2az Fse Engine Repair Manual (Rm1083e)

01−1
INTRODUCTION − HOW TO USE THIS ENGINE REPAIR MANUAL
HOW TO USE THIS ENGINE REPAIR MANUAL

0108M−02
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ”Removing and Installing, Replacing, Disassembling, Installing and Checking,
Adjusting”, but ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Non−reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
OVERHAUL Camshaft,
No. 3 Camshaft Sub−assy
Camshaft Drive Gear
Camshaft Timing Tube Assy
7.5 (80, 66 in.·lbf)

No. 2 Camshaft,
Seal Washer No. 4 Camshaft Sub−assy
z Camshaft Setting Oil Seal Camshaft Driven Main Gear

Screw Plug
78 (790, 58)
15 (150, 11) Wave Washer Camshaft Timing Gear

Bolt Washer
Camshaft Sub Gear
N·m (kgf·cm, ft·lbf) : Specified torque Snap Ring
z Non−reusable part A54988
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

01−2
(d) Tightening torque, oil applying position, and non−reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step−by−step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
Illustration: Task heading: what to do

what to do and where
Detailed text:
Set part No. Component part No. how to do task
A59974
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.

01−3
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N×m (310 kgf×cm, 22 ft×lbf)

01−4 INTRODUCTION − REPAIR INSTRUCTION FOR ENGINE REPAIR
MANUAL
REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL

0108N−02
PRECAUTION
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES
(a) When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often
causes functional failure of the engine.
(1) Precaution before disassembly.
S Remove adequately all sand and mud adhere to the outside of engine .
(2) Precaution at reassembly.
S Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS
(a) The existence of scratches on the contact and revolving surfaces often causes oil leak and seisure.
(1) Precautions at disassembly and reassembly.
S When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).
S When fix the parts to the vise, do not directly catch it in the vise. Fix the parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas-
sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:
S Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.) is prohibited:
S Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS
(a) Each parts needs to be reassembled as the same position and direction as it disassembled.
(1) Precautions at disassembly and reassembly.
S Follow the directions when the manual designates to mark the matchmark and/or direction
mark.
S Disassembled parts needs to be put in order as disassembled, not to change position and/
or direction.
S Follow the directions when the manual instructs the position and direction.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES
8. NON−REUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW
PARTS
9. BASIC REPAIR HINT
(a) Precoated Parts:

(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.
INTRODUCTION − REPAIR INSTRUCTION FOR ENGINE REPAIR 01−5
MANUAL
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:

(1) In case of tightening by extending the entire length
L1 L2 of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
D02612 ing of the torque wrench by the formula.
(3) Formula T’ = T x L2/(L1 + L2)
T’ Reading of torque wrench {N×m (kgf×cm, ft×lbf)}
L1 L2 T Torque {N×m (kgf×cm, ft×lbf)}
L1 Length of SST or tool (cm)
L2 Length of torque wrench (cm)
D01201
L1 L2
D01202
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those
places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,
and do not spray much water so as to prevent slipping.
01−6 INTRODUCTION − REPAIR INSTRUCTION FOR ENGINE REPAIR
MANUAL
(3) Never use any electric equipment like an electric motor or a working light as they may cause
spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKE

PARTS
(a) If any metal tip is mixed in the inlet pass, that may give a
bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is
D01563 no mixing of a metal tip.
Flat Spring Clamp

12. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of inserting
portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force
Clamp Track to the arrow mark direction after the installation.
D25081

01−7
INTRODUCTION − TERMS FOR ENGINE REPAIR MANUAL
TERMS FOR ENGINE REPAIR MANUAL

0108O−02
ABBREVIATIONS USED IN MANUAL

Abbreviations Meaning
ABS Anti−Lock Brake System
A/C Air Conditioner
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACSD Automatic Cold Start Device
A.D.D. Automatic Disconnecting Differential
A/F Air−Fuel Ratio
AHC Active Height Control Suspension
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
APPROX. Approximately
ASSY Assembly
A/T Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
AUX Auxiliary
AVG Average
AVS Adaptive Variable Suspension
B+ Battery Voltage
BACS Boost Altitude Compensation System
BAT Battery
BDC Bottom Dead Center
B/L Bi−Level
B/S Bore−Stroke Ratio
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
CB Circuit Breaker
CCo Catalytic Converter For Oxidation
CD Compact Disc
CF Cornering Force
CG Center Of Gravity
CH Channel
CKD Complete Knock Down
COMB. Combination
CPE Coupe
CPS Combustion Pressure Sensor
CPU Central Processing Unit
CRS Child Restraint System
CTR Center
C/V Check Valve
CV Control Valve
CW Curb Weight
DC Direct Current
DEF Defogger
DFL Deflector

01−8
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overhead Cam
DP Dash Pot
DS Dead Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
ECAM Engine Control And Measurement System
ECD Electronic Controlled Diesel
ECDY Eddy Current Dynamometer
ECT Electronic Control Transmission
ECU Electronic Control Unit
ED Electro−Deposited Coating
EDU Electronic Driving Unit
EDIC Electric Diesel Injection Control
EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
EGR−VM EGR−Vacuum Modulator
ELR Emergency Locking Retractor
ENG Engine
ESA Electronic Spark Advance
ETCS Electronic Throttle Control System
EVAP Evaporative Emission Control
EVP Evaporator
E−VRV Electric Vacuum Regulating Valve
EX Exhaust
FE Fuel Economy
FF Front−Engine Front−Wheel−Drive
F/G Fuel Gauge
FIPG Formed In Place Gasket
FL Fusible Link
F/P Fuel Pump
FPU Fuel Pressure Up
FR Front
F/W Flywheel
FW/D Flywheel Damper
FWD Front−Wheel−Drive
GAS Gasoline
GND Ground
HAC High Altitude Compensator
H/B Hatchback
H−FUSE High Current Fuse
HI High
HID High Intensity Discharge (Head Lamp)
HSG Housing
HT Hard Top
HWS Heated Windshield System

01−9
IC Integrated Circuit
IDI Indirect Diesel Injection
IFS Independent Front Suspension
IG Ignition
IIA Integrated Ignition Assembly
IN Intake (Manifold, Valve)
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
ISC Idle Speed Control
J/B Junction Block
J/C Junction Connector
KD Kick−Down
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left−Hand
LHD Left−Hand Drive
L/H/W Length, Height, Width
LLC Long−Life Coolant
LNG Liquified Natural Gas
LO Low
LPG Liquified Petroleum Gas
LSD Limited Slip Differential
LSP & PV Load Sensing Proportioning And Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Indicator Lamp
MIN. Minimum
MP Multipurpose
MPI Multipoint Electronic Injection
MPX Multiplex Communication System
M/T Manual Transmission
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
NO. Number
O2S Oxygen Sensor
O/D Overdrive
OEM Original Equipment Manufacturing
OHC Overhead Camshaft
OHV Overhead Valve
OPT Option
O/S Oversize
P & BV Proportioning And Bypass Valve
PCS Power Control System
PCV Positive Crankcase Ventilation

01−10
PKB Parking Brake
PPS Progressive Power Steering
PS Power Steering
PTO Power Take−Off
P/W Power Window
R&P Rack And Pinion
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RRS Rigid Rear Suspension
RH Right−Hand
RHD Right−Hand Drive
RLY Relay
ROM Read Only Memory
RR Rear
RRS Rear−Wheel Drive
RWD Rear−Wheel Drive
SDN Sedan
SEN Sensor
SICS Starting Injection Control System
SOC State Of Charge
SOHC Single Overhead Camshaft
SPEC Specification
SPI Single Point Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
STJ Cold−Start Fuel Injection
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TBI Throttle Body Electronic Fuel Injection
TC Turbocharger
TCCS TOYOTA Computer−Controlled System
TCV Timing Control Valve
TDC Top Dead Center
TEMP. Temperature
TEMS TOYOTA Electronic Modulated Suspension
TFT Toyota Free−Tronic
TIS Total Information System For Vehicle Development
T/M Transmission
TMC TOYOTA Motor Corporation
TMMK TOYOTA Motor Manufacturing Kentucky, Inc.
TRC Traction Control System
TURBO Turbocharge
TWC Three−Way Catalyst
U/D Underdrive
U/S Undersize

01−11
VCV Vacuum Control Valve
VENT Ventilator
VIN Vehicle Identification Number
VPS Variable Power Steering
VSC Vehicle Skid Control
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
VVT−i Variable Valve Timing−intelligent
W/ With
WGN Wagon
W/H Wire Harness
W/O Without
1ST First
2ND Second
2WD Two Wheel Drive Vehicle (4 x 2)
3RD Third
4TH Fourth
4WD Four Wheel Drive Vehicle (4 x 4)
4WS Four Wheel Steering System
5TH Fifth

01−12
0108P−02
GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE TOYOTA TERMS
SAE TERMS
ABBREVIATIONS ( )−−ABBREVIATIONS
A/C Air Conditioning Air Conditioner

ACL Air Cleaner Air Cleaner, A/CL
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal −
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure HAC
CAC Charge Air Cooler Intercooler
CARB Carburettor Carburettor
CFI Continuous Fuel Injection −
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
CPP Clutch Pedal Position −
CTOX Continuous Trap Oxidizer −
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition −
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Comunication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode −
ECL Engine Control Level −
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
EEPROM Electrically Erasable Programmable Read Only Memory (EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition TOYOTA Distributorless Ignition (TDI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control −
Flash Electrically Erasable Programmable
FEEPROM −
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory −

FF Flexible Fuel −
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
01−13
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

IAC Idle Air Control Idle Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module −
IFI Indirect Fuel Injection Indirect Injection (IDL)
IFS Inertia Fuel−Shutoff −
ISC Idle Speed Control −
KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)

MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure −
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Lamp
MST Manifold Surface Temperature −
MVZ Manifold Vacuum Zone −
NVRAM Non−Volatile Random Access Memory −
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD On−Board Diagnostic On−Board Diagnostic System (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module −
PNP Park/Neutral Position −
PROM Programmable Read Only Memory −
PSP Power Steering Pressure −
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module −
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass E−ABV
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter −
SRI Service Reminder Indicator −
SRT System Readiness Test −
ST Scan Tool −
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
01−14
TCM Transmission Control Module Transmission ECU, ECT ECU

TP Throttle Position Throttle Position
TR Transmission Range −
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
Three−Way Catalytic (TWC)

TWC Three−Way Catalytic Converter Manifold Converter
CCRO
TWC+OC Three−Way + Oxidation Catalytic Converter CCR + CCo
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor
WOT Wide Open Throttle Full Throttle
WU−OC Warm Up Oxidation Catalytic Converter −
WU−TWC Warm Up Three−Way Catalytic Converter −
3GR Third Gear −
4GR Fourth Gear −

02−1
PREPARATION − ENGINE MECHANICAL
ENGINE MECHANICAL
023MZ−01
PREPARATION
SST
09011−38121 12 mm Socket Wrench for 12 CYLINDER BLOCK ASSY(2AZ−FSE)
Pointed Head
09032−00100 Oil Pan Seal Cutter PARTIAL ENGINE ASSY(2AZ−FSE)
09201−10000 Valve Guide Bushing Remover & CYLINDER HEAD ASSY(2AZ−FSE)

Replacer Set
(09201−01050) Valve Guide Bushing Remover & CYLINDER HEAD ASSY(2AZ−FSE)

Replacer 5
09201−41020 Valve Stem Oil Seal Replacer CYLINDER HEAD ASSY(2AZ−FSE)
09202−70020 Valve Spring Compressor CYLINDER HEAD ASSY(2AZ−FSE)
(09202−00010) Attachment CYLINDER HEAD ASSY(2AZ−FSE)
09213−54015 Crankshaft Pulley Holding Tool PARTIAL ENGINE ASSY(2AZ−FSE)
(91651−60855) Bolt PARTIAL ENGINE ASSY(2AZ−FSE)
09223−15030 Oil Seal & Bearing Replacer PARTIAL ENGINE ASSY(2AZ−FSE)
09223−22010 Crankshaft Front Oil Seal PARTIAL ENGINE ASSY(2AZ−FSE)

Replacer
09228−06501 Oil Filter Wrench PARTIAL ENGINE ASSY(2AZ−FSE)

02−2
09309−37010 Transmission Bearing Replacer PARTIAL ENGINE ASSY(2AZ−FSE)
09330−00021 Companion Flange Holding Tool PARTIAL ENGINE ASSY(2AZ−FSE)
09950−50013 Puller C Set PARTIAL ENGINE ASSY(2AZ−FSE)
(09951−05010) Hanger 150 PARTIAL ENGINE ASSY(2AZ−FSE)
(09952−05010) Slide Arm PARTIAL ENGINE ASSY(2AZ−FSE)
(09953−05020) Center Bolt 150 PARTIAL ENGINE ASSY(2AZ−FSE)
(09954−05021) Claw No.2 PARTIAL ENGINE ASSY(2AZ−FSE)
09950−60010 Replacer Set CYLINDER HEAD ASSY(2AZ−FSE)

CYLINDER BLOCK ASSY(2AZ−FSE)
(09951−00180) Replacer 18 CYLINDER HEAD ASSY(2AZ−FSE)
(09951−00200) Replacer 20 CYLINDER BLOCK ASSY(2AZ−FSE)
09950−70010 Handle Set PARTIAL ENGINE ASSY(2AZ−FSE)

CYLINDER HEAD ASSY(2AZ−FSE)
(09951−07100) Handle 100 PARTIAL ENGINE ASSY(2AZ−FSE)

CYLINDER HEAD ASSY(2AZ−FSE)
09960−10010 Variable Pin Wrench Set PARTIAL ENGINE ASSY(2AZ−FSE)

02−3
(09962−01000) Variable Pin Wrench Arm Assy PARTIAL ENGINE ASSY(2AZ−FSE)
(09963−00700) Pin 7 PARTIAL ENGINE ASSY(2AZ−FSE)
Recomended Tools
09031−00040 Pin Punch . CYLINDER HEAD ASSY(2AZ−FSE)
(09043−20060) Socket Hexagon Wrench 6 PARTIAL ENGINE ASSY(2AZ−FSE)
(09043−20120) Socket Hexagon Wrench 12 PARTIAL ENGINE ASSY(2AZ−FSE)
09043−50100 Bi−hexagon Wrench 10 mm PARTIAL ENGINE ASSY(2AZ−FSE)
SSM
08833−00070 ”Adhesive 1324,” CYLINDER BLOCK ASSY(2AZ−FSE)
THREE BOND 1324 or equivalent
Equipment
Angle gauge
Cylinder gauge
Dial indicator
Feeler gauge
Micro meter
Piston heater
Piston ring compressor
Plastigage
Reamer
Sandpaper (#400)
Slide calipers
Spring tension gauge
Straight edge
Torque wrench
V−block
Wooden block

02−4
PREPARATION − LUBRICATION
LUBRICATION
023N1−01
PREPARATION
Equipment
Feeler gauge
Straight edge
Torque wrench

02−5
PREPARATION − STARTING & CHARGING
STARTING & CHARGING

023N0−01
PREPARATION
SST
09285−76010 Injection Pump Camshaft Bearing GENERATOR ASSY (2AZ−FSE)
Cone Replacer
Recomended Tools
09041−00020 Torx Driver T25 STARTER ASSY (2AZ−FSE)
09904−00010 Expander Set STARTER ASSY (2AZ−FSE)
(09904−00050) No. 4 Claw STARTER ASSY (2AZ−FSE)
Equipment
Dial indicator
Ohmmeter
Torque wrench
Vernier caliper
V−block

03−1
SERVICE SPECIFICATIONS − STANDARD BOLT
STANDARD BOLT
030LK−08
HOW TO DETERMINE BOLT STRENGTH
Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt
4 4T
No Mark No Mark No Mark
5 5T
6 6T
w/ Washer w/ Washer
7 7T
8 8T
9 9T
10 10T
11 11T
B06431

03−2
030LL−08
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
6 1 5 55 48 in.·lbf 6 60 52 in.·lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 − − −
6 1 6.5 65 56 in.·lbf 7.5 75 65 in.·lbf

8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 − − −
6 1 8 80 69 in.·lbf 9 90 78 in.·lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 − − −
6 1 10.5 110 8 12 120 9

8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 − − −
8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130

03−3
030LM−08
HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut
4N
No Mark
5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark
6N
6N
7N (5T)
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
03−4
SERVICE SPECIFICATIONS − ENGINE MECHANICAL
ENGINE MECHANICAL
031H1−04
SERVICE DATA
Oil pump drive gear
Gear diameter (w/chain) Minimum 48.2 mm (1.898 in.)
Oil pump drive shaft gear
Crankshaft timing gear or sprocket
Chain tensioner slipper
Wear Maximum 1.0 mm (0.039 in.)
Chain vibration damper No.1
Wear Maximum 1.0 mm (0.039 in.)
Cylinder head set bolt
Bolt length Standard 161.3 to 162.7 mm (6.350 to 6.406 in.)
Maximum 164.2 mm (6.465 in.)
Chain sub−assy
Elongation Maximum 115.4 mm (4.543 in.)
Camshaft timing gear or sprocket
Sprocket diameter (w/chain) Minimum 97.3 mm (3.831 in.)
Camshaft
Circle runout Maximum 0.03 mm (0.0012 in.)
Cam lobe height Standard 45.510 to 45.610 mm (1.7917 to 1.7957 in.)
Minimum 45.430 mm (1.7886 in.)
Camshaft No.2
Cam lobe height Standard 45.983 to 46.083 mm (1.8106 to 1.8143 in.)
Minimum 45.900 mm (1.8071 in.)
No. 1 journal diameter 35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter 22.959 to 22.975 mm (0.9039 to 0.9045 in.)
Thrust clearance
Intake Standard 0.040 to 0.095 mm (0.0016 to 0.0037 in.)
Maximum 0.11 mm (0.0043 in.)
Exhaust Standard 0.080 to 0.135 mm (0.0032 to 0.0053 in.)
Maximum 0.15 mm (0.0059 in.)
Oil clearance
Intake No. 1 journal bearing mark 1 Standard 0.007 to 0.038 mm (0.0028 to 0.00150 in.)
Exhaust No. 1 journal Standard 0.040 to 0.079 mm (0.00157 to 0.00311 in.)
Other journals Standard 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
Intake No. 1 journal Maximum 0.07 mm (0.0028 in.)
Other journals Maximum 0.10 mm (0.0039 in.)
Valve clearance (Cold)
Intake 0.19 to 0.29 mm (0.007 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.012 to 0.0160 in.)
Cylinder head
Warpage
Cylinder block side Maximum 0.05 mm (0.0020 in.)
Intake manifold side Maximum 0.08 mm (0.0031 in.)
Exhaust manifold side Maximum 0.08 mm (0.0031 in.)
Inner compression spring
Free length 45.7 mm (1.799 in.)
Deviation Maximum 1.6 mm (0.063 in.)
Intake valve
Overall length Standard 101.71 mm (4.0043in.)
Minimum 101.21 mm (3.9846in.)
Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Margin thickness Standard 1.05 to 1.45 mm (0.041 to 0.057 in.)
Minimum 0.75 mm (0.030 in.)
03−5
Exhaust valve
Overall length Standard 101.15 mm (3.9823in.)
Minimum 100.70 mm (3.9646 in.)
Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Margin thickness Standard 1.2 to 1.6 mm (0.047 to 0.063 in.)
Intake valve guide bush
Bushing inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
Oil clearance Standard 0.025 to 0.060 mm (0.00098 to 0.00236 in.)
Maximum 0.08 mm (0.0031 in.)
Diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Protrusion height 9.6 to 10.0 mm (0.3779 to 0.3937 in.)
Exhaust valve guide bush
Maximum 0.10 mm (0.0039 in.)
Diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Protrusion height 9.6 to 10.0 mm (0.3779 to 0.3937 in.)
Valve lifter
Lifter diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Lifter bore diameter 31.009 to 31.025 mm (1.2208 to 1.2215 in.)
Maximum 0.08 mm (0.0032 in.)
Ring w/head pin
Protrusion height 5.5 mm (0.217 in.)
Connecting rod
Thrust clearance Standard 0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum 0.362 mm (0.0143 in.)
Maximum 0.08 mm (0.0031 in.)
Maximum 0.05 mm (0.0020 in.)
Out−of−alignment Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Rod twist Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)
Cylinder block
Warpage Maximum 0.05 mm (0.0020 in.)
Bore diameter Standard 88.500 to 88.513 mm (3.4842 to 3.3848 in.)
Piston
Piston diameter 88.439 to 88.449 mm (3.4818 to 3.4822 in.)
Piston oil clearance Standard 0.051 to 0.074 mm (0.0020 to 0.0029 in.)
Maximum 0.1 mm (0.0039 in.)
Piston ring
Ring groove clearance No. 1 0.030 to 0.080 mm (0.0012 to 0.0031 in.)
No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
Oil (side rail) 0.020 to 0.070 mm (0.0008 to 0.0028 in.)
End gap Standard No. 1 0.22 to 0.32 mm (0.0087 to 0.0126 in.)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Maximum No. 1 0.89 mm (0.0350 in.)
No. 2 1.35 mm (0.0531 in.)
Oil (side rail) 0.73 mm (0.0287 in.)
Piston pin
Piston pin diameter 21.997 to 22.009 mm (0.8660 to 0.8665 in.)
Maximum 0.010 mm (0.0039 in.)
Connecting rod bolt
Diameter Standard 7.2 to 7.3 mm (0.283 to 0.287 in.)

03−6
Crankshaft
Thrust clearance Standard 0.040 to 0.240 mm (0.0016 to 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Thrust washer thickness 1.930 to 1.980 mm (0.0760 to 0.0780 in.)
Main journal diameter 54.988 to 55.000 mm (2.1648 to 2.06535 in.)
Maximum 0.050 mm (0.0020 in.)
Crank pin taper and out− of −round Maximum 0.003 mm (0.0001 in.)
Crank pin diameter 47.990 to 48.000 mm (1.8894 to 1.8898 in.)
Crankshaft bearing cap set bolt
Diameter Standard 7.5 to 7.6 mm (0.295 to 0.299 in.)

03−7
031H2−04
TORQUE SPECIFICATION
Part Tightened N×m kgf×cm ft×lbf
Stiffening crankcase assy x Cylinder block 33 332 24
Oil control valve filter x Cylinder block 30 306 22
Cylinder block water drain cock x Stiffening crankcase assy 25 255 18
Cylinder head x Cylinder block 1st 79 806 58
2nd Turn 90_ Turn 90_ Turn 90_
Camshaft timing gear assy x Camshaft 54 551 40
Camshaft timing sprocket x Camshaft 54 551 40
Camshaft bearing cap No. 1 x Cylinder head 30 301 22
Camshaft bearing cap No. 2 x Cylinder head 30 301 22
Camshaft bearing cap No. 3 x Cylinder head 9.0 92 80 in.×lbf
Oil pump assy x Stiffening crankcase assy 19 194 14
Chain tensioner plate x Stiffening crankcase assy 12 122 9
Oil pump drive sprocket x Oil pump 30 301 22
Chain vibration damper No. 1 x Cylinder head 9.0 92 80 in.×lbf
Chain vibration damper No. 1 x Cylinder block 9.0 92 80 in.×lbf
Chain tensioner slipper x Cylinder block 19 194 14
Timing chain guide x Crankshaft bearing cap No. 1 9.0 92 80 in.×lbf
Timing chain cover (See page 14−5) Bolt A 9.0 92 80 in.×lbf
Bolt B 21 214 15
Bolt C 43 438 32
Nut 9.0 92 80 in.×lbf
Oil pan x Stiffening crankcase assy 9.0 92 80 in.×lbf
Oil pan drain plug x Oil pan 25 255 18
Water pump assy x Cylinder block 9.0 92 80 in.×lbf
Water pump pulley x Water pump assy 26 265 19
Crankshaft position sensor x Timing chain cover 9.0 92 80 in.×lbf
Crankshaft pulley x Crankshaft 180 1,835 132
Chain tensioner assy No. 1 x Timing chain cover 9.0 92 80 in.×lbf
Camshaft position sensor x Cylinder head 9.0 92 80 in.×lbf
Cylinder head cover x Cylinder head (See page 14−5) Bolt A 11 112 8
Bolt B 14 143 10
Bolt C 21 214 15
Nut 11 112 8
Oil filter union x Stiffening crankcase assy 30 306 22
Spark plug x Cylinder head 19 194 14
Ventilation valve x Cylinder head cover 19 194 14
Stud bolt x Cylinder head (See page 14−42) Bolt A 5.0 51 44 in.×lbf
Bolt B 5.0 51 44 in.×lbf
Bolt C 9.5 97 84 in.×lbf
Bolt D 9.5 97 84 in.×lbf
Connecting rod cap x Connecting rod 1st 25 250 18
2nd Turn 90_ Turn 90_ Turn 90_
Crankshaft bearing cap x Cylinder block 1st 20 204 15
2nd 40 408 30
Stud bolt x Cyllinder block (See page 14−56) Stud bolt A 5.0 51 44 in.×lbf
Stud bolt B 10 102 7
Stud bolt C 5.0 51 44 in.×lbf

03−8
SERVICE SPECIFICATIONS − LUBRICATION
LUBRICATION
031H5−04
SERVICE DATA
Oil pump
Side clearance Standard 0.030 to 0.085 mm (0.0012 to 0.0033 in.)
Maximum 0.16 mm (0.0063 in.)
Tip clearance Standard 0.080 to 0.160 mm (0.0031 to 0.0063 in.)
Maximum 0.35 mm (0.0138 in.)
Body clearance Standard 0.100 to 0.170 mm (0.00394 to 0.00669 in.)
Maximum 0.325 mm (0.01280 in.)

03−9
SERVICE SPECIFICATIONS − LUBRICATION
031H6−03
Oil pump x Oil pump cover 8.8 90 78 in.×lbf
Oil pump strainer x Oil pump cover 8.8 90 78 in.×lbf

03−10
SERVICE SPECIFICATIONS − STARTING & CHARGING
STARTING & CHARGING

031E6−05
SERVICE DATA
Magnetic switch resistance Terminal 50 − C Below 1 W
Terminal 50 − Switch body Below 1.5 W
Starter armature resistance Segments Below 1 W
Commutator − Coil core 10 kW or higher
Starter armature assy
Circle runout Standard 0.02 mm (0.0008 in.)
Maximum 0.05 mm (0.0020 in.)
Diameter Standard 29 mm (1.142 in.)
Minimum 28 mm (1.102 in.)
Starter brush holder assy
Brush length Standard 15.5 mm (0.610 in.)
Resistance (+) − (−) 10 kW or higher
Generator rotor assy
Rotor coil resistance at 20_C (68_F) 1.8 to 2.8 W
Slip ring diameter Standard 15.3 to 15.5 mm (0.602 to 0.610 in.)
Generator brush holder assy
Brush exposed length Standard 13.2 mm (0.520 in.) in new condition

03−11
SERVICE SPECIFICATIONS − STARTING & CHARGING
031E7−06
Starter commutator end frame assy x Starter brush holder assy 2.0 20 22 in.×lbf
Magnetic switch x Starter drive housing assy 2.3 23 20 in.×lbf
Starter commutator end frame assy x Starter drive housing assy 6.0 61 53 in.×lbf
Lead wire x Magnetic switch assy 5.9 60 52 in.×lbf
Pulley x Generator rotor assy 65 663 48
Drive end shield x Bearing retainer 3.1 32 27 in.×lbf
Stator sub−assy generator w/ rectifier x Drive end frame assy 3.5 36 31 in.×lbf
Regulator sub−assy generator w/ brush
x Stator sub−assy generator w/ rectifier
w/o washer 2.2 22 19 in.×lbf
w/ washer 1.2 12 11 in.×lbf
Generator rear end cover x Stator sub−assy generator w/ rectifier
(See page 19−9) Nut A 19.5 199 14
Nut B 12 122 9.0
Screw 2.4 24 21 in.×lbf

14−1
ENGINE MECHANICAL − PARTIAL ENGINE ASSY (2AZ−FSE)
PARTIAL ENGINE ASSY (2AZ−FSE)

141Q4−01
COMPONENTS
Oil Filler Cap Sub−assy
Oil Filler Cap Gasket x2
14 (143, 10)
11 (112, 8.0)
x2
x5 11 (112, 8.0)
Ventilation Valve
19 (194, 14)
Cylinder Head Cover Sub−assy
Cylinder Head Cover Gasket

Camshaft Position
Spark Plug Sensor
19 (194, 14)
x4
9.0 (92, 80 in.×lbf)
9.0 (92, 80 in.×lbf)
Bracket Water Pump Assy

Crankshaft Position Sensor
Water Pump Pulley
Oil Filter Union

26 (265, 19) 9.0 (92, 80 in.×lbf) 30 (306, 22)
Oil Filter Sub−assy

180 (1,835, 132)
Crankshaft Pulley
Oil Pan Sub−assy

z Gasket
Oil Pan Drain Plug
25 (255, 18) x 12
9.0 (92, 80 in.×lbf)
9.0 (92, 80 in.×lbf)
x2
N·m (kgf·cm, ft·lbf) : Specified torque

14−2
Chain Vibration
Damper No. 1
Chain Sub−assy Crankshaft Timing
Sprocket
Chain Tensioner Oil pump Drive

Slipper Shaft Sprocket
No. 2 Chain
Sub−assy
19 (194, 14)
Crankshaft Sensor Spring

Plate No. 1 Camshaft Timing Gear Sprocket
Chain Tensioner
9.0 (92, 80 in.×lbf) 30 (301, 22)

z Gasket
9.0 (92, 80 in.×lbf)
Timing Chain Guide 9.0 (92, 80 in.×lbf)

Oil Pump Assy
x2
19 (194, 14)
9.0 (92, 80 in.×lbf)
x2 9.0 (92, 80 in.×lbf)
Chain Tensioner Assy No. 1

x2
z Gasket
43 (438, 32)
43 (438, 32) x4
9.0 (92, 80 in.×lbf)
z Timing Chain Case Oil Seal
21 (214, 15) Timing Chain or Belt Cover Sub−assy

x8


14−3
x 16
9.0 (92, 80 in.×lbf)
30 (301, 22) x4
No. 1 Bearing Cap No. 3 Bearing Cap
Camshaft Bearing No. 1 No. 2 Bearing Cap

Camshaft
Camshaft Timing Gear Assy No. 2 Camshaft
Cylinder Head Bolt

54 (551, 39)
See page 14−5
54 (551, 39) 1st: 79 (806, 58)
2nd: Turn 90_
Camshaft Timing Sprocket
Camshaft Bearing No. 2

9.0 (92, 80 in.×lbf)
Oil Control Valve

z O−Ring
Cylinder Head Sub−assy
z Cylinder Head Gasket


14−4
z Engine Rear Oil Seal
z Gasket
Plug
30 (306, 22)
Oil Control Valve Filter

for Camshaft Timing
z O−ring
Stiffening Crankcase Assy
33 (337, 24) x5
x6
33 (337, 24)
No. 2 Balance Shaft
No. 1 Balance Shaft

Bearing
Balance Shaft Housing

See page 14−5
1st: 22 (224, 16) x8
2nd: Turn 90_
N×m (kgf×cm, ft×lbf) : Specified torque


14−5
141Q5−01
OVERHAUL
1. REMOVE OIL FILLER CAP SUB−ASSY
2. REMOVE OIL FILLER CAP GASKET
3. REMOVE VENTILATION VALVE SUB−ASSY
A77357
4. REMOVE SPARK PLUG

(a) Using a 16 mm plug wrench, remove the spark plugs.
16 mm Plug Wrench
A77236
5. REMOVE OIL FILTER SUB−ASSY

(a) Using SST, remove the oil filter.
SST 09228−06501
SST
A77425
6. REMOVE OIL FILTER UNION

(a) Using a 12 mm socket hexagon wrench, remove the oil fil-
ter union.
12 mm
Hexagon
Wrench
A77239

14−6
7. REMOVE CYLINDER HEAD COVER SUB−ASSY

(a) Remove the 9 bolts 2 nuts and cylinder head cover.
A64640
8. REMOVE CYLINDER HEAD COVER GASKET
9. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and sensor.
A77356
Timing Marks 10. REMOVE CRANKSHAFT PULLEY

(a) Turn the crankshaft pulley and align its groove with timing
mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing
sprockets are aligned with the timing marks of the No. 1
bearing cap, as shown in the illustration.
Timing Marks
Groove A77426
(c) Remove the crankshaft pulley.

(1) Using SST, fix the crankshaft pulley and loosen the
pulley set bolt.
SST
SST 09213−54015 (91651−60855), 09330−00021
A77380

14−7
(2) Using SST, remove the crankshaft pulley.

SST 09950−50013 (09951−05010, 09952−05010,
09953−05020, 09954−05021)
SST
A77381
11. REMOVE CHAIN TENSIONER ASSY NO.1

(a) Remove the 2 nuts, chain tensioner and gasket.
NOTICE:
Be sure not to operate the crankshaft without the chain tensioner.
12. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the 2 bolts and crankshaft position sensor.
A77359
13. REMOVE WATER PUMP PULLEY

(a) Using SST, remove the 4 bolts and pulley.
SST 09960−10010 (09962−01000, 09963−00700)
SST
A77427
14. REMOVE WATER PUMP ASSY

(a) Remove the 4 bolts, 2 nuts and clamp.
(b) Using a screwdriver, pry between the water pump and cyl-
inder block, and then remove the pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.
Pry
A64711
15. REMOVE OIL PAN DRAIN PLUG

14−8
16. REMOVE OIL PAN SUB−ASSY

(a) Remove the 12 bolts and 2 nuts.
A64641
(b) Insert the blade of SST between the crankcase and oil
pan. Cut off applied sealer and remove the oil pan.
SST 09032−00100
NOTICE:
Be careful not to damage the contact surface of the cylin-
der block and oil pan.
A00019
17. REMOVE TIMING CHAIN OR BELT COVER

SUB−ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Remove the timing chain cover by prying between the tim-
ing chain cover and cylinder head or cylinder block with
a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder block and cylinder head.
Pry
A64642
18. REMOVE TIMING GEAR CASE OR TIMING CHAIN

CASE OIL SEAL
(a) Using a screwdriver and a hammer, remove the oil seal.
A77242

14−9
19. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1

20. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.
21. REMOVE CHAIN VIBRATION DAMPER NO.1

(a) Remove the 2 bolts and damper.
A77355
22. REMOVE TIMING CHAIN GUIDE

(a) Remove the bolt and guide.
A77243
23. REMOVE CHAIN SUB−ASSY

24. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
90_ 25. REMOVE NO.2 CHAIN SUB−ASSY

(a) Turn the crankshaft counterclockwise by 90_, and align
Groove the adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
A77382

14−10
(b) Put a bar (f 4 mm) in the adjusting hole of the oil pump
drive shaft gear to temporarily lock the gear in position.
Remove the nut.
Adjusting Hole
A77383
(c) Remove the bolt, chain tensioner plate and spring.

(d) Remove the oil pump drive gear, oil pump drive shaft gear
and chain.
A66833
26. REMOVE OIL PUMP ASSY

(a) Remove the 3 bolts, oil pump and gasket.
A32684
1 3 5 4 2 27. REMOVE NO.2 CAMSHAFT

(a) Uniformly loosen and remove the No. 2 camshaft’s 10
bearing cap bolts in the sequence shown in the illustra-
tion. Then remove the 5 bearings.
(b) Remove the camshaft.
A77428
28. REMOVE CAMSHAFT

(a) Uniformly loosen and remove the No. 2 camshaft’s 10
tion. Then remove the 5 bearings.
(b) Remove the camshaft.
1 3 5 4 2 A77429

14−11
29. REMOVE CAMSHAFT BEARING NO.1
30. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

(a) Fix the camshaft with a vise and remove the camshaft tim-
ing sprocket.
NOTICE:
Be careful not to damage the camshaft.
A32167
31. REMOVE CAMSHAFT TIMING GEAR ASSY

Advance
(a) Fix the camshaft with a vise, and make sure that the cam-
Angle Port shaft timing gear does not move.
(b) Cover all the oil ports with vinyl tape except the advanced
angle side, as shown in the illustration.
A77413
(c) Using an air gun, apply about 150 kPa (1.5 kgf/cm, 21 psi)
of air pressure to the port on the advanced angle side.
CAUTION:
Some oil spraying will occur. Contain the spray with a shop
rag.
HINT:
This operation releases the lock pin for the extreme retarded
angle lock.
A31032 (d) Under the condition above, check that the camshaft tim-
ing gear can be turned by hand to the advanced angle
side (counterclockwise), the direction of the arrow in the
illustration.
Standard:
The camshaft timing gear can be turned by hand.
HINT:
The camshaft timing gear will turn to the advanced angle side
without applying force by hand depending on the force of the
air pressure applied. Also, if applying pressure to the oil path is
difficult as a result of air leakage from the port, the lock−pin may
be difficult to release.

14−12
(e) Remove the flange bolt from the camshaft timing gear.
Straight Pin NOTICE:
S Be sure not to remove the other 4 bolts.
S If planning to reuse the camshaft timing gear, release
the straight pin lock first, and then install the gear.
Flange Bolt
A32639
32. REMOVE CAMSHAFT BEARING NO.2
A32664
33. REMOVE CAMSHAFT HOUSING PLUG
A64712
3 7 9 6 2 34. REMOVE CYLINDER HEAD SUB−ASSY

(a) Using a 10 mm bi−hexagon wrench, uniformly loosen the
10 bolts in the sequence shown in the illustration. Re-
move the 10 cylinder head bolts and plate washers.
NOTICE:
S Be careful not to drop washers into the cylinder head.
S Head warpage or cracking could result from remov-
ing bolts in an incorrect order.
1 5 10 8 4
A77430
35. REMOVE CYLINDER HEAD GASKET

36. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB−ASSY
37. REMOVE OIL CONTROL VALVE FILTER
(a) Using a 12 mm hexagon wrench, remove the plug, gasket and filter.
38. REMOVE W/HEAD TAPER SCREW PLUG NO.1

14−13
39. REMOVE BALANCE SHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while
moving the balance shaft back and forth.
Standard thrust clearance:
0.050 to 0.090 mm (0.0020 to 0.0035 in.)
Maximum thrust clearance: 0.090 mm (0.0035 in.)
If the thrust clearance is greater than the maximum, replace the
balance shaft housing and bearings. If necessary, replace the
A53071 balance shaft.
40. REMOVE BALANCE SHAFT OIL CLEARANCE

(a) Uniformly loosen and remove the 8 bolts in the sequence
4 1 shown in the illustration.
NOTICE:
8 5
Be careful not to damage the contact surfaces of the bal-
6 7 ance shaft housing and crankcase.
HINT:
2 3
Keep the lower bearing and balance shaft housing together.
A92400 (b) Lift out the No. 1 and No. 2 balance shafts.
HINT:
Keep the upper bearing with the crankcase.
(c) Clean each bearing and journal.
(d) Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If nec-
essary, replace the balance shaft.
(e) Place the No. 1 and No. 2 balance shafts on the crank-
case.
(f) Lay a strip of Plastigage across each journal and install

the balance shaft housing.
(g) Apply a light coat of engine oil on the threads and under
Plastigage the heads of the balance shaft housing bolts.
A90849
(h) Uniformly tighten the 8 bolts in the sequence shown in the

illustration.
5 8 Torque: 22 N×m (220 kgf×cm, 16 ft×lbf)
HINT:
1 4
The balance shaft housing bolts are tightened in 2 progressive
3 2 steps.
7 6
A92400

14−14
(i) Mark the front side of each balance shaft housing bolt
Paint head with paint.
90_ Mark
(j) Retighten the bolts by 90_ as shown in the illustration.
Engine Front
(k) Check that the paint marks are now at a 90_ angle to the
front.
A50671
(l) Remove the balance shaft housing, and measure the

Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.031 mm (0.0002 to 0.0012 in.)
Maximum oil clearance: 0.031 mm (0.0012 in.)
(m) Completely remove the Plastigage after the inspection.
A13392
If the clearance is greater than the maximum, replace the bear-

ing. If necessary, replace the balance shaft.
If using a standard bearing, replace it with one of the same num-
ber.
Balance shaft housing journal bore diameter:
Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.)
Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.)
Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.)
Balance shaft journal diameter:
No. 1 22.985 to 23.000 mm (0.9049 to 0.9055 in.)
No. 1
Shaft FR Shaft RR Standard bearing center wall thickness:
Mark 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.)
Mark 2 1.490 to 1.492 mm (0.0587 to 0.0587 in.)
Mark 3 1.493 to 1.495 mm (0.0588 to 0.0589 in.)
No. 2 (n) Completely remove the Plastigage after the inspection.
Shaft FR No. 2
Shaft RR Mark
A53040
41. REMOVE BALANCE SHAFT

42. REMOVE BALANCE SHAFT BEARING NO. 1

14−15
43. REMOVE ENGINE REAR OIL SEAL

Tape (a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE:
After the removal, check the crankshaft for damage. If it is
damaged, smooth the surface with 400−grit sandpaper.
Cut Position
A77244
3 7 9 10 5
1 44. REMOVE STIFFENING CRANKCASE ASSY
(a) Uniformly loosen and remove the 11 bolts in the se-
quence shown in the illustration.
(b) Using a screwdriver, remove the crankcase by prying the
portions between the crankcase and cylinder block.
NOTICE:
Be careful not to damage the contact surfaces of the crank-
case and cylinder block.
6
4 8 11 2 A36837 (c) Remove the O−ring from the cylinder block.
45. INSPECT OIL PUMP DRIVE GEAR

(a) Wrap the chain around the drive gear.
(b) Using a vernier caliper, measure the drive gear diameter
with the chain.
Minimum gear diameter (w/chain): 48.2 mm (1.898 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
measurement.
EM2378 If the diameter is less than the minimum, replace the chain and
drive gear.
46. INSPECT OIL PUMP DRIVE SHAFT GEAR
(a) Wrap the chain around the drive shaft gear.
(b) Using a vernier caliper, measure the drive shaft gear di-
ameter with the chain.
NOTICE:
measurement.
A53036 If the diameter is less than the minimum, replace the chain and
drive shaft gear.
47. INSPECT CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the timing gear.
(b) Using a vernier caliper, measure the timing gear diameter
with the chain.
EM2378

14−16
NOTICE:
measurement.
If the diameter is less than the minimum, replace the chain and
timing gear.
48. INSPECT CHAIN TENSIONER SLIPPER
(a) Measure the tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the tensioner
slipper.
A33838
49. INSPECT CHAIN VIBRATION DAMPER NO.1

(a) Measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the chain
vibration damper.
A36686
50. INSPECT CYLINDER HEAD SET BOLT

(a) Using a vernier caliper, measure the length of the head
Overall Length bolts from the seat to the end.
Standard bolt length:
161.3 to 162.7 mm (6.350 to 6.406 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than the maximum, replace the bolt.
A94579
51. INSPECT CHAIN TENSIONER ASSY NO.1

Raise (a) Check that the plunger moves smoothly when the ratchet
pawl is raised.
Move
(b) Release the ratchet pawl and check that the plunger is
Lock locked in place by the ratchet pawl and does not move
when pushed with finger.
A77432

14−17
52. INSPECT CHAIN SUB−ASSY

115.4 mm (a) Using a vernier caliper, measure the length of the 15 links
(4.543 in.) with the chain fully stretched.
NOTICE:
Make the same measurements pulling at 3 or more random
places to obtain an average length.
Maximum chain elongation: 115.4 mm (4.543 in.)
15 Links If the elongation is greater than the maximum, replace the
A57478 chain.
53. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET

(a) Wrap the chain around the timing sprocket.
(b) Using a vernier caliper, measure the timing sprocket di-
ameter with the chain.
Minimum sprocket diameter (w/ chain):
97.3 mm (3.831 in.)
NOTICE:
A30206 measurement.
If the diameter is less than the minimum, replace the chain and
timing gear.
54. INSPECT CAMSHAFT

(a) Check 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.
EM1628
(b) Using a micrometer, measure the cam lobe height.

(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
45.510 to 45.610 mm (1.7917 to 1.7957 in.)
Minimum cam lobe height: 45.430 mm (1.7886 in.)
If the cam lobe height is less than the minimum, replace the
camshaft.
A36687

14−18
(c) Using a micrometer, measure the journal diameter.

No. 1 Journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9040 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
A36688
55. INSPECT NO.2 CAMSHAFT

(a) Check the camshaft for runout.
(1) Place the camshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
camshaft.
EM1628
(b) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:
45.983 to 46.083 mm (1.8106 to 1.8143 in.)
Minimum cam lobe height: 45.900 mm (1.8071 in.)
If the cam lobe height is less than the minimum, replace the
camshaft.
A36687
(c) Using a micrometer, measure the journal diameter.

No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
ance.
A36688
56. INSTALL BALANCE SHAFT BEARING NO. 1

(a) Install the bearings in the crankcase and balance shaft housing.
(b) Apply a light coat of engine oil on the bearings.

14−19
Matchmarks 57. INSTALL BALANCE SHAFT NO. 1 AND NO. 2

(a) Rotate the driven gear No. 1 of the balance shaft No. 1 as
indicated by the arrow in the illustration until it hits the
stopper.
(b) Confirm that the matchmarks on driven gear No. 1 and
No. 2 are matched.
Rotating Direction
A90850
(c) Align the timing marks of the No. 1 and No. 2 balance
Timing Marks shafts as shown in the illustration.
(d) Place the No. 1 and No. 2 balance shafts on the crank-
case.
(e) Apply a light coat of engine oil under the heads of the bal-
ance shaft housing bolts.
A13508
(f) Uniformly tighten the 8 bolts in the sequence shown in the

illustration.
5 8 Torque: 22 N×m (220 kgf×cm, 16 ft×lbf)
HINT:
1 4
The balance shaft housing bolts are tightened in 2 progressive
3 2 steps.
7 6
A92400
(g) Mark the front side of each balance shaft housing bolt
Paint head with paint.
90_ Mark
(h) Retighten the bolts by 90_ as shown in the illustration.
Engine Front
(i) Check that the painted marks are now at a 90_ angle to
the front.
A50671

14−20
58. INSTALL STIFFENING CRANKCASE ASSY

Seal Packing
(a) Apply seal packing in a continuous bead (seal width: 2.5
to 3 mm (0.10 to 0.12 in.)) to the places shown in the il-
lustration.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
S Install the crankcase within 3 minutes after applying
seal packing.
S Do not start the engine for at least 2 hours after the
installation.
7.5 mm
7.5 mm
(0.30 in.) A (0.30 in.) B C, D
4 mm
(0.16 in.)
A94182
(b) Place a new O−ring on the cylinder block, as shown in the

O−ring
illustration.
A53026
(c) Align the timing marks of the No. 1 and No. 2 balance
shafts as shown in the illustration.
(d) With the No. 1 crank pin of the crankshaft placed at 6
o’clock, place the No. 1 and No. 2 balance shafts on the
crankcase.
No. 1
Crank Pin Timing Mark
A91021
11 7 3 1 4 (e) Uniformly tighten the 11 bolts in the sequence shown in

8
the illustration.
10 6 2 5 9 A94183

14−21
Timing Marks (f) Confirm that the timing marks of the balance shafts are
matched when the key groove is placed at 6 o’clock, as
shown in the illustration.
Key
A92495
59. INSTALL ENGINE REAR OIL SEAL

(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign materials.
(b) Using SST and a hammer, evenly tap the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223−15030, 09950−70010 (09951−07100)
NOTICE:
SST A77434 Wipe off extra grease on the crankshaft.
60. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign substance is on the mesh part of the
filter.
(b) Using a 6 mm socket hexagon wrench, install a new gas-
Mesh Part ket and the oil control valve filter with the screw plug.
A77435
61. INSTALL CYLINDER HEAD GASKET

Lot No.
(a) Place a new gasket on the cylinder block surface with the
Intake Side Lot No. stamp placed upward.
NOTICE:
S Remove any oil from contact surface.
S Be careful of the installation direction.
Front S To avoid damage to the gasket, place the cylinder
Side head on the gasket carefully.
Exhaust Side
A77408

14−22
62. INSTALL CYLINDER HEAD SUB−ASSY

HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the 10 bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
9 3 2 6 8 (c) Using a 10 mm bi−hexagon wrench, uniformly tighten the

10 bolts in the sequence shown in the illustration.
7 5 1 4 10
A77438
(d) Mark the front side of each cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90_ in the sequence
90_
(f) Check that the painted marks are now at a 90_ angle to
Engine the front.
Front
Paint Mark
A00976 A77411
63. INSTALL CAMSHAFT HOUSING PLUG

(a) Apply engine oil to a new O−ring, and install the camshaft
housing plug.
NOTICE:
S Install the plug with its flange portions faced the man-
ifold.
S Insert the plug into the cylinder head until its flange
portions reach the installation surface of the cylinder
head.
Flange
A77247

14−23
64. INSTALL CAMSHAFT BEARING NO.2
65. INSTALL CAMSHAFT TIMING GEAR ASSY

Straight Pin
(a) Put the camshaft timing gear and the camshaft together
with the straight pin and key groove.
(b) Turn the camshaft timing gear (as shown in the illustra-
tion) while pushing it lightly against the camshaft. Push
further at the position where the pin enters the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
Key Groove A94185 angle side (to the right angle).
(c) Check that there is no clearance between the gear’s
flange and the camshaft.
(d) Tighten the flange bolt with the camshaft timing gear
fixed.
(e) Check that the camshaft timing gear can move to the re-
tarded angle side (the right direction) and is locked at the
extreme retarded angle position.
66. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET

(a) Fix the camshaft with a vise, and install the camshaft No.
2 timing gear.
A32167
67. INSTALL CAMSHAFT BEARING NO.1

14−24
68. INSTALL CAMSHAFT

(a) Examine the front marks and numbers of the 5 bearing
caps and install them. Then install the 10 bearing cap
bolts. Uniformly tighten the bolts in the sequence shown
in the illustration.
Torque:
30 N×m (301 kgf×cm, 22 ft×lbf) for bearing cap No. 1
9.0 N×m (92 kgf×cm, 80 in.×lbf) for bearing cap No. 3
5 3 1 2 4 NOTICE:
S Tighten the bolts after deciding the position for the
thrust direction of the camshaft by the bearing cap
No. 1.
S Install the camshaft with its timing mark of the cam-
No. 1 cylinder A77439 shaft timing gear on top.
69. INSTALL NO.2 CAMSHAFT

No. 1 cylinder
(a) Examine the front marks and numbers of the 5 bearing
Torque:
5 3 1 2 4
NOTICE:
S Tighten the bolts after deciding the position for the
thrust direction of the camshaft by the bearing cap
No. 2.
S Install the camshaft with its timing mark of the cam-
A77440 shaft timing gear on top.
70. INSTALL OIL PUMP ASSY

(a) Install a new gasket and the oil pump with the 3 bolts.
71. INSTALL NO.2 CHAIN SUB−ASSY

(a) Set the crankshaft key into the left horizontal position.
(b) Turn the cutout of the driveshaft to the top.
B11424

14−25
Mark Link (c) Align the mark links (yellow colored links) of he chain with
the timing marks of the gears as shown in the illustration.
Timing Mark
(d) Insert the gear with the chain into the crankshaft and oil
pump shaft.
(e) Temporarily tighten the oil pump drive shaft gear with the
nut.
Timing Mark
Mark Link A77384
Chain Tensioner Plate (f) Insert the damper spring into the adjusting hole, and
install the chain tensioner plate with the bolt.
Bolt Torque: 12 N×m (122 kgf×cm, 9 ft×lbf)
Spring
A90851
(g) Align the adjusting hole of the sprocket with the groove of
the oil pump.
(h) Put a bar (f 4 mm) into the adjusting hole of the sprocket
to temporarily lock the gear in position. Install the nut.
Groove
A77386
(i) Rotate the crankshaft clockwise by 90_, and align the

crankshaft key with the top.
90_
A77387

14−26
72. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
73. INSTALL CHAIN SUB−ASSY

(a) Set the No. 1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing gear/
sprocket and bearing caps (No. 1 and No. 2).
Timing Marks
Timing Marks
A77441
(2) Using the crankshaft pulley bolt, turn the crankshaft

and set the set key on the crankshaft upward.
A52505
(b) Align the mark link (blue or orange colored link) of the
chain with the timing mark of the crankshaft timing sprock-
et.
Timing Mark
Mark Link
A77442
(c) Using SST, tap in the sprocket.

SST 09309−37010
SST
A77443

14−27
Mark Links (d) Align the mark links (gold or yellow colored links) of the
Timing Marks Timing Mark
chain with the timing marks of the camshaft timing gear
and camshaft timing sprocket, and install the chain.
A77389
74. INSTALL TIMING CHAIN GUIDE

Torque: 9.0 N×m (92 kgf×cm, 80 in.×lbf)
75. INSTALL CHAIN VIBRATION DAMPER NO.1
76. INSTALL CHAIN TENSIONER SLIPPER
77. INSTALL CRANKSHAFT POSITION SENSOR PLATE

NO.1
(a) Install the sensor plate with the F mark facing forward.
A53064
78. INSTALL TIMING GEAR CASE OR TIMING CHAIN

CASE OIL SEAL
SST (a) Using SST, tap in a new oil seal until its surface is flush
with the timing chain cover edge.
SST 09223−22010
(b) Apply a light coat of MP grease to the lip of a new oil seal.
NOTICE:
Keep the gap between the timing chain cover edge and the
A77444 oil seal free of foreign matter.
79. INSTALL TIMING CHAIN OR BELT COVER SUB−ASSY

NOTICE:
S Install the chain cover within 3 minutes after applying
seal packing.
installation.
(a) Remove any old packing (FIPG) material and be careful
Seal Packing
A77445 not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
14−28
(b) Apply seal packing in a continuous bead (seal width: 2

mm (0.08 in.)) as shown in the illustration.
(c) Apply seal packing in a continuous bead (seal width: 3 to

Seal Packing 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
4 mm (0.16 in.)
A
A
A to A
2.5 mm
(0.098 in.)
Seal Width: 3 to 4 mm
A77391
(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
9.0 N×m (92 kgf×cm, 80 in.×lbf) for bolt A
Nut Nut
C 21 N×m (214 kgf×cm, 15 ft×lbf) for bolt B
C 43 N×m (438 kgf×cm, 32 ft×lbf) for bolt C
C
9.0 N×m (92 kgf×cm, 80 in.×lbf) for nut
C C
A
B B
B
B
B
B
A77251

14−29
80. INSTALL OIL PAN SUB−ASSY

NOTICE:
Seal Packing S Remove any oil from the contact surface.
S Install the oil pan within 3 minutes after applying seal
packing.
installation.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the cylinder
6 mm (0.24 in.) block and oil pan.
(b) Apply seal packing in a continuous bead (seal width: 3 to
4 mm (0.12 to 0.16 in.)) as shown in the illustration, and
Seal width: 3 to 4 mm install the oil pan.
A77392 Seal packing: Part No. 08826−00080 or equivalent
(c) Install the oil pan with the 12 bolts and 2 nuts.
A64641
81. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and oil pan drain plug with a new gasket.
82. INSTALL WATER PUMP ASSY

(a) Clean the contact surface of the cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.2
to 2.5 mm (0.09 to 0.10 in.)) to the outside edge of the wa-
0.5 to 1.0 mm ter pump.
(0.019 to 0.039 in.) Seal packing: Part No. 08826−00100 or equivalent
NOTICE:
Seal width S Remove any oil from the contact surface.
2.2 to 2.5 mm
A77446 S Install the water pump within 5 minutes after applying
seal packing.
S Do not start the engine for at least 2 hours after instal-
ling.

14−30
(c) Install the water pump with the 4 bolts and 2 nuts.
NOTICE:
Tighten the outside bolts and nuts with the clamp.
A64722
83. INSTALL WATER PUMP PULLEY

(a) Using SST, install the water pump pulley.
SST 09960−10010 (09962−01000, 09963−00700)
84. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O−ring.
(b) Install the crankshaft position sensor with the bolt.
SST Torque: 9.0 N×m (92 kgf×cm, 80 in.×lbf)
A77447
(c) Confirm that the wire harness of the sensor is placed as

Wire Harness shown in the illustration.
Clamp
Rib
A77448
85. INSTALL CRANKSHAFT PULLEY

(a) Install the pulley.
(b) Using SST, tighten the set bolt.
SST
SST 09213−54015 (91651−60855), 09330−00021
Torque: 180 N×m (1,835 kgf×cm, 132 ft×lbf)
A77393
86. INSTALL CHAIN TENSIONER ASSY NO.1

(a) Release the ratchet pawl, fully push in the plunger and ap-
Raise ply the hook to the pin so that the plunger cannot spring
out.
Push
Hook
Pin
A77394

14−31
(b) Install a new gasket and the chain tensioner with the 2
nuts.
NOTICE:
If the hook is released while inserting, apply the hook
again, and insert the chain tensioner.
Engine
Front
A77395
(c) Turn the crankshaft pulley counterclockwise, and check

that the plunger knock pin is free from the hook.
Disconnect
Pin
Hook Turn
A77396
(d) Turn the crankshaft clockwise and check that the slipper
is pushed by the plunger.
Plunger
Push
Turn A77397
Timing Marks 87. INSPECT VALVE CLEARANCE

(a) Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing gear
and sprocket are aligned with the timing marks of the
bearing cap No. 1 and No. 2 as shown in the illustration.
HINT:
Timing Marks Inspect and adjust the valve clearance when the engine is cold.
Groove A77449

14−32
No. 1 Cylinder TDC/Compression (c) Check only the valve indicated on the left.
IN (1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and the camshaft.
(2) Record valve clearance measurements that are out
of the specified range. These measurements will be
used later to determine the size of the adjustment
shim to be installed.
EX Valve clearance (Cold):
A77378 Item Specified Condition
Intake 0.19 to 0.29 mm (0.008 to 0.011 in.)
(d) Turn the crankshaft clockwise 1 revolution (360_) and set
the No. 4 cylinder to TDC/compression.
No. 4 Cylinder TDC/Compression (e) Check only the valve indicated on the left.
(1) Using a feeler gauge, measure the clearance be-
IN
tween the valve lifter and the camshaft.
(2) Record valve clearance measurements that are out
of the specified range. These measurements will be
used later to determine the size of the adjustment
shim to be installed.
Valve clearance (Cold):
EX
A77379 Item Specified Condition
Intake 0.19 to 0.29 mm (0.008 to 0.011 in.)
Paint Mark Paint Mark 88. ADJUST VALVE CLEARANCE

NOTICE:
Be sure not to turn the crankshaft without the chain ten-
sioner.
(a) Turn the crankshaft 1 revolution (360_) clockwise, and set
Timing Mark the No. 1 cylinder to TDC/compression.
Timing Mark
Groove
(b) Place matchmarks on the timing chain and camshaft tim-
ing gear.
A77450 (c) Remove the 2 bolts and the chain tensioner.
Loosen Hold (d) Fix the camshaft with a wrench and then loosen the
sprocket bolt.
NOTICE:
Be careful not to damage the valve lifter.
A77412

14−33
(e) Uniformly loosen and remove the No. 2 camshaft’s 10

tion. Then remove the 5 bearing caps.
1 3 5 4 2 A77451
(f) Raise the No. 2 camshaft and remove it. Then remove the
sprocket bolt.
(g) Remove the camshaft timing sprocket and the timing
chain from the No. 2 camshaft.
(h) Remove the camshaft timing sprocket from the timing
chain.
A87614
1 3 5 4 2
(i) Uniformly loosen and remove the No. 1 camshaft’s 10
tion. Then remove the 5 bearing caps.
(j) Remove the camshaft.
A77452
(k) Tie the timing chain with a string.

NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(l) Remove the valve lifters.
A32556
(m) Using a micrometer, measure the thickness of the re-

moved lifter.
(n) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified valve.
A Thickness of the new lifter
B Thickness of the used lifter
C Measured valve clearance
A01082

14−34
Valve clearance:
Item Specified Condition
Intake A = B + (C − 0.24 mm (0.0094 in.))
Exhaust A = B + (C − 0.35 mm (0.0138 in.))
EXAMPLE: (Intake)
Measured valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) − 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.)
(Measured value − Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. ”50”
(o) Select a new lifter with a thickness as close as possible
to the calculated values.
HINT:
S Lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.)
S Refer to new lifter thickness table on the following 2
pages.

Valve Lifter Selection Chart (Intake)

ENGINE MECHANICAL
−
New Lifter Thickness mm (in.)

Lifter Lifter Lifter
Thickness Thickness Thickness
No. No. No.
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)

Intake valve clearance (Cold): 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
0.19 to 0.29 mm (0.008 to 0.011 in.)
22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter is installed, and the measured 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
(0.2067 in.) lifter with a new No. 42 lifter. 28 5.280 (0.2079) 52 5.520 (0.2173)
A77296
14−35
Valve Lifter Selection Chart (Exhaust)
14−36

ENGINE MECHANICAL
−
New lifter thickness mm (in.)

Lifter Lifter Lifter
Thickness Thickness Thickness
No. No. No.
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)
Exhaust valve clearance (Cold): 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
0.30 to 0.40 mm (0.012 to 0.016 in.)
22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter is installed, and the measured 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
(0.2102 in.) lifter with a new No. 42 lifter. 5.280 (0.2079) 52 5.520 (0.2173)
28
A77297
14−37
(p) Install the timing chain on the No. 1 camshaft timing gear,
Paint Mark
with the paint mark aligned with the timing marks on the
camshaft timing gear.
Timing Mark
A77254
5 3 1 2 4 (q) Examine the front marks and numbers of the 5 bearing

Torque:
Bearing Cap No. 3
Bearing Cap No. 1 A77415
Paint Mark (r) Put the No. 2 camshaft on the cylinder head with the paint
mark of the chain aligned with the timing mark on the cam-
shaft timing sprocket.
Timing Mark A77453
(s) Raise the No. 2 camshaft and temporarily tighten the

sprocket bolt.
A52473
Bearing Cap No. 2 Bearing Cap No. 3 (t) Examine the front marks and numbers of the 5 bearing
Torque:
5 3 1 2 4 A77416

14−38
Tighten Hold (u) Fix the camshaft with a wrench, then tighten the sprocket
bolt.
NOTICE:
Be careful not to damage the valve lifter.
A77417
(v) Check that the timing chain paint marks are aligned with
the camshaft timing sprocket timing mark and the cam-
shaft timing gear timing mark. Also check the alignment
7 Links of the pulley groove and chain cover timing mark.
Paint Mark Paint Mark
Timing Marks Timing Mark

Groove
A77454
(w) Install the chain tensioner.

(1) Release the ratchet pawl, fully push in the plunger
Raise and apply the hook to the pin so that the plunger
cannot spring out.
Push
Hook
Pin
A77394
(2) Install a new gasket and the chain tensioner with the
2 nuts.
NOTICE:
When installing the tensioner, set the hook again if the
hook releases the plunger.
Engine
Front
A77395

14−39
(3) Turn the crankshaft counterclockwise, and discon-

nect the plunger knock pin from the hook.
Disconnect
Pin
Hook Turn
A77396
(4) Turn the crankshaft clockwise, and check that the

slipper is pushed by the plunger.
Plunger
Push
Turn
A77510
89. INSTALL CAMSHAFT POSITION SENSOR

90. INSTALL CYLINDER HEAD COVER GASKET
91. INSTALL CYLINDER HEAD COVER SUB−ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations shown in the illustra-
Seal Packing tion.
NOTICE:
S Install the cylinder head cover within 5 minutes after
applying seal packing.
S Do not apply engine oil for at least 2 hours after the
A77399 installation.
(c) Install the cylinder head cover with the 9 bolts and 2 nuts.
A A C C Torque:
A
11 N×m (112 kgf×cm, 8 ft×lbf) for bolt A
B B 14 N×m (143 kgf×cm, 10 ft×lbf) for bolt B
21 N×m (214 kgf×cm, 15 ft×lbf) for bolt C
11 N×m (112 kgf×cm, 8 ft×lbf) for nut
A Nut
Nut A A77346
92. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, install the oil filter union.

14−40
93. INSTALL OIL FILTER SUB−ASSY

(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228−06501
SST
A77425
94. INSTALL SPARK PLUG

95. INSTALL VENTILATION VALVE SUB−ASSY
(a) Apply adhesive on the threads of the ventilation valve.
Adhesive: Part No. 08833−00070 THREE BOND 1324 or equivalent
96. INSTALL OIL FILLER CAP GASKET
97. INSTALL OIL FILLER CAP SUB−ASSY

14−41
ENGINE MECHANICAL − CYLINDER HEAD ASSY (2AZ−FSE)
CYLINDER HEAD ASSY (2AZ−FSE)

141Q6−01
COMPONENTS
Valve Lifter
Valve Retainer Lock
Retainer
Inner Compression Spring

Intake Valve Guide Bush z Valve Stem Oil Seal
Valve Spring Seat
Exhaust Valve Guide Bush
Stud Bolt
Ring w/ Head Pin
Cylinder Head Assy
Exhaust Valve
Intake Valve
z Non−reusable part
A77366

14−42
141Q7−01
OVERHAUL
1. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
2. REMOVE INTAKE VALVE

SST (a) Using SST and wooden blocks, compress and remove
the 8 valve spring retainer locks.
SST 09202−70020 (09202−00010)
(b) Remove the retainer, valve spring and valve.
HINT:
Arrange the removed parts in the correct order.
Wooden Blocks A77455
3. REMOVE EXHAUST VALVE

SST
(a) Using SST and wooden blocks, compress and remove
the 8 valve spring retainer locks.
SST 09202−70020 (09202−00010)
(b) Remove the retainer, valve spring and valve.
HINT:
Arrange the removed parts in the correct order.
Wooden Blocks
A77456
4. REMOVE VALVE STEM OIL SEAL

(a) Using needle−nose pliers, remove the oil seals.
A14202
5. REMOVE VALVE SPRING SEAT

(a) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Store the removed parts in the correct order so that they can be
returned to the original locations when re−assembling.
A14192
6. REMOVE STUD BOLT

14−43
7. INSPECT CYLINDER HEAD FOR FLATNESS

(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side 0.05 mm (0.0020 in.)
Intake manifold side 0.08 mm (0.0031 in.)
Exhaust manifold
0.08 mm (0.0031 in.)
side
Cylinder Block Side
If the warpage is greater than the maximum, replace the cylin-
der head.
Intake Manifold Side
Exhaust Manifold Side
A77255
8. INSPECT CYLINDER HEAD FOR CRACKS

(a) Using a dye penetrant, check the intake ports, exhaust
ports and cylinder surface for cracks.
If cracked, replace the cylinder head.
A14180
9. INSPECT VALVE SEATS

(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat according to the fol-
Width lowing procedure.
(1) If blue appears 360_ around the valve face, the
valve face is concentric. If not, replace the valve.
A77457

14−44
(2) If blue appears 360_ around the valve seat, the

guide and valve face are concentric. If not, resur-
face the valve seat.
(3) Check that the valve seat contact is in the middle of
the valve face with the width between 1.0 to 1.4 mm
(0.039 to 0.055 in.).
10. REPAIR VALVE SEATS
NOTICE:
Keep the lip free of foreign matter.
(a) If the seating is too high on the valve face, use 30_ and
45_ 45_ cutters to correct the seat.
30_
1.0 to 1.4 mm (0.039 to 0.055 in.) A77502
(b) If the seating is too low on the valve face, use 75_ and 45_
75_
cutters to correct the seat.
45_ (c) Hand−rub the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
1.0 to 1.4 mm (0.039 to 0.055 in.) A77503
11. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Intake 0.040 to 0.095 mm (0.0016 to 0.0037 in.)
A36626 Maximum thrust clearance:
Intake 0.11 mm (0.0043 in.)
Exhaust 0.15 mm (0.0059 in.)
cylinder head. If the thrust surface is damaged, replace the
camshaft.

14−45
12. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nal.
A36627
(d) Install the bearing caps.

Torque:
30 N×m (301 kgf×cm, 22 ft×lbf) for No. 1 bearing cap
30 N×m (301 kgf×cm, 22 ft×lbf) for No. 2 bearing cap
9.0 N×m (92 kgf×cm, 80 in.×lbf) for No. 3 bearing cap
NOTICE:
Do not turn the camshaft.
A32645
(e) Remove the bearing cap and measure the Plastigage at

its widest point.
Intake No. 1 journal
0.007 to 0.038 mm (0.00028 to 0.0015 in.)
bearing mark 1
0.080 to 0.038 mm (0.00031 to 0.015 in.)
bearing mark 2
A36628 0.080 to 0.038 mm (0.00031 to 0.015 in.)
bearing mark 3
Exhaust No. 1 journal 0.040 to 0.079 mm (0.00157 to 0.00311 in.)
Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
Maximum oil clearance:
Intake No. 1 journal 0.07 mm (0.0028 in.)
Other journals 0.10 mm (0.0039 in.)
NOTICE:
Completely remove the plastigage after the inspection.
If the oil clearance is greater than the maximum, replace the
camshaft. If necessary, replace the cylinder head.

14−46
If the oil clearance on the No. 1 journal is greater than the maxi-
mum, choose a new bearing and install it.
Cylinder head journal bore diameter:
Mark 1 40.000 to 40.008 mm (1.57480 to 1.57511 in.)
Mark 2 40.009 to 40.017 mm (1.57515 to 1.57547 in.)
Number Mark Mark 3 40.018 to 40.025 mm (1.57551 to 1.57578 in.)

Standard bearing center wall thickness:
Mark 1 2.000 to 2.004 mm (0.07874 to 0.07890 in.)
Number Mark A77460 Mark 2 2.005 to 2.008 mm (0.07894 to 0.07905 in.)
Mark 3 2.009 to 2.012 mm (0.07909 to 0.07921 in.)
Camshaft journal diameter:
35.971 to 35.985 mm (1.41648 to 1.41673 in.)
13. INSPECT INNER COMPRESSION SPRING

(a) Using a vernier caliper, measure the free length of the
valve spring.
Free length: 45.7 mm (1.799 in.)
If the free length is not as specified, replace the valve spring.
EM0801
(b) Using steel squares, measure the deviation of the valve

Deviation spring.
Maximum deviation: 1.6 mm (0.063 in.)
If the deviation is greater than the maximum, replace the valve
spring.
A77461
14. INSPECT INTAKE VALVE

(a) Using a vernier caliper, measure the valve overall length.
Standard overall length: 101.71 mm (4.0043 in.)
Minimum overall length: 101.21 mm (3.9846 in.)
If the overall length is less than the minimum, replace the valve.
EM2534

14−47
(b) Using a micrometer, measure the diameter of the valve

stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
A32770
(c) Using a vernier caliper, measure the valve head margin

thickness.
Standard margin thickness:
1.05 to 1.45 mm (0.041 to 0.057 in.)
Minimum margin thickness: 0.75 mm (0.030 in.)
If the margin thickness is less than the minimum, replace the
Margin
valve.
Thickness
A77462
15. INSPECT EXHAUST VALVE

(a) Using a vernier caliper, measure the valve overall length.
Standard overall length: 101.15 mm (3.9823 in.)
Minimum overall length: 100.70 mm (3.9646 in.)
Overall Length If the overall length is less than the minimum, replace the valve.
EM2534
(b) Using a micrometer, measure the diameter of the valve

stem.
Valve stem diameter:
5.465 to 5.480 mm (0.2152 to 0.2157 in.)
Z00052
(c) Using a vernier caliper, measure the valve head margin

thickness.
Standard margin thickness:
1.2 to 1.6 mm (0.047 to 0.063 in.)
Minimum margin thickness: 0.9 mm (0.035 in.)
If the margin thickness is less than the minimum, replace the
Margin
valve.
Thickness
A77462

14−48
16. INSPECT INTAKE VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the inside diameter of the
guide bush.
Bushing inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the
guide bush inside diameter measurement.
A13367 0.025 to 0.060 mm (0.00098 to 0.00236 in.)
If the clearance is greater than the maximum, replace the valve
and guide bush (see steps 18 and 20).
17. INSPECT EXHAUST VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the inside diameter of the
guide bush.
Bushing inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
A13367 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
If the clearance is greater than the maximum, replace the valve
and guide bush (see steps 19 and 21).
18. REMOVE INTAKE VALVE GUIDE BUSH

(a) Gradually heat the cylinder head to 80 to 100_C (176 to
212_F).
A13100
(b) Using SST and a hammer, tap out the guide bush.
SST 09201−10000 (09201−01050), 09950−70010
(09951−07100)
SST
A77463

14−49
19. REMOVE EXHAUST VALVE GUIDE BUSH

(a) Gradually heat the cylinder head to 80 to 100_C (176 to
212_F).
A13100
(b) Using SST and a hammer, tap out the guide bush.
SST SST 09201−10000 (09201−01050), 09950−70010
(09951−07100)
A77464
20. INSTALL INTAKE VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter
of the cylinder head.
(b) Select a new guide bush (STD or O/S 0.05).
Bush size Bush bore diameter
Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
If the bush bore diameter of the cylinder head is greater than
A50496 10.306 mm (0.4057 in.), machine the bush bore diameter to be-
tween 10.333 and 10.344 mm (0.4068 to 0.4072 in.).
10.344 mm (0.4072 in.), replace the cylinder head.
(c) Using SST and a hammer, tap in a new guide bush to the
specified protrusion height.
Protrusion height:
SST
9.6 to 10.0 mm (0.3779 to 0.3937 in.)
SST 09201−10000 (09201−01050), 09950−70010
(09951−07100), 23801
(d) Using a sharp 5.5 mm reamer, ream the guide bush to ob-
tain the standard specified clearance between the guide
A77465 bush and valve stem.
0.025 to 0.060 mm (0.00098 to 0.00236 in.)

14−50
21. INSTALL EXHAUST VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter
(b) Select a new guide bush (STD or O/S 0.05).
Bush size Bush bore diameter
Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
A50498 10.306 mm (0.4057 in.), machine the bush bore diameter to be-
tween 10.333 and 10.344 mm (0.4068 to 0.4072 in.).
10.344 mm (0.4072 in.), replace the cylinder head.
(c) Using SST and a hammer, tap in a new guide bush to the
SST specified protrusion height.
Protrusion height:
9.6 to 10.0 mm (0.3779 to 0.3937 in.)
(d) Using a sharp 5.5 mm reamer, ream the guide bush to ob-
tain the standard specified clearance between the guide
bush and valve stem.
SST 09201−10000 (09201−01050), 09950−70010
A77466 (09951−07100), 23801
0.030 to 0.065 mm (0.00118 to 0.00256 in.)
22. INSPECT VALVE LIFTER

(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
P16860
(b) Using a caliper gauge, measure the lifter bore diameter

Lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
ance.
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
A13374

14−51

0.033 to 0.059 mm (0.0013 to 0.0023 in.)
If the oil clearance is greater than the maximum, replace the lift-
er. If necessary, replace the cylinder head.
23. INSTALL RING W/HEAD PIN
5.5 mm
Upper Side (a) Using a plastic−faced hammer, tap in a new ring pin to the
(0.217 in.)
Protrusion height: 5.5 mm (0.217 in.)
11 mm
(0.433 in.)
5.5 mm
(0.217 in.)
11 mm
(0.433 in.) A94186
24. INSTALL RING PIN

Upper Side
(a) Using a plastic−faced hammer, tap in a new ring pin to the
Protrusion height: 6.5 mm (0.256 in.)
5 mm
(0.197 in.)
6.5 mm
(0.256 in.)
13.8 mm
(0.543 in.)
A94187
25. INSTALL TIGHT PLUG

(a) Apply seal packing to the cylinder head as shown in the
illustration.
(b) Using SST, tap in plug to the specified protrusion height.
SST 09950−60010 (09951−00180), 09950−70010
(09951−07100)
Protrusion height: 1.5 to 2.5 mm (0.059 to 0.098 in.)
1.5 to 2.5 mm
(0.059 to 0.098
in.)
2AZ−FSE ENGINE REPAIR MANUAL Seal Packing

(RM1083E)
A77258
14−52
26. INSTALL STUD BOLT

Torque:
5.0 N×m (51 kgf×cm, 44 in.×lbf) for bolt A
5.0 N×m (51 kgf×cm, 44 in.×lbf) for bolt B
9.5 N×m (97 kgf×cm, 84 in.×lbf) for bolt C
9.5 N×m (97 kgf×cm, 84 in.×lbf) for bolt D
Front Upper
Intake Manifold Side
20
(0.79)
93.5
(3.68)
12
(0.47)
46.5 18
14
(1.83) (0.71) 37.5
(0.55) 31.5
(1.24) (1.48)
9 12 16 13
(0.35) (0.47) (0.63) (0.51)
A94377
27. INSTALL VALVE SPRING SEAT

14−53
28. INSTALL VALVE STEM OIL SEAL

Intake Side Exhaust Side (a) Apply a light coat of engine oil on a new oil seal.
NOTICE:
Gray Pay close attention when installing the intake and exhaust
oil seals. For example, installing the intake oil seal into the
Black exhaust or installing the exhaust oil seal to the intake can
cause installation problems later.
HINT:
A77467 The intake valve oil seal is gray and the exhaust valve oil seal
is black.
(b) Using SST, push in the oil seal.
SST 09201−41020
SST
A77468
29. INSTALL INTAKE VALVE

SST (a) Install the valve, spring and retainer to the cylinder head.
(b) Using SST and wooden blocks, compress the spring and
install the 2 retainer locks.
SST 09202−70020 (09202−00010)
Wooden Blocks A77455
(c) Using a plastic−faced hammer and a discarded valve with

Vinyl Tape
its tip wrapped in tape, lightly tap the installed valve to en-
sure that it is securely fit.
NOTICE:
Be careful not to damage the valve stem tip.
Valve Stem A77469
SST 30. INSTALL EXHAUST VALVE

(a) Install the valve, spring and retainer to the cylinder head.
(b) Using SST and wooden blocks, compress the spring and
install the 2 retainer locks.
SST 09202−70020 (09202−00010)
Wooden Blocks
A77456

14−54
(c) Using a plastic−faced hammer and a discarded valve with

Vinyl Tape
its tip wrapped in tape, lightly tap the installed valve to en-
sure that it is securely fit.
NOTICE:
Be careful not to damage the valve stem tip.
Valve Stem A77469
31. INSTALL VALVE LIFTER

(a) Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied.
NOTICE:
Install the valve lifters in their original places.

14−55
ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2AZ−FSE)
CYLINDER BLOCK ASSY (2AZ−FSE)

141Q8−01
COMPONENTS
Piston Ring Set
z Snap Ring
Piston
z Snap Ring Piston Pin
Connecting Rod
Connecting Rod Bearing
Cylinder Block Assy
Crankshaft Thrust Washer
Crankshaft Bearing
Crankshaft
Connecting Rod Bearing Crankshaft Bearing
Connecting Rod Cap Crankshaft Bearing Cap

Connecting Rod Cap Bolt Crankshaft Bearing Cap Bolt
See page 14−56
See page 14−56
1st: 25 (250, 18)
1st: 20 (204, 15)
2nd: Turn 90_
2nd: 40 (410, 30)
3rd: Turn 90_

14−56
141Q9−01
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE

moving the connecting rod back and forth.
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
connecting rod assembly(s). If necessary, replace the crank-
A36642 shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE

HINT:
The connecting rod cap bolts are tightened in 2 progressive
steps.
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure the correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
A13397 suring the correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 connecting
rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and the lower bearing by wiggling
the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
(f) Lay a strip of Plastigage on the crank pin.
A13400

14−57
(g) Check that the front mark of the connecting rod cap is fac-
Front Mark
ing in the correct direction.
(h) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(i) Install the connecting cap (see step 37).
NOTICE:
Do not turn the crankshaft.
(j) Remove the 2 bolts and connecting rod cap.
A52515
(k) Measure the Plastigage at its widest point.

0.024 to 0.048 mm (0.0009 to 0.0019 in.)
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
A36644
HINT:
If replacing a bearing, replace it with one that has the same
number as the connecting rod. There are 3 sizes of standard
Mark bearings: 1, 2 and 3.
1, 2 or 3 Standard bearing center wall thickness:
Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586 in.)
Mark 2 1.489 to 1.491 mm (0.0586 to 0.0587 in.)
Mark Mark 3 1.492 to 1.494 mm (0.0587 to 0.0588 in.)
1, 2 or 3
A13840 (l) Completely remove the Plastigage.
3. REMOVE PISTON SUB−ASSY W/CONNECTING ROD

(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
S Keep the bearing, connecting rod and cap together.
S Arrange the piston and connecting rod assemblies in the
A13469 correct order.
4. REMOVE CONNECTING ROD BEARING

14−58
5. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
A36647
6. REMOVE PISTON PIN HOLE SNAP RING

(a) Using a small screwdriver, pry out the 2 snap rings.
A13478
80 to 90_C 7. REMOVE PISTON

(a) Gradually heat the piston to approximately 80 to 90_C
(176 to 194_F).
A01178
(b) Using a plastic−faced hammer and brass bar, lightly tap

out the piston pin and remove the connecting rod.
HINT:
S The piston and pin are a matched set.
S Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.
A01179
8. INSPECT CRANKSHAFT THRUST CLEARANCE

prying the crankshaft back and forth with a screwdriver.
0.040 to 0.240 mm (0.0016 to 0.0094 in.)
thrust washers as a set.
A36645 Thrust washer thickness:
1.930 to 1.980 mm (0.0760 to 0.0780 in.)
14−59
9. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Uniformly loosen and remove the 10 main bearing cap
2 6 10 8 4 bolts in the sequence shown in the illustration.
1 5 9 7 3
A87780
(b) Use 2 removed main bearing cap bolts to remove the 5

main bearing caps and 5 lower bearings.
NOTICE:
Insert the bolts into one of the caps. Ease the cap out by
gently pulling up and applying force toward the front and
back side of the cylinder block, as shown in the illustration.
Take care not to damage the contact surfaces of the cap
and cylinder block.
A87781 HINT:
S Keep the lower bearing and main bearing cap together.
S Arrange the main bearing caps in the correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.
(f) Place the crankshaft on the cylinder block.

Plastigage
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (see step 36).
HINT:
Do not turn the crankshaft.
(i) Remove the main bearing cap (see steps (a) to (b)
above).
A87782
(j) Measure the Plastigage at its widest point.

0.017 to 0.040 mm (0.00067 to 0.00157 in.)
bearings. If necessary, replace the crankshaft.
A87783

14−60
Number Mark (k) If using a standard bearing, replace it with one having the
same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together
the numbers imprinted on the cylinder block and crank-
shaft, and then selecting the bearing according to the
chart below. There are 4 sizes of standard bearings: 1, 2,
3 and 4.
Cylinder block
(A)
0 to 2 3 to 5 6 to 8 9 to 11
+
Crankshaft (B)
Use bearing 1 2 3 4
No. 1
HINT:
EXAMPLE
No. 2 No. 3 Cylinder block 4 (A) + Crankshaft 3 (B) =
No. 4
No. 5 Total number 7 (Use bearing 3)
Number Mark
A87784
Reference:
Item Mark Specified Condition
Cylinder block main journal bore diameter (A) 0 59.000 to 59.002 mm (2.08683 to 2.32291 in.)
1 59.003 to 59.004 mm (2.08694 to 2.32299 in.)
2 59.005 to 59.006 mm (2.08701 to 2.32307 in.)
3 59.007 to 59.009 mm (2.08708 to 2.32318 in.)
4 59.010 to 59.011 mm (2.08718 to 2.32326 in.)
5 59.012 to 59.013 mm (2.08725 to 2.32334 in.)
6 59.014 to 59.016 mm (2.08733 to 2.32346 in.)
Crankshaft main journal diameter (B) 0 54.999 to 55.000 mm (1.94528 to 2.16535 in.)
1 54.997 to 54.998 mm (1.94521 to 2.16527 in.)
2 54.995 to 54.996 mm (1.94514 to 2.16519 in.)
3 54.993 to 54.994 mm (1.94507 to 2.16511 in.)
4 54.991 to 54.992 mm (1.94500 to 2.16504 in.)
5 54.988 to 54.990 mm (1.94493 to 2.16496 in.)
Standard bearing center wall thickness 1 1.993 to 1.996 mm (0.07846 to 0.07858 in.)
2 1.996 to 1.999 mm (0.07858 to 0.07870 in.)
3 2.000 to 2.002 mm (0.07874 to 0.07882 in.)
4 2.003 to 2.005 mm (0.07886 to 0.07894 in.)
(l) Completely remove the Plastigage.

10. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in the correct order.
11. REMOVE CRANKSHAFT THRUST WASHER UPPER
12. REMOVE CRANKSHAFT BEARING
HINT:
Arrange the bearings in the correct order.
13. REMOVE CRANKSHAFT BEARING NO.2
HINT:
Arrange the main bearings and thrust washers in the correct order.
14. REMOVE STUD BOLT
14−61
15. CLEAN CYLINDER BLOCK

NOTICE:
If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block.
Always wash the cylinder block at a temperature of 45_C (113_F) or less.
16. INSPECT CYLINDER BLOCK FOR FLATNESS

(a) Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace the cylin-
der block.
A36648
17. INSPECT CYLINDER BORE

(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A and B in the thrust and axial directions.
Standard diameter:
88.500 to 88.513 mm (3.4843 to 3.4848 in.)
Maximum diameter: 88.633 (3.4895 in.)
If the diameter is greater than the maximum, replace the cylin-
der block.
Thrust Direction
Front
Axial Direction
A 10 mm
B
A88899

14−62
18. INSPECT PISTON DIAMETER

(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 30.3 mm (1.193 in.)
from the piston head.
Piston diameter:
88.439 to 88.449 mm (3.4818 to 3.4822 in.)
30.3 mm
A92496
19. INSPECT PISTON CLEARANCE

(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.051 to 0.074 mm (0.0020 to 0.0029 in.)
If the clearance is greater than the maximum, replace all the 4 pistons.
If necessary, replace the cylinder block.
20. INSPECT RING GROOVE CLEARANCE

(a) Using a feeler gauge, measure the clearance between
the piston ring and the wall of the ring groove.
Ring groove clearance:
No. 1 0.030 to 0.080 mm (0.0011 to 0.0031 in.)
No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
A36650 If the clearance is not as specified, replace the piston.
21. INSPECT PISTON RING END GAP

(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
110 mm
Piston Ring A53017
(b) Using a feeler gauge, measure the end gap.

Standard end gap:
No. 1 0.22 to 0.32 mm (0.0087 to 0.0126 in.)
No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.)
EM2552

14−63
Maximum end gap:

No. 1 0.89 mm (0.0350 in.)
No. 2 1.35 mm (0.0531 in.)
Oil (side rail) 0.73 mm (0.0287 in.)
If the end gap is greater than the maximum, replace the piston
ring.
If the end gap is greater than the maximum even with a new pis-
ton ring, replace the cylinder block.
22. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the pin hole bush diame-
ter of the piston.
Pin hole diameter (Reference):
Mark Specified Condition
A 22.001 to 22.004 mm (0.8662 to 0.8663 in.)
B 22.005 to 22.007 mm (0.8663 to 0.8664 in.)
C 22.008 to 22.010 mm (0.8665 to 0.8665 in.)
A13490 If the diameter is not as specified, check the oil clearance.
(b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter (Reference):
A 21.997 to 22.000 mm (0.8660 to 0.8661 in.)
B 22.001 to 22.003 mm (0.8662 to 0.8663 in.)
C 22.004 to 22.006 mm (0.8663 to 0.8664 in.)
D 22.007 to 22.009 mm (0.8664 to 0.8665 in.)
EM0227
(c) Using a caliper gauge, measure the inside diameter of the

connecting rod bush.
Bush inside diameter:
A 22.005 to 22.008 mm (0.8663 to 0.8665 in.)
B 22.008 to 22.011 mm (0.8665 to 0.8666 in.)
C 22.011 to 22.014 mm (0.8666 to 0.8667 in.)
(d) Subtract the piston pin diameter measurement from the
A01185 piton pin hole diameter measurement.
0.001 to 0.007 mm (0.00004 to 0.00028 in.)

14−64

connecting rod. If necessary, replace the piston and piston pin
as a set.
Piston Bushing
(e) Subtract the piston pin diameter measurement from the
Inside Diameter
Mark bushing inside diameter measurement.
Front Mark Specified oil clearance:
0.005 to 0.100 mm (0.0002 to 0.0020 in.)
connecting rod. If necessary, replace the connecting rod and
piston pin as a set.
Front Mark
Connecting Rod
Bushing Inside Diameter Mark
A62247
23. INSPECT CONNECTING ROD SUB−ASSY

(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for out−of−alignment.
Maximum out−of−alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the out−of−alignment is greater than the maximum, replace
the connecting rod assembly.
Z00064
(2) Check for twist.

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting
rod assembly.
Z00065
24. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.
A01470

14−65
25. INSPECT CRANKSHAFT

(a) Using a dial indicator and V−blocks, measure the circle
runout, as shown in the illustration.
crankshaft.
A13491
(b) Using a micrometer, measure the diameter of each main

journal.
Diameter: 54.988 to 55.000 (2.1648 to 2.06535 in.)
If the diameter is not as specified, check the oil clearance (see
step 9). If necessary, replace the crankshaft.
(c) Check each main journal for taper and out−of−round as
No. 1
Maximum taper and out−of−round:
No. 2 No. 3 0.003 mm (0.0001 in.)
If the taper and out−of−round is greater than the maximum, re-
No. 4 No. 5
place the crankshaft.
Diameter (Reference):
0 54.999 to 55.000 mm (2.16531 to 2.16535 in.)
1 54.997 to 54.998 mm (2.16523 to 2.16528 in.)
2 54.995 to 54.996 mm (2.16515 to 2.16520 in.)
3 54.993 to 54.994 mm (2.16507 to 2.16512 in.)
4 54.991 to 54.992 mm (2.16500 to 2.16504 in.)
5 54.988 to 54.990 mm (2.16490 to 2.16496 in.)
A92497
(d) Using a micrometer, measure the diameter of each crank

pin.
Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.)
If the diameter is not as specified, check the oil clearance (see
step 2). If necessary, replace the crankshaft.
(e) Check each crank pin for taper and out−of−round as
Maximum taper and out−of−round:
ZF6928 0.003 mm (0.0001 in.)
If the taper and out−of−round is greater than the maximum, re-
place the crankshaft.

14−66
26. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the tension portion diam-
eter of the bolt.
If the diameter is less than the minimum, replace the bolt.
EM6347 A15065
27. INSTALL RING PIN

(a) Using a plastic−faced hammer, tap into the ring pin.
Bottom Side
Upper Side
B
14 mm 13 mm B
(0.551 in.) (0.512 in.)
6 mm (0.236 in.)
12 mm for Ring Pin A
(0.472 in.) 5 mm (0.197 in.)
for Ring Pin B
12 mm
(0.472 in.)
A92498

14−67
28. INSTALL TIGHT PLUG

(a) Apply adhesive around the tight plugs.
Adhesive: Part No. 08833−00070, THREE BOND 1324
or equivalent
(b) Using SST, install new tight plugs as shown in the illustra-
tion.
SST 09950−60010 (09951−00200), 09950−70010
(09951−07100)
Standard depth:
Engine front
1.7 to 2.7 mm (0.067 to 0.106 in.)
Engine rear
2.2 to 3.2 mm (0.087 to 0.126 in.)
A62239
29. INSTALL STUD BOLT

(a) Install the stud bolts as shown in the illustration.
Torque:
5.0 N×m (51 kgf×cm, 44 in.×lbf) for stud bolt A
10 N×m (102 kgf×cm, 7 ft×lbf) for stud bolt B
5.0 N×m (51 kgf×cm, 44 in.×lbf) for stud bolt C
Front Side C Exhaust Side
16 mm
B
18 mm (0.63 in.)
(0.71 in.)
14 mm
84 mm
(0.55 in.)
31.5 mm (3.31 in.)
27.5 mm
(1.24 in.)
(1.08 in.)
9 mm 9 mm
A (M16) B (M10) 20 mm C (M6)
(0.35 in.) (0.35 in.)
(0.79 in.) A92499

14−68
30. INSTALL STRAIGHT PIN

(a) Using a plastic−faced hammer, tap into the straight pin.
Back Side Bottom Side Front Side
A
A
B
A
B
A
10 mm
8 mm (0.39 in.)
(0.31 in.)
7.5 mm (0.30 in.)
for Pin A
15 mm 22 mm
12 mm (0.47 in.)
(0.59 in.) (0.87 in.)
for Pin B
A B
A92500
31. INSTALL PISTON

(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
(b) Gradually heat the piston to approximately 80 to 90_C
(176 to 194_F).
P12418 A32958
(c) Align the front marks of the piston and connecting rod,
and push in the piston with your thumb.
Front Mark
(d) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
Front Mark
A13497

14−69
32. INSTALL PISTON RING SET

(a) Install the coil by hand.
(b) Using a piston ring expander, install the oil ring.
A94209
Oil Ring Ends HINT:

Face the end gap of the oil ring in the opposite direction of coil
joint.
Coil Joint
A94210
(c) Using a piston ring expander, install the 2 compression

rings with the painted mark as shown in the illustration.
NOTICE:
Install the compression ring No. 2 with the code mark (T2)
facing upward.
Upward
No. 1
Painted Mark
No. 2
Code Mark (T2)

A94208
No. 1 Compression (d) Position the piston rings so that the ring ends are as
and Oil Ring shown in the illustration.
30_
Front
30_
No. 2 Compression A94211

14−70
33. INSTALL CRANKSHAFT BEARING

(a) Install the upper bearing with an oil groove on the cylinder
block.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oil.
A53029
34. INSTALL CRANKSHAFT BEARING NO.2

(a) Install the lower bearing on bearing cap.
NOTICE:
and oil.
A33379
35. INSTALL CRANKSHAFT THRUST WASHER UPPER

(a) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
36. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crank-
shaft on the cylinder block.
(b) Apply engine oil to the lower bearing.
A13501
(c) Examine the front marks and install the bearing caps on
the cylinder block.
(d) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.
A13502
7 3 1 5 9 (e) Uniformly install and tighten the 16 main bearing cap bolts
in the sequence shown in the illustration.
Torque:
20 N×m (204 kgf×cm, 15 ft×lbf) for 1st
40 N×m (408 kgf×cm, 30 ft×lbf) for 2nd
8 4 2 6 10 A36657

14−71
(f) Mark the front of the bearing cap bolts with paint.
Paint (g) Retighten the bearing cap bolts by 90_ same sequence
90_ Mark
as step (e).
Engine Front
(h) Check that the painted mark is now at a 90_ angle to the
front.
(i) Check that the crankshaft turns smoothly.
A50671
Claw 37. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
NOTICE:
and oil.
38. INSTALL PISTON
A50672 NOTICE:
The connecting rod cap bolts are tightened in 2 progres-
sive steps.
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num-

Front Mark bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
Front
A52528
(d) Check that the protrusion of the connecting rod cap is fac-
Front Mark
ing in the correct direction.
(e) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(f) Using a 12 mm socket wrench, uniformly tighten the 2
bolts.
(g) Mark the front of the connecting cap bolts with paint.
A52515

14−72
(h) Retighten the cap bolts by 90_ as shown in the illustration.

Paint (i) Check that the crankshaft turns smoothly.
90_ Mark
Engine Front
A50671

16−1
COOLING − WATER PUMP ASSY (2AZ−FSE)
WATER PUMP ASSY (2AZ−FSE)

160UF−01
INSPECTION
1. INSPECT WATER PUMP ASSY

(a) Visually check the drain hole coolant leakage.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If moves roughly or noisily, replace the water pump.
A36661

17−1
LUBRICATION − OIL PUMP ASSY (2AZ−FSE)
OIL PUMP ASSY (2AZ−FSE)

170JO−01
COMPONENTS
Oil Pump Strainer Set
8.8 (90, 78 in.×lbf)

8.8 (90, 78 in.×lbf)
Drive Rotor
Oil Pump Relief Valve Spring z Gasket
Oil Pump Cover

Driven Rotor
Oil Pump Assy

Oil Pump
Relief Valve Plug
Oil Pump Relief Valve


17−2
170JP−01
OVERHAUL
1. REMOVE OIL PUMP STRAINER SET

(a) Remove 2 nuts and oil pump strainer.
B11430
2. REMOVE OIL PUMP RELIEF VALVE

(a) Using a socket wrench (27mm), remove the plug.
(b) Remove the valve spring and relief valve.
A52074
3. REMOVE OIL PUMP COVER

(a) Remove 5 bolts and oil pump cover.
B11431
4. INSPECT OIL PUMP RELIEF VALVE

(a) Check the relief valve.
(1) Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If it does not, replace the relief valve. If necessary, replace the
oil pump assy.
B11419

17−3
5. INSPECT OIL PUMP ROTOR

(a) Check the rotor side clearance.
(1) Using a feeler gauge and precision straight edge,
measure the clearance between the rotors and pre-
cision straight edge.
Standard side clearance:
0.030 to 0.085 mm (0.0012 to 0.0033 in.)
Maximum side clearance: 0.16 mm (0.0063 in.)
B11420 If the side clearance is greater than the maximum, replace the
oil pump assy.
(b) Check the rotor tip clearance.
tween the drive and driven rotor tips.
Standard tip clearance:
0.080 to 0.160 mm (0.0031 to 0.0063 in.)
Maximum tip clearance: 0.35 mm (0.0138 in.)
If the tip clearance is greater than the maximum, replace the oil
pump assy.
B11421
(c) Check the rotor body clearance.

tween the driven rotor and body.
Standard body clearance:
0.100 to 0.170 mm (0.00394 to 0.00669 in.)
Maximum body clearance: 0.325 mm (0.01280 in.)
(d) Remove the oil pump rotors.
If the body clearance is greater than the maximum, replace the
B11422 oil pump assy.
6. REMOVE OIL PUMP ROTOR
7. INSTALL OIL PUMP ROTOR

(a) Coat the drive rotor and driven rotors with engine oil.
(b) Place the drive and driven rotors into pump body with the
marks facing the pump cover side.
B11423

17−4
8. INSTALL OIL PUMP COVER

(a) Install the pump body cover with the 5 bolts.
B11431
9. INSTALL OIL PUMP RELIEF VALVE

(a) Coat the relief valve with engine oil.
(b) Insert the relief valve and spring into the pump body hole.
(c) Using a socket wrench (27 mm), install the plug.
A52074
10. INSTALL OIL PUMP STRAINER SET

(a) Place a new gasket on the oil pump.
(b) Install the oil strainer with the 2 nuts.
B11430

19−1
STARTING & CHARGING − STARTER ASSY (2AZ−FSE)
STARTER ASSY (2AZ−FSE)

190VX−01
COMPONENTS
Magnetic Switch Assy
Plunger
Return Spring
2.3 (23, 20 in.×lbf)
Planetary Gear
Starter Yoke Assy

5.9 (60, 52 in.×lbf)
Starter Armature Assy
Starter Brush
Holder Assy
6.0 (61, 53 in.×lbf)
Clutch & Bearing Center
Starter Armature Plate
2.0 (20, 22 in.×lbf) Starter Drive Housing Assy

6.0 (61, 53 in.×lbf)
Starter Commutator (w/ Clutch & Drive Lever & Center Bearing)
End Frame Assy
N·m (kgf·cm, ft·lbf) : Specified torque A94225

19−2
190VY−01
OVERHAUL
1. REMOVE MAGNETIC SWITCH ASSY

(a) Remove the nut and disconnect the lead wire from the
magnetic switch.
A81555
(b) Remove the 3 nuts holding the magnetic switch to the

starter drive housing.
(c) Remove the magnetic switch.
(d) Remove the return spring and plunger form the starter
drive housing.
A82635
2. REMOVE STARTER YOKE ASSY

(a) Using a torx driver T25, remove the 2 through bolts, and
pull out the yoke together with the starter commutator end
frame.
A82636
(b) Remove the yoke from the starter commutator end frame.
A82637
3. REMOVE STARTER ARMATURE ASSY

(a) Remove the starter armature from the yoke.

19−3
4. REMOVE STARTER ARMATURE PLATE

(a) Remove the armature plate from the yoke.
A79722
5. REMOVE STARTER BRUSH HOLDER ASSY

(a) Remove the 2 screws and brush holder from the commu-
tator end frame.
A82638
6. REMOVE PLANETARY GEAR

(a) Remove the 3 planetary gears from the starter housing.
A82639
7. INSPECT MAGNETIC SWITCH ASSY

(a) Check the plunger.
(1) Push in the plunger and check that it returns quickly
to its original position.
If necessary, replace the magnetic switch assy.
A82640
(b) Check if the pull−in coil has an open circuit.

Terminal C (1) Measure the resistance between terminals 50 and
C.
Standard: Below 1 W
If the result is not as specified, replace the magnetic switch
assy.
Terminal 50
Below 1 W A82641

19−4
(c) Check if the hold−in coil has an open circuit.

Below 1.5 W (1) Measure the resistance between terminal 50 and
the switch body.
Standard: Below 1.5 W
If the result is not as specified, replace the magnetic switch
assy.
Terminal 50
A82642
8. INSPECT STARTER ARMATURE ASSY

Below 1 W (a) Check if the commutator has an open circuit.
(1) Measure the resistance between the segments of
the commutator.
Standard: Below 1 W
If the result is not as specified, replace the armature assy.
A82643
(b) Check if the commutator is grounded.

(1) Measure the resistance between the commutator
and armature coil core.
Standard: 10 kW or higher
If the result is not as specified, replace the armature assy.
(c) Check the commutator for dirty or burned surface.
If the surface is dirty or burnt, smooth the surface with 400−grit
sandpaper.
10 kW or Higher A82644
(d) Check for the commutator circle runout.

(1) Place the commutator on V−blocks.
(2) Using a dial indicator, measure the circle runout.
Standard runout: 0.02 mm (0.0008 in.)
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the armature
assy.
A82645
(e) Using a vernier caliper, measure the commutator diame-

29 mm
ter.
Standard length: 29 mm (1.142 in.)
Minimum length: 28 mm (1.102 in.)
If the diameter is less than the minimum, replace the armature
assy.
A82646

19−5
9. INSPECT STARTER BRUSH HOLDER ASSY

(a) Using a vernier caliper, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Length Minimum length: 9.0 mm (0.354 in.)
If the length is less than the minimum, replace the starter brush
holder assy.
A82647
10 kW or Higher (b) Check the brush insulation.

(1) Measure the resistance between the positive (+)
terminal and negative (−) terminal of the brush.
If the result is not as specified, repair or replace the brush holder
assy.
A94226
10. INSPECT CLUTCH & BEARING CENTER

Lock
(a) Check the starter clutch.
(1) Rotate the clutch pinion gear counterclockwise and
check that it turns freely. Try to rotate the clutch pin-
ion gear clockwise and check that it locks.
If necessary, replace the starter drive housing assy.
Free
A82649
11. INSTALL PLANETARY GEAR

(a) Apply grease to the planetary gears and pin parts of the
Apply Grease planetary shaft.
(b) Install the 3 planetary gears.
A82650
12. INSTALL STARTER BRUSH HOLDER ASSY

(a) Install the brush holder to the starter armature.
A82651

19−6
13. INSTALL STARTER COMMUTATOR END FRAME

ASSY
(a) Install the commutator end frame with the 2 screws.
A82652
14. INSTALL STARTER ARMATURE ASSY

(a) Align the rubber with the convex cutout of the field frame.
(b) Install the starter armature with the brush holder to the
field frame.
A94227
Key 15. INSTALL STARTER ARMATURE PLATE

(a) Insert the starter armature plate to the yoke.
Keyway
(b) Align the keyway of the starter plate with the key inside the
yoke, and install the starter plate.
A82654
16. INSTALL STARTER YOKE ASSY

(a) Align the key of the yoke with the keyway located on the
starter drive housing.
Key
Keyway
A81586
(b) Using a torx driver T25, install the field frame with the 2
through bolts.
17. INSTALL MAGNETIC SWITCH ASSY
(a) Apply grease to the hook.
(b) Set the plunger and hook of the drive housing to the drive
lever.
(c) Install the plunger and return spring.
A82636

19−7
(d) Install the magnetic switch with the 3 nuts.

A82635
(e) Connect the lead wire to the magnetic switch. Tighten the
nut.
A81555

19−8
STARTING & CHARGING − GENERATOR ASSY (2AZ−FSE)
GENERATOR ASSY (2AZ−FSE)

190VZ−01
COMPONENTS
Drive End Frame Assy
Pulley Drive End Shield

65 (663, 48)
Spacer Ring z Front Bearing
Bearing Retainer
Spring Washer Fitting Ring
3.1 (32, 27 in.×lbf)
Generator Rotor Assy

z Rear Bearing
3.5 (36, 31 in.×lbf)
2.2 (22, 19 in.×lbf)
19.5 (199, 14)
Terminal
Cover
Stator Sub−assy
Generator w/ Rectifire
2.4 (24, 21 in.×lbf)
Regulator Sub−assy 1.2 (12, 11 in.×lbf)
12 (122, 9)
Generator w/ Brush
Generator Rear End Cover
z Non−reusable part B09747

19−9
190W0−01
OVERHAUL
1. REMOVE GENERATOR REAR END COVER

(a) Remove the 2 terminal covers by turning them counter-
clockwise.
A80108
(b) Remove the screw, 2 nuts and end cover.
B09748
2. REMOVE REGULATOR SUB−ASSY GENERATOR

W/BRUSH
(a) Remove the 3 screws and regulator.
B09749
3. REMOVE STATOR SUB−ASSY GENERATOR

W/RECTIFIRE
(a) Remove the 4 bolts.
B09750

19−10
(b) Using a screwdriver, pry out the stator.

4. REMOVE BEARING SET GENERATOR
B10446
5. REMOVE PULLEY SET GENERATOR

(a) Clamp the swivel arm in a vise.
NOTICE:
Be careful not to damage the fan.
(b) Using an impact wrench, remove the nut and spring
washer, then detach the pulley.
B10014
6. REMOVE GENERATOR ROTOR ASSY

(a) Using a press, press out the rotor and spacer ring.
B10015
Ohmmeter 7. INSPECT GENERATOR ROTOR ASSY

(a) Check the rotor for open circuit.
Slip Ring (1) Using an ohmmeter, measure the resistance be-
tween the slip rings.
Standard resistance: 1.8 to 2.8 W at 20_C (68_F)
If the resistance is not as specified, replace the rotor assy.
B10452
Ohmmeter
(b) Check the rotor for ground.
(1) Using an ohmmeter, measure the resistance be-
tween the slip ring and rotor core.
If the resistance is not as specified, replace the rotor assy.
(c) Inspect slip rings.
Rotor (1) Check that the slip rings are not rough or scored.
Core 10 kW or Higher If rough or scored, replace the rotor assy.
B10453

19−11
(d) Inspect the slip rings.

(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor assy.
(2) Using a vernier caliper, measure the slip ring diame-
ter.
If the diameter is less than the minimum, replace the rotor assy.
B00896
8. INSPECT STATOR SUB−ASSY GENERATOR

Negative (−) Terminal Rectifier Terminal
W/RECTIFIRE
(a) Using an ohmmeter, measure the resistance between the
Ohmmeter generator’s negative (−) terminal and rectifier terminal.
(1) Connect the ohmmeter’s positive (+) probe to the
generator’s negative (−) terminals and the negative
(−) probe to the rectifier terminals. Measure the re-
sistance one by one.
10 kW or Higher
B09843 Standard: 10 kW or higher
(2) Connect the ohmmeter’s positive (+) probe to the
rectifier terminals and the negative (−) probe to the
generator’s negative (−) terminals. Measure the re-
sistance one by one.
Standard: Below 1 W
If the result is not as specified, replace the stator sub−assy gen-
erator w/ rectifier.
(b) Using an ohmmeter, measure the resistance between the

Rectifier Terminal
rectifier terminals.
Standard: Below 1 W
Ohmmeter If the result is not as specified, replace the stator sub−assy gen-
erator w/ rectifier.
Below 1 W
B09844
Length 9. INSPECT BRUSH

(a) Using a vernier caliper, measure the exposed brush
length.
Standard exposed length:
13.2 mm (0.520 in.) in new condition
Minimum exposed length: 6.0 mm (0.236 in.)
If the exposed length is less than the minimum, replace the reg-
ulator sub−assy generator w/ brush.
B09845

19−12
10. INSTALL GENERATOR ROTOR ASSY

(a) Using SST and a press, press in the rotor.
SST SST 09285−76010
NOTICE:
Avoid misalignment during pressing.
B10019
11. INSTALL PULLEY SET GENERATOR

(a) Clamp the rotor in a soft jaw vise.
(b) Install the pulley with the spring washer and nut.
B10014
12. INSTALL BEARING SET GENERATOR

(a) Insert the fitting ring into the position shown in the illustra-
tion.
(b) Align the key of the fitting ring with the keyway of the sta-
tor.
(c) Install the bearing.
B09847
13. INSTALL STATOR SUB−ASSY GENERATOR

W/RECTIFIRE
(a) Align the key of the drive end frame with the keyway of the
stator generator.
(b) Install the stator with the 4 bolts.
B09750
14. INSTALL REGULATOR SUB−ASSY GENERATOR

W/BRUSH
(a) Attach the brushes and terminals to the rectifier end
frame of the regulator.
B09848

19−13
(b) Install the regulator with the 3 screws.

With Washer
Torque:
2.2 N×m (22 kgf×cm, 19 in.×lbf) for screw without wash-
er
1.2 N×m (12 kgf×cm, 11 in.×lbf) for screw with washer
HINT:
Install the screw with the plate washer to the position shown in
Without
the illustration.
Washer
B10021
Nut A Screw 15. INSTALL GENERATOR REAR END COVER

(a) Install the end cover with the 2 nuts and screw.
Torque:
19.5 N×m (199 kgf×cm, 14 ft×lbf) for nut A
12 N×m (122 kgf×cm, 9 ft×lbf) for nut B
2.4 N×m (24 kgf×cm, 21 in.×lbf) for screw
Nut B
B09748
(b) Install the 2 terminal covers by turning them clockwise.
A80108

2az Fse Engine Repair Manual (Rm1083e)

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2az Fse Engine Repair Manual (Rm1083e)

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01−1

INTRODUCTION − HOW TO USE THIS ENGINE REPAIR MANUAL

HOW TO USE THIS ENGINE REPAIR MANUAL

Camshaft Drive Gear

Camshaft Timing Tube Assy

7.5 (80, 66 in.·lbf)

z Camshaft Setting Oil Seal Camshaft Driven Main Gear

15 (150, 11) Wave Washer Camshaft Timing Gear

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

Illustration: Task heading: what to do

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL

(a) Precoated Parts:

(d) Torque When Using Extension Tool with Torque Wrench:

10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

11. REMOVAL AND INSTALLATION OF ENGINE INTAKE

Flat Spring Clamp

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

TERMS FOR ENGINE REPAIR MANUAL

ABBREVIATIONS USED IN MANUAL

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

GLOSSARY OF SAE AND TOYOTA TERMS

A/C Air Conditioning Air Conditioner

FEPROM Flash Erasable Programmable Read Only Memory −

HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

Electric Bleed Air Control Valve (EBCV)

TCM Transmission Control Module Transmission ECU, ECT ECU

Three−Way Catalytic (TWC)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

09032−00100 Oil Pan Seal Cutter PARTIAL ENGINE ASSY(2AZ−FSE)

09201−10000 Valve Guide Bushing Remover & CYLINDER HEAD ASSY(2AZ−FSE)

(09201−01050) Valve Guide Bushing Remover & CYLINDER HEAD ASSY(2AZ−FSE)

09201−41020 Valve Stem Oil Seal Replacer CYLINDER HEAD ASSY(2AZ−FSE)

09202−70020 Valve Spring Compressor CYLINDER HEAD ASSY(2AZ−FSE)

(09202−00010) Attachment CYLINDER HEAD ASSY(2AZ−FSE)

09213−54015 Crankshaft Pulley Holding Tool PARTIAL ENGINE ASSY(2AZ−FSE)

(91651−60855) Bolt PARTIAL ENGINE ASSY(2AZ−FSE)

09223−15030 Oil Seal & Bearing Replacer PARTIAL ENGINE ASSY(2AZ−FSE)

09223−22010 Crankshaft Front Oil Seal PARTIAL ENGINE ASSY(2AZ−FSE)

09228−06501 Oil Filter Wrench PARTIAL ENGINE ASSY(2AZ−FSE)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

09309−37010 Transmission Bearing Replacer PARTIAL ENGINE ASSY(2AZ−FSE)

09330−00021 Companion Flange Holding Tool PARTIAL ENGINE ASSY(2AZ−FSE)

09950−50013 Puller C Set PARTIAL ENGINE ASSY(2AZ−FSE)

(09951−05010) Hanger 150 PARTIAL ENGINE ASSY(2AZ−FSE)

(09952−05010) Slide Arm PARTIAL ENGINE ASSY(2AZ−FSE)

(09953−05020) Center Bolt 150 PARTIAL ENGINE ASSY(2AZ−FSE)

(09954−05021) Claw No.2 PARTIAL ENGINE ASSY(2AZ−FSE)

09950−60010 Replacer Set CYLINDER HEAD ASSY(2AZ−FSE)

(09951−00180) Replacer 18 CYLINDER HEAD ASSY(2AZ−FSE)

(09951−00200) Replacer 20 CYLINDER BLOCK ASSY(2AZ−FSE)

09950−70010 Handle Set PARTIAL ENGINE ASSY(2AZ−FSE)

(09951−07100) Handle 100 PARTIAL ENGINE ASSY(2AZ−FSE)

09960−10010 Variable Pin Wrench Set PARTIAL ENGINE ASSY(2AZ−FSE)

2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)

(09962−01000) Variable Pin Wrench Arm Assy PARTIAL ENGINE ASSY(2AZ−FSE)

(09963−00700) Pin 7 PARTIAL ENGINE ASSY(2AZ−FSE)

(09043−20060) Socket Hexagon Wrench 6 PARTIAL ENGINE ASSY(2AZ−FSE)