Toyota Camry 2007-2009 Service Manual - 2AZ-FE_Engine_Mechanical

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.

EM–2

EM

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

EM

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

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

EM

Timing Mark

Timing Mark

Groove

A098345E09

No. 1 Cylinder TDC/Compression

IN

EX

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

IN

EX

A098171E04

A001082E01

(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.
					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

EM

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)	-	-

EM

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)	-	-

EM

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

3

1

5

9

7

8

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.

EM

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

3

1

5

9

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 N*m (551 kgf*cm, 40 ft.*lbf)
	NOTICE:
	Be careful not to damage the valve lifter.

Hold

A098173E04

	7 Links
Paint Mark	Paint Mark

EM

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)

EM

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

EM

			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, 8)				11 (110, 8)
		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)
N*m (kgf*cm, 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, 8)

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)
N*m (kgf*cm, ft.*lbf) : Specified torque	TIMING CHAIN COVER SUB-ASSEMBLY
Non-reusable part

A134923E01

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

REMOVAL

A112210E01

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

A127550E02

(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.

EM

A114333

SST

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.

A112212

(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

M/T

A060825E02

A138332

(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

EM

A052481

A132571

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.

EM

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

EM

(c) Remove the bolt, chain tensioner plate and spring.

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 N*m (122 kgf*cm, 9 ft.*lbf)
			Bolt

Spring

Chain Tensioner Plate

A090851E03

EM

Groove

A052512E02

(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

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
	Timing Marks		located on the No. 1 and No. 2 bearing caps as
				EM
			shown in the illustration.

Timing Marks

A053018E05

A052505

Timing Mark

(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.

Mark Link

A094576E01

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.

EM

Timing Mark

Timing Mark

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

A125373

A124770

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)