toyota Probox (2012) Workshop manual

1NZ-FE ENGINE MECHANICAL – ENGINE

ENGINE

ON-VEHICLE INSPECTION

1. INSPECT ENGINE COOLANT (See page CO-1)

2. INSPECT ENGINE OIL (See page LU-1)

3. INSPECT BATTERY (See page CH-4)

4. INSPECT AIR CLEANER FILTER ELEMENT SUB­ASSEMBLY

(a) Remove the air cleaner filter element sub-assembly.
(b) Visually check that there is no dirt, blockage, 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.

5. INSPECT SPARK PLUG (See page IG-5)

EM–1

EM

DLC3

CAN VIM

Intelligent Tester

A125658E01

6. INSPECT IGNITION TIMING

(a) When using an intelligent tester:

(1) Warm up and stop the engine.

(2) Connect the intelligent tester to the DLC3.
(3) Turn the ignition switch ON.
(4) Select the following menu items:

DIAGNOSIS / ENHANCED OBD II/ ACTIVE
TEST / TC (TE1) / ON.
HINT:
Refer to the intelligent tester operator's manual
for further details.

(5) Inspect the ignition timing during idling.

Ignition timing:

8 to 12 degrees BTDC

NOTICE:

• Turn all the electrical systems and the A/
C off.

• Inspect the ignition timing with the
cooling fan off.

• When checking the ignition timing, shift
the transmission to the neutral position.

(6) Select the following menu items: TC (TE1) /

OFF.
(7) Turn the ignition switch OFF.
(8) Disconnect the intelligent tester from the DLC3.

(b) When not using an intelligent tester:

(1) Remove cylinder head cover No. 2 (see page

IG-9).

EM

EM–2

DLC3

CG

8

2

34

1

910111213141516

6

5

7

TC

1NZ-FE ENGINE MECHANICAL – ENGINE

(2) Pull out the wire harness (brown) shown in the

illustration.

NOTICE:
After checking, wrap the wire harness with
tape.

(3) Warm up and stop the engine.
(4) Connect the clip of the timing light to the wire

harness.

NOTICE:

A116196

Use a timing light that detects the first
signal.

(5) Turn the ignition switch ON.

(6) Using SST, connect terminals 13 (TC) and 4

(CG) of the DLC3.

SST 09843-18040
NOTICE:
Examine the terminal numbers before
connecting them. Connecting the wrong
terminals could damage the engine.

(7) Inspect the ignition timing during idling.

Ignition timing:

A082779E23

8 to 12 degrees BTDC

NOTICE:

• Turn all the electrical systems and the A/
C off.

• Inspect the ignition timing with the
cooling fan off.

• When checking the ignition timing, shift
the transmission to the neutral position.

(8) Disconnect terminals 13 (TC) and 4 (CG) of the

DLC3.
(9) Turn the ignition switch OFF.
(10) Remove the timing light.
(11) Install cylinder head cover No. 2 (see page IG-

10).

DLC3

CAN VIM

Intelligent Tester

A125658E01

7. INSPECT ENGINE IDLING SPEED

(a) When using an intelligent tester:

(1) Warm up and stop the engine.

(2) Connect the intelligent tester to the DLC3.
(3) Turn the ignition switch ON.
(4) Select the following menu items:

DIAGNOSIS / ENHANCED OBD II/ DATA LIST

/ PRIMARY / ENGINE SPD.

HINT:

Refer to the intelligent tester operator's manual

for further details.
(5) Inspect the engine idling speed.

Idling speed:

550 to 650 rpm for manual transaxle
650 to 750 rpm for automatic transaxle

NOTICE:

• Turn all the electrical systems and the A/
C off.

DLC3

12

34 5 67

910111213141516

TAC

1NZ-FE ENGINE MECHANICAL – ENGINE

• Inspect the idling speed with the cooling
fan off.

• When checking the idling speed, shift the
transmission to either the neutral
position or the parking position.

(6) Turn the ignition switch OFF.
(7) Disconnect the intelligent tester from the DLC3.

(b) When not using an intelligent tester.

(1) Warm up and stop the engine.

(2) Install SST to terminal 9 (TAC) of the DLC3,

then connect a tachometer.

SST 09843-18040
NOTICE:
Examine the terminal numbers before

8

connecting them. Connecting the wrong
terminals could damage the engine.

(3) Turn the ignition switch ON.
(4) Inspect the engine idling speed.

A082779E24

Idling speed:

550 to 650 rpm for manual transaxle
650 to 750 rpm for automatic transaxle

(5) Turn the ignition switch OFF.
(6) Disconnect the tachometer.
(7) Remove SST from terminal 9 (TAC).

EM–3

EM

A116195

8. INSPECT COMPRESSION

(a) Warm up and stop the engine.
(b) Remove cylinder head cover No. 2 (see page IG-9).
(c) Remove the 4 ignition coils (see page IG-9).
(d) Remove the 4 spark plugs.
(e) Disconnect the 4 fuel injector connectors.

(f) Inspect 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:

1,471kPa (15.0 kgf/cm

2

, 213 psi)

Minimum pressure:

2

1,079 kPa (11.0 kgf/cm

, 156 psi)

Difference between each cylinder:

2

98 kPa (1.0 kgf/cm

, 14 psi) or less

NOTICE:

• Use a fully-charged battery so the engine
speed can be increased to 250 rpm or
more.

• Inspect the other cylinders in the same
way.

• Measure the compression in as short a
time as possible.

EM

EM–4

1NZ-FE ENGINE MECHANICAL – ENGINE

(4) If the cylinder compression is low, pour a light

coat of engine oil into the cylinder through the
spark plug hole, then inspect it again.
HINT:

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

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

(g) Connect the 4 fuel injector connectors.
(h) Install the 4 spark plugs.

Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

(i) Install the 4 ignition coils (see page IG-9).
(j) Install cylinder head cover No. 2 (see page IG-10).

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 while idling.

(d) Check the CO/HC concentration during idling and

when running at 2,500 rpm.
HINT:
When doing the 2 mode (with the engine idling/
running at 2,500 rpm) test, the measuring
procedures are determined by applicable local
regulations.
If the CO/HC concentration does not comply with
the regulations, troubleshoot in the order given
below.
(1) Check the heated oxygen sensor operation

(see page ES-276).

(2) See the table below for possible causes, then

inspect the applicable parts and repair them if
necessary.

CO HC Problems Possible Causes

Normal High Rough idling 1. Faulty ignition:

Low High Rough idling

(Fluctuating HC reading)

High High Rough idling

(Black smoke from exhaust)

– Incorrect timing
– Fouled, shorted or improperly gapped plugs

2. Incorrect valve clearance

3. Leakage from intake and exhaust valves

4. Leakage from cylinders

1. Vacuum leaks:
– PCV hoses
– Intake manifold
– Throttle body
– Brake booster line

2. Lean mixture causing misfire

1. Restricted air cleaner filter element

2. Plugged PCV valve

3. Faulty EFI systems:
– Faulty pressure regulator
– Faulty engine coolant temperature sensor
– Faulty mass air flow meter
–Faulty ECM
– Faulty injectors
– Throttle body

ENGINE1NZ-FE ENGINE MECHANICAL

DRIVE BELT

COMPONENTS

1NZ-FE ENGINE MECHANICAL – DRIVE BELT

EM–5

EM

5.0 (51, 44 in.*lbf)

N*m (kgf*cm, ft.*lbf)

ENGINE UNDER COVER RH

: Specified torque

A115143E01

EM

EM–6

1NZ-FE ENGINE MECHANICAL – DRIVE BELT

FAN AND GENERATOR V BELT

N*m (kgf*cm, ft.*lbf)

19 (189, 14)

54 (551, 40)

: Specified torque

A116199E01

1NZ-FE ENGINE MECHANICAL – DRIVE BELT

REMOVAL

1. REMOVE ENGINE UNDER COVER RH

2. REMOVE FAN AND GENERATOR V BELT

(a) Loosen bolts A and B.

A

(b) Release the fan and generator V belt tension and

remove the fan and generator V belt.

EM–7

B

A116197E01

INSPECTION

EM

B000543

1. INSPECT FAN AND GENERATOR V BELT

(a) Visually check the belt for excessive wear, frayed

cords etc. If any defects are found, replace the belt.
HINT:

• If any defects are found, replace the belt.

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

EM

EM–8

OK

1NZ-FE ENGINE MECHANICAL – DRIVE BELT

INSTALLATION

1. INSTALL FAN AND GENERATOR V BELT

(a) Provisionally install the fan and generator V belt

onto each pulley.

NOTICE:
Make sure that the V-belt is securely fitted into
the rib groove of the pulley.

2. ADJUST FAN AND GENERATOR V BELT

NG

A116198E01

A

(a) Insert an adjusting bar between the engine

mounting bracket and generator assembly. Push the
adjusting bar toward the vehicle front to adjust the
generator V belt tension.

NOTICE:
Do not insert the adjusting bar between the
camshaft timing oil control valve assembly and
generator assembly. It could damage the
camshaft timing oil control valve assembly.

(b) First tighten bolt A, then tighten bolt B.

Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) for bolt A

54 N*m (551 kgf*cm, 40 ft.*lbf) for bolt B

w/o Air Conditioner

w/ Air Conditioner

B

A116197E01

3. INSPECT FAN AND GENERATOR V BELT

(a) Check the V belt deflection and tension.

Deflection

Item Specified Condition

New belt 7.0 to 8.5 mm (0.28 to 0.33 in)

Used belt 11 to 13 mm (0.43 to 0.51 in)

Tension

Item Specified Condition

New belt 539 to 637 N (55 to 65 kg, 121 to 143 ld)

Used belt 245 to 392 N (25 to 40 kg, 55 to 88 ld)

If the belt deflection is not as specified, adjust it.
HINT:

• Check the V belt deflection at the specified point.

• Check the drive belt deflection at the specified
point.

• When installing a new belt, set its tension to the
specified value.

• When inspecting a belt which has been used for

A116200E01

over 5 minutes, apply the used belt
specifications.

1NZ-FE ENGINE MECHANICAL – DRIVE BELT

• When reinstalling a belt which has been used for
over 5 minutes, adjust its deflection and tension
to the intermediate values of each used belt
specification.

• V-ribbed belt tension and deflection should be
checked after 2 revolutions of engine cranking.

• When using a belt tension gauge, confirm its
accuracy by using a master gauge first.

4. INSTALL ENGINE UNDER COVER RH

EM–9

EM

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

VALVE CLEARANCE

ADJUSTMENT

1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL

2. REMOVE ENGINE UNDER COVER RH

3. REMOVE CYLINDER HEAD COVER NO. 2 (See page

IG-9)

4. REMOVE IGNITION COIL NO. 1 (See page IG-9)

5. DISCONNECT VENTILATION HOSE (See page FU-13)

6. DISCONNECT VENTILATION HOSE NO. 2 (See page

FU-13)

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page FU-13)

8. INSPECT VALVE CLEARANCE

HINT:
Inspect the valve clearance when the engine is cold.

EM–9

EM

Timing Marks

(a) Set the No. 1 cylinder to TDC/compression.

(1) Turn the crankshaft damper and align its timing

notch with the timing mark "0" of the oil pump.

Timing Notch

A116203E01

(2) Check that both timing marks on the camshaft

timing sprocket and camshaft timing gear are
facing upward, as shown in the illustration.
HINT:
If not, turn the crankshaft 1 complete revolution
(360°) and align the marks as above.

A116204E01

(b) Check the valves indicated in the illustration.

(1) Using a feeler gauge, measure the clearance

between the valve lifter and camshaft.

Valve clearance (cold):

for intake:

0.15 to 0.25 mm (0.006 to 0.010 in.)

for exhaust:

0.25 to 0.35 mm (0.010 to 0.014 in.)

A116201

EM

EM–10

Matchmark

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

(2) Record any out-of-specification valve clearance

measurements. They will be used later to
determine the required replacement adjusting
shim.

(c) Turn the crankshaft 1 complete revolution (360°)

and align its timing notch with the timing mark "0" of
the oil pump.

(d) Check the valves indicated in the illustration.

(1) Using a feeler gauge, measure the clearance

between the valve lifter and camshaft.

Valve clearance (cold):

for intake:

0.15 to 0.25 mm (0.006 to 0.010 in.)

for exhaust:

0.25 to0.35 mm (0.010 to 0.014 in.)

(2) Record any out-of-specification valve clearance

A116202

measurements. They will be used later to
determine the required replacement adjusting
shim.

9. ADJUST VALVE CLEARANCE
NOTICE:
When rotating the camshaft with the timing chain
removed, rotate the crankshaft damper
counterclockwise 40° from the TDC and align its
timing notch with the matchmark of the timing chain
cover to prevent the pistons from coming into
contact with the valves.

(a) Remove the fan and generator V belt (See page

A116206E01

EM-7).

(b) Remove the engine mounting insulator sub-

assembly RH (See page LU-17).

Timing Marks

(c) Set the No. 1 cylinder to TDC/compression.

(1) Turn the crankshaft damper and align its timing

notch with the timing mark "0" of the oil pump.

Timing Notch

A116203E01

(2) Check that both timing marks on the camshaft

timing sprocket and camshaft timing gear are
facing upward, as shown in the illustration.
HINT:
If not, turn the crankshaft 1 complete revolution
(360°) and align the marks as above.

A116204E01

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

EM–11

Timing Marks

Paint Marks

A116207E01

G100163

(d) Place paint marks on the chain in the places where

the timing marks of the camshaft timing sprocket
and the camshaft timing gear are located.

(e) Using an 8 mm hexagon wrench, remove the screw

plug.

EM

(f) Insert a screwdriver into the service hole in the

chain tensioner to pull the stopper plate of the chain
tensioner upward.

Plunger

Stopper Plate

A116209E01

(g) Using a wrench, rotate camshaft No. 2 clockwise to

push in the plunger of the chain tensioner.

A116210E01

EM–12

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

(h) Remove the screwdriver from the service hole, then

align the hole in the stopper plate with the service
hole and insert a 3 mm (0.12 in.) diameter bar into
the holes to hold the stopper plate.
HINT:

• Fix the stopper plate using the bar while rotating
the camshaft right and left slightly.

• Hold the bar with tape so that the bar does not
come off.

EM

12345

A116212

(i) Using a wrench, hold the hexagonal lobe of

camshaft No. 2 and remove the fringe bolt.

A116213

(j) Using several steps, loosen and remove the 11

bearing cap bolts uniformly in the sequence shown
in the illustration, then remove camshaft bearing
cap No. 1 and camshaft bearing cap No. 2.

NOTICE:
Loosen each bolt uniformly while keeping the
camshaft level.

A116214E01

A116215

(k) Remove the fringe bolt and remove the camshaft

timing sprocket.

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

24 31

A116216

A116217E01

(l) Remove camshaft No. 2.

(m) Using several steps, loosen and remove the 8

bearing cap bolts uniformly in the sequence shown
in the illustration, then remove camshaft bearing
cap No. 2.

NOTICE:
Loosen each bolt uniformly while keeping the
camshaft level.

EM–13

EM

A116218

A035227E01

(n) Hold the chain by hand and remove the camshaft

and the camshaft timing gear assembly.

(o) Tie the chain with a piece of string as shown in the

illustration.

(p) Remove the 16 valve lifters.

(q) Using a micrometer, measure the thickness of the

removed lifter.

(r) Calculate the thickness of a new lifter so that the

valve clearance comes to within the specified
values.

A001082

A Thickness of new lifter

B Thickness of used lifter

C Measured valve clearance

EM

EM–14

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

Valve clearance:

Intake A = B + (C - 0.20 mm (0.008 in.))
Exhaust A = B + (C - 0.30 mm (0.012 in.))

(s) Select a new lifter with a thickness as close to the

calculated values as possible.
HINT:
Lifters are available in 35 sizes in increments of

0.020mm (0.0008 in.), from 5.060 mm (0.1992 in.)

to 5.740 mm (0.2260 in.).

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

EM–15

EM

A117457

EM

EM–16

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

Intake valve clearance (cold):

0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE:

A 5.250 mm (0.2067 in.) lifter is installed, and
the measured clearance is 0.400 mm (0.0158
in.). Replace the 5.250 mm (0.2067 in.) lifter
with a new No. 46 lifter.

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness

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

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)

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

EM–17

EM

A117458

EM

EM–18

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE:

A 5.340 mm (0.2102 in.) lifter is installed, and
the measured clearance is 0.440 mm (0.0173
in.). Replace the 5.340 mm (0.2102 in.) lifter
with a new No. 48 lifter.

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness

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

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)

Paint Mark

(t) Install the selected valve lifter.
(u) Apply a light coat of engine oil to the camshaft and

camshaft journals.

(v) Install the chain onto the camshaft timing gear with

the paint mark and the timing mark aligned as
shown in the illustration.

Timing Mark

A116220E01

(w) Examine the front marks and the numbers on

camshaft bearing cap No. 2 and check that the
sequence is as shown in the illustration. Then
uniformly tighten the bolts in several steps in the
sequence shown in the illustration.

Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf)
NOTICE:
Tighten each bolt uniformly while keeping the
camshaft level.

31 24

A116222E01

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

(x) Install camshaft No. 2.

A116216

EM–19

Paint Mark

Timing Mark

5

Pin

A116224E01

A116215

31 2 4

Bearing Cap No. 2Bearing Cap No. 1

(y) Hold the chain, and align the timing mark on the

camshaft timing sprocket with the paint mark of the
chain.

(z) Align the alignment pin hole in the camshaft timing

sprocket with the alignment pin of the camshaft, and
install the sprocket onto the camshaft.

(aa) Provisionally install the flange bolt.

(ab) Examine the front marks and the numbers of

camshaft bearing cap No. 1 and camshaft bearing
cap No. 2 and check that the sequence is as shown
in the illustration. Then uniformly tighten the bolts in
several steps, in the sequence shown in the
illustration.

Torque: for bearing cap No. 2

13 N*m (129 kgf*cm, 9.4 ft.*lbf)
for bearing cap No. 1

23 N*m (235 kgf*cm, 17 ft.*lbf)
NOTICE:
Tighten each bolt uniformly while keeping the
camshaft level.

EM

A116223E01

EM

EM–20

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

(ac) Using a wrench, hold the hexagonal lobe of

camshaft No. 2 and install the flange bolt.

Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
SST 09023-38400

(ad) Remove the bar from the timing chain tensioner.

SST

A116225E01

(ae) Turn the crankshaft damper and align its timing

notch with the timing mark "0" of the oil pump.

Timing Marks

Timing Notch

Paint Marks

A116203E01

A116207E01

G100163

(af) Check that all the pairs of timing marks are aligned.
(ag) Apply adhesive to the 2 or 3 threads of the screw

plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent

(ah) Using an 8 mm hexagon wrench, install the screw

plug.

Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

(ai) Install the engine mounting insulator sub-assembly

RH (See page LU-26). (for Hatchback)

(aj) Install the engine mounting insulator sub-assembly

RH (See page LU-26). (for Sedan)

(ak) Install the fan and generator V belt (See page EM-

7).

(al) Adjust the fan and generator V belt (See page EM-

7).

(am)Inspect the fan and generator V belt (See page EM-

8).

10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page FU-19)

11. CONNECT VENTILATION HOSE NO. 2 (See page FU-

20)

12. CONNECT VENTILATION HOSE (See page FU-20)

13. INSTALL IGNITION COIL NO. 1 (See page IG-9)

1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

14. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

15. CHECK FOR ENGINE OIL LEAKAGE

16. INSTALL CYLINDER HEAD COVER NO. 2 (See page

IG-10)

17. INSTALL ENGINE UNDER COVER RH

EM–21

EM

EM

EM–22

ENGINE1NZ-FE ENGINE MECHANICAL

TIMING CHAIN

COMPONENTS

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

5.0 (51, 44 in.*lbf)

N*m (kgf*cm, ft.*lbf)

ENGINE UNDER COVER RH

: Specified torque

A115143E01

7.0 (71, 62 in.*lbf)

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

7.0 (71, 62 in.*lbf)

CYLINDER HEAD COVER NO. 2

EM–23

EM

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115136E01

EM

EM–24

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

FAN AND GENERATOR V BELT

N*m (kgf*cm, ft.*lbf)

19 (189, 14)

54 (551, 40)

: Specified torque

A116199E01

for Hatchback:

11 (112, 8.1)

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM–25

54 (551, 40)

19 (189, 14)

9.8 (100, 7.2)

FAN BELT ADJUSTING BAR

GENERATOR
ASSEMBLY

45 (459, 33)

ENGINE MOUNTING INSULATOR
SUB-ASSEMBLY RH

52 (530, 38)

x2

EM

x3

52 (530, 38)

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

A116193E06

EM–26

for Sedan:

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

11 (112, 8.1)

EM

54 (551, 40)

19 (189, 14)

9.8 (100, 7.2)

FAN BELT ADJUSTING BAR

GENERATOR
ASSEMBLY

52 (530, 38)

ENGINE MOUNTING INSULATOR
SUB-ASSEMBLY RH

52 (530, 38)

x2

x3

52 (530, 38)

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

A133594E01

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

9.0 (92, 80 in.*lbf)

IGNITION COIL NO. 1

EM–27

EM

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115486E01

EM

EM–28

WIRE HARNESS BRACKET

10 (102, 7.0)

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

13 (133, 9.6)

10 (102, 7.0)

SEAL WASHER

x7

10 (102, 7.0)

10 (102, 7.0)

CYLINDER HEAD COVER
SUB-ASSEMBLY

VENTILATION HOSE NO. 2

VENTILATION HOSE

CYLINDER HEAD COVER GASKET

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115504E01

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM–29

EM

x3

15 (153, 11)

11 (112, 8.1)

x2

WATER PUMP PULLEY

x3

11 (112, 8.1)

GASKET

WATER PUMP ASSEMBLY

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

Non-reusable part

A116194E01

EM–30

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM

O-RING

CAMSHAFT TIMING OIL
CONTROL VALVE ASSEMBLY

7.5 (76, 66 in.*lbf)

11 (112, 8.1)

19 (189, 14)

FAN BELT
ADJUSTING BAR

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

Non-reusable part

A116180E01

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET

55 (561, 41)

24 (245, 18)

x4

EM–31

EM

32 (326, 24)

24 (245, 18)

x2

x11

11 (112, 8.1)

7.5 (76, 66 in.*lbf)

11 (112, 8.1)

CRANKSHAFT
POSITION SENSOR

128 (1305, 95)

OIL PUMP SEAL

CRANKSHAFT DAMPER SUB-ASSEMBLY

CRANKSHAFT STRAIGHT PIN

OIL PUMP ASSEMBLY

N*m (kgf*cm, ft.*lbf)

Non-reusable part

O-RING

: Specified torque

Apply MP grease

A116559E01

EM

EM–32

9.0 (92, 80 in.*lbf)

CHAIN SUB-ASSEMBLY

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

CHAIN TENSIONER ASSEMBLY NO. 1

CHAIN TENSIONER
SLIPPER

9.0 (92, 80 in.*lbf)

N*m (kgf*cm, ft.*lbf)

CHAIN VIBRATION DAMPER NO. 1

: Specified torque

A116579E01

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL

2. REMOVE FRONT WHEEL RH

3. REMOVE ENGINE UNDER COVER RH

4. DRAIN ENGINE OIL

5. DRAIN ENGINE COOLANT (See page CO-8)

6. REMOVE CYLINDER HEAD COVER NO. 2 (See page

IG-9)

7. REMOVE FAN AND GENERATOR V BELT (See page

EM-7)

EM–33

8. REMOVE GENERATOR ASSEMBLY (See page CH-10)

9. REMOVE IGNITION COIL NO. 1 (See page IG-9)

10. DISCONNECT VENTILATION HOSE (See page FU-13)

11. DISCONNECT VENTILATION HOSE NO. 2 (See page

FU-13)

12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page FU-13)

13. REMOVE ENGINE MOUNTING INSULATOR SUB­ASSEMBLY RH (See page LU-17)

14. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY
(See page LU-18)

15. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-403)

16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-396)

17. REMOVE WATER PUMP PULLEY (See page CO-15)

18. REMOVE WATER PUMP ASSEMBLY (See page CO-

15)

EM

19. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET (See page LU-18)

20. REMOVE OIL PUMP ASSEMBLY (See page LU-19)

21. REMOVE OIL PUMP SEAL (See page LU-21)

22. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1
NOTICE:

• Do not rotate the crankshaft with the chain

tensioner removed.

• When rotating the camshaft with the timing chain

removed, rotate the crankshaft counterclockwise
40° from the TDC first.

EM

EM–34

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

(a) Pull up the stopper plate and hold it with its lock

released.

Stopper Plate

A116564E01

(b) Unlock the plunger of the tensioner and push it in to

the end.

Plunger

Stopper Plate

A116565E01

(c) Pull down the stopper plate with the plunger pushed

to the end and lock the plunger.

A116566E01

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

(d) Insert a 3 mm (0.12 in.) diameter bar into the hole in

the stopper plate and lock the plunger.

EM–35

A116567

A116568

A116569

EM

(e) Remove the 2 bolts and remove chain tensioner

assembly No. 1.

23. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

A116570

24. REMOVE CHAIN VIBRATION DAMPER NO. 1

(a) Remove the 2 bolts and remove chain vibration

damper No. 1.

25. REMOVE CHAIN SUB-ASSEMBLY

EM

EM–36

TDC:

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

INSPECTION

1. INSPECT CHAIN SUB-ASSEMBLY

(a) Using a spring scale, apply 140 N (14.3 kgf, 31.5 lb)

to the timing chain and measure its length.

Maximum chain elongation:

123.2 mm (4.850 in.)

If the elongation is greater than the maximum,
replace the chain.

A050062

HINT:
Perform the same measurement at 3 or more
random places and calculate the average length.

INSTALLATION

1. INSTALL CHAIN SUB-ASSEMBLY

Timing Marks

(a) Make sure that all the timing marks are in the

positions (TDC) shown in the illustration.
HINT:
The positions of the timing marks may differ from
the predetermined positions due to the force of the
valve spring.

10q

Timing Mark

40° to 140° ATDC

A116571E01

Timing Mark

A116573E01

(b) Set the timing mark of the crankshaft in a position

between 40 and 140°ATDC as illustrated.

20° ATDC:

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

(c) Set the camshaft timing gear and the camshaft

timing sprocket in the positions ( 20°ATDC) shown

Timing Marks

in the illustration.

(d) Set the crankshaft in the position ( 20°ATDC) shown

in the illustration.

30°

EM–37

EM

Timing Mark

A116574E01

A116576

(e) Install chain vibration damper No. 1 with the 2 bolts.

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

EM

EM–38

Timing Mark

Timing Marks

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

(f) Align the timing marks of the camshaft with the mark

Mark Plates

plates of the timing chain and install the timing
chain.
HINT:
Align the timing marks with the mark plates while
turning the hexagonal service portion of the
camshaft using a wrench.

Mark Plate

A116577E01

A116569

A116568

2. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

3. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1

(a) Install chain tensioner assembly No. 1 with the 2

bolts.

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

(b) Remove the bar from chain tensioner assembly No.

1.

4. INSTALL OIL PUMP SEAL (See page LU-21)

5. INSTALL OIL PUMP ASSEMBLY (See page LU-22)

6. INSTALL TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET (See page LU-26)

7. INSTALL WATER PUMP ASSEMBLY (See page CO-

16)

8. INSTALL WATER PUMP PULLEY (See page CO-16)

9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-397)

10. INSTALL CRANKSHAFT POSITION SENSOR (See
page ES-403)

1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

11. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
(See page LU-26)

12. INSTALL ENGINE MOUNTING INSULATOR SUB­ASSEMBLY RH (See page LU-26)

13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page FU-19)

14. CONNECT VENTILATION HOSE NO. 2 (See page FU-

20)

15. CONNECT VENTILATION HOSE (See page FU-20)

16. INSTALL IGNITION COIL NO. 1 (See page IG-9)

17. INSTALL GENERATOR ASSEMBLY (See page CH-17)

EM–39

18. INSTALL FAN AND GENERATOR V BELT (See page

EM-7)

19. ADJUST FAN AND GENERATOR V BELT (See page

EM-7)

20. INSPECT FAN AND GENERATOR V BELT (See page

EM-8)

21. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

22. ADD ENGINE OIL

23. ADD ENGINE COOLANT (See page CO-8)

24. CHECK ENGINE OIL LEVEL (See page LU-1)

25. CHECK FOR ENGINE OIL LEAKAGE

26. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-1)

27. INSTALL CYLINDER HEAD COVER NO. 2 (See page

IG-10)

28. INSTALL ENGINE UNDER COVER RH

EM

29. INSTALL FRONT WHEEL RH
Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)

EM

EM–40

ENGINE1NZ-FE ENGINE MECHANICAL

CAMSHAFT

COMPONENTS

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

5.0 (51, 44 in.*lbf)

N*m (kgf*cm, ft.*lbf)

ENGINE UNDER COVER RH

: Specified torque

A115143E01

7.0 (71, 62 in.*lbf)

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

7.0 (71, 62 in.*lbf)

EM–41

CYLINDER HEAD COVER NO. 2

EM

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115136E01

EM–42

for Hatchback:

52 (530, 38)

45 (459, 33)

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

x2

45 (459, 33)

EM

ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

52 (530, 38)

N*m (kgf*cm, ft.*lbf)

: Specified torque

A116232E04

for Sedan:

52 (530, 38)

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

x2

EM–43

52 (530, 38)

52 (530, 38)

ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

EM

52 (530, 38)

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

A133595E01

EM

EM–44

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

9.0 (92, 80 in.*lbf)

IGNITION COIL NO. 1

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115486E01

WIRE HARNESS BRACKET

10 (102, 7.0)

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

13 (133, 9.6)

10 (102, 7.0)

SEAL WASHER

x7

10 (102, 7.0)

EM–45

EM

10 (102, 7.0)

CYLINDER HEAD COVER
SUB-ASSEMBLY

VENTILATION HOSE NO. 2

VENTILATION HOSE

CYLINDER HEAD COVER GASKET

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115504E01

EM–46

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

x16

13 (129, 9.4)

23 (235, 17)

EM

CAMSHAFT BEARING CAP NO. 1

CAMSHAFT TIMING
SPROCKET

64 (653, 47)

64 (653, 47)

CAMSHAFT TIMING GEAR ASSEMBLY

x8

CAMSHAFT BEARING CAP NO. 2

NO. 2 CAMSHAFT

CAMSHAFT

15 (153, 11)

N*m (kgf*cm, ft.*lbf)

: Specified torque

A116233E02

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL

2. REMOVE ENGINE UNDER COVER RH

3. REMOVE CYLINDER HEAD COVER NO. 2 (See page

IG-9)

4. REMOVE IGNITION COIL NO. 1 (See page IG-9)

5. DISCONNECT VENTILATION HOSE (See page FU-13)

6. DISCONNECT VENTILATION HOSE NO. 2 (See page

FU-13)

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page FU-13)

8. REMOVE FAN AND GENERATOR V BELT (See page

EM-7)

9. REMOVE ENGINE MOUNTING INSULATOR SUB­ASSEMBLY RH (See page LU-17)

EM–47

EM

Matchmark

10. REMOVE NO. 2 CAMSHAFT
NOTICE:
When rotating the camshaft with the timing chain
removed, rotate the crankshaft damper
counterclockwise 40 ° from the TDC and align its
timing notch with the matchmark of the timing chain
cover to prevent the pistons from coming into
contact with the valves.

A116206E01

(a) Set the No. 1 cylinder to TDC / compression.

(1) Turn the crankshaft damper, and align its timing

notch with the timing mark "0" of the oil pump.

Timing Notch

A116203E01

(2) Check that the timing marks on both the

camshaft timing sprocket and the camshaft
timing gear are facing upward, as shown in the
illustration.
HINT:
If not, turn the crankshaft 1 complete revolution
(360°) and align the marks as above.

Timing Marks

A116204E01

EM–48

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

Timing Marks

Paint Marks

A116207E01

G100163

(b) Place paint marks on the chain in the places where

the timing marks of the camshaft timing sprocket
and the camshaft timing gear are located.

(c) Using an 8 mm hexagon wrench, remove the screw

plug.

(d) Insert a screwdriver into the service hole in the

chain tensioner to pull the stopper plate of the chain
tensioner upward.

Plunger

Stopper Plate

A116209E01

(e) Using a wrench, rotate camshaft No. 2 clockwise to

push in the plunger of the chain tensioner.

A116210E01

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

(f) Remove the screwdriver from the service hole, then

align the hole in the stopper plate with the service
hole and insert a 3 mm (0.12 in.) diameter bar into
the holes to hold the stopper plate.
HINT:

• Fix the stopper plate using the bar while rotating
the camshaft right and left slightly.

• Hold the bar with tape so that it does not come
off.

EM–49

12345

A116212

A116213

A116214E01

EM

(g) Using a wrench, hold the hexagonal lobe of

camshaft No. 2 and remove the flange bolt.

(h) Using several steps, loosen and remove the 11

bearing cap bolts uniformly in the sequence shown
in the illustration, then remove camshaft bearing
caps No. 1 and No. 2.

NOTICE:
Loosen the bolts uniformly while keeping the
camshaft level.

A116215

(i) Remove the flange bolt and remove the camshaft

timing sprocket.

EM

EM–50

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

24 31

(j) Remove camshaft No. 2.

A116216

11. REMOVE CAMSHAFT

(a) Using several steps, loosen and remove the 8

bearing cap bolts uniformly in the sequence shown
in the illustration, then remove camshaft bearing
cap No. 2.

NOTICE:
Loosen each bolt uniformly while keeping the
camshaft level.

A116217E01

A116218

A035227E01

(b) Hold the chain by hand, and remove the camshaft

and the camshaft timing gear assembly.

(c) Tie the chain with a piece of string as shown in the

illustration.

12. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Clamp the camshaft in a vise and confirm that it is

locked.

NOTICE:
Do not damage the camshaft.

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM–51

Retard Side
Paths

Closed

Open

Vinyl Tape

Retard
Side Path

Advance
Side Paths

Open

Closed

Rubber Piece

A116226E04

Advance
Side Path

(b) Cover the 4 oil paths of the cam journal with tape as

shown in the illustration.
HINT:
One of the 2 grooves located on the cam journal is
for retarding cam timing (upper) and the other is for
advancing cam timing (lower). Each groove has 2 oil
paths. Plug one of the oil paths for each groove with
a piece of rubber before wrapping the cam journal
with the tape.

(c) Puncture the tape covering the advance oil path and

the retard oil path on the opposite side from the
advance oil path.

2

(d) Apply air at about 150 kPa (1.5 kgf*cm

) pressure
into the 2 broken paths (the advance side path and
the retard side path).

NOTICE:
Cover the paths with a shop rag or piece of cloth
to prevent oil splashes.

EM

Retard
Side Path

Decompress

A116227E02

Advance
Side Path

Hold Pressure

A116228E02

(e) Confirm that the camshaft timing gear assembly

revolves in the timing advance direction when the
air pressure on the timing retard path is reduced.
HINT:
The lock pin is released, and the camshaft timing
gear revolves in the advance direction.

(f) When the camshaft timing gear reaches the most

advanced position, release the air pressure on the
timing retard side path, and then release the air
pressure on the timing advance side path.

NOTICE:
The camshaft timing gear assembly
occasionally shifts to the retard side abruptly, if
the air pressure on the advance side path is
released first. This often results in breakage of
the lock pin.

EM

EM–52

Flange Bolt

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

(g) Remove the flange bolt and remove the camshaft

timing gear assembly.

NOTICE:

• Do not remove the other 4 bolts.

• When reusing the camshaft timing gear,
unlock the lock pin inside the camshaft
timing gear first.

A116229E01

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

INSPECTION

1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the lock of camshaft timing gear.

(1) Clamp the camshaft in a vice, and check that

the camshaft timing gear is locked.

NOTICE:
Do not damage the camshaft.

EM–53

Retard Side
Paths

Closed

Open

Vinyl Tape

Retard
Side Path

Advance
Side Paths

Open

Closed

Rubber Piece

A116226E05

Advance
Side Path

(b) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with

tape as shown in the illustration.
HINT:
One of the 2 grooves located on the cam
journal is for retarding cam timing (upper) and
the other is for advancing cam timing (lower).
Each groove has 2 oil paths. Plug one of the oil
paths for each groove with a piece of rubber
before wrapping the cam journal with the tape.

(2) Puncture the tape covering the advance oil

path and the retard oil path on the opposite side
from the advance oil path.

(3) Apply air at about 150 kPa (1.5kgf*cm

pressure into the 2 broken paths (the advance
side path and the retard side path).

NOTICE:
Cover the paths with a shop rag or piece of
cloth to prevent oil splashes.

EM

2

)

A116227E02

EM

EM–54

Retard
Side Path

Decompress

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

(4) Confirm that the camshaft timing gear

assembly revolves in the timing advance
direction when the air pressure on the timing

Advance
Side Path

retard path is reduced.
HINT:
The lock pin is released and the camshaft
timing gear revolves in the advance direction.

(5) When the camshaft timing gear reaches the

most advanced position, release the air
pressure on the timing retard side path, and
then release the air pressure on the timing
advance side path.

Hold Pressure

NOTICE:
Camshaft timing gear assembly

A116228E02

occasionally shifts to the retard side
abruptly if the air pressure on the advance
side path is released first. This often results
in breakage of the lock pin.

(c) Check the revolution.

(1) Rotate the valve timing assembly back and

forth several times, except where the lock pin
meets it at the most retarded angle. Check the
movable range and that it rotates smoothly.

Standard:

Smooth movable range is about 22.5°
NOTICE:
Perform this check by hand, instead of
using air pressure.

(d) Check that the gear locks in the most retarded

position.
(1) Confirm that the camshaft timing gear

assembly is locked in the most retarded
position.

Groove

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

INSTALLATION

1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
NOTICE:
Install the camshaft timing gear assembly onto the
camshaft with the lock pin of the camshaft timing
gear assembly released.

(a) Put the camshaft timing gear assembly and

Straight Pin

A116230E01

camshaft together with the straight pin of the
groove.

(b) Turn the camshaft timing gear assembly clockwise

while pushing it gently toward the camshaft. When
the pin fits the groove, push to ensure a good fit.

NOTICE:
Do not turn the camshaft timing gear in the
retard direction (clockwise).

(c) Check that there is no clearance between the gear

flange and the camshaft.

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

fixed.

Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
NOTICE:

• Do not lock the camshaft timing gear
assembly when tightening the bolt.

• Release the lock pin of the camshaft timing
gear assembly first, and tighten the bolt when
the lock pin is locked in the most retarded
position.

• Tightening the bolts with the lock pin locked
could cause breakage of the lock pin.

(e) Check that the camshaft timing gear assembly

moves smoothly in the retard direction (clockwise)
and is locked in the most retarded position.

EM–55

EM

Paint Mark

2. INSTALL CAMSHAFT

(a) Apply a light coat of engine oil to the camshaft and

camshaft journals.

(b) Install the chain onto the camshaft timing gear with

the paint mark and the timing mark aligned as
shown in the illustration.

Timing Mark

A116220E01

EM–56

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

(c) Examine the front marks and numbers on camshaft

bearing cap No. 2 and check that the sequence is
as shown in the illustration. Then uniformly tighten
the bolts, in several steps, in the sequence shown in
the illustration.

Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf)
NOTICE:
Tighten each bolt uniformly while keeping the
camshaft level.

31 24

EM

Paint Mark

Timing Mark

A116222E01

3. INSTALL NO. 2 CAMSHAFT

(a) Install camshaft No. 2.

A116216

(b) Hold the chain and align the timing mark on the

camshaft timing sprocket with the paint mark of the
chain.

(c) Align the alignment pin hole in the camshaft timing

sprocket with the alignment pin of the camshaft, and
install the sprocket onto the camshaft.

Pin

A116224E01

A116215

(d) Provisionally install the flange bolt.

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM–57

(e) Examine the front marks and numbers on camshaft

31 2 4

bearing caps No. 1 and No. 2 and check that the
sequence is as shown in the illustration. Then
uniformly tighten the bolts, in several steps, in the

5

sequence shown in the illustration.

Torque: for bearing cap No. 2

13 N*m (129 kgf*cm, 9.4 ft.*lbf)
for bearing cap No. 1

23 N*m (235 kgf*cm, 17 ft.*lbf)
NOTICE:
Tighten each bolt uniformly while keeping the
camshaft level.

Bearing Cap No. 2Bearing Cap No. 1

SST

Timing Notch

A116223E01

A116225E01

A116203E01

EM

(f) Using a wrench, hold the hexagonal lobe of

camshaft No. 2 and install the flange bolt.

SST 09023-38400
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)

(g) Remove the bar from the timing chain tensioner.

(h) Turn the crankshaft damper and align its timing

notch with the timing mark "0" of the oil pump.

Timing Marks

Paint Marks

A116207E01

(i) Check that all the pairs of timing marks are aligned.
(j) Apply adhesive to the end 2 or 3 threads of the

screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent

EM–58

1NZ-FE ENGINE MECHANICAL – CAMSHAFT

(k) Using an 8 mm hexagon wrench, install the screw

plug.

Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

4. INSPECT VALVE CLEARANCE (See page EM-9)

5. ADJUST VALVE CLEARANCE (See page EM-10)

6. INSTALL ENGINE MOUNTING INSULATOR SUB­ASSEMBLY RH (See page LU-26)

EM

G100163

7. INSTALL FAN AND GENERATOR V BELT (See page

EM-7)

8. ADJUST FAN AND GENERATOR V BELT (See page

EM-7)

9. INSPECT FAN AND GENERATOR V BELT (See page

EM-8)

10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page FU-19)

11. CONNECT VENTILATION HOSE NO. 2 (See page FU-

20)

12. CONNECT VENTILATION HOSE (See page FU-20)

13. INSTALL IGNITION COIL NO. 1 (See page IG-9)

14. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

15. CHECK FOR ENGINE OIL LEAKAGE

16. INSTALL CYLINDER HEAD COVER NO. 2 (See page

IG-10)

17. INSTALL ENGINE UNDER COVER RH

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

ENGINE1NZ-FE ENGINE MECHANICAL

CYLINDER HEAD

COMPONENTS

for Hatchback:

FRONT WIPER ARM AND BLADE ASSEMBLY LH

FRONT WIPER ARM AND BLADE ASSEMBLY RH

COWL TOP VENTILATOR LOUVER CENTER NO. 1

CLIP

FRONT WIPER
ARM HEAD CAP

26 (265, 19)

EM–57

FRONT WIPER
ARM HEAD CAP

26 (265, 19)

EM

COWL TOP VENTILATOR
LOUVER SUB-ASSEMBLY

HOOD TO COWL TOP SEAL

COWL TO REGISTER
DUCT SUB-ASSEMBLY
NO. 2

6.5 (66, 58 in.*lbf)

CLIP

CLIP

COWL TOP VENTILATOR
LOUVER LH

FRONT WIPER MOTOR AND LINK

x9

5.5 (56, 49 in.*lbf)

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

COWL TOP PANEL OUTER

A118803E10

EM–58

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

for Sedan:

FRONT WIPER ARM AND
BLADE ASSEMBLY RH

COWL SIDE VENTILATOR
SUB-ASSEMBLY RH

COWL TOP VENTILATOR LOUVER
SUB-ASSEMBLY

FRONT AIR SHUTTER
SEAL

FRONT WIPER
ARM HEAD CAP

X2

5.5 (56, 49 in.*lbf)

FRONT WIPER ARM AND
BLADE ASSEMBLY LH

FRONT WIPER
ARM HEAD CAP

26 (265, 19)

26 (265, 19)

X3

CLIP

COWL SIDE VENTILATOR
SUB-ASSEMBLY LH

6.5 (66, 58 in.*lbf)

N*m (kgf*cm, ft.*lbf)

WINDSHIELD WIPER MOTOR AND LINK

X8

6.5 (66, 58 in.*lbf)

COWL TOP PANEL OUTER
CENTER BRACKET

COWL TOP PANEL OUTER

: Specified torque

A133320E03

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM–59

EM

5.0 (51, 44 in.*lbf)

N*m (kgf*cm, ft.*lbf)

ENGINE UNDER COVER RH

: Specified torque

A115143E01

EM

EM–60

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

7.0 (71, 62 in.*lbf)

CYLINDER HEAD COVER NO. 2

7.0 (71, 62 in.*lbf)

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115136E01

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

FUEL VAPOR FEED HOSE NO. 2

VENTILATION HOSE
NO. 2

EM–61

FUEL VAPOR FEED
HOSE NO. 1

EM

AIR CLEANER CAP SUB-ASSEMBLY
WITH AIR CLEANER HOSE NO. 1

A133592E01

EM

EM–62

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

FAN AND GENERATOR V BELT

N*m (kgf*cm, ft.*lbf)

19 (189, 14)

54 (551, 40)

: Specified torque

A116199E01

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

HEATED OXYGEN SENSOR BRACKET

EM–63

BATTERY CLAMP SUB-ASSEMBLY

BATTERY

EM

BATTERY TRAY

BOOSTER VACUUM TUBE

WATER FILLER SUB-ASSEMBLY

RADIATOR HOSE NO. 3

RESERVE TANK HOSE

44 (449, 33)

FUEL TUBE SUB-ASSEMBLY

FUEL TUBE SUB-ASSEMBLY

7.5 (76, 66 in.*lbf)

x2

x3

MANIFOLD SUPPORT BRACKET

GASKET

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

x2

43 (438, 32)

EXHAUST PIPE ASSEMBLY FRONT

Non-reusable part

A116961E01

EM–64

for Hatchback:

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

11 (112, 8.1)

EM

54 (551, 40)

19 (189, 14)

9.8 (100, 7.2)

FAN BELT ADJUSTING BAR

GENERATOR
ASSEMBLY

45 (459, 33)

ENGINE MOUNTING INSULATOR
SUB-ASSEMBLY RH

52 (530, 38)

x2

x3

52 (530, 38)

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

A116193E06

for Sedan:

11 (112, 8.1)

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM–65

54 (551, 40)

19 (189, 14)

9.8 (100, 7.2)

FAN BELT ADJUSTING BAR

GENERATOR
ASSEMBLY

52 (530, 38)

ENGINE MOUNTING INSULATOR
SUB-ASSEMBLY RH

x3

52 (530, 38)

x2

52 (530, 38)

EM

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

A133594E01

EM

EM–66

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

9.0 (92, 80 in.*lbf)

IGNITION COIL NO. 1

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115486E01

WIRE HARNESS BRACKET

10 (102, 7.0)

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

13 (133, 9.6)

10 (102, 7.0)

SEAL WASHER

x7

10 (102, 7.0)

EM–67

EM

10 (102, 7.0)

CYLINDER HEAD COVER
SUB-ASSEMBLY

VENTILATION HOSE NO. 2

VENTILATION HOSE

CYLINDER HEAD COVER GASKET

N*m (kgf*cm, ft.*lbf)

: Specified torque

A115504E01

EM

EM–68

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

x3

15 (153, 11)

11 (112, 8.1)

x2

WATER PUMP PULLEY

x3

11 (112, 8.1)

GASKET

WATER PUMP ASSEMBLY

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

Non-reusable part

A116194E01

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM–69

O-RING

CAMSHAFT TIMING OIL
CONTROL VALVE ASSEMBLY

EM

7.5 (76, 66 in.*lbf)

11 (112, 8.1)

19 (189, 14)

FAN BELT
ADJUSTING BAR

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

Non-reusable part

A116180E01

EM

EM–70

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET

55 (561, 41)

24 (245, 18)

x4

32 (326, 24)

24 (245, 18)

x2

x11

11 (112, 8.1)

7.5 (76, 66 in.*lbf)

11 (112, 8.1)

CRANKSHAFT
POSITION SENSOR

128 (1305, 95)

OIL PUMP SEAL

CRANKSHAFT DAMPER SUB-ASSEMBLY

CRANKSHAFT STRAIGHT PIN

OIL PUMP ASSEMBLY

N*m (kgf*cm, ft.*lbf)

Non-reusable part

O-RING

: Specified torque

Apply MP grease

A116559E01

9.0 (92, 80 in.*lbf)

CHAIN SUB-ASSEMBLY

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

CHAIN TENSIONER ASSEMBLY NO. 1

EM–71

EM

CHAIN TENSIONER
SLIPPER

9.0 (92, 80 in.*lbf)

N*m (kgf*cm, ft.*lbf)

CHAIN VIBRATION DAMPER NO. 1

: Specified torque

A116579E01

EM

EM–72

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

INTAKE MANIFOLD TO
HEAD GASKET NO. 1

INTAKE MANIFOLD

30 (306, 22)

OIL LEVEL GAUGE SUB-ASSEMBLY

OIL LEVEL GAUGE GUIDE

x2

30 (306, 22)

UNION TO CONNECTOR
TUBE HOSE

x3

WATER BY-PASS HOSE NO. 2

VENTILATION HOSE

WATER BY-PASS
HOSE

9.0 (92, 80 in.*lbf)

O-RING

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

Non-reusable part

A121463E01

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

x16

23 (235, 17)

x3

13 (129, 9.4)

CAMSHAFT BEARING CAP NO. 2

CAMSHAFT BEARING CAP NO. 1

NO. 2 CAMSHAFT

CAMSHAFT

EM–73

EM

1st: 29 (300, 22)
2nd: Turn 90°

3rd: Turn 90°

CYLINDER HEAD SUB-ASSEMBLY

CYLINDER HEAD GASKET

x10

PLATE WASHER

HEATER WATER
INLET HOSE A

9.0 (92, 80 in.*lbf)

WATER BY-PASS PIPE NO. 1

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

Non-reusable part

A116963E01

EM

EM–74

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

x4

8.0 (82, 71 in.*lbf)

EXHAUST MANIFOLD HEAT INSULATOR NO. 1

x3

27 (275, 20)

EXHAUST MANIFOLD
TO HEAD GASKET

EXHAUST MANIFOLD

x2

27 (275, 20)

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

Non-reusable part

A116967E01

19 (194, 14)

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM–75

x2

O-RING

FUEL INJECTOR ASSEMBLY

x4

INJECTOR VIBRATION INSULATOR

x2

DELIVERY PIPE NO. 1 SPACER

FUEL DELIVERY PIPE SUB-ASSEMBLY

9.0 (92, 80 in.*lbf)

EM

BOOSTER VACUUM TUBE

9.0 (92, 80 in.*lbf)

HARNESS BRACKET

13 (131, 9.5)

HARNESS BRACKET

WATER BY-PASS HOSE

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

CAMSHAFT POSITION SENSOR

Non-reusable part

13 (131, 9.5)

GASKET

20 (204, 15)

ENGINE COOLANT
TEMPERATURE SENSOR

8.0 (82, 71 in.*lbf)

A116965E01

EM–76

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

VALVE STEM OIL SEAL

VALVE SPRING SEAT

EXHAUST VALVE GUIDE
BUSH

CAMSHAFT BEARING
CAP RING PIN

x8

x8

x8

x8

x8

x8

x8

x8

x8

x8

VALVE LIFTER

x8

RETAINER LOCK

x8

RETAINER

x8

VALVE SPRING

x8

INTAKE VALVE GUIDE BUSH

44 (449, 33)

WITH HEAD TAPER SCREW PLUG NO. 1

GASKET

9.0 (92, 80in.*lbf)

STUD BOLT

10 (102, 7.4)

STUD BOLT

INTAKE VALVE

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

4.0 (41, 35in.*lbf)

STUD BOLT

10 (102, 7.4)

STUD BOLT

OIL CONTROL VALVE FILTER

GASKET

30 (306, 22)

WITH HEAD TAPER
SCREW PLUG NO. 2

EXHAUST VALVE

Non-reusable part

A117451E03

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

(See Page FU-1)

2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL

3. REMOVE FRONT WIPER ARM HEAD CAP (for
Hatchback) (See page WW-17)

4. REMOVE FRONT WIPER ARM HEAD CAP (for
Sedan) (See page WW-9)

5. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY LH (for Hatchback) (See page WW-17)

6. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY LH (for Sedan) (See page WW-9)

7. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY RH (for Hatchback) (See page WW-17)

8. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY RH (for Sedan) (See page WW-9)

EM–77

EM

9. REMOVE HOOD TO COWL TOP SEAL (for
Hatchback) (See page WW-18)

10. REMOVE COWL TOP VENTILATOR LOUVER SUB­ASSEMBLY (for Hatchback) (See page WW-18)

11. REMOVE COWL TOP VENTILATOR LOUVER LH (for
Hatchback) (See page WW-18)

12. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY
LH (for Sedan) (See page WW-10)

13. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY
RH (for Sedan) (See page WW-10)

14. REMOVE COWL TOP VENTILATOR LOUVER SUB­ASSEMBLY (for Sedan) (See page WW-10)

15. REMOVE FRONT WIPER MOTOR AND LINK (for
Hatchback) (See page WW-19)

16. REMOVE FRONT WIPER MOTOR AND LINK (for
Sedan) (See page WW-10)

17. REMOVE COWL TO REGISTER DUCT SUB­ASSEMBLY NO. 2 (for Hatchback) (See page EM-122)

18. REMOVE FRONT AIR SHUTTER SEAL RH (for
Sedan) (See page ES-432)

19. REMOVE COWL TOP PANEL OUTER (for Hatchback)
(See page EM-123)

20. REMOVE COWL TOP PANEL OUTER (for Sedan)
(See page ES-432)

21. REMOVE BATTERY

22. REMOVE BATTERY TRAY

23. REMOVE FRONT WHEEL RH

EM

EM–78

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

24. REMOVE ENGINE UNDER COVER RH

25. DRAIN ENGINE OIL

26. DRAIN ENGINE COOLANT (See page CO-8)

27. REMOVE CYLINDER HEAD COVER NO. 2 (See page

IG-9)

28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH
AIR CLEANER HOSE NO. 1 (See page ES-410)

29. DISCONNECT RADIATOR HOSE NO. 3

(a) Disconnect radiator hose No. 3.

A116580

A116581

A116739

30. DISCONNECT RESERVE TANK HOSE

(a) Disconnect the reserve tank hose.

31. REMOVE WATER FILLER SUB-ASSEMBLY

(a) Separate radiator hose No. 1 from the cylinder

head.

(b) Remove the 2 nuts and remove the water filler sub-

assembly.

32. DISCONNECT WATER BY-PASS HOSE NO. 2

(a) Disconnect water by-pass hose No. 2.

A116740

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

33. DISCONNECT WATER BY-PASS HOSE

(a) Disconnect the water by-pass hose.

A116741

34. DISCONNECT THROTTLE WITH MOTOR BODY
CONNECTOR

(a) Separate the wire harness clamp.
(b) Remove the nut and separate the throttle with motor

body connector.

A116742

EM–79

EM

A116973

A116744

35. DISCONNECT VENTILATION HOSE

(a) Disconnect the ventilation hose.

36. DISCONNECT UNION TO CONNECTOR TUBE HOSE

(a) Disconnect the union to connector tube hose.

37. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

38. REMOVE INTAKE MANIFOLD

(a) Separate the 3 wire harness clamps shown in the

illustration.

A116745

EM–80

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

(b) Remove the 3 bolts and 2 nuts and remove the

intake manifold.

A116746

39. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the wire harness clamp and the bolt and

remove the oil level gauge guide.

EM

40. DISCONNECT FUEL TUBE SUB-ASSEMBLY (See
page FU-14)

A116747

41. DISCONNECT BOOSTER VACUUM TUBE

(a) Disconnect the booster vacuum tube.

A116748

42. DISCONNECT CAMSHAFT POSITION SENSOR
CONNECTOR

(a) Disconnect the camshaft position sensor connector.

A116749

A116750

43. DISCONNECT ENGINE COOLANT TEMPERATURE
SENSOR CONNECTOR

(a) Disconnect the engine coolant temperature sensor

connector.

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

44. DISCONNECT HEATED OXYGEN SENSOR
CONNECTOR

(a) Remove the bolts and separate the sensor bracket.
(b) Disconnect the heated oxygen sensor connector.

A116751

45. DISCONNECT HEATER WATER INLET HOSE A

(a) Disconnect heater water inlet hose A.

A116752

EM–81

EM

A116753

A116755

46. SEPARATE WATER BY-PASS PIPE NO. 1

(a) Remove the bolt and separate water by-pass pipe

No. 1.

47. DISCONNECT WIRE HARNESS

(a) Remove the 2 bolts and disconnect the wire

harness.

48. SEPARATE EXHAUST PIPE ASSEMBLY FRONT

(a) Remove the 2 bolts and 2 compression springs and

separate the exhaust pipe assembly front.

A116756

EM–82

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

49. REMOVE MANIFOLD SUPPORT BRACKET

(a) Remove the 3 bolts and remove the manifold

support bracket.

50. REMOVE FAN AND GENERATOR V BELT (See page

EM-7)

51. REMOVE GENERATOR ASSEMBLY (See page CH-10)

52. REMOVE IGNITION COIL NO. 1 (See page IG-9)

EM

A116757

53. REMOVE VENTILATION HOSE (See page FU-13)

54. REMOVE VENTILATION HOSE NO. 2 (See page FU-

13)

55. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page FU-13)

56. REMOVE ENGINE MOUNTING INSULATOR SUB­ASSEMBLY RH (See page LU-17)

57. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY
(See page LU-18)

58. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-403)

59. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-396)

60. REMOVE WATER PUMP PULLEY (See page CO-15)

61. REMOVE WATER PUMP ASSEMBLY (See page CO-

15)

62. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET (See page LU-17)

63. REMOVE OIL PUMP ASSEMBLY (See page LU-19)

64. REMOVE OIL PUMP SEAL (See page LU-21)

65. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 (See
page EM-33)

66. REMOVE CHAIN TENSIONER SLIPPER (See page

EM-35)

67. REMOVE CHAIN VIBRATION DAMPER NO. 1 (See
page EM-35)

68. REMOVE CHAIN SUB-ASSEMBLY

69. REMOVE CAMSHAFT
NOTICE:
When rotating the camshaft with the timing chain
removed, rotate the crankshaft counterclockwise 40°
from the TDC first.

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

(a) Using several steps, uniformly loosen and remove

the 19 bearing cap bolts in the sequence shown in
the illustration, and then remove camshaft bearing
cap No. 1 and camshaft bearing cap No. 2.

NOTICE:
Loosen each bolt uniformly while keeping the
camshaft level.

(b) Remove the camshaft and camshaft No. 2.

A035758E01

70. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Using several steps, uniformly loosen and remove

the 10 cylinder head bolts with an 8 mm bi-hexagon
wrench in the sequence shown in the illustration.
Remove the 10 plate washers.

NOTICE:

• Do not drop the washers into the cylinder
head.

• Head warpage or cracking could result from

A035286

removing the bolts in the wrong order.

EM–83

EM

A116758

A116759

71. REMOVE CYLINDER HEAD GASKET

(a) Remove the cylinder head gasket.

72. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO. 1

(a) Remove the 4 bolts and remove exhaust manifold

heat insulator No. 1.

73. REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts and 2 nuts and remove the

exhaust manifold.

A116761

EM

EM–84

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

74. REMOVE HARNESS BRACKET

(a) Remove the bolt and remove the harness bracket.

A116762

75. REMOVE BOOSTER VACUUM TUBE

(a) Remove the 2 bolts and remove the booster

vacuum tube.

A116763

SST

76. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and remove the camshaft position

sensor.

A116764

77. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR

(a) Using SST, remove the engine coolant temperature

sensor connector.

SST 09817-33190

A116765E01

78. REMOVE WATER BY-PASS HOSE

(a) Remove the water by-pass hose.

A116766

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

79. REMOVE HARNESS BRACKET

(a) Remove the bolt and remove the harness bracket.

A116767

80. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Remove the 3 bolts and remove the fuel delivery

pipe sub-assembly with 4 fuel injectors.

NOTICE:
Do not drop the fuel injectors when removing
the fuel delivery pipe sub-assembly.

81. REMOVE FUEL INJECTOR ASSEMMBLY (See page

FU-16)

A116768

EM–85

EM

A116955

A116956

82. REMOVE DELIVERY PIPE NO. 1 SPACER

(a) Remove the 2 delivery pipe No. 1 spacers.

83. REMOVE INJECTOR VIBRATION INSULATOR

(a) Remove the 4 injector vibration insulators.

DISASSEMBLY

A062890E01

1. REMOVE WITH HEAD TAPER SCREW PLUG NO. 1

(a) Using a 10 mm socket hexagon wrench, remove the

taper screw plug and the gasket.

2. REMOVE VALVE LIFTER

HINT:
Keep the valve lifters in the correct order so that they can
be returned to their original locations when reassembled.

EM

EM–86

SST

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

3. REMOVE WITH HEAD TAPER SCREW PLUG NO. 2

(a) Using an 8 mm hexagon wrench, remove the taper

screw plug.

4. REMOVE OIL CONTROL VALVE FILTER

A038128E01

5. REMOVE INTAKE VALVE

(a) Using SST, compress the valve spring and remove

the 2 retainer locks, retainer and valve spring.

SST 09202-70020 (09202-00010)

HINT:
Keep the valves, valve springs, spring seats and
spring retainers in the correct order so that they can
be returned to their original locations when
reassembled.

A037109E03

6. REMOVE EXHAUST VALVE

(a) Using SST, compress the valve spring and remove

the 2 retainer locks, retainer and valve spring.

SST 09202-70020 (09202-00010)

HINT:
Keep the valves, valve springs, spring seats and
spring retainers in the correct order so that they can
be returned to their original locations when
reassembled.

A080961E01

A080962E01

7. REMOVE VALVE STEM OIL SEAL

(a) Using needle-nose pliers, remove the oil seal.

8. REMOVE VALVE SPRING SEAT

(a) Using compressed air and a magnetic finger,

remove the valve spring seats.

9. REMOVE STUD BOLT

(a) Using "Torx" socket wrenches E5 and E7, remove

the 7 stud bolts.

10. REMOVE CAMSHAFT BEARING CAP SETTING RING
PIN

Cylinder Block Side

Intake Manifold Side

Exhaust Manifold Side

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

INSPECTION

1. INSPECT CYLINDER HEAD FOR WARPAGE

(a) Using a precision straightedge and feeler gauge,

measure the warpage of the surface that is in
contact with the cylinder block and the manifolds.

Maximum warpage

Surface Specified Condition

Cylinder block side 0.05 mm (0.0020 in.)

Intake manifold side 0.10 mm (0.0039 in.)

Exhaust manifold side 0.10 mm (0.0039 in.)

If the warpage is greater than the maximum, replace
the cylinder head.

A050931E01

EM–87

EM

Underhead Length

2. INSPECT CYLINDER HEAD FOR CRACKS

(a) Using a dye penetrate, check the combustion

chamber, intake ports, exhaust ports and cylinder
block surface for cracks.
If cracked, replace the cylinder head.

A001071E01

3. INSPECT CYLINDER HEAD SET BOLT

(a) Using vernier calipers, measure the length of the

head bolts from the seat to the end.

Standard length:

142.8 to 144.2 mm (5.622 to 5.677 in.)

Maximum length:

147.1 mm (5.791 in.)

If the length is greater than the maximum, replace
the bolt.

A098332E01

4. INSPECT INTAKE VALVE

(a) Check the overall valve length.

Standard overall length:

89.25 mm (3.5138 in.)

Minimum overall length:

88.75 mm (3.4941 in.)

If the overall length is less than the minimum,
replace the valve.

EM02534E06

EM

EM–88

Margin Thickness

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

(b) Using a micrometer, measure the diameter of the

valve stem.

Standard valve stem diameter:

4.970 to 4.985 mm (0.1957 to 0.1963 in.)

Z000052E01

(c) Check the valve head margin thickness.

Standard margin thickness:

1.0 mm (0.039 in.)

Minimum margin thickness:

0.5 mm (0.020 in.)

If the margin thickness is less than the minimum,
replace the valve.

5. INSPECT EXHAUST VALVE

EM00181E03

(a) Check the overall valve length.

Standard overall length:

87.90 mm (3.4606 in.)

Minimum overall length:

87.40 mm (3.4409 in.)

If the overall length is less than the minimum,
replace the valve.

(b) Using a micrometer, measure the diameter of the

valve stem.

Standard valve stem diameter:

4.965 to 4.980 mm (0.1955 to 0.1961 in.)

(c) Check the valve head margin thickness.

Standard margin thickness:

1.15 mm (0.045 in.)

Minimum margin thickness:

0.5 mm (0.020 in.)

If the margin thickness is less than the minimum,
replace the valve.

EM00801E01

6. INSPECT VALVE SPRING

(a) Using vernier calipers, measure the free length of

the valve spring.

Standard free length:

45.05 to 45.15 mm (1.774 to 1.778 in.)

If the free length is not as specified, replace the
spring.

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

(b) Using a steel square, measure the deviation of the

valve spring.

Maximum deviation:

1.6 mm (0.063 in.)

Maximum angle (reference):

2°

If the deviation is greater than the maximum,
replace the spring.

EM00988E01

(c) Using a spring tester, measure the tension of the

valve spring at the specified installed length.

Standard installed tension:

149 to 165 N (15.2 to 16.8 kgf, 33.5 to 37.1 lbf)
at 32.5 mm (1.280 in.)

Maximum working tension:

286 to 316 N (29.1 to 32.2 kgf, 64.2 to 71.0 lbf)
at 23.9 mm (0.941 in.)

If the installed tension is not as specified, replace

EM00281E01

the valve spring.

EM–89

EM

A001478E02

7. INSPECT VALVE GUIDE BUSH OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter

of the guide bush.

Bush inside diameter:

5.010 to 5.030 mm (0.1972 to 0.1980 in.)

(b) Subtract the valve stem diameter measurement

from the guide bush inside diameter measurement
to calculate the oil clearance.

Standard oil clearance

Guide Bush Specified Condition

Intake

Exhaust

0.025 to 0.060 mm

(0.0010 to 0.0024 in.)

0.030 to 0.065 mm

(0.0012 to 0.0026 in.)

Maximum oil clearance

Guide Bush Specified Condition

Intake 0.08 mm (0.0032 in.)

Exhaust 0.10 mm (0.0039 in.)

If the clearance is greater than the maximum,
replace the valve and guide bush (see page EM-

92).

8. INSPECT INTAKE VALVE SEAT

(a) Apply a light coat of prussian blue to the valve face.
(b) Lightly press the valve against the seat.

EM

EM–90

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

(c) Check the valve face and seat in accordance with

the following procedure.
(1) If blue appears 360° around the face, the valve

is concentric. If not, replace the valve.

(2) If blue appears 360° around the valve seat, the

Width

guide and face are concentric. If not, resurface
the seat.

(3) Check that the seat contact is in the middle of

the valve face with the width between 1.0 to 1.4

A050036E01

mm (0.039 to 0.055 in.).

9. INSPECT VALVE LIFTER

(a) Using a micrometer, measure the lifter diameter.

Standard lifter diameter:

30.966 to 30.976 mm (1.2191 to 1.2195 in.)

P016860E01

A001080E01

EM01628E01

10. INSPECT VALVE LIFTER OIL CLEARANCE

(a) Using a caliper gauge, measure the lifter bore

diameter of the cylinder head.

Standard lifter bore diameter:

31.000 to 31.025 mm (1.2205 to 1.2215 in.)

(b) Subtract the lifter diameter measurement from the

lifter bore diameter measurement to calculate the oil
clearance.

Standard oil clearance:

0.024 to 0.059 mm (0.0009 to 0.0023 in.)

Maximum oil clearance:

0.1 mm (0.0039 in.)

If the oil clearance is greater than the maximum,
replace the lifter. If necessary, replace the cylinder
head.

11. INSPECT CAMSHAFT

(a) Inspect the camshaft for runout.

(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout

at the center journal.

Maximum circle runout:

0.03 mm (0.0012 in.)

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

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

(b) Inspect the cam lobes.

(1) Using a micrometer, measure the cam lobe

height.

Standard cam lobe height:

44.617 to 44.717 mm (1.7566 to 1.7605 in.)

Minimum cam lobe height:

43.16 mm (1.6992 in.)

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

A037113E01

(c) Inspect the camshaft journals.

(1) Using a micrometer, measure the journal

diameter.

Standard journal diameter

Journal Specified Condition

No. 1 journal

Other journals

A037114E01

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

EM–91

EM

34.449 to 34.465 mm
(1.3563 to 1.3569 in.)

22.949 to 22.965 mm
(0.9035 to 0.9041 in.)

12. INSPECT NO. 2 CAMSHAFT

(a) Inspect the camshaft for runout.

(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout

at the center journal.

Maximum circle runout:

0.03 mm (0.0012 in.)

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

(b) Inspect the cam lobes.

(1) Using a micrometer, measure the cam lobe

height.

Standard cam lobe height:

44.666 to 44.766 (1.7585 to 1.7624 in.)

Minimum cam lobe height:

44.52 mm (1.7528 in.)

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

(c) Inspect the camshaft journals.

(1) Using a micrometer, measure the journal

diameter.

Standard journal diameter

Journal Specified Condition

No. 1 journal

Other journals

34.449 to 34.465 mm
(1.3563 to 1.3569 in.)

22.949 to 22.965 mm
(0.9035 to 0.9041 in.)

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

EM

EM–92

Plastigage

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

13. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshafts.

(b) Using a dial indicator, measure the thrust clearance

while moving the camshaft back and forth.

Standard thrust clearance:

0.040 to 0.095 mm (0.0016 to 0.0037 in.)

Maximum thrust clearance:

0.11 mm (0.0043 in.)

If the thrust clearance is greater than the maximum,
replace the camshaft. If necessary, replace the
bearing caps and the cylinder head together.

A001455E01

14. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the bearing caps and the camshaft journals.
(b) Place the camshafts on the cylinder head.

(c) Lay a strip of Plastigage across each of the

camshaft journals.

(d) Install the bearing caps (see page EM-97).

NOTICE:
Do not turn the camshaft.

(e) Remove the bearing caps.

80 to 100°C (176 to 212°F)

A001452E01

A001453E01

A001067E02

(f) Measure the Plastigage at its widest point.

Standard oil clearance:

0.035 to 0.072 mm (0.0014 to 0.0028 in.)

Maximum oil clearance:

0.08 mm (0.0031 in.)

If the oil clearance is greater than the maximum,
replace the camshaft. If necessary, replace the
bearing caps and the cylinder head together.

NOTICE:
Completely remove the Plastigage after the
measurement.

REPLACEMENT

1. REMOVE INTAKE VALVE GUIDE BUSH

(a) Heat the cylinder head to 80 to 100°C (176 to

212°F).

SST

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

(b) Using SST and a hammer, tap out the guide

bushing.

SST 09201-10000 (09201-01050), 09950-70010

(09951-07100)

2. REMOVE EXHAUST VALVE GUIDE BUSH

(a) Heat the cylinder head to 80 to 100°C (176 to

212°F).

(b) Using SST and a hammer, tap out the guide

A037110E02

bushing.

SST 09201-10000 (09201-01050), 09950-70010

(09951-07100)

3. INSTALL INTAKE VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bushing bore

diameter of the cylinder head.

Inside Diameter:

9.685 to 9.706 mm (0.3813 to 0.3821 in.)

If the bushing bore diameter of the cylinder head is
greater than 9.706 mm (0.3821 in.), machine the
bushing bore to the dimension of 9.735 to 9.755 mm
(0.3833 to 0.3841 in.).

A001445E01

Bushing bore diameter

mm (in.)

9.685 to 9.706

(0.3813 to 0.3821)

9.735 to 9.755

(0.3833 to 0.3841)

EM–93

EM

Bushing size

STD

O/S 0.05

SST

Reamer

9.0 to 9.4 mm

A080977E02

A001447E02

(b) Heat the cylinder head to 80 to 100°C (176 to

212°F).

(c) Using SST and a hammer, tap a new guide bushing

in to the specified protrusion height.

SST 09201-10000 (09201-01050), 09950-70010

(09951-07100)

Protrusion height:

9.0 to 9.4 mm (0.354 to 0.370 in.)

(d) Using a sharp 5 mm reamer, ream the guide

bushing to obtain the standard oil clearance
between the guide bushing and valve stem.

Standard oil clearance:

0.025 to 0.060 mm (0.0010 to 0.0024 in.)

4. INSTALL EXHAUST VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bushing bore

diameter of the cylinder head.

Inside Diameter:

9.685 to 9.706 mm (0.3813 to 0.3821 in.)

EM–94

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

If the bushing bore diameter of the cylinder head is
greater than 9.706 mm (0.3821 in.), machine the
bushing bore to the dimension of 9.735 to 9.755 mm
(0.3833 to 0.3841 in.).

EM

Bushing bore diameter

mm (in.)

9.685 to 9.706

(0.3813 to 0.3821)

9.735 to 9.755

(0.3833 to 0.3841)

Bushing size

STD

O/S 0.05

(b) Heat the cylinder head to 80 to 100°C (176 to

212°F).

(c) Using SST and a hammer, tap a new guide bushing

in to the specified protrusion height.

SST 09201-10000 (09201-01050), 09950-70010

(09951-07100)

Protrusion height:

9.0 to 9.4 mm (0.354 to 0.370 in.)

(d) Using a sharp 5 mm reamer, ream the guide

bushing to obtain the standard oil clearance
between the guide bushing and valve stem.

Standard oil clearance:

0.030 to 0.065 mm (0.0012 to 0.0026 in.)

REASSEMBLY

1. INSTALL CAMSHAFT BEARING CAP SETTING RING
PIN

(a) Using a plastic-faced hammer, tap a new ring pin in

to the specified protrusion height.

Protrusion height:

8.5 to 9.5 mm (0.335 to 0.374 in.)

8.5 to 9.5 mm

A080980E02

2. INSTALL STUD BOLT

(a) Using "Torx" socket wrenches E5 and E7, install the

7 stud bolts.

Torque:

Stud bolt A:

10 N*m (102 kgf*cm, 7.4 ft.*lbf)

Stud bolt B:

4.0 N*m (41 kgf*cm, 35 in.*lbf)

Stud bolt C:

10 N*m (102 kgf*cm, 7.4 ft.*lbf)

Stud bolt D:

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

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

A

EM–95

C

EM

D

B

26.5

43.5

12

Stud Bolt A Stud Bolt B Stud Bolt DStud Bolt C

19.5

38.5

12

28.5

13

49.5

22.5

37.5

13

[mm]

A050180E03

3. INSTALL VALVE STEM OIL SEAL

ExhaustIntake

(a) Apply a light coat of engine oil to new valve stem oil

seals.

NOTICE:

Gray

Installing the oil seals for the intake and exhaust
onto the opposite valve guide bush as may

Black

cause failures.

HINT:
The intake valve oil seal is gray and the exhaust

A050182E02

valve oil seal is black.

SST

(b) Using SST, push in the oil seals.

SST 09201-41020

A001063E02

EM

EM–96

SST

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

4. INSTALL INTAKE VALVE

(a) Install the valve, spring seat, valve spring, and

spring retainer.

NOTICE:
Install the parts in their original locations in the
original order.

A001065E01

(b) Using SST, compress the valve spring and place the

2 retainer locks around the valve stem.

SST 09202-70020 (09202-00010)

A037109E03

A007307E01

(c) Using a plastic-faced hammer and the valve stem

(not in use) with its tip wrapped in tape, gently tap
the valve stem tip to ensure a proper fit.

NOTICE:
Do not damage the valve stem tip.

5. INSTALL EXHAUST VALVE

(a) Install the valve, spring seat, valve spring, and

spring retainer.

(b) Using SST, compress the valve spring and place the

2 retainer locks around the valve stem.

SST 09202-70020 (09202-00010)

(c) Using a plastic-faced hammer and the valve stem

(not in use) with its tip wrapped in tape, lightly tap
the valve stem tip to ensure a proper fit.

NOTICE:
Do not damage the valve stem tip.

6. INSTALL OIL CONTROL VALVE FILTER

(a) Install the oil control valve filter.

7. INSTALL WITH HEAD TAPER SCREW PLUG NO. 2

(a) Using an 8 mm hexagon wrench, install the taper

screw plug and a new gasket.

Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

A038128E01

8. INSTALL VALVE LIFTER

(a) Apply a light coat of engine oil to the 16 valve lifters.
(b) Install the 16 valve lifters.
(c) Check that the valve lifters rotate smoothly by hand.

1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

9. INSTALL WITH HEAD TAPER SCREW PLUG NO. 1

(a) Using a 10 mm socket hexagon wrench, install the

taper screw plug with a new gasket.

Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)

A062890E01

INSTALLATION

1. INSTALL INJECTOR VIBRATION INSULATOR

(a) Install 4 new injector vibration insulators onto the

cylinder head.

A116956

EM–97

EM

2. INSTALL DELIVERY PIPE NO. 1 SPACER

(a) Install the 2 delivery pipe No. 1 spacers onto the

cylinder head.

NOTICE:
Install the delivery pipe No. 1 spacer in the
correct direction.

3. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-

17)

A116957

4. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Provisionally install the fuel delivery pipe sub-

assembly with the 4 fuel injectors using the 3 bolts.

NOTICE:

• Do not drop the fuel injectors when installing
the fuel delivery pipe sub-assembly.

• Check that the fuel injectors rotate smoothly
after installing the fuel delivery pipe sub­assembly.

A116768

(b) Tighten the 3 bolts to the specified torque.

A

A

Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A

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

B

A116768E01