 48 50
3834 40 42 44 46 48 50 52
3836 40 42 44 46 48 50 52
4036 42 44 46 48 50 52 54
40
38 42 44 46 48 50 52 54
4238 44 46 48 50 52 54 56
4240 44 46 48 50 52 54 56
4440 46 48 50 52 54 56 58
4642 48 50 52 54 56 58 60
4844 50 52 54 56 58 60 62
5046 52 54 56 58 60 62 64
5248 54 56 58 60 62 64 66
5450 56 58 60 62 64 66 68
5652 58 60 62 64 66 68 70
5854 60 62 64 66 68 70 72
0.131 - 0.150 (0.0052 - 0.0059)
0.190 - 0.290 (0.0075 - 0.0114)
0.291 - 0.310 (0.0115 - 0.0122)
0.151 - 0.170 (0.0059 - 0.0067)
0.171 - 0.189 (0.0067 - 0.0074)
0.111 - 0.130 (0.0044 - 0.0051)
0.051 - 0.070 (0.0020 - 0.0028)
0.071 - 0.090 (0.0028 - 0.0035)
0.091 - 0.110 (0.0036 - 0.0043)
0806 10
0806 10 12
0806 10 12 14
0806 10 12 14 16
18 200806 10 12 14 16
18 200806 10 12 14 16
18 200806 10 12 14 16
18 20 2208 10 12 14 16
18 20 2208060610 12 14 16
18 20 22 2410 12 14 16
18 20 22 2408 10 12 14 16
18 20 22 241208 2614 16
18 20 22 24 26101012 14 16
18 20 22 24 26 2814 16
18 20 22 24 26 281412 16
22 24 26 28 30 32
0.311 - 0.330 (0.0122 - 0.0130)
0.331 - 0.350 (0.0130 - 0.0138)
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 707274
12
1406 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 707274
160806
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 707274
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 707274
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 707274
22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274
180806 10 12 14 16
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
42 44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
44 46 48 50 52 54 56 58 60 62 64 66 68 707274 74
46 48 50 52 54 56 58 60 62 64 66 68 70
46 48 50 52 54 56 58 60 62 64 66 68 707274 74
48 50 52 54 56 58 60 62 64 66 68 707274 74
48 50 52 54 56 58 60 62 64 66 68 707274 74
50 52 54 56 58 60 62 64 66 68 707274 74
50 52 54 56 58 60 62 64 66 68 707274 74
52 54 56 58 60 62 64 66 68 707274 74
52 54 56 58 60 62 64 66 68 707274 74
54 56 58 60 62 64 66 68 707274 74
54 56 58 60 62 64 66 68 707274 74
56 58 60 62 64 66 68 707274 74
56 58 60 62 64 66 68 707274 74
58 60 62 64 66 68 707274 74
58 60 62 64 66 68 707274 74
60 62 64 66 68 707274 74
60 62 64 66 68 707274 74
62 64 66 68 707274 74
62 64 66 68 707274 74
64 66 68 707274 74
64 66 68 707274 74
66 68 707274 74
66 68 707274 74
68 707274 74
707274 74 74
72
74 74 74
74 74 74
747474
0.431 - 0.450 (0.0170 - 0.0177)
0.351 - 0.370 (0.0138 - 0.0146)
0.391 - 0.410 (0.0154 - 0.0161)
0.451 - 0.470 (0.0178 - 0.0185)
0.471 - 0.490 (0.0185 - 0.0193)
0.411 - 0.430 (0.0162 - 0.0169)
0.371 - 0.390 (0.0146 - 0.0154)
0.571 - 0.590 (0.0225 - 0.0232)
0.531 - 0.550 (0.0209 - 0.0217)
0.551 - 0.570 (0.0217 - 0.0224)
0.511 - 0.530 (0.0201 - 0.0209)
0.491 - 0.510 (0.0193 - 0.0201)
72
74 74
0.691 - 0.710 (0.0272 - 0.0280)
0.611 - 0.630 (0.0241 - 0.0248)
0.651 - 0.670 (0.0256 - 0.0264)
0.591 - 0.610 (0.0233 - 0.0240)
0.631 - 0.650 (0.0248 - 0.0256)
0.751 - 0.770 (0.0296 - 0.0303)
0.671 - 0.690 (0.0264 - 0.0272)
0.711 - 0.730 (0.0280 - 0.0287)
0.731 - 0.750 (0.0288 - 0.0295)
0.771 - 0.790 (0.0304 - 0.0311)
0.831 - 0.850 (0.0327 - 0.0335)
0.811 - 0.830 (0.0319 - 0.0327)
0.791 - 0.810 (0.0311 - 0.0319)
0.851 - 0.870 (0.0335 - 0.0343)
0.871 - 0.890 (0.0343 - 0.0350)
New lifter thickness
Lifter No. Thickness
mm (in.)
06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
Lifter No. Thickness
mm (in.)
Lifter No. Thickness
mm (in.)
0.891 - 0.910 (0.0351 - 0.0358)
0.911 - 0.930 (0.0359 - 0.0366)
EM
A126931E02
EM–12
2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE
EM
Lifter No. Thickness
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) - -
Lifter No. Thickness
mm (in.)
Lifter No. Thickness
mm (in.)
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.
Measured clearance
Measured clearance
Installed lifter
thickness
mm (in.)
2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE
(h) Valve lifter selection chart (exhaust).
mm (in.)
EM–13
Installed lifter thickness
mm (in.)
mm (in.)
5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.210 (0.2051)
5.220 (0.2055)
5.230 (0.2059)
5.240 (0.2063)
5.250 (0.2067)
5.260 (0.2071)
5.270 (0.2075)
5.280 (0.2079)
5.290 (0.2083)
5.300 (0.2087)
5.310 (0.2091)
5.320 (0.2094)
5.330 (0.2098)
5.340 (0.2102)
5.350 (0.2106)
5.360 (0.2110)
5.370 (0.2114)
5.380 (0.2118)
5.390 (0.2122)
5.400 (0.2126)
5.410 (0.2130)
5.420 (0.2134)
5.430 (0.2138)
5.440 (0.2142)
5.450 (0.2146)
5.460 (0.2150)
5.470 (0.2154)
5.480 (0.2157)
5.490 (0.2161)
5.500 (0.2165)
5.510 (0.2169)
5.520 (0.2173)
5.530 (0.2177)
5.540 (0.2181)
5.550 (0.2185)
5.560 (0.2189)
5.570 (0.2193)
5.580 (0.2197)
5.590 (0.2201)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260)
0.000 - 0.030 (0.0000 - 0.0012)
0.031 - 0.050 (0.0012 - 0.0020)
12 14 16 18 20 22 24 26 28 30 32 34 361008
12 14 16 18 20 22 24 26 28 30 32 34 361008
12 14 16 18 20 22 24 26 28 30 32 34 36 3810
10
12 14 16 18 20 22 24 26 28 30 32 34 36 38
12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
34 36 38 40 42 44 46 48 50 52 54 56 58 60 62
36 38 40 42 44 46 48 50 52 54 56 58 60 62 64
38 40 42 44 46 48 50 52 54 56 58 60 62 64 66
40 42 44 46 48 50 52 54 56 58 60 62 64 66 68
42 44 46 48 50 52 54 56 58 60 62 64 66 68 70
44 46 48 50 52 54 56 58 60 62 64 66 68 7270
0.131 - 0.150 (0.0052 - 0.0059)
0.111 - 0.130 (0.0044 - 0.0051)
0.071 - 0.090 (0.0028 - 0.0035)
0.091 - 0.110 (0.0036 - 0.0043)
0.051 - 0.070 (0.0020 - 0.0028)
12 14 16 18 20 22 24 26100806
12 14 16 18 20 22 24 26100806
12 14 16 18 20 22 24 26 28100806
12 14 16 18 20 22 24 26 28100806
12 14 16 18 20 22 24 26 28100806
12 14 16 18 20 22 24 26 283030100806
12 14 16 18 20 22 24 26 28 30 32100806
12 14 16 18 20 22 24 26 28 30 32100806
12 14 16 18 20 22 24 26 28 30 32 34100806
12 14 16 18 20 22 24 26 28 30 32 34100806
0.231 - 0.250 (0.0091 - 0.0098)
0.151 - 0.170 (0.0059 - 0.0067)
0.211 - 0.230 (0.0083 - 0.0091)
0.251 - 0.270 (0.0099 - 0.0106)
0.191 - 0.210 (0.0075 - 0.0083)
0.171 - 0.190 (0.0067 - 0.0075)
12 14 16 18 20 22
100806
12 14 16 18 20 22100806
12 14 16 18 20 22 24100806
12 14 16 18 20 22 24100806
0.271 - 0.290 (0.0107 - 0.0114)
06 08 10
12 14100806
12 14 16100806
12 14 16 18100806
12 14 16 18 20100806
12 14 16 18 20100806
0.481 - 0.500 (0.0189 - 0.0197)
0.291 - 0.299 (0.0115 - 0.0118)
06 14 16 18
12100806
0.461 - 0.480 (0.0181 - 0.0189)
0.300 - 0.400 (0.0118 - 0.0157)
0.441 - 0.460 (0.0174 - 0.0181)
0.401 - 0.420 (0.0158 - 0.0165)
160806
18
20
22
24
26
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
7474
74
0.501 - 0.520 (0.0197 - 0.0205)
0.421 - 0.440 (0.0166 - 0.0173)
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
70686664
747474727068
7474747270
74747472
747474
7474
0.561 - 0.580 (0.0221 - 0.0228)
0.641 - 0.660 (0.0252 - 0.0260)
0.681 - 0.700 (0.0268 - 0.0276)
0.621 - 0.640 (0.0244 - 0.0252)
0.601 - 0.620 (0.0237 - 0.0244)
0.541 - 0.560 (0.0213 - 0.0220)
0.521 - 0.540 (0.0205 - 0.0213)
0.581 - 0.600 (0.0229 - 0.0236)
32 34 36 38 40
28 30
54525048464442403836
60585654525048464442
74747472706866646260585654
747474727068666462605856
747474727068666462605856
7474747270686664626058
7474747270686664626058
74747472706866646260
74747472706866646260
747474727068666462
747474727068666462
74747472
7474747270686664
74747472706866
0.721 - 0.740 (0.0284 - 0.0291)
0.741 - 0.760 (0.0292 - 0.0299)
0.661 - 0.680 (0.0260 - 0.0268)
0.701 - 0.720 (0.0276 - 0.0283)
42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 7474
747474727068666462605856545250484644
7474747270686664626058565452504846
7474747270686664626058565452504846
7474
7472706866646260585654525048
74747472706866646260585654525048
747474727068666462605856545250
747474727068666462605856545250
7474747270686664626058565452
7474747270686664626058565452
74747472706866646260585654
0.881 - 0.900 (0.0347 - 0.0354)
0.861 - 0.880 (0.0339 - 0.0346)
0.821 - 0.840 (0.0323 - 0.0331)
0.801 - 0.820 (0.0315 - 0.0323)
0.761 - 0.780 (0.0300 - 0.0307)
0.781 - 0.800 (0.0307 - 0.0315)
6260585654525048464442403836343230282624
727068666462605856545250484644424038363432
7474747270686664626058565452504846444240383634
74747472706866646260585654525048464442403836
747474727068666462605856
747474727068666462605856545250484644424038
747474727068666462605856545250484644424038
7474747270686664626058565452504846444240
7474747270686664626058565452504846444240
747474727068666462
74747472706866646260585654525048464442
747474727068666462605856545250484644
0.921 - 0.940 (0.0363 - 0.0370)
0.841 - 0.860 (0.0331 - 0.0339)
0.901 - 0.920 (0.0355 - 0.0362)
0.941 - 0.960 (0.0370 - 0.0378)
7474747270686664
747474727068666462605856545250484644424038363432302826
7474747270686664626058565452504846444240383634323028
7474747270686664626058565452504846444240383634323028
7474
747270686664626058565452504846444240383634323028
74747472706866646260585654525048464442403836343230
74747472706866646260585654525048464442403836343230
747474727068666462605856545250484644424038363432
747474
7474747270686664626058565452504846444240383634
0.961 - 0.980 (0.0378 - 0.0386)
)
New lifter thickness
Lifter No. Thickness
mm (in.)
06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
Lifter No. Thickness
mm (in.)
Lifter No. Thickness
mm (in.)
0.981 - 1.000 (0.0386 - 0.0394)
1.061 - 1.080 (0.0418 - 0.0425)
1.001 - 1.020 (0.0394 - 0.0402)
1.021 - 1.040 (0.0402 - 0.0409)
1.041 - 1.060 (0.0410 - 0.0417)
74
74747472706866646260585654525048464442403836343230282624222018
747474727068666462605856545250484644424038363432302826242220
7474747270686664626058565452504846444240383634323028262422
A114356E01
EM
EM–14
2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE
EM
Lifter No. Thickness
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) - -
Lifter No. Thickness
mm (in.)
Lifter No. Thickness
mm (in.)
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.
Paint Mark
Timing Mark
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
gear with the paint mark aligned with the timing
mark on the camshaft timing gear as shown in the
illustration.
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
No. 1
7
8
2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE
315 9
426
10
A098177E06
EM–15
(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
9.0 N*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.
Timing Mark
Paint Mark
(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
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.
7
8
No. 2
A098174E05
3
159
(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
4
26
10
A098174E07
9.0 N*m (92 kgf*cm, 80 in.*lbf)
EM–16
Paint Mark
Tighten
7 Links
2AZ-FE ENGINE MECHANICAL – VALVE CLEARANCE
(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)
NOTICE:
Be careful not to damage the valve lifter.
Hold
A098173E04
(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
Paint Mark
crankshaft pulley groove is aligned with the timing
mark "0" of the timing chain cover.
EM
Timing Mark Timing Mark
Groove
A098180E04
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 EM-
33)
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
ENGINE2AZ-FE ENGINE MECHANICAL
TIMING CHAIN
COMPONENTS
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
EM–17
64 (653, 47)
52 (531, 38)
64 (653, 47)
NO. 2 ENGINE MOUNTING STAY RH
V-RIBBED BELT
9.8 (100, 87 in.*lbf)
52 (531, 38)
21 (214, 15)
NO. 2 ENGINE MOUNTING BRACKET RH
9.0 (92, 80 in.*lbf)
EM
NO. 1 ENGINE COVER SUB-ASSEMBLY
GENERATOR ASSEMBLY
N*m (kgf*cm, ft.*lbf)
: Specified torque
FRONT FENDER APRON SEAL RH
A134948E01
EM
EM–18
43 (439, 32)
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
VANE PUMP ASSEMBLY
EXHAUST PIPE GASKET
62 (633, 46)
FRONT EXHAUST PIPE NO. 1
SUPPORT BRACKET
33 (337, 24)
33 (337, 24)
ENGINE UNDER COVER RH
FRONT EXHAUST
PIPE ASSEMBLY
56 (571, 41)
EXHAUST PIPE GASKET
REAR EXHAUST PIPE NO. 1
SUPPORT BRACKET
N*m (kgf*cm, ft.*lbf)
: Specified torque
ENGINE UNDER COVER LH
Non-reusable part
A134947E01
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
14 (143, 10)
EM–19
9.0 (92, 80 in.*lbf)
IGNITION COIL ASSEMBLY
14 (143, 10)
11 (110, 8)
CYLINDER HEAD COVER SUB-ASSEMBLY
CYLINDER HEAD COVER GASKET
x6
11 (110, 8)
x2
EM
TMMK: 170 (1,733, 125)
TMC: 180 (1,835, 133)
N*m (kgf*cm, ft.*lbf)
CRANKSHAFT PULLEY
25 (255, 18)
OIL PAN DRAIN PLUG
: Specified torque
GASKET
Non-reusable part
9.0 (92, 80 in.*lbf)
x2
9.0 (92, 80 in.*lbf)
CRANK POSITION
SENSOR
OIL PAN SUB-ASSEMBLY
9.0 (92, 80 in.*lbf)
x12
A134922E01
EM–20
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
EM
CHAIN SUB-ASSEMBLY
CHAIN TENSIONER
SLIPPER
19 (194, 14)
NO. 1 CRANKSHAFT
POSITION SENSOR
PLATE
9.0 (92, 80 in.*lbf)
NO. 1 CHAIN VIBRATION DAMPER
CRANKSHAFT TIMING SPROCKET
NO. 2 CHAIN SUB-ASSEMBLY
OIL PUMP DRIVE SPROCKET
SPRING
CHAIN TENSIONER
12 (122, 9.0)
30 (301, 22)
OIL PUMP DRIVEN SPROCKET
V-RIBBED BELT
TENSIONER
ASSEMBLY
60 (607, 44)
TIMING CHAIN GUIDE
9.0 (92, 80 in.*lbf)
GASKET
TIMING CHAIN CASE OIL SEAL
NO. 1 CHAIN TENSIONER
ASSEMBLY
55 (561, 41)
22 (220, 16)
STUD BOLT
9.0 (92, 80 in.*lbf)
11 (112, 8)
x4
x8
25 (255, 18)
N*m (kgf*cm, ft.*lbf)
Non-reusable part
: Specified torque
TIMING CHAIN COVER SUB-ASSEMBLY
A134923E01
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
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.
9. REMOVE NO. 2 ENGINE MOUNTING STAY RH (See
page EM-95)
10. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95)
EM–21
EM
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.
A112210E01
EM
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 ES-
411)
A127550E02
22. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 12 bolts and 2 nuts.
A114333
SST
No. 1 Engine Hanger
SST
A000019E05
A098348E01
No. 2 Engine Hanger
A052507E05
(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 conta ct 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.
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
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.
A112212
26. REMOVE ENGINE MOUNTING INSULATOR
(a) Attach the engine chain hoist to the engine hangers.
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.
EM–23
EM
M/T
A059880
(c) M/T:
Remove the bolt and disconnect the engine lateral
control rod.
A060825E02
(d) Remove the 2 bolts and disconnect the steering
gear return tube clamps from the frame.
A138332
EM
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)
A052481
A132571
A125372
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.
32. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and chain vibration damper.
A125371
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
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
EM–25
EM
90°
35. REMOVE CRANKSHAFT TIMING SPROCKET
(a) Remove the crankshaft timing sprocket.
A125374
36. REMOVE NO. 2 CHAIN SUB-ASSEMBLY
(a) Turn the crankshaf t 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
EM–26
Groove
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.
A098352E01
(c) Remove the bolt, chain tensioner plate and spring.
Bolt
Spring
Chain Tensioner Plate
B011415E03
A063847
(d) Remove the chain tensioner, oil pump driven
sprocket and chain.
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
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-
140)
8. INSPECT NO. 1 CHAIN TENSIONER (See page EM-
140)
INSTALLATION
EM–27
EM
Mark Link
Timing Mark
Oil Pump Drive
Shaft Sprocket
Mark Link
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
(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) T emporarily tighten the oil pump drive shaf t sprocket
with the nut.
Oil Pump
Drive Sprocket
Timing Mark
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 N*m (122 kgf*cm, 9 ft.*lbf)
Bolt
Spring
Chain Tensioner Plate
A090851E03
EM
(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)
Groove
A052512E02
(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
Timing Marks
A132570
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
located on the No. 1 and No. 2 bearing caps as
shown in the illustration.
EM–29
EM
Timing Marks
Timing Mark
Mark Link
A053018E05
(2) Using the crankshaft pulley bolt, turn the
crankshaft to position with the key on the
crankshaft upward.
A052505
(b) Install the chain onto the crankshaft timing sprocket
with the gold or pink mark link aligned with the
timing mark on the crankshaft.
A094576E01
EM–30
SST
2AZ-FE ENGINE MECHANICAL – TIMING CHAIN
(c) Using SST and a hammer, tap in the crankshaft
timing sprocket.
SST 09309-37010
A098369E01
EM
Mark Link
Timing Mark
Hold
(d) Align the gold or yellow link with each timing mark
located on the camshaft timing gear and sprocket,
then install the chain.
Timing Mark
A098370E01
5. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N*m (194 kgf*cm, 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)
A125373
A124770
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)
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