Download: M ENGINE ON-VEHICLE INSPECTION ASSEMBLY

1NZ-FE ENGINE MECHANICAL – ENGINE EM–1 M ENGINE ON-VEHICLE INSPECTION 1. INSPECT ENGINE COOLANT (See page CO-1) 2. INSPECT ENGINE OIL (See page LU-1) 3. INSPECT BATTERY (See page CH-4) 4. INSPECT AIR CLEANER FILTER ELEMENT SUB- ASSEMBLY (a) Remove the air cleaner filter element sub-assembly. (b) Visually check that there is no dirt, blockage, or damage to the air cleaner filter element. HINT: • If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air. E • If any dirt or a blockage remains even after cleaning the air cleaner filter element with compress...
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1NZ-FE ENGINE MECHANICAL – ENGINE EM–1

M ENGINE ON-VEHICLE INSPECTION

1. INSPECT ENGINE COOLANT (See page CO-1) 2. INSPECT ENGINE OIL (See page LU-1) 3. INSPECT BATTERY (See page CH-4) 4. INSPECT AIR CLEANER FILTER ELEMENT SUB-

ASSEMBLY

(a) Remove the air cleaner filter element sub-assembly. (b) Visually check that there is no dirt, blockage, or damage to the air cleaner filter element. HINT: • If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air. E • If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it. 5. INSPECT SPARK PLUG (See page IG-5) 6. INSPECT IGNITION TIMING (a) When using an intelligent tester: (1) Warm up and stop the engine. (2) Connect the intelligent tester to the DLC3. Intelligent Tester (3) Turn the ignition switch ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ ACTIVE TEST / TC (TE1) / ON. HINT: DLC3 Refer to the intelligent tester operator's manual CAN VIM for further details. (5) Inspect the ignition timing during idling. A125658E01 Ignition timing: 8 to 12 degrees BTDC NOTICE: • Turn all the electrical systems and the A/ C off. • Inspect the ignition timing with the cooling fan off. • When checking the ignition timing, shift the transmission to the neutral position. (6) Select the following menu items: TC (TE1) / OFF. (7) Turn the ignition switch OFF. (8) Disconnect the intelligent tester from the DLC3. (b) When not using an intelligent tester: (1) Remove cylinder head cover No. 2 (see page IG-9)., EM–2 1NZ-FE ENGINE MECHANICAL – ENGINE

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(2) Pull out the wire harness (brown) shown in the illustration. NOTICE: After checking, wrap the wire harness with tape. (3) Warm up and stop the engine. (4) Connect the clip of the timing light to the wire harness. NOTICE: A116196 Use a timing light that detects the first signal. (5) Turn the ignition switch ON. (6) Using SST, connect terminals 13 (TC) and 4 DLC3 (CG) of the DLC3. CG SST 09843-18040 NOTICE: Examine the terminal numbers before12345678connecting them. Connecting the wrong terminals could damage the engine. 9 10111213141516 (7) Inspect the ignition timing during idling. Ignition timing:

TC

A082779E23 8 to 12 degrees BTDC NOTICE: • Turn all the electrical systems and the A/ C off. • Inspect the ignition timing with the cooling fan off. • When checking the ignition timing, shift the transmission to the neutral position. (8) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (9) Turn the ignition switch OFF. (10) Remove the timing light. (11) Install cylinder head cover No. 2 (see page IG- 10). 7. INSPECT ENGINE IDLING SPEED (a) When using an intelligent tester: (1) Warm up and stop the engine. (2) Connect the intelligent tester to the DLC3. Intelligent Tester (3) Turn the ignition switch ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ DATA LIST / PRIMARY / ENGINE SPD. HINT: DLC3 Refer to the intelligent tester operator's manual CAN VIM for further details. (5) Inspect the engine idling speed. A125658E01 Idling speed: 550 to 650 rpm for manual transaxle 650 to 750 rpm for automatic transaxle NOTICE: • Turn all the electrical systems and the A/ C off., 1NZ-FE ENGINE MECHANICAL – ENGINE EM–3

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• Inspect the idling speed with the cooling fan off. • When checking the idling speed, shift the transmission to either the neutral position or the parking position. (6) Turn the ignition switch OFF. (7) Disconnect the intelligent tester from the DLC3. (b) When not using an intelligent tester. (1) Warm up and stop the engine. (2) Install SST to terminal 9 (TAC) of the DLC3, then connect a tachometer. DLC3 SST 09843-18040 NOTICE: Examine the terminal numbers before12345678connecting them. Connecting the wrong terminals could damage the engine. E 9 10111213141516 (3) Turn the ignition switch ON. (4) Inspect the engine idling speed.

TAC

A082779E24 Idling speed: 550 to 650 rpm for manual transaxle 650 to 750 rpm for automatic transaxle (5) Turn the ignition switch OFF. (6) Disconnect the tachometer. (7) Remove SST from terminal 9 (TAC). 8. INSPECT COMPRESSION (a) Warm up and stop the engine. (b) Remove cylinder head cover No. 2 (see page IG-9). (c) Remove the 4 ignition coils (see page IG-9). (d) Remove the 4 spark plugs. (e) Disconnect the 4 fuel injector connectors. (f) Inspect the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression: 1,471kPa (15.0 kgf/cm2, 213 psi) Minimum pressure: A116195 1,079 kPa (11.0 kgf/cm2, 156 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less NOTICE: • Use a fully-charged battery so the engine speed can be increased to 250 rpm or more. • Inspect the other cylinders in the same way. • Measure the compression in as short a time as possible., EM–4 1NZ-FE ENGINE MECHANICAL – ENGINE

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(4) If the cylinder compression is low, pour a light coat of engine oil into the cylinder through the spark plug hole, then inspect it again. HINT: • If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. • If the pressure stays low, the valve may be stuck or seated improperly, or there may be leakage from the gasket. (g) Connect the 4 fuel injector connectors. (h) Install the 4 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) (i) Install the 4 ignition coils (see page IG-9). (j) Install cylinder head cover No. 2 (see page IG-10). 9. INSPECT CO/HC (a) Start the engine. (b) Run the engine at 2,500 rpm for approximately 180 seconds. (c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe while idling. (d) Check the CO/HC concentration during idling and when running at 2,500 rpm. HINT: When doing the 2 mode (with the engine idling/ running at 2,500 rpm) test, the measuring procedures are determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below. (1) Check the heated oxygen sensor operation (see page ES-276). (2) See the table below for possible causes, then inspect the applicable parts and repair them if necessary. CO HC Problems Possible Causes Normal High Rough idling 1. Faulty ignition: – Incorrect timing – Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leakage from intake and exhaust valves 4. Leakage from cylinders Low High Rough idling 1. Vacuum leaks: (Fluctuating HC reading) – PCV hoses – Intake manifold – Throttle body – Brake booster line 2. Lean mixture causing misfire High High Rough idling 1. Restricted air cleaner filter element (Black smoke from exhaust) 2. Plugged PCV valve 3. Faulty EFI systems: – Faulty pressure regulator – Faulty engine coolant temperature sensor – Faulty mass air flow meter – Faulty ECM – Faulty injectors – Throttle body, 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–5

M DE1NZG-IFNEE ENGINRE MECHANICIAL VE BELT COMPONENTS E

ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115143E01,

EM–6 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM

19 (189, 14) 54 (551, 40) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A116199E01, 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–7

M REMOVAL

1. REMOVE ENGINE UNDER COVER RH 2. REMOVE FAN AND GENERATOR V BELT (a) Loosen bolts A and B. A (b) Release the fan and generator V belt tension and remove the fan and generator V belt.

B

A116197E01

INSPECTION

1. INSPECT FAN AND GENERATOR V BELT E (a) Visually check the belt for excessive wear, frayed cords etc. If any defects are found, replace the belt. HINT: • If any defects are found, replace the belt. • Cracks on the rib side of a belt are considered acceptable. If the belt has pieces missing from the ribs, it should be replaced. B000543, EM–8 1NZ-FE ENGINE MECHANICAL – DRIVE BELT

EM INSTALLATION

1. INSTALL FAN AND GENERATOR V BELT (a) Provisionally install the fan and generator V belt onto each pulley. NOTICE: Make sure that the V-belt is securely fitted into the rib groove of the pulley. 2. ADJUST FAN AND GENERATOR V BELT (a) Insert an adjusting bar between the engine

NG

mounting bracket and generator assembly. Push the adjusting bar toward the vehicle front to adjust the generator V belt tension. OK NOTICE: Do not insert the adjusting bar between the camshaft timing oil control valve assembly and generator assembly. It could damage the A116198E01 camshaft timing oil control valve assembly. (b) First tighten bolt A, then tighten bolt B. Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) for boltAA54 N*m (551 kgf*cm, 40 ft.*lbf) for bolt B

B

A116197E01 3. INSPECT FAN AND GENERATOR V BELT w/o Air Conditioner (a) Check the V belt deflection and tension. Deflection Item Specified Condition New belt 7.0 to 8.5 mm (0.28 to 0.33 in) Used belt 11 to 13 mm (0.43 to 0.51 in) Tension Item Specified Condition New belt 539 to 637 N (55 to 65 kg, 121 to 143 ld) w/ Air Conditioner Used belt 245 to 392 N (25 to 40 kg, 55 to 88 ld) If the belt deflection is not as specified, adjust it. HINT: • Check the V belt deflection at the specified point. • Check the drive belt deflection at the specified point. • When installing a new belt, set its tension to the specified value. • When inspecting a belt which has been used for A116200E01 over 5 minutes, apply the used belt specifications., 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–9

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• When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the intermediate values of each used belt specification. • V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking. • When using a belt tension gauge, confirm its accuracy by using a master gauge first. 4. INSTALL ENGINE UNDER COVER RH

E

, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–9

M VALVE CLEARANCE ADJUSTMENT

1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

2. REMOVE ENGINE UNDER COVER RH 3. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 4. REMOVE IGNITION COIL NO. 1 (See page IG-9) 5. DISCONNECT VENTILATION HOSE (See page FU-13) 6. DISCONNECT VENTILATION HOSE NO. 2 (See page FU-13) E 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) 8. INSPECT VALVE CLEARANCE HINT: Inspect the valve clearance when the engine is cold. (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01 (b) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) for exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) A116201, EM–10 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

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(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. (c) Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark "0" of the oil pump. (d) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) for exhaust: 0.25 to0.35 mm (0.010 to 0.014 in.) (2) Record any out-of-specification valve clearance A116202 measurements. They will be used later to determine the required replacement adjusting shim. 9. ADJUST VALVE CLEARANCE Matchmark NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves. (a) Remove the fan and generator V belt (See page A116206E01 EM-7). (b) Remove the engine mounting insulator sub- assembly RH (See page LU-17). (c) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–11

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(d) Place paint marks on the chain in the places where Paint Marks the timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Timing Marks A116207E01 (e) Using an 8 mm hexagon wrench, remove the screw plug.

E

G100163 (f) Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward. Stopper Plate A116209E01 (g) Using a wrench, rotate camshaft No. 2 clockwise to push in the plunger of the chain tensioner. Plunger A116210E01, EM–12 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

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(h) Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and inserta3mm (0.12 in.) diameter bar into the holes to hold the stopper plate. HINT: • Fix the stopper plate using the bar while rotating the camshaft right and left slightly. • Hold the bar with tape so that the bar does not come off. A116212 (i) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and remove the fringe bolt. A116213 (j) Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown13542in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. A116214E01 (k) Remove the fringe bolt and remove the camshaft timing sprocket. A116215, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–13

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(l) Remove camshaft No. 2. A116216 (m) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2. NOTICE: E Loosen each bolt uniformly while keeping the camshaft level. 2431A116217E01 (n) Hold the chain by hand and remove the camshaft and the camshaft timing gear assembly. A116218 (o) Tie the chain with a piece of string as shown in the illustration. (p) Remove the 16 valve lifters. A035227E01 (q) Using a micrometer, measure the thickness of the removed lifter. (r) Calculate the thickness of a new lifter so that the valve clearance comes to within the specified values. A Thickness of new lifter B Thickness of used lifter C Measured valve clearance A001082, EM–14 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

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Valve clearance: Intake A = B + (C - 0.20 mm (0.008 in.)) Exhaust A = B + (C - 0.30 mm (0.012 in.)) (s) Select a new lifter with a thickness as close to the calculated values as possible. HINT: Lifters are available in 35 sizes in increments of 0.020mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.)., 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–15

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A117457,

EM–16 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM Intake valve clearance (cold):

0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE: A 5.250 mm (0.2067 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700(0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173), 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–17

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A117458,

EM–18 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE: A 5.340 mm (0.2102 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) (t) Install the selected valve lifter. (u) Apply a light coat of engine oil to the camshaft and camshaft journals. (v) Install the chain onto the camshaft timing gear with Paint Mark the paint mark and the timing mark aligned as shown in the illustration. Timing Mark A116220E01 (w) Examine the front marks and the numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.

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

camshaft level. 3124A116222E01, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–19

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(x) Install camshaft No. 2. A116216 (y) Hold the chain, and align the timing mark on the Paint Mark camshaft timing sprocket with the paint mark of the chain. (z) Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and E install the sprocket onto the camshaft. Timing Mark Pin A116224E01 (aa) Provisionally install the flange bolt. A116215 (ab) Examine the front marks and the numbers of3124camshaft bearing cap No. 1 and camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps, in the sequence shown in the 5 illustration. Torque: for bearing cap No. 2 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the Bearing Cap No. 1 Bearing Cap No. 2 camshaft level. A116223E01, EM–20 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

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(ac) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and install the flange bolt. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) SST 09023-38400 (ad) Remove the bar from the timing chain tensioner.

SST

A116225E01 (ae) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (af) Check that all the pairs of timing marks are aligned. Paint Marks (ag) Apply adhesive to the 2 or 3 threads of the screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Timing Marks A116207E01 (ah) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) (ai) Install the engine mounting insulator sub-assembly RH (See page LU-26). (for Hatchback) (aj) Install the engine mounting insulator sub-assembly RH (See page LU-26). (for Sedan) (ak) Install the fan and generator V belt (See page EM- 7). G100163 (al) Adjust the fan and generator V belt (See page EM- 7). (am)Inspect the fan and generator V belt (See page EM- 8). 10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 11. CONNECT VENTILATION HOSE NO. 2 (See page FU- 20) 12. CONNECT VENTILATION HOSE (See page FU-20) 13. INSTALL IGNITION COIL NO. 1 (See page IG-9), 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–21

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14. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 15. CHECK FOR ENGINE OIL LEAKAGE 16. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 17. INSTALL ENGINE UNDER COVER RH

E

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EM–22 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

E1TNZG-IFNEE ENGIINE MMECHANICAL ING CHAIN

COMPONENTS

ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115143E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–23

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7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2 7.0 (71, 62 in.*lbf)

E

N*m (kgf*cm, ft.*lbf) : Specified torque A115136E01,

EM–24 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

19 (189, 14) 54 (551, 40) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A116199E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–25

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for Hatchback: 11 (112, 8.1) FAN BELT ADJUSTING BAR 19 (189, 14) 54 (551, 40) 52 (530, 38) GENERATOR x2 ASSEMBLY E 45 (459, 33) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft.*lbf) : Specified torque A116193E06,

EM–26 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

for Sedan: 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR 54 (551, 40) 52 (530, 38) GENERATOR x2

ASSEMBLY

52 (530, 38) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR 52 (530, 38) SUB-ASSEMBLY RH N*m (kgf*cm, ft*lbf) : Specified torque A133594E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–27

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9.0 (92, 80 in.*lbf)

E

IGNITION COIL NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A115486E01,

EM–28 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

13 (133, 9.6) WIRE HARNESS BRACKET 10 (102, 7.0) SEAL WASHER 10 (102, 7.0) x7 10 (102, 7.0) 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY VENTILATION HOSE NO. 2 VENTILATION HOSE CYLINDER HEAD COVER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A115504E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–29

M E GASKET

11 (112, 8.1) x2 x3 x3 WATER PUMP ASSEMBLY 15 (153, 11) 11 (112, 8.1) WATER PUMP PULLEY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116194E01,

EM–30 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

CAMSHAFT TIMING OIL O-RING CONTROL VALVE ASSEMBLY 7.5 (76, 66 in.*lbf) 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116180E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–31

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TRANSVERSE ENGINE ENGINE MOUNTING BRACKET x4 55 (561, 41)

E

24 (245, 18) 32 (326, 24) x2 24 (245, 18) x11 11 (112, 8.1) OIL PUMP ASSEMBLY 7.5 (76, 66 in.*lbf) 11 (112, 8.1)

CRANKSHAFT

POSITION SENSOR 128 (1305, 95) OIL PUMP SEAL CRANKSHAFT DAMPER SUB-ASSEMBLY CRANKSHAFT STRAIGHT PIN O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A116559E01,

EM–32 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

CHAIN TENSIONER ASSEMBLY NO. 1 9.0 (92, 80 in.*lbf) CHAIN SUB-ASSEMBLY CHAIN TENSIONER

SLIPPER

9.0 (92, 80 in.*lbf) CHAIN VIBRATION DAMPER NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A116579E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–33

M REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

2. REMOVE FRONT WHEEL RH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE OIL 5. DRAIN ENGINE COOLANT (See page CO-8) 6. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 7. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 8. REMOVE GENERATOR ASSEMBLY (See page CH-10) E 9. REMOVE IGNITION COIL NO. 1 (See page IG-9) 10. DISCONNECT VENTILATION HOSE (See page FU-13) 11. DISCONNECT VENTILATION HOSE NO. 2 (See page FU-13) 12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) 13. REMOVE ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-17) 14. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-18) 15. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-403) 16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-396) 17. REMOVE WATER PUMP PULLEY (See page CO-15) 18. REMOVE WATER PUMP ASSEMBLY (See page CO- 15) 19. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page LU-18) 20. REMOVE OIL PUMP ASSEMBLY (See page LU-19) 21. REMOVE OIL PUMP SEAL (See page LU-21) 22. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 NOTICE: • Do not rotate the crankshaft with the chain tensioner removed. • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first., EM–34 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM

(a) Pull up the stopper plate and hold it with its lock released. Stopper Plate A116564E01 (b) Unlock the plunger of the tensioner and push it in to the end. Plunger A116565E01 (c) Pull down the stopper plate with the plunger pushed to the end and lock the plunger. Stopper Plate A116566E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–35

M

(d) Inserta3mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger. A116567 E (e) Remove the 2 bolts and remove chain tensioner assembly No. 1. A116568 23. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the chain tensioner slipper. A116569 24. REMOVE CHAIN VIBRATION DAMPER NO. 1 (a) Remove the 2 bolts and remove chain vibration damper No. 1. 25. REMOVE CHAIN SUB-ASSEMBLY A116570, EM–36 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM INSPECTION

1. INSPECT CHAIN SUB-ASSEMBLY (a) Using a spring scale, apply 140 N (14.3 kgf, 31.5 lb) to the timing chain and measure its length. Maximum chain elongation: 123.2 mm (4.850 in.) If the elongation is greater than the maximum, replace the chain. HINT: A050062 Perform the same measurement at 3 or more random places and calculate the average length.

INSTALLATION

TDC: 1. INSTALL CHAIN SUB-ASSEMBLY Timing Marks (a) Make sure that all the timing marks are in the positions (TDC) shown in the illustration. HINT: The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring. Timing Mark A116571E01 (b) Set the timing mark of the crankshaft in a position Timing Mark between 40 and 140°ATDC as illustrated. 40° to 140° ATDC A116573E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–37

M

(c) Set the camshaft timing gear and the camshaft 20° ATDC: timing sprocket in the positions ( 20°ATDC) shown Timing Marks in the illustration. (d) Set the crankshaft in the position ( 20°ATDC) shown in the illustration.

E

30° Timing Mark A116574E01 (e) Install chain vibration damper No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116576, EM–38 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM

(f) Align the timing marks of the camshaft with the mark Mark Plates plates of the timing chain and install the timing chain. HINT: Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench. Timing Marks Mark Plate Timing Mark A116577E01 2. INSTALL CHAIN TENSIONER SLIPPER (a) Install the chain tensioner slipper. A116569 3. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 (a) Install chain tensioner assembly No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Remove the bar from chain tensioner assembly No. 1. 4. INSTALL OIL PUMP SEAL (See page LU-21) 5. INSTALL OIL PUMP ASSEMBLY (See page LU-22) A116568 6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page LU-26) 7. INSTALL WATER PUMP ASSEMBLY (See page CO- 16) 8. INSTALL WATER PUMP PULLEY (See page CO-16) 9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-397) 10. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-403), 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–39

M

11. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-26) 12. INSTALL ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-26) 13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 14. CONNECT VENTILATION HOSE NO. 2 (See page FU- 20) 15. CONNECT VENTILATION HOSE (See page FU-20) 16. INSTALL IGNITION COIL NO. 1 (See page IG-9) 17. INSTALL GENERATOR ASSEMBLY (See page CH-17) 18. INSTALL FAN AND GENERATOR V BELT (See page EM-7) E 19. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 20. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 21. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 22. ADD ENGINE OIL 23. ADD ENGINE COOLANT (See page CO-8) 24. CHECK ENGINE OIL LEVEL (See page LU-1) 25. CHECK FOR ENGINE OIL LEAKAGE 26. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-1) 27. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 28. INSTALL ENGINE UNDER COVER RH 29. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf),

EM–40 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

E1CNZG-IFNEE ENGINAE MECHANICMAL SHAFT

COMPONENTS ENGINE UNDER COVER RH

5.0 (51, 44 in.*lbf)

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

A115143E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–41

M

7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2 7.0 (71, 62 in.*lbf)

E

N*m (kgf*cm, ft.*lbf) : Specified torque A115136E01,

EM–42 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

for Hatchback: 52 (530, 38) x2 45 (459, 33) 45 (459, 33) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft.*lbf) : Specified torque A116232E04, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–43

M

for Sedan: 52 (530, 38) x2 52 (530, 38) 52 (530, 38) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

E

52 (530, 38) N*m (kgf*cm, ft*lbf) : Specified torque A133595E01,

EM–44 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

9.0 (92, 80 in.*lbf) IGNITION COIL NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A115486E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–45

M

13 (133, 9.6) WIRE HARNESS BRACKET 10 (102, 7.0) SEAL WASHER

E

10 (102, 7.0) x7 10 (102, 7.0) 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY VENTILATION HOSE NO. 2 VENTILATION HOSE CYLINDER HEAD COVER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A115504E01,

EM–46 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

x16 13 (129, 9.4) 23 (235, 17) CAMSHAFT BEARING CAP NO. 2 CAMSHAFT BEARING CAP NO. 1 x8 CAMSHAFT TIMING NO. 2 CAMSHAFT

SPROCKET CAMSHAFT

64 (653, 47) 64 (653, 47) CAMSHAFT TIMING GEAR ASSEMBLY 15 (153, 11) N*m (kgf*cm, ft.*lbf) : Specified torque A116233E02, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–47

M REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

2. REMOVE ENGINE UNDER COVER RH 3. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 4. REMOVE IGNITION COIL NO. 1 (See page IG-9) 5. DISCONNECT VENTILATION HOSE (See page FU-13) 6. DISCONNECT VENTILATION HOSE NO. 2 (See page FU-13) 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) E 8. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 9. REMOVE ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-17) 10. REMOVE NO. 2 CAMSHAFT Matchmark NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40 ° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves. A116206E01 (a) Set the No. 1 cylinder to TDC / compression. (1) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that the timing marks on both the camshaft timing sprocket and the camshaft timing gear are facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01, EM–48 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(b) Place paint marks on the chain in the places where Paint Marks the timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Timing Marks A116207E01 (c) Using an 8 mm hexagon wrench, remove the screw plug. G100163 (d) Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward. Stopper Plate A116209E01 (e) Using a wrench, rotate camshaft No. 2 clockwise to push in the plunger of the chain tensioner. Plunger A116210E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–49

M

(f) Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and inserta3mm (0.12 in.) diameter bar into the holes to hold the stopper plate. HINT: • Fix the stopper plate using the bar while rotating the camshaft right and left slightly. • Hold the bar with tape so that it does not come off. A116212 E (g) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and remove the flange bolt. A116213 (h) Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown13542in the illustration, then remove camshaft bearing caps No. 1 and No. 2. NOTICE: Loosen the bolts uniformly while keeping the camshaft level. A116214E01 (i) Remove the flange bolt and remove the camshaft timing sprocket. A116215, EM–50 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(j) Remove camshaft No. 2. A116216 11. REMOVE CAMSHAFT (a) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the2431camshaft level. A116217E01 (b) Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly. A116218 (c) Tie the chain with a piece of string as shown in the illustration. 12. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (a) Clamp the camshaft in a vise and confirm that it is locked. NOTICE: Do not damage the camshaft. A035227E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–51

M

(b) Cover the 4 oil paths of the cam journal with tape as Retard Side shown in the illustration. Paths HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil Advance paths. Plug one of the oil paths for each groove with Side Paths a piece of rubber before wrapping the cam journal with the tape. (c) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed E Open Vinyl Tape Rubber Piece A116226E04 (d) Apply air at about 150 kPa (1.5 kgf*cm2) pressure Retard Advance into the 2 broken paths (the advance side path and Side Path Side Path the retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02 (e) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. HINT: Retard Advance Side Path Side Path The lock pin is released, and the camshaft timing gear revolves in the advance direction. (f) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. NOTICE: The camshaft timing gear assembly Decompress Hold Pressure occasionally shifts to the retard side abruptly, if the air pressure on the advance side path is released first. This often results in breakage of A116228E02 the lock pin., EM–52 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(g) Remove the flange bolt and remove the camshaft timing gear assembly. NOTICE: • Do not remove the other 4 bolts. • When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first. Flange Bolt A116229E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–53

M INSPECTION

1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Check the lock of camshaft timing gear. (1) Clamp the camshaft in a vice, and check that the camshaft timing gear is locked. NOTICE: Do not damage the camshaft. (b) Release the lock pin. Retard Side (1) Cover the 4 oil paths of the cam journal with Paths tape as shown in the illustration. HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and Advance the other is for advancing cam timing (lower). Side Paths Each groove has 2 oil paths. Plug one of the oil E paths for each groove with a piece of rubber before wrapping the cam journal with the tape. (2) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed Open Vinyl Tape Rubber Piece A116226E05 (3) Apply air at about 150 kPa (1.5kgf*cm2) Retard Advance pressure into the 2 broken paths (the advance Side Path Side Path side path and the retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02, EM–54 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(4) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. Retard Advance Side Path Side Path HINT: The lock pin is released and the camshaft timing gear revolves in the advance direction. (5) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. Decompress Hold Pressure NOTICE: Camshaft timing gear assembly occasionally shifts to the retard side A116228E02 abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock pin. (c) Check the revolution. (1) Rotate the valve timing assembly back and forth several times, except where the lock pin meets it at the most retarded angle. Check the movable range and that it rotates smoothly. Standard: Smooth movable range is about 22.5° NOTICE: Perform this check by hand, instead of using air pressure. (d) Check that the gear locks in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked in the most retarded position., 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–55

M INSTALLATION

1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY NOTICE: Install the camshaft timing gear assembly onto the camshaft with the lock pin of the camshaft timing gear assembly released. (a) Put the camshaft timing gear assembly and camshaft together with the straight pin of the Straight Pin groove. (b) Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits the groove, push to ensure a good fit. NOTICE: Do not turn the camshaft timing gear in the Groove retard direction (clockwise). E A116230E01 (c) Check that there is no clearance between the gear flange and the camshaft. (d) Tighten the flange bolt with the camshaft timing gear fixed. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: • Do not lock the camshaft timing gear assembly when tightening the bolt. • Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position. • Tightening the bolts with the lock pin locked could cause breakage of the lock pin. (e) Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position. 2. INSTALL CAMSHAFT (a) Apply a light coat of engine oil to the camshaft and camshaft journals. (b) Install the chain onto the camshaft timing gear with Paint Mark the paint mark and the timing mark aligned as shown in the illustration. Timing Mark A116220E01, EM–56 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(c) Examine the front marks and numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the camshaft level. 3124A116222E01 3. INSTALL NO. 2 CAMSHAFT (a) Install camshaft No. 2. A116216 (b) Hold the chain and align the timing mark on the Paint Mark camshaft timing sprocket with the paint mark of the chain. (c) Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft. Timing Mark Pin A116224E01 (d) Provisionally install the flange bolt. A116215, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–57

M

(e) Examine the front marks and numbers on camshaft3124bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration. 5 Torque: for bearing cap No. 2 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the camshaft level. Bearing Cap No. 1 Bearing Cap No. 2 A116223E01 E (f) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and install the flange bolt. SST 09023-38400 Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) (g) Remove the bar from the timing chain tensioner.

SST

A116225E01 (h) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (i) Check that all the pairs of timing marks are aligned. Paint Marks (j) Apply adhesive to the end 2 or 3 threads of the screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Timing Marks A116207E01, EM–58 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(k) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 4. INSPECT VALVE CLEARANCE (See page EM-9) 5. ADJUST VALVE CLEARANCE (See page EM-10) 6. INSTALL ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-26) G100163 7. INSTALL FAN AND GENERATOR V BELT (See page EM-7) 8. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 9. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 11. CONNECT VENTILATION HOSE NO. 2 (See page FU- 20) 12. CONNECT VENTILATION HOSE (See page FU-20) 13. INSTALL IGNITION COIL NO. 1 (See page IG-9) 14. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 15. CHECK FOR ENGINE OIL LEAKAGE 16. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 17. INSTALL ENGINE UNDER COVER RH, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–57

M CE1NZG-IFNEE ENGINYE MECHANILCAL INDER HEAD COMPONENTS

for Hatchback: FRONT WIPER ARM HEAD CAP FRONT WIPER ARM AND BLADE ASSEMBLY LH FRONT WIPER ARM HEAD CAP 26 (265, 19) FRONT WIPER ARM AND BLADE ASSEMBLY RH 26 (265, 19) COWL TOP VENTILATOR LOUVER CENTER NO. 1 E

CLIP

COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

CLIP CLIP

HOOD TO COWL TOP SEAL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 COWL TOP VENTILATOR LOUVER LH 6.5 (66, 58 in.*lbf) FRONT WIPER MOTOR AND LINK x9 5.5 (56, 49 in.*lbf) COWL TOP PANEL OUTER N*m (kgf*cm, ft*lbf) : Specified torque A118803E10,

EM–58 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

for Sedan: FRONT WIPER FRONT WIPER ARM AND ARM HEAD CAP BLADE ASSEMBLY LH FRONT WIPER ARM AND BLADE ASSEMBLY RH FRONT WIPER ARM HEAD CAP COWL SIDE VENTILATOR SUB-ASSEMBLY RH 26 (265, 19) 26 (265, 19) X3

CLIP

COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY FRONT AIR SHUTTER SEAL COWL SIDE VENTILATOR 5.5 (56, 49 in.*lbf) SUB-ASSEMBLY LH X2 WINDSHIELD WIPER MOTOR AND LINK X8 6.5 (66, 58 in.*lbf) COWL TOP PANEL OUTER 6.5 (66, 58 in.*lbf) CENTER BRACKET COWL TOP PANEL OUTER N*m (kgf*cm, ft.*lbf) : Specified torque A133320E03, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–59

M E

ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115143E01,

EM–60 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2 7.0 (71, 62 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115136E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–61

M

VENTILATION HOSE NO. 2 FUEL VAPOR FEED HOSE NO. 1 FUEL VAPOR FEED HOSE NO. 2

E

AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 A133592E01,

EM–62 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

19 (189, 14) 54 (551, 40) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A116199E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–63

M

BATTERY CLAMP SUB-ASSEMBLY

BATTERY E

BATTERY TRAY HEATED OXYGEN SENSOR BRACKET BOOSTER VACUUM TUBE FUEL TUBE SUB-ASSEMBLY WATER FILLER SUB-ASSEMBLY FUEL TUBE SUB-ASSEMBLY 7.5 (76, 66 in.*lbf) x2 x3 44 (449, 33) RADIATOR HOSE NO. 3 MANIFOLD SUPPORT BRACKET RESERVE TANK HOSE x2 43 (438, 32) GASKET EXHAUST PIPE ASSEMBLY FRONT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116961E01,

EM–64 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

for Hatchback: 11 (112, 8.1) FAN BELT ADJUSTING BAR 19 (189, 14) 54 (551, 40) 52 (530, 38) GENERATOR x2

ASSEMBLY

45 (459, 33) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft.*lbf) : Specified torque A116193E06, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–65

M

for Sedan: 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR 54 (551, 40) 52 (530, 38) GENERATOR x2 E

ASSEMBLY

52 (530, 38) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR 52 (530, 38) SUB-ASSEMBLY RH N*m (kgf*cm, ft*lbf) : Specified torque A133594E01,

EM–66 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

9.0 (92, 80 in.*lbf) IGNITION COIL NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A115486E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–67

M

13 (133, 9.6) WIRE HARNESS BRACKET 10 (102, 7.0) SEAL WASHER

E

10 (102, 7.0) x7 10 (102, 7.0) 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY VENTILATION HOSE NO. 2 VENTILATION HOSE CYLINDER HEAD COVER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A115504E01,

EM–68 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM GASKET

11 (112, 8.1) x2 x3 x3 WATER PUMP ASSEMBLY 15 (153, 11) 11 (112, 8.1) WATER PUMP PULLEY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116194E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–69

M

CAMSHAFT TIMING OIL O-RING CONTROL VALVE ASSEMBLY

E

7.5 (76, 66 in.*lbf) 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116180E01,

EM–70 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

TRANSVERSE ENGINE ENGINE MOUNTING BRACKET x4 55 (561, 41) 24 (245, 18) 32 (326, 24) x2 24 (245, 18) x11 11 (112, 8.1) OIL PUMP ASSEMBLY 7.5 (76, 66 in.*lbf) 11 (112, 8.1)

CRANKSHAFT

POSITION SENSOR 128 (1305, 95) OIL PUMP SEAL CRANKSHAFT DAMPER SUB-ASSEMBLY CRANKSHAFT STRAIGHT PIN O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A116559E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–71

M

CHAIN TENSIONER ASSEMBLY NO. 1 9.0 (92, 80 in.*lbf)

E

CHAIN SUB-ASSEMBLY CHAIN TENSIONER

SLIPPER

9.0 (92, 80 in.*lbf) CHAIN VIBRATION DAMPER NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A116579E01,

EM–72 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

UNION TO CONNECTOR TUBE HOSE 30 (306, 22) x3 VENTILATION HOSE INTAKE MANIFOLD TO HEAD GASKET NO. 1 WATER BY-PASS INTAKE MANIFOLD HOSE 30 (306, 22) x2 WATER BY-PASS HOSE NO. 2 OIL LEVEL GAUGE SUB-ASSEMBLY OIL LEVEL GAUGE GUIDE 9.0 (92, 80 in.*lbf) O-RING N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A121463E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–73

M

x16 x3 13 (129, 9.4) 23 (235, 17) CAMSHAFT BEARING CAP NO. 2 CAMSHAFT BEARING CAP NO. 1 NO. 2 CAMSHAFT

CAMSHAFT E

1st: 29 (300, 22) x10 2nd: Turn 90° PLATE WASHER 3rd: Turn 90° HEATER WATER INLET HOSE A CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET 9.0 (92, 80 in.*lbf) WATER BY-PASS PIPE NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116963E01,

EM–74 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

x4 8.0 (82, 71 in.*lbf) EXHAUST MANIFOLD HEAT INSULATOR NO. 1 EXHAUST MANIFOLD TO HEAD GASKET EXHAUST MANIFOLD x3 27 (275, 20) x2 27 (275, 20) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116967E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–75

M

19 (194, 14) x2 DELIVERY PIPE NO. 1 SPACER x2 FUEL DELIVERY PIPE SUB-ASSEMBLY 9.0 (92, 80 in.*lbf)

E

O-RING BOOSTER VACUUM TUBE FUEL INJECTOR ASSEMBLY x4 INJECTOR VIBRATION INSULATOR 9.0 (92, 80 in.*lbf) HARNESS BRACKET 13 (131, 9.5)

GASKET

13 (131, 9.5) 20 (204, 15) HARNESS BRACKET ENGINE COOLANT TEMPERATURE SENSOR WATER BY-PASS HOSE CAMSHAFT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 8.0 (82, 71 in.*lbf) A116965E01,

EM–76 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

x8 x8 VALVE LIFTER x8 x8 RETAINER LOCK x8 x8

RETAINER

x8 x8 VALVE SPRING VALVE STEM OIL SEAL x8 x8 x8 x8 VALVE SPRING SEAT x8 x8 INTAKE VALVE GUIDE BUSH EXHAUST VALVE GUIDE

BUSH

44 (449, 33) WITH HEAD TAPER SCREW PLUG NO. 1 CAMSHAFT BEARING CAP RING PIN GASKET 4.0 (41, 35in.*lbf) STUD BOLT 9.0 (92, 80in.*lbf) STUD BOLT 10 (102, 7.4) STUD BOLT 10 (102, 7.4) STUD BOLT OIL CONTROL VALVE FILTER

GASKET

30 (306, 22) WITH HEAD TAPER SCREW PLUG NO. 2 INTAKE VALVE EXHAUST VALVE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117451E03, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–77

M REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE (See Page FU-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

3. REMOVE FRONT WIPER ARM HEAD CAP (for Hatchback) (See page WW-17) 4. REMOVE FRONT WIPER ARM HEAD CAP (for Sedan) (See page WW-9) 5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) (See page WW-17) 6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) (See page WW-9) E 7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) (See page WW-17) 8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) (See page WW-9) 9. REMOVE HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-18) 10. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-18) 11. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-18) 12. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-10) 13. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-10) 14. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Sedan) (See page WW-10) 15. REMOVE FRONT WIPER MOTOR AND LINK (for Hatchback) (See page WW-19) 16. REMOVE FRONT WIPER MOTOR AND LINK (for Sedan) (See page WW-10) 17. REMOVE COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (See page EM-122) 18. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan) (See page ES-432) 19. REMOVE COWL TOP PANEL OUTER (for Hatchback) (See page EM-123) 20. REMOVE COWL TOP PANEL OUTER (for Sedan) (See page ES-432) 21. REMOVE BATTERY 22. REMOVE BATTERY TRAY 23. REMOVE FRONT WHEEL RH, EM–78 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

24. REMOVE ENGINE UNDER COVER RH 25. DRAIN ENGINE OIL 26. DRAIN ENGINE COOLANT (See page CO-8) 27. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 (See page ES-410) 29. DISCONNECT RADIATOR HOSE NO. 3 (a) Disconnect radiator hose No. 3. A116580 30. DISCONNECT RESERVE TANK HOSE (a) Disconnect the reserve tank hose. A116581 31. REMOVE WATER FILLER SUB-ASSEMBLY (a) Separate radiator hose No. 1 from the cylinder head. (b) Remove the 2 nuts and remove the water filler sub- assembly. A116739 32. DISCONNECT WATER BY-PASS HOSE NO. 2 (a) Disconnect water by-pass hose No. 2. A116740, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–79

M

33. DISCONNECT WATER BY-PASS HOSE (a) Disconnect the water by-pass hose. A116741 34. DISCONNECT THROTTLE WITH MOTOR BODY

CONNECTOR

(a) Separate the wire harness clamp. (b) Remove the nut and separate the throttle with motor body connector. E A116742 35. DISCONNECT VENTILATION HOSE (a) Disconnect the ventilation hose. A116973 36. DISCONNECT UNION TO CONNECTOR TUBE HOSE (a) Disconnect the union to connector tube hose. 37. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY A116744 38. REMOVE INTAKE MANIFOLD (a) Separate the 3 wire harness clamps shown in the illustration. A116745, EM–80 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

(b) Remove the 3 bolts and 2 nuts and remove the intake manifold. A116746 39. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the wire harness clamp and the bolt and remove the oil level gauge guide. 40. DISCONNECT FUEL TUBE SUB-ASSEMBLY (See page FU-14) A116747 41. DISCONNECT BOOSTER VACUUM TUBE (a) Disconnect the booster vacuum tube. A116748 42. DISCONNECT CAMSHAFT POSITION SENSOR

CONNECTOR

(a) Disconnect the camshaft position sensor connector. A116749 43. DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR (a) Disconnect the engine coolant temperature sensor connector. A116750, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–81

M

44. DISCONNECT HEATED OXYGEN SENSOR

CONNECTOR

(a) Remove the bolts and separate the sensor bracket. (b) Disconnect the heated oxygen sensor connector. A116751 45. DISCONNECT HEATER WATER INLET HOSE A (a) Disconnect heater water inlet hose A.

E

A116752 46. SEPARATE WATER BY-PASS PIPE NO. 1 (a) Remove the bolt and separate water by-pass pipe No. 1. A116753 47. DISCONNECT WIRE HARNESS (a) Remove the 2 bolts and disconnect the wire harness. A116755 48. SEPARATE EXHAUST PIPE ASSEMBLY FRONT (a) Remove the 2 bolts and 2 compression springs and separate the exhaust pipe assembly front. A116756, EM–82 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

49. REMOVE MANIFOLD SUPPORT BRACKET (a) Remove the 3 bolts and remove the manifold support bracket. 50. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 51. REMOVE GENERATOR ASSEMBLY (See page CH-10) 52. REMOVE IGNITION COIL NO. 1 (See page IG-9) A116757 53. REMOVE VENTILATION HOSE (See page FU-13) 54. REMOVE VENTILATION HOSE NO. 2 (See page FU- 13) 55. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) 56. REMOVE ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-17) 57. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-18) 58. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-403) 59. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-396) 60. REMOVE WATER PUMP PULLEY (See page CO-15) 61. REMOVE WATER PUMP ASSEMBLY (See page CO- 15) 62. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page LU-17) 63. REMOVE OIL PUMP ASSEMBLY (See page LU-19) 64. REMOVE OIL PUMP SEAL (See page LU-21) 65. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 (See page EM-33) 66. REMOVE CHAIN TENSIONER SLIPPER (See page EM-35) 67. REMOVE CHAIN VIBRATION DAMPER NO. 1 (See page EM-35) 68. REMOVE CHAIN SUB-ASSEMBLY 69. REMOVE CAMSHAFT NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first., 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–83

M

(a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration, and then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. (b) Remove the camshaft and camshaft No. 2. A035758E01 70. REMOVE CYLINDER HEAD SUB-ASSEMBLY (a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 plate washers. E NOTICE: • Do not drop the washers into the cylinder head. • Head warpage or cracking could result from A035286 removing the bolts in the wrong order. 71. REMOVE CYLINDER HEAD GASKET (a) Remove the cylinder head gasket. A116758 72. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (a) Remove the 4 bolts and remove exhaust manifold heat insulator No. 1. A116759 73. REMOVE EXHAUST MANIFOLD (a) Remove the 3 bolts and 2 nuts and remove the exhaust manifold. A116761, EM–84 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

74. REMOVE HARNESS BRACKET (a) Remove the bolt and remove the harness bracket. A116762 75. REMOVE BOOSTER VACUUM TUBE (a) Remove the 2 bolts and remove the booster vacuum tube. A116763 76. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and remove the camshaft position sensor. A116764 77. REMOVE ENGINE COOLANT TEMPERATURE

SENSOR

(a) Using SST, remove the engine coolant temperature sensor connector. SST 09817-33190

SST

A116765E01 78. REMOVE WATER BY-PASS HOSE (a) Remove the water by-pass hose. A116766, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–85

M

79. REMOVE HARNESS BRACKET (a) Remove the bolt and remove the harness bracket. A116767 80. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors. NOTICE: Do not drop the fuel injectors when removing E the fuel delivery pipe sub-assembly. 81. REMOVE FUEL INJECTOR ASSEMMBLY (See page FU-16) A116768 82. REMOVE DELIVERY PIPE NO. 1 SPACER (a) Remove the 2 delivery pipe No. 1 spacers. A116955 83. REMOVE INJECTOR VIBRATION INSULATOR (a) Remove the 4 injector vibration insulators. A116956

DISASSEMBLY

1. REMOVE WITH HEAD TAPER SCREW PLUG NO. 1 (a) Using a 10 mm socket hexagon wrench, remove the taper screw plug and the gasket. 2. REMOVE VALVE LIFTER HINT: Keep the valve lifters in the correct order so that they can be returned to their original locations when reassembled. A062890E01, EM–86 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

3. REMOVE WITH HEAD TAPER SCREW PLUG NO. 2 (a) Using an 8 mm hexagon wrench, remove the taper screw plug. 4. REMOVE OIL CONTROL VALVE FILTER A038128E01 5. REMOVE INTAKE VALVE (a) Using SST, compress the valve spring and remove SST the 2 retainer locks, retainer and valve spring. SST 09202-70020 (09202-00010) HINT: Keep the valves, valve springs, spring seats and spring retainers in the correct order so that they can be returned to their original locations when reassembled. A037109E03 6. REMOVE EXHAUST VALVE (a) Using SST, compress the valve spring and remove the 2 retainer locks, retainer and valve spring. SST 09202-70020 (09202-00010) HINT: Keep the valves, valve springs, spring seats and spring retainers in the correct order so that they can be returned to their original locations when reassembled. 7. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seal. A080961E01 8. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seats. 9. REMOVE STUD BOLT (a) Using "Torx" socket wrenches E5 and E7, remove the 7 stud bolts. 10. REMOVE CAMSHAFT BEARING CAP SETTING RING

PIN

A080962E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–87

M INSPECTION

1. INSPECT CYLINDER HEAD FOR WARPAGE (a) Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder block and the manifolds. Maximum warpage Surface Specified Condition Cylinder Block Side Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.10 mm (0.0039 in.) Exhaust manifold side 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace Intake Manifold Side the cylinder head.

E

Exhaust Manifold Side A050931E01 2. INSPECT CYLINDER HEAD FOR CRACKS (a) Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. A001071E01 3. INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the length of the Underhead Length head bolts from the seat to the end. Standard length: 142.8 to 144.2 mm (5.622 to 5.677 in.) Maximum length: 147.1 mm (5.791 in.) If the length is greater than the maximum, replace the bolt. A098332E01 4. INSPECT INTAKE VALVE (a) Check the overall valve length. Standard overall length: 89.25 mm (3.5138 in.) Minimum overall length: 88.75 mm (3.4941 in.) If the overall length is less than the minimum, replace the valve. EM02534E06, EM–88 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

(b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.970 to 4.985 mm (0.1957 to 0.1963 in.) Z000052E01 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, Margin Thickness replace the valve. 5. INSPECT EXHAUST VALVE (a) Check the overall valve length. EM00181E03 Standard overall length: 87.90 mm (3.4606 in.) Minimum overall length: 87.40 mm (3.4409 in.) If the overall length is less than the minimum, replace the valve. (b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.965 to 4.980 mm (0.1955 to 0.1961 in.) (c) Check the valve head margin thickness. Standard margin thickness: 1.15 mm (0.045 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. 6. INSPECT VALVE SPRING (a) Using vernier calipers, measure the free length of the valve spring. Standard free length: 45.05 to 45.15 mm (1.774 to 1.778 in.) If the free length is not as specified, replace the spring. EM00801E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–89

M

(b) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring. EM00988E01 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Standard installed tension: 149 to 165 N (15.2 to 16.8 kgf, 33.5 to 37.1 lbf) at 32.5 mm (1.280 in.) E Maximum working tension: 286 to 316 N (29.1 to 32.2 kgf, 64.2 to 71.0 lbf) at 23.9 mm (0.941 in.) If the installed tension is not as specified, replace EM00281E01 the valve spring. 7. INSPECT VALVE GUIDE BUSH OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.010 to 5.030 mm (0.1972 to 0.1980 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement to calculate the oil clearance. Standard oil clearance A001478E02 Guide Bush Specified Condition Intake 0.025 to 0.060 mm(0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm(0.0012 to 0.0026 in.) Maximum oil clearance Guide Bush Specified Condition Intake 0.08 mm (0.0032 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see page EM- 92). 8. INSPECT INTAKE VALVE SEAT (a) Apply a light coat of prussian blue to the valve face. (b) Lightly press the valve against the seat., EM–90 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

(c) Check the valve face and seat in accordance with the following procedure. (1) If blue appears 360° around the face, the valve is concentric. If not, replace the valve. (2) If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface Width the seat. (3) Check that the seat contact is in the middle of the valve face with the width between 1.0 to 1.4 A050036E01 mm (0.039 to 0.055 in.). 9. INSPECT VALVE LIFTER (a) Using a micrometer, measure the lifter diameter. Standard lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) P016860E01 10. INSPECT VALVE LIFTER OIL CLEARANCE (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Standard lifter bore diameter: 31.000 to 31.025 mm (1.2205 to 1.2215 in.) (b) Subtract the lifter diameter measurement from the lifter bore diameter measurement to calculate the oil clearance. Standard oil clearance: A001080E01 0.024 to 0.059 mm (0.0009 to 0.0023 in.) Maximum oil clearance: 0.1 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 11. INSPECT CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. EM01628E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–91

M

(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 44.617 to 44.717 mm (1.7566 to 1.7605 in.) Minimum cam lobe height: 43.16 mm (1.6992 in.) If the cam lobe height is less than the minimum, replace the camshaft. A037113E01 (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition E No. 1 journal 34.449 to 34.465 mm(1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm(0.9035 to 0.9041 in.) A037114E01 If the journal diameter is not as specified, check the oil clearance. 12. INSPECT NO. 2 CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 44.666 to 44.766 (1.7585 to 1.7624 in.) Minimum cam lobe height: 44.52 mm (1.7528 in.) If the cam lobe height is less than the minimum, replace the camshaft. (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition No. 1 journal 34.449 to 34.465 mm(1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm(0.9035 to 0.9041 in.) If the journal diameter is not as specified, check the oil clearance., EM–92 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

13. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshafts. (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head together. A001455E01 14. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps and the camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the Plastigage camshaft journals. (d) Install the bearing caps (see page EM-97). NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. A001452E01 (f) Measure the Plastigage at its widest point. Standard oil clearance: 0.035 to 0.072 mm (0.0014 to 0.0028 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head together. NOTICE: A001453E01 Completely remove the Plastigage after the measurement. 80 to 100°C (176 to 212°F) REPLACEMENT 1. REMOVE INTAKE VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). A001067E02, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–93

M

(b) Using SST and a hammer, tap out the guide SST bushing. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 2. REMOVE EXHAUST VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Using SST and a hammer, tap out the guide bushing. A037110E02 SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 3. INSTALL INTAKE VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Inside Diameter: E 9.685 to 9.706 mm (0.3813 to 0.3821 in.) If the bushing bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bushing bore to the dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). A001445E01 Bushing bore diameter mm (in.) Bushing size 9.685 to 9.706 (0.3813 to 0.3821) STD 9.735 to 9.755 (0.3833 to 0.3841) O/S 0.05 (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Using SST and a hammer, tap a new guide bushing in to the specified protrusion height. SST SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) 9.0 to 9.4 mm A080977E02 (d) Using a sharp 5 mm reamer, ream the guide Reamer bushing to obtain the standard oil clearance between the guide bushing and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) 4. INSTALL EXHAUST VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Inside Diameter: A001447E02 9.685 to 9.706 mm (0.3813 to 0.3821 in.), EM–94 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

If the bushing bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bushing bore to the dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). Bushing bore diameter mm (in.) Bushing size 9.685 to 9.706 (0.3813 to 0.3821) STD 9.735 to 9.755 (0.3833 to 0.3841) O/S 0.05 (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Using SST and a hammer, tap a new guide bushing in to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) (d) Using a sharp 5 mm reamer, ream the guide bushing to obtain the standard oil clearance between the guide bushing and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

REASSEMBLY

1. INSTALL CAMSHAFT BEARING CAP SETTING RING

PIN

(a) Using a plastic-faced hammer, tap a new ring pin in to the specified protrusion height. Protrusion height: 8.5 to 9.5 mm (0.335 to 0.374 in.) 2. INSTALL STUD BOLT (a) Using "Torx" socket wrenches E5 and E7, install the 7 stud bolts. 8.5 to 9.5 mm Torque: Stud bolt A: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) Stud bolt B: A080980E02 4.0 N*m (41 kgf*cm, 35 in.*lbf) Stud bolt C: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) Stud bolt D: 9.0 N*m (92 kgf*cm, 80 in.*lbf), 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–95

M A C E D B

28.5 19.5 26.5 22.5 43.5 38.5 49.5 37.5 12 12 13 13 Stud Bolt A Stud Bolt B Stud Bolt C Stud Bolt D [mm] A050180E03 3. INSTALL VALVE STEM OIL SEAL (a) Apply a light coat of engine oil to new valve stem oil Intake Exhaust seals. NOTICE: Gray Installing the oil seals for the intake and exhaust onto the opposite valve guide bush as may Black cause failures. HINT: The intake valve oil seal is gray and the exhaust A050182E02 valve oil seal is black. (b) Using SST, push in the oil seals. SST 09201-41020

SST

A001063E02, EM–96 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

4. INSTALL INTAKE VALVE (a) Install the valve, spring seat, valve spring, and spring retainer. NOTICE: Install the parts in their original locations in the original order. A001065E01 (b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem. SST SST 09202-70020 (09202-00010) A037109E03 (c) Using a plastic-faced hammer and the valve stem (not in use) with its tip wrapped in tape, gently tap the valve stem tip to ensure a proper fit. NOTICE: Do not damage the valve stem tip. 5. INSTALL EXHAUST VALVE (a) Install the valve, spring seat, valve spring, and spring retainer. (b) Using SST, compress the valve spring and place the A007307E01 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) (c) Using a plastic-faced hammer and the valve stem (not in use) with its tip wrapped in tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Do not damage the valve stem tip. 6. INSTALL OIL CONTROL VALVE FILTER (a) Install the oil control valve filter. 7. INSTALL WITH HEAD TAPER SCREW PLUG NO. 2 (a) Using an 8 mm hexagon wrench, install the taper screw plug and a new gasket. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 8. INSTALL VALVE LIFTER (a) Apply a light coat of engine oil to the 16 valve lifters. (b) Install the 16 valve lifters. (c) Check that the valve lifters rotate smoothly by hand. A038128E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–97

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9. INSTALL WITH HEAD TAPER SCREW PLUG NO. 1 (a) Using a 10 mm socket hexagon wrench, install the taper screw plug with a new gasket. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A062890E01

INSTALLATION

1. INSTALL INJECTOR VIBRATION INSULATOR (a) Install 4 new injector vibration insulators onto the cylinder head. E A116956 2. INSTALL DELIVERY PIPE NO. 1 SPACER (a) Install the 2 delivery pipe No. 1 spacers onto the cylinder head. NOTICE: Install the delivery pipe No. 1 spacer in the correct direction. 3. INSTALL FUEL INJECTOR ASSEMBLY (See page FU- 17) A116957 4. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Provisionally install the fuel delivery pipe sub- assembly with the 4 fuel injectors using the 3 bolts. NOTICE: • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub- assembly. A116768 (b) Tighten the 3 bolts to the specified torque. A Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for boltAA9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt B

B

A116768E01, EM–98 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

5. INSTALL HARNESS BRACKET (a) Install the harness bracket with the bolt. Torque: 13 N*m (131 kgf*cm, 9.5 ft.*lbf) A116767 6. INSTALL WATER BY-PASS HOSE (a) Install the water by-pass hose. A116766 7. INSTALL ENGINE COOLANT TEMPERATURE

SENSOR

(a) Provisionally install the engine coolant temperature sensor through a new gasket. (b) Using SST, tighten the engine coolant temperature sensor. SST 09817-33190 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

SST

A116765E01 8. INSTALL CAMSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring on the camshaft position sensor. (b) Install the camshaft position sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Do not twist the O-ring. A116764 9. INSTALL BOOSTER VACUUM TUBE (a) Install the booster vacuum tube with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116763, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–99

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10. INSTALL HARNESS BRACKET (a) Install the harness bracket with the bolt. Torque: 13 N*m (131 kgf*cm, 9.5 ft.*lbf) A116762 11. INSTALL EXHAUST MANIFOLD (a) Using several steps, install a new exhaust manifold 1 gasket and the exhaust manifold with the 3 bolts45and 2 nuts in the sequence shown in the illustration. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) E A116761E01 12. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (a) Install exhaust manifold heat insulator No. 1 with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A116759 13. INSTALL CYLINDER HEAD GASKET Lot No. (a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward. NOTICE: • Remove any oil from the contact surfaces. • Check the mounting orientation of the cylinder head gasket. • Place the cylinder head on the cylinder head gently in order not to damage the gasket. A117469E01 14. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: The cylinder head bolts are tightened in 2 successive steps. (a) Apply a light coat of engine oil to the threads of the cylinder head bolts., EM–100 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

(b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench, in the sequence shown in the illustration. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) (c) Mark the front of the cylinder head bolt with paint. A035288 (d) Retighten the cylinder head bolts 90° and then an additional by 90° as shown in the illustration. (e) Check that the paint mark is now at a 180° angle from the front. 90 90 Paint Mark42589107613A116959E01 (f) Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as shown in the illustration. Cylinder Head Seal Packing: Toyota Genuine Seal Packing Black, Three Diameter: Bond 1207B or Equivalent 4.5 to 5.5 mm NOTICE: • Remove any oil from the contact surfaces. Cylinder Head • Install the oil pump assembly within 3 Gasket minutes and tighten the bolts within 15 minutes of applying the seal packing. Cylinder Block Seal Packing A073748E02, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–101

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15. INSTALL CAMSHAFT (a) Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then provisionally tighten the 19 bolts. A117473 E (b) Uniformly tighten the bolts in several steps in the sequence shown in the illustration and install53124camshaft bearing cap No. 1 and camshaft bearing cap No. 2. Torque: Camshaft bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf) Camshaft bearing cap No. 2 13 N*m (129 kgf*cm, 9.4 ft.*lbf) NOTICE: 3124Tighten each bolt uniformly while keeping the camshaft level. 16. INSTALL CHAIN SUB-ASSEMBLY (See page EM-36) 17. INSTALL CHAIN TENSIONER SLIPPER (See page Bearing Cap No. 2 EM-38) 18. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 (See page EM-38) 19. INSTALL OIL PUMP SEAL (See page LU-21) 20. INSTALL OIL PUMP ASSEMBLY (See page LU-22) 21. INSTALL TRANSVERSE ENGINE ENGINE Bearing Cap Bearing Cap No. 2 MOUNTING BRACKET (See page LU-26) No. 1 22. INSTALL WATER PUMP ASSEMBLY (See page CO- 16) A117472E01 23. INSTALL WATER PUMP PULLEY (See page CO-16) 24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-397) 25. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-403) 26. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-26) 27. INSTALL ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-26), EM–102 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

28. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 29. INSTALL VENTILATION HOSE NO. 2 (See page FU- 20) 30. INSTALL VENTILATION HOSE (See page FU-20) 31. INSTALL IGNITION COIL NO. 1 (See page IG-9) 32. INSTALL GENERATOR ASSEMBLY (See page CH-17) 33. INSTALL FAN AND GENERATOR V BELT (See page EM-7) 34. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 35. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 36. INSTALL MANIFOLD SUPPORT BRACKET (a) Install the manifold support bracket with the 3 bolts. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A116757 37. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Using vernier calipers, measure the free length of the compression spring. Minimum length: 40.5 mm (1.594 in.) If the length is not as specified, replace the compression spring. A104634 (b) Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold. NOTICE: Wooden • Install the exhaust pipe gasket in the correct Block direction. • Do not damage the outer surface of the exhaust pipe gasket. Gasket • Do not reuse the exhaust pipe gasket. A104635E01 • Do not push in the gasket with the exhaust pipe when installing., 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–103

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(c) Install the exhaust front pipe assembly with the 2 compression springs and 2 bolts. Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) A116756 38. CONNECT WIRE HARNESS (a) Connect the wire harness with the 2 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)

E

A116755 39. INSTALL WATER BY-PASS HOSE NO. 1 (a) Install water by-pass pipe No. 1 with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116753 40. CONNECT HEATER WATER INLET HOSE A (a) Connect heater water inlet hose A. A116752 41. CONNECT HEATED OXYGEN SENSOR CONNECTOR (a) Connect the heated oxygen sensor connector. (b) Install the sensor bracket with the bolt. A116751, EM–104 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

42. CONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR (a) Connect the engine coolant temperature sensor connector. A116750 43. CONNECT CAMSHAFT POSITION SENSOR

CONNECTOR

(a) Connect the camshaft position sensor connector. A116749 44. CONNECT BOOSTER VACUUM TUBE (a) Connect the booster vacuum tube. 45. CONNECT FUEL TUBE SUB-ASSEMBLY (See page FU-18) A116748 46. INSTALL OIL LEVEL GAUGE GUIDE (a) Apply engine oil to a new O-ring. (b) Install the oil level gauge guide with the bolt through a new O-ring. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install the wire harness. 47. INSTALL INTAKE MANIFOLD (a) Install a new gasket onto the intake manifold. A116747 (b) Install the intake manifold with the 3 bolts and 2 nuts. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) A116746, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–105

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(c) Connect the 3 wire harness clamps shown in the illustration. 48. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY A116745 49. CONNECT UNION TO CONNECTOR TUBE HOSE (a) Connect the union to connector tube hose.

E

A116744 50. CONNECT VENTILATION HOSE (a) Connect the ventilation hose. A116973 51. CONNECT THROTTLE WITH MOTOR BODY

CONNECTOR

(a) Install the throttle with motor body connector bracket with the nut. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Connect the throttle with motor body connector. (c) Connect the wire harness clamp. A116742 52. CONNECT WATER BY-PASS HOSE (a) Connect the water by-pass hose. A116741, EM–106 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

53. CONNECT WATER BY-PASS HOSE NO. 2 (a) Connect water by-pass hose No. 2. A116740 54. INSTALL WATER FILLER SUB-ASSEMBLY (a) Install the water filler sub-assembly with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (b) Connect radiator hose No. 1 to the cylinder head. A116739 55. CONNECT RESERVE TANK HOSE (a) Connect the reserve tank hose. A116581 56. CONNECT RADIATOR HOSE NO. 3 (a) Connect radiator hose No. 3. 57. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 (See page ES-414) 58. INSTALL BATTERY TRAY 59. INSTALL BATTERY 60. ADD ENGINE OIL A116580 61. ADD ENGINE COOLANT (See page CO-8) 62. CHECK ENGINE OIL LEVEL (See page LU-1) 63. CHECK FOR ENGINE OIL LEAKAGE 64. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-1) 65. CHECK FOR EXHAUST GAS LEAKAGE 66. CHECK FOR FUEL LEAKAGE (See page FU-7) 67. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10), 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–107

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68. INSTALL ENGINE UNDER COVER RH 69. INSTALL FRONT WHEEL RH 70. INSTALL COWL TOP PANEL OUTER (for Hatchback) (See page EM-146) 71. INSTALL COWL TOP PANEL OUTER (for Sedan) (See page ES-434) 72. INSTALL COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (See page EM-147) 73. INSTALL FRONT AIR SHUTTER SEAL RH (for Sedan) (See page ES-435) 74. INSTALL FRONT WIPER MOTOR AND LINK (for Hatchback) (See page WW-21) 75. INSTALL FRONT WIPER MOTOR AND LINK (for E Sedan) (See page WW-12) 76. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-21) 77. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-21) 78. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Sedan) (See page WW-12) 79. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-13) 80. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-13) 81. INSTALL HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-22) 82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) (See page WW-22) 83. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) (See page WW-13) 84. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) (See page WW-23) 85. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) (See page WW-14) 86. INSTALL FRONT WIPER ARM HEAD CAP (for Hatchback) (See page WW-23) 87. INSTALL FRONT WIPER ARM HEAD CAP (for Sedan) (See page WW-15), EM–108 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM REPAIR

45° 1. REPAIR INTAKE VALVE (a) Repair the intake valve seat. 20° NOTICE: Releasing the seat-cutter pressure gradually helps to make the valve seat face smoother. (b) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. 1.0 to 1.4 mm A067983E01 (c) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. 75° (d) Hand-lap the valve and valve seat with an abrasive compound. 45° (e) Recheck the valve seating position. 2. REPAIR EXHAUST VALVE NOTICE: Releasing the seat-cutter pressure gradually helps 1.0 to 1.4 mm to make the valve seat face smoother. A080979E04 (a) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. (b) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (c) Hand-lap the valve and valve seat with an abrasive compound. (d) Recheck the valve seating position., 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–109

M EE1NZG-IFNEE ENGINNE MECHANIGCAL INE ASSEMBLY COMPONENTS

for Hatchback: FRONT WIPER ARM HEAD CAP FRONT WIPER FRONT WIPER ARM RH ARM HEAD CAP26 (265, 19) 26 (265, 19) COWL TOP VENTILATOR LOUVER CONTER NO. 1 E FRONT WIPER CLIP ARM LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

CLIP CLIP

HOOD TO COWL TOP SEAL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 COWL TOP VENTILATOR LOUVER LH 6.5 (66, 58 in.*lbf) x2 FRONT WIPER MOTOR AND LINK x9 5.5 (56, 49 in.*lbf) COWL TOP PANEL OUTER N*m (kgf*cm, ft*lbf) : Specified torque A118803E11,

EM–110 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM

for Sedan: FRONT WIPER ARM HEAD CAP FRONT WIPER ARM LH FRONT WIPER ARM RH FRONT WIPER ARM HEAD CAP COWL SIDE 26 (265, 19) 26 (265, 19)

VENTILATOR

SUB-ASSEMBLY RH CLIP x2 COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY COWL SIDE VENTILATOR SUB-ASSEMBLY LH FRONT AIR 5.5 (56, 49 in.*lbf)

SHUTTER

SEAL RH x2 FRONT WIPER MOTOR AND LINK 6.5 (66, 58 in.*lbf) x8 COWL TOP x2 COWL TOP TO COWL PANEL OUTER INNER BRACE 6.5 (66, 58 in.*lbf) N*m (kgf*cm, ft*lbf) : Specified torque A133320E11, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–111

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7.0 (71, 62 in.*lbf) 7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2

E

3.5 (36, 31 in.*lbf) AIR CLEANER HOSE NO. 1 BATTERY CLAMP AIR CLEANER ASSEMBLY

BATTERY

7.8 (80, 69 in.*lbf) BATTERY TRAY AIR CLEANER INLET NO. 1 17 (175, 13) 19 (194, 14) x5 BATTERY CARRIER 5.0 (51, 44 in.*lbf) AIR CLEANER BRACKET 5.0 (51, 44 in.*lbf) ENGINE UNDER COVER RH ENGINE UNDER COVER LH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A108442E08, EM–112 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

UNION TO CHECK VALVE HOSE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) HEATER WATER INLET HOSE A FUEL TUBE SUB-ASSEMBLY FUEL PIPE CLAMP NO. 1 RADIATOR RESERVOIR TANK HOSE RADIATOR HOSE NO. 3 RADIATOR HOSE NO. 2 A108443E08, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–113

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for Hatchback: SHIFT LEVER KNOB SUB-ASSEMBLY (for FAN AND GENERATOR V BELT Manual Transaxle) CONSOLE BOX SHIFTING HOLE COVER REAR COVER SUB-ASSEMBLY (for Manual Transaxle) 52 (530, 38) 45 (459, 33) 5.0 (51, 44 in.*lbf) 45 (459, 33) E ENGINE MOUNTING INSULATOR RH 52 (530, 38) 28 (290, 21)

CLIP

CONSOLE BOX ASSEMBLY REAR STEERING SLIDING YOKE SUB-ASSEMBLY 52 (530, 38) ENGINE MOUNTING INSULATOR LH COLUMN HOLE COVER SILENCER SHEET WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque A108444E13, EM–114 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

for Sedan: CONSOLE UPPER REAR PANEL SUB-ASSEMBLY FAN AND GENERATOR V BELT SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE BOX (for Manual Transaxle) CARPET SHIFTING HOLE COVER SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY 52 (530, 38) 52 (530, 38) INSTRUMENT PANEL FINISH PANEL END LH CONSOLE BOX ASSEMBLY REAR ENGINE MOUNTING INSULATOR RH INSTRUMENT PANEL FINISH PANEL LOWER CLIP CENTER STEERING SLIDING YOKE SUB-ASSEMBLY

INSTRUMENT

PAD LOWER LH 28 (290, 21) COLUMN HOLE COVER 52 (530, 38) SILENCER SHEET ENGINE MOUNTING INSULATOR LH WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) 25 (255, 18) N*m (kgf*cm, ft*lbf) : Specified torque A128444E03, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–115

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29 (300, 21) SPEED SENSOR FRONT LH (w/ ABS) 8.0 (82, 71 in.*lbf) E 74 (755, 55) COTTER PIN 49 (500, 36) TIE ROD END SUB-ASSEMBLY LH 216 (2,203, 160) FRONT AXLE HUB LH NUT FRONT STABILIZER CLIP LINK ASSEMBLY LH 98 (999, 72) FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A108449E06,

EM–116 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM GASKET

43 (438, 32) 43 (438, 32) EXHAUST PIPE GASKET ASSEMBLY FRONT 43 (438, 32) 44 (449, 33) 43 (438, 32) HEATED OXYGEN SENSOR N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A136509E01, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–117

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FRONT SUSPENSION

CROSSMEMBER

SUB-ASSEMBLY STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1 E 120 (1,224, 89) x2 (for Automatic Transaxle) 95 (969, 70) x2 70 (714, 52) x2 160 (1,631, 118) 120 (1,224, 89) (for Manual Transaxel) N*m (kgf*cm, ft.*lbf) : Specified torque A108445E05,

EM–118 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM

for Automatic Transaxle: FRONT DRIVE SHAFT ASSEMBLY RH 18 (183, 13) DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY LH 30 (301, 22) x5 DRIVE PLATE SPACER FR

CLIP

TRANSMISSION CONTROL x6 88 (900, 65) CABLE ASSEMBLY x6 27 (275, 20) DRIVE PLATE SPACER RR x2 DRIVE PLATE AND 30 (301, 22) TORQUE CONVERTER DRIVE PLATE AND RING CLUTCH SETTING BOLT GEAR SUB-ASSEMBLY 12 (122, 9) FLYWHEEL HOUSING 9.8 (100, 87 in.*lbf) UNDER COVER OIL COOLER OUTLET HOSE 37 (378, 27) STARTER ASSEMBLY AUTOMATIC TRANSAXLE 37 (378, 27) OIL COOLER INLET HOSE ASSEMBLY FLYWHEEL HOUSING SIDE COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117318E08, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–119

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for Manual Transaxle: 18 (183, 13) DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY RH FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY LH

E

33 (336, 24)

CLIP

1st: 49 (500, 38) CLIP 2nd: Turn 90° PLATE

WASHER CLIP

PLATE WASHER CLIP x5 TRANSMISSION CONTROL CABLE ASSEMBLY x6 33 (336, 24) 19 (195, 14) 25 (250, 18) FLYWHEEL SUB-ASSEMBLY x6 x2 CLUTCH DISC 9.8 (100, 87 in.*lbf)

ASSEMBLY

CONTROL CABLE

BRACKET

37 (378, 27) 37 (378, 27) STARTER ASSEMBLY MANUAL TRANSAXLE FLYWHEEL HOUSING ASSEMBLY12 (122, 8.9) SIDE COVER x2 CLUTCH COVER ASSEMBLY CLUTCH RELEASE CYLINDER ASSEMBLY 12 (120, 9) N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A117354E09,

EM–120 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM

FUEL TUBE SUB-ASSEMBLY FUEL PIPE CLAMP NO. 2 VENTILATION HOSE RADIO SETTING CONDENSER

VENTILATION

40 (408, 30) 60 (612, 44) HOSE NO. 2 FAN BELT ADJUSTING

SLIDER

OXYGEN SENSOR WIRING BRACKET 11 (408, 30) BOOSTER VACUUM TUBE 19 (194, 14) 9.0 (92, 80 in.*lbf) 54 (551, 40) 9.8 (100, 87 in.*lbf) HEATER WATER INLET HOSE A GENERATOR ASSEMBLY 10 (102, 89 in.*lbf) 7.5 (76, 66 in.*lbf) WATER FILLER SUB-ASSEMBLY WIRE HARNESS CLAMP BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque A117343E02, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–121

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8.0 (82, 71 in.*lbf) 9.0 (92, 80 in.*lbf) x4 EXHAUST MANIFOLD HEAT INSULATOR NO. 1 27 (275, 20) IGNITION COIL NO. 1 x3 x2 EXHAUST MANIFOLD EXHAUST MANIFOLD GASKET E 44 (449, 33) MANIFOLD SUPPORT BRACKET OIL LEVEL GAUGE SUB-ASSEMBLY INTAKE MANIFOLD GASKET 30 (306, 22) 9.0 (92, 80 in.*lbf) x3 9.0 (92, 80 in.*lbf) WATER BY-PASS PIPE NO. 1 x2 30 (306, 22) INTAKE MANIFOLD 9.0 (92, 80 in.*lbf) WATER BY-PASS PIPE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A108468E05, EM–122 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE 2. REMOVE BATTERY (a) Disconnect the cable from the battery terminal. (b) Loosen the nut and remove the battery clamp. (c) Remove the battery. 3. REMOVE BATTERY TRAY 4. REMOVE FRONT WHEELS 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE ENGINE UNDER COVER RH 7. DRAIN ENGINE COOLANT (See page CO-8) 8. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-158) 9. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-26) 10. REMOVE FRONT WIPER ARM HEAD CAP (See page WW-9) 11. REMOVE FRONT WIPER ARM LH (See page WW-9) 12. REMOVE FRONT WIPER ARM RH (See page WW-9) 13. REMOVE HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-18) 14. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-18) 15. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-18) 16. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-10) 17. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-10) 18. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Sedan) (See page WW-10) 19. REMOVE FRONT WIPER MOTOR AND LINK (See page WW-19) 20. REMOVE COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (a) Disengage the claw and remove cowl to register duct sub-assembly No. 2. A108437, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–123

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21. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan) (a) Disengage the 3 claws and remove the front air shutter seal RH. A133324 E 22. REMOVE COWL TOP PANEL OUTER (for Hatchback) (a) Disengage the wire harness clamp. A108438 (b) Remove the 9 bolts and remove the cowl top panel outer. A115392 23. REMOVE COWL TOP PANEL OUTER (for Sedan) (a) Disengage the wire harness clamp. A128446, EM–124 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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(b) Remove the 2 bolts and remove the cowl top to cowl inner brace. A128447 (c) Remove the 8 bolts and remove the cowl top panel outer. A128448 24. REMOVE AIR CLEANER ASSEMBLY (a) Separate the intake air flow meter connector and the wire harness clamp. (b) Separate the fuel vapor feed hose and fuel vapor feed hose No. 1 from the vacuum switching valve assembly. (c) Separate the vacuum switching valve connector and the wire harness clamp. (d) Separate the ventilation hose from the air cleaner hose. (e) Release the air cleaner cap sub-assembly with air cleaner hose No. 1. (f) Loosen the air cleaner hose clamp on the throttle body side and remove the air cleaner cap and the air cleaner hose. A117355 (g) Remove the air cleaner element. (h) Separate the wire harness clamp from the air cleaner case. (i) Remove the 2 bolts and remove the air cleaner case with air cleaner inlet No. 1. A104895, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–125

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25. REMOVE AIR CLEANER BRACKET (a) Separate the wire harness clamp from the air cleaner bracket. (b) Remove the 2 bolts and remove the air cleaner bracket. A117308 26. REMOVE BATTERY CARRIER (a) Separate the wire harness clamp from the battery carrier. (b) Remove the 5 bolts and remove the battery carrier. E A117309 27. DISCONNECT RADIATOR HOSE NO. 3 (a) Disconnect radiator hose No. 3 from the water filler. A117310 28. DISCONNECT RADIATOR RESERVOIR TANK HOSE (a) Disconnect the radiator reservoir tank hose from the water filler. A117356 29. DISCONNECT RADIATOR HOSE NO. 2 (a) Disconnect radiator hose No. 2 from the water inlet. A104893, EM–126 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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30. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) (a) Loosen the clip and disconnect the oil cooler outlet hose. A117306 31. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) (a) Loosen the clip and disconnect the oil cooler inlet hose. 32. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 33. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) (See page AX- A117307 106) 34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) (See page MX-27) 35. DISCONNECT UNION TO CHECK VALVE HOSE (a) Disconnect the union to check valve hose from the booster vacuum tube. 36. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) (a) Disconnect heater water outlet hose A from the heater unit. I100777 37. DISCONNECT HEATER WATER INLET HOSE A (a) Disconnect heater water inlet hose A from the heater unit. I100779, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–127

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38. DISCONNECT FUEL TUBE SUB-ASSEMBLY (a) Remove fuel pipe clamp No. 1. A105667 (b) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe. NOTICE: • Remove any dirt and foreign matter from the fuel tube connector before performing this E work. • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the A117321 pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube. • If the fuel tube connector and pipe are stuck, push and pull to release them. 39. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 40. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) (a) Disconnect the connector. (b) Remove the 4 bolts and separate the with pulley compressor assembly. HINT: Remove the compressor assembly together with the low and high pressure hoses, then suspend them from the body with a piece of rope. 41. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) (See page MX-27), EM–128 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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42. DISCONNECT ENGINE WIRE (a) Pull up the lever and disconnect the connector of the engine control computer. A107314 (b) Remove the 2 connectors and the clamp from the engine room junction block and disconnect the wire harness. A104339 (c) Remove the bolt and separate the earth wire of the engine room wire harness. (d) Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine. 43. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page PS-74) 44. SEPARATE STEERING SLIDING YOKE SUB- A108450 ASSEMBLY (See page PS-74) 45. REMOVE STEERING COLUMN HOLE COVER SUB- ASSEMBLY NO. 1 (See page PS-75) 46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) 47. REMOVE SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle) (See page PB-6) 48. REMOVE CONSOLE BOX REAR COVER (for Hatchback) (See page PB-6) 49. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (for Sedan) (See page ME-138) 50. REMOVE INSTRUMENT PANEL FINISH PANEL END LH (for Sedan) (See page ME-138) 51. REMOVE INSTRUMENT PAD LOWER LH (for Sedan) (See page IP-44) 52. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for Sedan) (See page IP-84) 53. REMOVE CONSOLE UPPER REAR PANEL SUB- ASSEMBLY (for Sedan) (See page IP-84), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–129

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54. REMOVE CONSOLE BOX CARPET (for Sedan) (See page PB-7) 55. REMOVE REAR CONSOLE BOX ASSEMBLY (See page PB-8) 56. REMOVE HEATED OXYGEN SENSOR (See page EC- 22) 57. REMOVE EXHAUST PIPE ASSEMBLY FRONT (See page EX-5) 58. REMOVE FRONT AXLE HUB LH NUT (See page DS- 3) 59. REMOVE FRONT AXLE HUB RH NUT (See page AX- 159) 60. SEPARATE SPEED SENSOR FRONT LH (w/ ABS) E (See page DS-3) 61. SEPARATE SPEED SENSOR FRONT RH (w/ ABS) (See page AX-159) 62. SEPARATE TIE ROD END SUB-ASSEMBLY LH (See page DS-3) 63. SEPARATE TIE ROD END SUB-ASSEMBLY RH (See page AX-160) 64. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-4) 65. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH (See page AX-160) 66. SEPARATE FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 LH (See page DS-4) 67. SEPARATE FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 RH (See page AX-160) 68. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-4) 69. SEPARATE FRONT AXLE ASSEMBLY RH (See page MX-29) 70. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-5) 71. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-5) 72. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle), EM–130 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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73. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) (a) Remove the 6 torque converter set bolts. A117323 74. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine lifter. G100156 (b) Remove the 5 bolts and the nut and remove the engine mounting insulator RH. G100143 (c) Remove the through bolt and the nut and separate the engine mounting insulator LH. G100158 (d) Remove the 6 bolts, and remove the engine assembly with transaxle and the front suspension crossmember from the vehicle. 75. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Remove the bolt and remove the radio setting condenser. (b) Remove the bolt and remove the oxygen sensor wiring bracket. G100157, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–131

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(c) Install the engine hangers with the bolts, as shown Front Rear in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) Part No.: 12281-21010 for engine hanger 91642-81025 for bolt (d) Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember. A070012E01 (e) Remove the through bolt from the engine moving control rod and remove the front suspension crossmember. 76. REMOVE VENTILATION HOSE (a) Loosen the 2 clips and remove the ventilation hose. 77. REMOVE VENTILATION HOSE NO. 2 E (a) Loosen the clips and remove ventilation hose No. 2. 78. REMOVE FUEL TUBE SUB-ASSEMBLY (a) Disengage the claw and remove fuel pipe clamp No. 2. A107342 (b) Pinch the fuel tube connector retainer from both sides, disconnect the fuel tube connector and separate the fuel tube from the pipe. NOTICE: • Remove any dirt and foreign matter from the fuel tube connector before performing this work. • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel A107343 tube connector has the O-rings that seal the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube. • If the fuel tube connector and pipe are stuck, push and pull to release them. 79. REMOVE WATER FILLER SUB-ASSEMBLY (a) Disconnect radiator hose No. 1 from the cylinder head. (b) Remove the 2 nuts and remove the water filler sub- assembly., EM–132 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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80. REMOVE HEATER WATER INLET HOSE A (a) Disconnect heater water inlet hose A from the cylinder head. 81. REMOVE FLYWHEEL HOUSING SIDE COVER (See page ST-9) 82. REMOVE STARTER ASSEMBLY (See page ST-9) 83. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) (a) Remove the 7 bolts and remove the automatic transaxle with torque converter. C118504 84. REMOVE DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (for Automatic Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Remove the 6 bolts, drive plate spacer FR, drive plate and ring gear sub-assembly and drive plate spacer RR. 85. REMOVE CONTROL CABLE BRACKET (for Manual SST Transaxle) (See page MX-28) A107285E01 86. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) (See page MX-30) 87. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-15) 88. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 89. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Remove the 6 bolts and flywheel. 90. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 91. REMOVE IGNITION COIL NO. 1 SST (a) Disconnect the connectors of the ignition coils. A107285E01 (b) Remove the bolt and remove all the ignition coils. 92. REMOVE GENERATOR ASSEMBLY (See page CH-10), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–133

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93. REMOVE INTAKE MANIFOLD (a) Disconnect the union to connector tube hose from the booster vacuum tube. (b) Disconnect the engine wire from the intake manifold. A117312 (c) Disconnect the water by-pass hose from the cylinder head.

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A117313 (d) Disconnect the water by-pass hose from water bypass pipe No. 1. (e) Disconnect the throttle with motor body assembly connector. A117314 (f) Remove the 3 bolts and 2 nuts in the order shown in the illustration and remove the intake manifold. (g) Remove the gasket from the intake manifold. 4351A035213E01 94. REMOVE WATER BY-PASS PIPE NO. 1 (a) Remove the 2 bolts and 2 nuts and remove water by-pass pipe No. 1. A117315, EM–134 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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95. REMOVE BOOSTER VACUUM TUBE (a) Remove the 2 bolts and remove the booster vacuum tube. 96. REMOVE ENGINE WIRE (a) Disconnect all the sensor connectors and wire harness clamps from the engine assembly and remove the engine wire harness. A117316 97. REMOVE WIRE HARNESS CLAMP BRACKET (a) Remove the 2 bolts and remove the 2 wire harness clamp brackets. 98. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (a) Remove the 4 bolts and remove the exhaust manifold heat insulator. 99. REMOVE MANIFOLD SUPPORT BRACKET A107284 (a) Remove the 3 bolts and remove the manifold support bracket. 100.REMOVE EXHAUST MANIFOLD (a) Remove the 3 bolts and 2 nuts and remove the exhaust manifold. 101.REMOVE DRIVE SHAFT HEAT INSULATOR SUB-

ASSEMBLY

(a) Remove the bolt and nut and remove the drive shaft heat insulator. A117317

INSTALLATION

1. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-

ASSEMBLY

(a) Install the drive shaft heat insulator sub-assembly with the bolt and nut. Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf) A117317, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–135

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2. INSTALL EXHAUST MANIFOLD (a) Tighten the exhaust manifold nuts and bolts, in the415order shown in the illustration, through a new gasket. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 3. INSTALL MANIFOLD SUPPORT BRACKET23(a) Install the manifold bracket with the 3 bolts. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A067694E01 4. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (a) Install the exhaust manifold insulator with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 5. INSTALL WIRE HARNESS CLAMP BRACKET (a) Install the 2 wire harness clamp brackets with the2Ebolts. Torque: 10 N*m (102 kgf*cm, 89 in.*lbf) 6. INSTALL ENGINE WIRE (a) Connect all the sensor connectors and wire harness clamps to the engine assembly and install the engine wire harness. A107284 7. INSTALL BOOSTER VACUUM TUBE (a) Install the booster vacuum tube with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A117316 8. INSTALL WATER BY-PASS PIPE NO. 1 (a) Install water by-pass pipe No. 1 through a new gasket with the 2 bolts and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 9. INSTALL INTAKE MANIFOLD (a) Install a new gasket onto the intake manifold. A117315, EM–136 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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(b) Provisionally tighten the intake manifold nuts and bolts in the order shown in the illustration, and then tighten them to the specified torque. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) (c) Connect the engine wire to the intake manifold. 2315A035197E01 (d) Connect the water by-pass hose to water bypass pipe No. 1. A117314 (e) Connect the water by-pass hose to the cylinder head. (f) Connect the union to connector tube hose to the booster vacuum tube. (g) Connect the throttle with motor body assembly connector. 10. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY 11. INSTALL GENERATOR ASSEMBLY (See page CH-17) A117313 12. INSTALL IGNITION COIL NO.1 (See page IG-9) 13. INSTALL DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (for Automatic Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Clean the 6 bolts and their holes.

SST

A107285E01 (c) Apply adhesive to the end 2 or 3 threads of the Adhesive bolts. Adhesive: Part No. 08833-0070, three bond 1324 or the equivalent. (d) Install the drive plate spacer RR, drive plate and ring gear sub-assembly and drive plate spacer FR. A057108E01, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–137

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(e) Install and uniformly tighten the 6 bolts in several steps, in the sequence shown in the illustration. 1 Torque: 88 N*m (900 kgf*cm, 65 ft.*lbf) 6 NOTICE:4 Do not start the engine for at least 1 hour after performing the installation. 2 3 A050929E02 14. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) (a) Make sure that the knock pin is installed on the engine side. (b) Install the automatic transaxle with torque converter E with the 7 bolts. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) CAUTION: Make sure that the torque converter rotates. C118504 15. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Clean the 6 bolts and their holes.

SST

A107285E01 (c) Apply adhesive to the end 2 or 3 threads of new Adhesive bolts. Adhesive: Part No. 08833-0070, three bond 1324 or the equivalent. A057108E01 (d) Install the flywheel with the 6 bolts in the order shown in the illustration. 1 Torque: 49 N*m (500 kgf*cm, 38 ft.*lbf) 6 (e) Mark a paint mark on each bolt head on the engine 4 upper side. 2 3 A050929E02, EM–138 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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(f) Tighten the bolts 90° in the sequence shown in the illustration. NOTICE: Do not start the engine for at least 1 hour after 90° performing the installation. 16. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See page CL-16) 17. INSTALL CLUTCH COVER ASSEMBLY (for Manual A068530E01 Transaxle) (See page CL-17) 18. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-17) 19. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) (See page MX-30) 20. INSTALL CONTROL CABLE BRACKET (for Manual Transaxle) (See page MX-32) 21. INSTALL STARTER ASSEMBLY (See page ST-17) 22. INSTALL FLYWHEEL HOUSING SIDE COVER (See page ST-17) 23. CONNECT HEATER WATER INLET HOSE A (a) Connect heater water inlet hose A to the cylinder head. 24. INSTALL WATER FILLER SUB-ASSEMBLY (a) Connect radiator hose No. 1 to the cylinder head. (b) Install the water filler sub-assembly with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (c) Connect radiator hose No. 1 to the water filler. 25. INSTALL FUEL TUBE SUB-ASSEMBLY (a) Connect the fuel tube connector and pipe and install fuel pipe clamp No. 2. CAUTION: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the the tip of the pipe. After connecting, pull the pipe and A107342 connector to make sure that they are securely connected. 26. INSTALL VENTILATION HOSE NO. 2 (a) Install ventilation hose No. 2 with the clip. 27. INSTALL VENTILATION HOSE (a) Install the ventilation hose with the clip. 28. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Install the engine moving control rod with the through bolt. Torque: 120 N*m (1,224 kgf*cm, 89 ft.*lbf) (b) Remove the 2 bolts and remove the 2 engine hangers., 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–139

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(c) Install the oxygen sensor wiring bracket with the bolt. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) (d) Install the radio setting condenser with the bolt. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (for Hatchback) (a) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter. (b) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed. G100156 E (c) Install the engine mounting insulator LH with the through bolt and nut. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) G100158 (d) Install the engine mounting insulator RH with the5AAbolts and nut. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) for Bolt A 52 N*m (530 kgf*cm, 38 ft.*lbf) for Bolt B 52 N*m (530 kgf*cm, 38 ft.*lbf) for Nut C (e) Operate the engine lifter and provisionally install the B front suspension crossmember onto the vehicle with the 6 bolts. ABCG100143E02 (f) Insert SST into the datum holes in the front suspension crossmembers RH and LH alternately and tighten bolts A, B and C on both sides in several sequences. Bolt A SST 09670-00010Bolt A Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for Bolt A Bolt B 160 N*m (1,631 kgf*cm, 118 ft.*lbf) for Bolt B Bolt B Bolt C Bolt C 95 N*m (969 kgf*cm, 70 ft.*lbf) for Bolt C G100157E01 CAUTION: • Insert SST into the datum hole vertically. • If impossible to insert SST vertically, loosen all the bolts and then insert SST again., EM–140 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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Front Datum Hole Bolt A Bolt A Bolt B Bolt B Bolt C Bolt C OK NG OK NG A117079E01 30. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (for Sedan) (a) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter. (b) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed. G100156 (c) Install the engine mounting insulator LH with the through bolt and nut. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) G100158 (d) Install the engine mounting insulator RH with the 5 bolts and nut. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) G100143, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–141

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(e) Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts. Bolt A (f) Insert SST into the datum holes of the front Bolt A suspension crossmembers RH and LH alternately Bolt B and tighten bolts A, B and C on both sides in several Bolt B sequences. Bolt C Bolt C SST 09670-00010 G100157E01 Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for Bolt A 160 N*m (1,631 kgf*cm, 118 ft.*lbf) for Bolt B 95 N*m (969 kgf*cm, 70 ft.*lbf) for Bolt C CAUTION: • Insert SST into the datum hole vertically. • If impossible to insert SST vertically, loosen E all the bolts and then insert SST again. Front Datum Hole Bolt A Bolt A Bolt B Bolt B Bolt C Bolt C OK NG OK NG A117079E01 31. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) (a) Tighten the 6 torque converter set bolts. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 32. INSTALL FLYWHEEL HOUSING UNDER COVER 33. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-13) 34. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See A117323 page DS-14) 35. INSTALL FRONT AXLE ASSEMBLY LH (See page DS- 14) 36. INSTALL FRONT AXLE ASSEMBLY RH (See page DS-14), EM–142 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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37. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-14) 38. INSTALL FRONT STABILIZER LINK ASSEMBLY RH (See page MX-31) 39. INSTALL FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 LH (See page DS-14) 40. INSTALL FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 RH (See page MX-31) 41. INSTALL TIE ROD END SUB-ASSEMBLY LH (See page DS-15) 42. INSTALL TIE ROD END SUB-ASSEMBLY RH (See page MX-31) 43. INSTALL SPEED SENSOR FRONT LH (w/ ABS) (See page DS-15) 44. INSTALL SPEED SENSOR FRONT RH (w/ ABS) (See page MX-31) 45. INSTALL FRONT AXLE HUB LH NUT (See page DS- 15) 46. INSTALL FRONT AXLE HUB RH NUT (See page MX- 31) 47. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See page EX-8) 48. INSTALL HEATED OXYGEN SENSOR (See page EC- 23) 49. INSTALL CONSOLE BOX ASSEMBLY REAR (See page PB-10) 50. INSTALL CONSOLE BOX REAR COVER (for Hatchback) (See page PB-11) 51. INSTALL SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle) (See page PB-12) 52. INSTALL CONSOLE BOX CARPET (for Sedan) (See page PB-11) 53. INSTALL CONSOLE UPPER REAR PANEL SUB- ASSEMBLY (for Sedan) (See page IP-89) 54. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for Sedan) (See page IP-89) 55. INSTALL INSTRUMENT PAD LOWER LH (for Sedan) (See page IP-55) 56. INSTALL INSTRUMENT PANEL FINISH PANEL END LH (for Sedan) (See page ME-141) 57. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (for Sedan) (See page ME-142) 58. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–143

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59. INSTALL STEERING COLUMN HOLE COVER SUB- ASSEMBLY NO. 1 (See page PS-79) 60. INSTALL STEERING SLIDING YOKE SUB- ASSEMBLY (See page PS-79) 61. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page PS-79) 62. CONNECT ENGINE WIRE (a) Install the earth wire of the engine room wire harness with the bolt.

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A108450 (b) Connect the 2 engine wire harness connectors and wire harness clamp to the engine room junction block. A104339 (c) Connect the engine wire harness connector to the ECM. 63. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) (See page MX-32) 64. INSTALL WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) (See page AC-209) 65. INSTALL FAN AND GENERATOR V BELT (See page EM-7) A107314 66. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 67. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Connect the fuel tube connector and fuel pipe, and install fuel pipe clamp No. 1. CAUTION: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the the tip of the pipe. After connecting, pull the pipe and A105667 connector to make sure that they are securely connected., EM–144 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

68. CONNECT HEATER WATER INLET HOSE A (a) Connect heater water inlet hose A to the heater unit. I100779 69. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) (a) Connect heater water outlet hose A to the heater unit. 70. CONNECT UNION TO CHECK VALVE HOSE (a) Connect the union to check valve hose to the booster vacuum tube. 71. INSTALL TRANSMISSION CONTROL CABLE I100777 ASSEMBLY (for Automatic Transaxle) (See page AX- 109) 72. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) (See page MX-32) 73. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 74. CONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) (a) Connect the oil cooler inlet hose with the clip. A117307 75. CONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) (a) Connect the oil cooler outlet hose with the clip. A117306, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–145

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76. CONNECT RADIATOR HOSE NO. 2 (a) Connect radiator hose No. 2 to the water inlet. A104893 77. CONNECT RADIATOR RESERVOIR TANK HOSE (a) Connect the radiator reservoir tank hose to the water filler.

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A117356 78. CONNECT RADIATOR HOSE NO. 3 (a) Connect radiator hose No. 3 to the water filler. A117310 79. INSTALL BATTERY CARRIER (a) Install the battery carrier with the 5 bolts. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) (b) Install the clamp. A117309 80. INSTALL AIR CLEANER BRACKET (a) Install the air cleaner bracket with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) (b) Connect the wire harness clamp to the air cleaner bracket. A117308, EM–146 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

81. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner case with air cleaner inlet No. 1 with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) (b) Connect the wire harness to the air cleaner case. (c) Install the air cleaner element. A104895 (d) Install and lock the air cleaner cap and the air cleaner hose and then tighten the air cleaner hose clamp. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (e) Connect the ventilation hose to the air cleaner hose. (f) Connect the vacuum switching valve connector and the wire harness clamp. (g) Connect the fuel vapor feed hose and fuel vapor feed hose No. 1 to the vacuum switching valve assembly. (h) Connect the intake air flow meter connector and the wire harness clamp. A117355 82. INSTALL COWL TOP PANEL OUTER (for Hatchback) (a) Install the cowl top panel with the 9 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 ft.*lbf) A115392 (b) Connect the wire harness clamp. A108438, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–147

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83. INSTALL COWL TOP PANEL OUTER (for Sedan) (a) Install the cowl top panel outer with the 8 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) A128448 (b) Install the cowl top to cowl inner brace with the 2 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf)

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A128447 (c) Connect the wire harness clamp. A128446 84. INSTALL COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (a) Engage the claw and install cowl to register duct No. 2. A108437, EM–148 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

85. INSTALL FRONT AIR SHUTTER SEAL RH (for Sedan) (a) Engage the 3 claws to install the front air shutter seal RH. 86. INSTALL FRONT WIPER MOTOR AND LINK (See page WW-21) 87. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-21) 88. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-21) 89. INSTALL HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-22) 90. INSTALL COWL TOP VENTILATOR LOUVER SUB- A133324 ASSEMBLY (for Sedan) (See page WW-12) 91. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-13) 92. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-13) 93. INSTALL FRONT WIPER ARM LH (See page WW-22) 94. INSTALL FRONT WIPER ARM RH (See page WW-23) 95. INSTALL FRONT WIPER ARM HEAD CAP (See page WW-23) 96. INSTALL BATTERY TRAY 97. INSTALL BATTERY (a) Install the battery onto the vehicle with the battery clamp. Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) (b) Connect the cable to the battery terminal. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 98. ADD ENGINE COOLANT (See page CO-8) 99. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-169) 100. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-93) 101.ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) 102. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-2) 103. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 104.CHECK FOR FUEL LEAKAGE (See page FU-7) 105.CHECK FOR ENGINE OIL LEAKAGE 106.CHECK FOR EXHAUST GAS LEAKAGE 107.CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-1), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–149

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108. INSTALL ENGINE UNDER COVER RH 109. INSTALL ENGINE UNDER COVER LH 110. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 111. INSPECT IGNITION TIMING (See page EM-1) 112. INSPECT ENGINE IDLING SPEED (See page EM-2) 113. INSPECT CO/HC (See page EM-4) 114. INSPECT FRONT WHEEL ALIGNMENT 115. INSPECT ABS SENSOR SIGNAL (w/ ABS)

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EM–150 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

E1ENZG-IFNEE ENGINNE MECHANIGCAL INE UNIT

COMPONENTS

9.0 (92, 80 in.*lbf) x2 19 (194, 14) O-RING FUEL DELIVERY PIPE SUB-ASSEMBLY FUEL INJECTOR ASSEMBLY x4 INJECTOR VIBRATION INSULATOR x2 DELIVERY PIPE NO. 1 SPACER 20 (204, 15) SPARK PLUG ENGINE COOLANT TEMPERATURE SENSOR 18 (184, 13) GASKET x4 8.0 (82, 71 in.*lbf) CAMSHAFT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117466E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–151

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20 (204, 15) 7.5 (76, 66 in.*lbf) KNOCK SENSOR 15 (153, 11) CRANKSHAFT POSITION SENSOR ENGINE OIL PRESSURE SWITCH ASSEMBLY O-RING CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 7.5 (76, 66 in.*lbf) OIL LEVEL GAUGE GUIDE 9.0 (92, 80 in.*lbf) O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117467E01,

EM–152 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

TRANSVERSE ENGINE ENGINE MOUNTING BRACKET x4 55 (561, 41) 24 (245, 18) OIL PUMP ASSEMBLY 32 (326, 24) x2 24 (245, 18) x11 11 (112, 8.1) 11 (112, 8.1) 128 (1,305, 95) OIL PUMP SEAL CRANKSHAFT DAMPER SUB-ASSEMBLY CRANKSHAFT STRAIGHT PIN O-RING 11 (112, 8.1) WATER PUMP PULLEY GASKET x2 x3 WATER PUMP ASSEMBLY 15 (153, 11) x3 11 (112, 8.1) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A117447E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–153

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CHAIN TENSIONER ASSEMBLY NO. 1 9.0 (92, 80 in.*lbf)

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CHAIN TENSIONER SLIPPER CHAIN SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) CHAIN VIBRATION DAMPER NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A117448E01,

EM–154 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

10 (102, 7.0) OIL FILLER CAP SUB-ASSEMBLY SEAL WASHER 10 (102, 7.0) OIL FILLER CAP x7 27 (275, 20)

GASKET

VENTILATION VALVE SUB-ASSEMBLY 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY CYLINDER HEAD COVER GASKET x3 23 (235, 17) x16 13 (129, 9.4) CAMSHAFT BEARING CAP NO. 2 CAMSHAFT BEARING CAP NO. 1 x4 NO. 2 CAMSHAFT CAMSHAFT TIMING

SPROCKET CAMSHAFT

64 (653, 47) 64 (653, 47) CAMSHAFT TIMING GEAR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A117449E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–155

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1st: 29 (300, 22) 2nd: turn 90° x10 3rd: turn 90° CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET

E THERMOSTAT GASKET

WATER INLET x2 O-RING 9.0 (92, 80 in.*lbf) CYLINDER BLOCK SUB-ASSEMBLY ENGINE REAR OIL SEAL OIL PAN SUB-ASSEMBLY 30 (306, 22) OIL FILTER UNION OIL FILTER SUB-ASSEMBLY x13 24 (245, 18) 5.0 (51, 44 in.*lbf) STUD BOLT 5.0 (51, 44 in.*lbf) GASKET STUD BOLT OIL STRAINER SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) 11 (112, 8.1) x9 38 (382, 28) 11 (112, 8.1) GASKET OIL PAN SUB-ASSEMBLY NO. 2 9.0 (92, 80 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A117468E01,

EM–156 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

35 (357, 26) 5.0 (51, 44in.*lbf) CYLINDER BLOCK WATER DRAIN COCK STUD BOLT STRAIGHT PIN STRAIGHT PIN STRAIGHT PIN x2 OIL PUMP SET RING PIN 11 (112, 8.1) STUD BOLT STRAIGHT PIN 5.0 (51, 44in.*lbf) STUD BOLT OIL PUMP SET RING PIN 5.0 (51, 44in.*lbf) STRAIGHT PIN x2 STUD BOLT CRANKSHAFT THRUST CRANKSHAFT BEARING WASHER UPPER

CRANKSHAFT

CRANKSHAFT BEARING 1st: 22 (224, 16) 2nd: turn 90° CRANKSHAFT BEARING N*m (kgf*cm, ft.*lbf) : Specified torque CAP SET BOLT A117453E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–157

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PISTON RING SET WITH PIN PISTON SUB-ASSEMBLY E CONNECTING ROD SUB-ASSEMBLY

CONNECTING

ROD BEARING 1st: 15 (153, 11) 2nd: turn 90° CONNECTING ROD

BOLT

N*m (kgf*cm, ft.*lbf) : Specified torque A117452E03, EM–158 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM DISASSEMBLY

1. REMOVE SPARK PLUG (a) Using a spark plug wrench, remove the 4 spark plugs. A080968E01 2. REMOVE KNOCK SENSOR (a) Remove the nut and remove the knock sensor. A117462 3. REMOVE ENGINE OIL PRESSURE SWITCH

ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the oil pressure switch. A117463 4. REMOVE ENGINE COOLANT TEMPERATURE

SENSOR

SST (a) Using SST, remove the engine coolant temperature sensor. SST 09817-33190 A117464E01 5. REMOVE WATER INLET (a) Remove the 2 nuts and remove the water inlet. A080960E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–159

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6. REMOVE THERMOSTAT (a) Remove the thermostat. (b) Remove the gasket from the thermostat. A116187 7. REMOVE OIL FILLER CAP SUB-ASSEMBLY (a) Remove the oil filler cap from the cylinder head cover.

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A080967E01 8. REMOVE OIL FILLER CAP GASKET (a) Using a screwdriver, remove the gasket from the oil filler cap. 9. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and the crankshaft position sensor. A065656E01 10. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Remove the ventilation valve from the cylinder head cover. A080963E01 11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly. 12. REMOVE CYLINDER HEAD COVER GASKET (a) Remove the gasket from the cylinder head cover. A066472E01, EM–160 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE

ASSEMBLY

(a) Remove the bolt and the camshaft timing oil control valve. 14. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the bolt and the oil level gauge guide. A064872E01 15. REMOVE WATER PUMP PULLEY (a) Using SST, hold the pump pulley. SST 09960-10010 (09962-01000, 09963-00700) (b) Remove the 3 bolts and the pump pulley.

SST

A116191E01 16. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Set cylinder No. 1 to TDC/compression. (1) Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that the timing marks on the camshaft timing sprocket and the camshaft timing gear are all facing upward, as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01 (b) Using 2 SSTs, loosen the bolt while holding the crankshaft damper sub-assembly. SST SST 09213-14010 (91651-60865), 09330-00021 NOTICE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly. (c) Remove the SSTs and the bolt. A117461E01 (d) Remove the crankshaft damper sub-assembly., 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–161

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17. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (a) Remove the 4 bolts and remove the transverse engine mounting bracket. A080957E01 18. REMOVE WATER PUMP ASSEMBLY (a) Remove the 3 bolts and the 2 nuts and remove the water pump and the gasket.

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A116192 19. REMOVE OIL PUMP ASSEMBLY (a) Remove the 15 bolts and the nut. A116554 (b) Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it. NOTICE: Do not damage the contact surface of the oil pump assembly and oil pan sub-assembly. Tape A050903E01, EM–162 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(c) Remove the 2 O-rings from the cylinder block and oil pan sub-assembly. A116556 20. REMOVE OIL PUMP SEAL Wooden Blocks (a) Using a screwdriver with its tip wrapped in tape, remove the oil seal. 21. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 NOTICE: • Do not rotate the crankshaft with the chain tensioner removed. • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise A035281E04 40° from the TDC first. (a) Pull up the stopper plate and hold it with its lock released. Stopper Plate A116564E01 (b) Unlock the plunger of the tensioner and push it in to the end. Plunger A116565E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–163

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(c) Pull down the stopper plate with the plunger pushed to the end and lock the plunger. Stopper Plate A116566E01 E (d) Inserta3mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger. A116567 (e) Remove the 2 bolts and remove chain tensioner assembly No. 1. A116568 22. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the chain tensioner slipper. A116569, EM–164 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

23. REMOVE CHAIN VIBRATION DAMPER NO. 1 (a) Remove the 2 bolts and remove chain vibration damper No. 1. 24. REMOVE CHAIN SUB-ASSEMBLY A116570 25. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors. NOTICE: Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly. A115494 26. REMOVE DELIVERY PIPE NO. 1 SPACER (a) Remove the 2 delivery pipe No. 1 spacers. A115496 27. REMOVE INJECTOR VIBRATION INSULATOR (a) Remove the 4 injector vibration insulators. A115497 28. REMOVE FUEL INJECTOR ASSEMBLY Pull (a) Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly. A115498E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–165

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29. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and the camshaft position sensor. 30. REMOVE NO. 2 CAMSHAFT NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. A080958E01 (a) Using several steps, uniformly loosen and remove13542the 11 bearing cap bolts in the sequence shown in the illustration, then remove camshaft bearing cap No. 1, camshaft bearing cap No. 2 and camshaft No. 2. E NOTICE: Loosen each bolt uniformly while keeping the camshaft level. A037074E01 31. REMOVE CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vice. (b) Remove the flange bolt and the camshaft timing sprocket. NOTICE: Do not damage the camshaft. A064874E01 32. REMOVE CAMSHAFT (a) Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, then remove camshaft bearing cap No. 2 and the camshaft. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. 243133. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY A037075E01 (a) Clamp the camshaft in a vise, and confirm that it is locked. NOTICE: Do not damage the camshaft., EM–166 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(b) Cover the 4 oil paths of the cam journal with tape as Retard Side shown in the illustration. Paths HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil Advance paths. Plug one of the oil paths for each groove with Side Paths a piece of rubber before wrapping the cam journal with the tape. (c) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed Open Vinyl Tape Rubber Piece A116226E04 (d) Apply about 150 kPa (1.5 kgf*cm2) air pressure into Retard Advance the 2 broken paths (the advance side path and the Side Path Side Path retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02 (e) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. HINT: Retard Advance Side Path Side Path The lock pin is released and the camshaft timing gear revolves in the advance direction. (f) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. NOTICE: Camshaft timing gear assembly occasionally Decompress Hold Pressure shifts to the retard side abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock A116228E02 pin., 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–167

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(g) Remove the flange bolt and remove the camshaft timing gear assembly. NOTICE: • Do not remove the other 4 bolts. • When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first. Flange Bolt A116229E01 34. REMOVE CYLINDER HEAD SUB-ASSEMBLY392(a) Using several steps, uniformly loosen and remove76the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and the plate E washers. NOTICE: • Do not drop the washers into the cylinder151084head. A035286E01 • Head warpage or cracking could result from removing bolts in the wrong order. 35. REMOVE CYLINDER HEAD GASKET 36. REMOVE OIL FILTER SUB-ASSEMBLY (a) Using SST, remove the oil filter. SST 09228-06501

SST

A038018E02 37. REMOVE OIL FILTER UNION (a) Using a 12 mm hexagon wrench, remove the oil filter union. A079679E01, EM–168 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

38. REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal. NOTICE: After removal, check the crankshaft for any damage. If damaged, smooth the surface with 400-grit sandpaper. 39. REMOVE OIL PAN SUB-ASSEMBLY NO. 2 A051764E01 (a) Remove the oil pan drain plug and gasket. (b) Remove the 9 bolts and 2 nuts. A079680E01 (c) Insert the blade of SST between oil pan No. 1 and oil pan No. 2, and cut off the applied sealer and remove oil pan No. 2. SST 09032-00100 NOTICE: Do not damage oil pan No. 1 or oil pan No. 2. 40. REMOVE OIL STRAINER SUB-ASSEMBLY (a) Remove the bolt and 2 nuts. (b) Remove the oil strainer and the gasket. A001456E01 41. REMOVE OIL PAN SUB-ASSEMBLY (a) Loosen and remove the 13 bolts uniformly in several steps. A050902E01 (b) Using a screwdriver, remove oil pan No. 1 by prying between the cylinder block and oil pan No. 1. NOTICE: Do not damage the contact surfaces of oil pan No. 1 or the cylinder block. (c) Remove the 2 O-rings from the cylinder block. A011272E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–169

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42. REMOVE STUD BOLT (a) Remove the 4 stud bolts. A117459 43. REMOVE PISTON SUB-ASSEMBLY WITH 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 E upper bearing down through the top of the cylinder block to remove them. HINT: • Keep the bearing, connecting rod and cap A001166E01 together. • Keep the piston and the connecting rod assemblies in the correct order so that they can be returned to their original locations when reassembled. 44. REMOVE CONNECTING ROD BEARING 45. REMOVE CRANKSHAFT (a) Using several steps, loosen and remove the 10 bearing cap sub-assembly bolts uniformly with SST15973in the sequence shown in the illustration. SST 09011-38121 (b) Remove the bearing cap and the crankshaft. 46. REMOVE CRANKSHAFT BEARING26108447. REMOVE CRANKSHAFT THRUST WASHER UPPER A037365E02 48. REMOVE PISTON RING SET NOTICE: Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when reassembled. (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and the oil ring by hand. A037363E01, EM–170 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

49. REMOVE WITH PIN PISTON SUB-ASSEMBLY (a) Using SST, press the piston pin out of the piston. SST 09221-25026 (09221-00021, 09221-00030, SST 09221-00090, 09221-00150, 09221-00100) NOTICE: SST Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembled. 50. REMOVE CYLINDER BLOCK WATER DRAIN COCK SST SUB-ASSEMBLY SST 51. REMOVE STUD BOLT (a) Using "Torx" socket wrench E5, remove the 7 stud Connecting Piston Pin bolts. Rod 52. REMOVE RING PIN 53. REMOVE STRAIGHT PIN Piston

SST

A092172E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–171

M INSPECTION

1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Check the lock of camshaft timing gear. (1) Clamp the camshaft in a vice, and check that the camshaft timing gear is locked. NOTICE: Do not damage the camshaft. (b) Release the lock pin. Retard Side (1) Cover the 4 oil paths of the cam journal with Paths tape as shown in the illustration. HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and Advance the other is for advancing cam timing (lower). Side Paths Each groove has 2 oil paths. Plug one of the oil E paths for each groove with a piece of rubber before wrapping the cam journal with the tape. (2) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed Open Vinyl Tape Rubber Piece A116226E04 (3) Apply air at about 150 kPa (1.5 kgf*cm2) Retard Advance pressure into the 2 broken paths (the advance Side Path Side Path side path and the retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02, EM–172 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(4) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. Retard Advance Side Path Side Path HINT: The lock pin is released and the camshaft timing gear revolves in the advance direction. (5) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. Decompress Hold Pressure NOTICE: Camshaft timing gear assembly occasionally shifts to the retard side A116228E02 abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock pin. (c) Check that the revolution is smooth. (1) Rotate the valve timing assembly back and forth several times, except where the lock pin meets it at the most retarded angle. Check the movable range and that it rotates smoothly. Standard: Smooth movable range is about 22.5° NOTICE: Perform this check by hand, instead of using air pressure. (d) Check that the gear locks in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked in the most retarded position. 2. INSPECT CHAIN SUB-ASSEMBLY (a) Using a spring scale, apply 140 N (14.3 kgf, 31.5 lb) to the timing chain and measure its length. Maximum chain elongation: 123.2 mm (4.850 in.) Measuring Area If the elongation is greater than the maximum, replace the chain. HINT: 01234516 Perform the same measurement at 3 or more A032117E01 random places and calculate the average length. 3. INSPECT CHAIN TENSIONER ASSEMBLY NO. 1 (a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. (b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. A011223E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–173

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4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Wrap the chain around the timing sprocket. (b) Using vernier calipers, measure the diameter of the timing gear with the chain. Minimum gear diameter (with chain): 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the camshaft timing gear. NOTICE: A037071E01 Make sure that the vernier calipers are in contact with the chain link when measuring. 5. INSPECT CAMSHAFT TIMING SPROCKET (a) Wrap the chain around the timing sprocket. (b) Using vernier calipers, measure the diameter of the timing gear with the chain. Minimum gear diameter (with chain): E 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the camshaft timing sprocket. NOTICE: A037072E01 Make sure that the vernier calipers are in contact with the chain link when measuring. 6. INSPECT CHAIN TENSIONER SLIPPER (a) Check the chain tensioner slipper. Minimum thickness: 1.0 mm (0.039 in.) If the thickness is less than the minimum, replace the chain tensioner slipper. A037065E01 7. INSPECT CHAIN VIBRATION DAMPER NO. 1 (a) Check the vibration damper. Minimum thickness: 1.0 mm (0.039 in.) If the thickness is less than the minimum, replace the chain vibration damper. A037066E01, EM–174 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

8. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.16 to 0.36 mm (0.0063 to 0.0142 in.) Maximum thrust clearance: 0.36 mm (0.0142 in.) 9. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod A037347E01 and cap are aligned to ensure correct reassembly. (b) Using SST, remove the 2 connecting rod cap bolts. SST 09205-16010 SST (c) Clean the crank pin and bearing. (d) Check the crank pin and bearing for pitting and scratches. A037361E02 (e) Lay a strip of Plastigage across the crank pin. Plastigage A050668E03 (f) Make sure that the connecting rod and its cap are in Front the correct combination and that the front mark of Mark the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod. (g) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. A050673E02 (h) Using SST, tighten the bolts in several steps to the specified torque.

SST

SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A037360E03, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–175

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(i) Mark the front of the connecting cap bolts with paint. (j) Retighten the cap bolts by 90° as shown in the Front illustration. NOTICE: Do not turn the crankshaft. (k) Remove the 2 bolts, connecting rod cap and lower bearing. Paint Mark A065715E02 (l) Measure the Plastigage at its widest point. Plastigage Standard oil clearance: 0.012 to 0.038 mm (0.00047 to 0.00015 in.) Maximum oil clearance: 0.058 mm (0.0028in.) E NOTICE: Completely remove the Plastigage after the measurement. A037349E02 (m) When replacing a bearing, replace it with one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly. Standard bearing center wall thickness Mark mm (in.) 1 1.491 to 1.494 (0.0587 to 0.0588) 2 1.494 to 1.497 (0.0588 to 0.0589) Mark 1 , 2 or 3 Front Mark 3 1.497 to 1.500 (0.0589 to 0.0591) A051826E02 10. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.09 to 0.19 mm (0.0035 to 0.0075 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, A037350E01 replace the thrust washers as a set. Check the crankshaft and block for wear. Repair or replace the parts if necessary. HINT: Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.976 in.), EM–176 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

11. INSPECT CYLINDER BLOCK FOR WARPAGE (a) Using a precision straight edge and feeler gauge, Straight Edge measure the warpage of the surface which is in contact with the cylinder head gasket. Maximum warpage: 0.05 mm (0.0020 in.) A037353E02 12. INSPECT CYLINDER BORE (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both the thrust and axial directions. Standard Inside diameter: 75.000 to 75.013 mm (2.9528 to 2.9533 in.) (b) Calculate the difference between the maximum diameter and the minimum diameter of the 4 measured values. Difference limit: 0.10 mm (0.0039 in.) Thrust Direction If the difference is greater than the limit, replace the Front cylinder block. Axial Direction 10 mm A (0.39 in.) B Center A081899E02 13. INSPECT WITH PIN PISTON SUB-ASSEMBLY (a) Using a micrometer, measure the piston diameter at a right angle to the piston pin center line, and at the position 27.6 to 27.8 mm (1.0866 to 1.0945 in.) from the top of the piston head. Piston diameter: 74.935 to 74.945 mm (2.9502 to 2.9506 in.) 27.6 to 27.8 mm (1,0866 to 1,0945 in.) A050666E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–177

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(b) Using a caliper gauge, measure the piston pin hole diameter. Piston pin hole diameter: 18.013 to 18.016 mm (0.7092 to 0.7093 in.) at 20°C (68°F) (c) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 18.001 to 18.004 mm (0.7087 to 0.7088 in.) (d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement to calculate the oil clearance. Standard oil clearance: 0.009 to 0.015 mm (0.0004 to 0.0006 in.) EM00227 Maximum oil clearance: 0.050 mm (0.0020 in.) E If necessary, replace the piston and piston pin together. 14. INSPECT PISTON CLEARANCE (a) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.045 to 0.068 mm (0.0018 to 0.0027 in.) Maximum oil clearance: 0.08 mm (0.0032 in.) 15. INSPECT CONNECTING ROD SUB-ASSEMBLY (a) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the misalignment is greater than the maximum, replace the connecting rod assembly. Z000064E01 (2) Check for twist. Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z000065E01, EM–178 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

16. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance: No. 1: 0.03 to 0.07 mm (0.0012 to 0.0028 in.) No. 2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.) A001171E01 17. INSPECT PISTON RING END GAP (a) Using a piston, push the piston ring, a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. 110 mm (4.33 in.) A037354E02 (b) Using a feeler gauge, measure the end gap. Standard end gap: No. 1: 0.25 to 0.35 mm (0.0098 to 0.0138 in.) No. 2: 0.35 to 0.50 mm (0.0138 to 0.0197 in.) Oil (Side Rail): 0.10 to 0.35 mm (0.0039 to 0.0138 in.) Maximum end gap: EM07639 No. 1: 0.91 mm (0.0358 in.) No. 2: 1.06 mm (0.0417 in.) Oil (Side Rail): 0.82 mm (0.323 in.) 18. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the diameter of the bolt at the elongated portion. Standard diameter: 6.6 to 6.7 mm (0.260 to 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than the minimum, replace the bolt. A001470, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–179

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19. INSPECT CRANKSHAFT (a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) A011241E01 (b) Using a micrometer, measure the diameter of each main journal. Outside diameter: 45.988 to 46.000 mm (1.8106 to 1.8110 in.) (c) Check each main journal for taper and out-of- E roundness as shown. Maximum taper and out-of-roundness: 0.02 mm (0.0008 in.) A037157E01 (d) Using a micrometer, measure the diameter of each crank pin. Outside diameter: 39.992 to 40.000 mm (1.5745 to 1.5748 in.) (e) Check each crank pin for taper and out-of- roundness as shown. Maximum taper and out-of-roundness: 0.02 mm (0.0008 in.) ZF06928E01 (f) Wrap the chain around the timing sprocket. (g) Using vernier calipers, measure the timing sprocket diameter with the chain. Standard sprocket diameter (with chain): 51.72 mm (2.0362 in.) Minimum sprocket diameter (with chain): 50.5 mm (1.988 in.) NOTICE: Make sure that the vernier calipers are in A038171E01 contact with the chain rollers when measuring. 20. INSPECT CRANKSHAFT BEARING CAP SET BOLT (a) Using vernier calipers, measure the tension portion diameter of the elongated portion. Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter: 7.2 mm (0.283 in.) If the diameter is less than the minimum, replace the bolt. A015065E03, EM–180 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

21. INSPECT CRANKSHAFT OIL CLEARANCE (a) Clean each main journal and bearing. (b) Install the bearing onto the cylinder block and bearing cap. (See page EM-183) (c) Place the crankshaft onto the cylinder block. (d) Lay a strip of Plastigage across each journal. Plastigage A050669E02 (e) Examine the front marks and numbers and install Bearriing Cap Bearing Cap the bearing cap onto the cylinder block. CNaop. 3N:o. 3: No. 1, 2, 4, 5: (f) Apply a light coat of engine oil to the threads of the bearing cap bolts. Numberr FrFornotn Mt Marakrk Frrontt Marrkk and Nanudm Nbeurmber A118660E01 (g) Using SST, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration. (*1) 95137SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 106248A037364E07 (h) Mark the front of the bearing cap bolts with paint. (i) Retighten the bearing cap bolts by 90° in the same Front sequence as step (*1). (j) Check that the painted mark is now at a 90° angle from the front. NOTICE: Do not turn the crankshaft. (k) Remove the bearing cap sub-assembly. Paint Mark A065715E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–181

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(l) Measure the Plastigage at its widest point. Plastigage Standard oil clearance: 0.01 to 0.023 mm (0.0004 to 0.0009 in.)

Maximum oil clearance:

0.07 mm (0.0028 in.)

NOTICE: Completely remove the Plastigage after the

mesurement. A037352E02 (m) When replacing a standard bearing, replace it with one with the same number. If the number of the bearing cannot be found, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then select the E bearing with the same number as the total. There are 4 sizes of standard bearings, marked 1, 2, 3 and No. 1 No. 2 4 accordingly. No. 3 EXAMPLE: Cylinder Block 4 (A) + Crankshaft 3 No. 4 (B) = Total 7 (Use Bearing 3)No. 5 Cylinder Block (A) + 0 to23to56to89to 11 Crankshaft (B) No. 1 No. 3 No. 5 Use Bearing1234Mark No. 2 No. 4 A010463E02 Item Mark mm (in.) 0 50.000 to 50.003 (1.96850 to 1.96862) 1 50.003 to 50.005 (1.96862 to 1.96870) 2 50.005 to 50.007 (1.96870 to 1.96878) Cylinder block main journal bore diameter (A) 3 50.007 to 50.010 (1.96878 to 1.96890) 4 50.010 to 50.012 (1.96890 to 1.96898) 5 50.012 to 50.014 (1.96898 to 1.96906) 6 50.014 to 50.016 (1.96906 to 1.96913) 0 45.998 to 46.000 (1.81094 to 1.81102) 1 45.996 to 45.998 (1.81087 to 1.81094) Crankshaft main journal diameter (B) 2 45.994 to 45.996 (1.81079 to 1.81087)3 45.992 to 45.994 (1.81071 to 1.81079) 4 45.990 to 45.992 (1.81063 to 1.81071) 5 45.988 to 45.990 (1.81055 to 1.81063) 1 1.992 to 1.995 (0.07843 to 0.07854) Standard bearing center wall thickness 2 1.995 to 1.998 (0.07854 to 0.07866)3 1.998 to 2.001 (0.07866 to 0.07878) 4 2.001 to 2.004 (0.07878 to 0.07890), EM–182 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM REASSEMBLY

1. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Apply adhesive to the end 2 or 3 threads of the drain union and install the water drain cock within 3 minutes of applying the adhesive. (b) After applying the specified torque, rotate the drain union clockwise until its drain port faces downward. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) NOTICE: • Do not add coolant within 1 hour of installation. • Do not rotate the drain union more than 360° in step (b), and never loosen it after setting 40 40 the union correctly. A064756E01 2. INSTALL STRAIGHT PIN Upper Side Front Side

A A C

Lower Side Rear Side

D B

18.5 to 11.5 to 8.5 to 8.5 to 19.5 mm 12.5 mm 9.5 mm 9.5 mm Pin A ( 8) Pin B ( 8) Pin D ( 10) Pin C ( 10) A107304E02 (a) Using a plastic-faced hammer, tap in the straight pin. Standard protrusion: Pin A:, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–183

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8.5 to 9.5 mm (0.335 to 0.374 in.) Pin B: 8.5 to 9.5 mm (0.335 to 0.374 in.) Pin C: 18.5 to 19.5 mm (0.728 to 0.768 in.) Pin D: 11.5 to 12.5 mm (0.453 to 0.492 in.) 3. INSTALL OIL PUMP SET RING PIN Front Side (a) Using a plastic-faced hammer, tap in a new ring pin. Standard protrusion: 3.5 to 4.5 mm (0.138 to 0.177 in.) 4. INSTALL STUD BOLT

E

3.5 to 4.5 mm A107305E01BC

D A

12 48 43.5 29 8.5 10 8 129 A (M6) B (M6) C (M12) D (M6) [mm] A107306E01 (a) Using "Torx" socket wrench E5, install the 7 stud bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (for Stud bolt A, B and D) 11 N*m (112 kgf*cm, 8.1 ft.*lbf) (for Stud bolt C) NOTICE: The lower threads of the bolt are installed into the cylinder block., EM–184 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

5. INSTALL CRANKSHAFT BEARING (a) Align the crankshaft bearing (upper) with the oil hole of the cylinder block and install the bearing. NOTICE: Do not apply engine oil to the bearing or its contact surface. NG OK A117086E01 (b) Align the crankshaft bearing (lower) with the bearing cap and install the crankshaft bearing cap. NOTICE: A • Install the bearing cap so that the gap between A and B is less than 0.7 mm (0.028 in.). • Do not apply engine oil to the bearing or its B contact surface. A117087E01 6. INSTALL CRANKSHAFT THRUST WASHER UPPER (a) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward. (b) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block. A001191E03 7. INSTALL CRANKSHAFT Bearriing Cap Bearing Cap (a) Examine the front marks and numbers and install CNaop. 3N:o. 3: No. 1, 2, 4, 5: the bearing caps onto the cylinder block. (b) Apply a light coat of engine oil to the threads of the bearing cap bolts. Numberr FrFornotn Mt Marakrk Frrontt Marrkk and Nanudm Nbeurmber A118660E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–185

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(c) Using SST, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration (*1). 95137SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) NOTICE: Check that the crankshaft turns smoothly. 106248A037364E07 (d) Mark the front of the bearing cap bolts with paint. (e) Retighten the bearing cap bolts by 90° in the same Paint Mark 90° sequence as step (*1). (f) Check that the painted mark is now at a 90° angle from the front. E 8. INSPECT CRANKSHAFT THRUST CLEARANCE (See Engine Front page EM-174) 9. INSPECT CRANKSHAFT OIL CLEARANCE (See page A050671E03 EM-179) 10. INSTALL WITH PIN PISTON SUB-ASSEMBLY (a) Coat the piston pin and pin holes in the piston with engine oil. Front (b) Align the cavity of the piston with the protruding Mark portion on the connecting rod. A050053E01, EM–186 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(c) Using SST, press in the piston pin. SST 09221-25026 (09221-00021, 09221-00030, 09221-00090, 09221-00150, 09221-00100)

SST

SST NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they SST can be returned to the original locations when reassembled.

SST SST

Piston Pin Connecting Piston Rod A130429E01 11. INSTALL CONNECTING ROD BEARING Claw (a) Align the bearing claw with the groove of the connecting rod or connecting cap. NOTICE: Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oil. A050672E03 12. INSTALL PISTON RING SET HINT: When reusing the piston rings, install them onto the No. 2 matched pistons with the surfaces facing correctly. (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings. A012128E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–187

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(c) Position the piston rings so that the ring ends are as No. 1 Compression Lower shown. and Expander Side Rail 13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. (b) Check the position of the piston ring ends. Front Upper Side Rail No. 2 Compression A118663E01 E (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston Front facing forward. Mark NOTICE: • Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oil. • Match the numbered connecting rod cap with A001205E02 the connecting rod. (d) Make sure that the connecting rod and its cap are in Front the correct combination and that the front mark of Mark the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod. (e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. A050673E02 (f) Using SST, tighten the bolts in several steps to the specified torque. SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A037360E01, EM–188 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(g) Mark the front of the connecting cap bolts with paint. (h) Retighten the cap bolts by 90° as shown. Paint Mark 90° (i) Check that the crankshaft turns smoothly. 14. INSPECT CONNECTING ROD THRUST CLEARANCE (See page EM-173) Engine Front 15. INSPECT CONNECTING ROD OIL CLEARANCE (See page EM-173) 16. INSTALL STUD BOLT A050671E03 (a) Using "Torx" socket wrench E5, install the 4 stud bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 22.5 (0.51) (0.886) 8.0 (0.32) A Stud Bolt A

B

16.5 B (0.650) 27.5 (1.083) 9.0 (0.35)

A

Stud Bolt B mm (in.) A117460E01 17. INSTALL OIL PAN SUB-ASSEMBLY (a) Remove any old packing material from the contact surface. (b) Apply a continuous bead of seal packing (Diameter Seal Packing 2.0 mm to 3.0 mm (0.079 to 0.118 in.)) to the oil pan 9 mm 4 mm mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. 4 mm • Install the oil pan within 3 minutes of applying 11 mm Seal Packing A050687E04 the seal packing. • Do not expose the seal to engine oil for at least within 2 hours after the installation. (c) Install 2 new O-rings onto the cylinder block., 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–189

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(d) Using several steps, install and tighten the 13 bolts 15 14 uniformly in the sequence shown in the illustration. 543213 12 Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) HINT: Each bolt length is as follows: ABCBolt A 49 mm (1.93 in.) B Bolt B 88 mm (3.47 in.) Bolt C 144 mm (5.67 in.) 678110 18. INSTALL OIL STRAINER SUB-ASSEMBLY 9 A037067E03 (a) Install a new gasket and the oil strainer with the 2 nuts and the bolt. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) 19. INSTALL OIL PAN SUB-ASSEMBLY NO. 2 (a) Remove any old packing material from the contact surface. E (b) Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying Seal Width 2.5 to 3.5 mm A081876E02 the seal packing. • Do not expose the seal to engine oil for at least 2 hours after the installation. • Do not start the engine for at least 2 hours after the installation. (c) Install oil pan No. 2 with the 9 bolts and the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (d) Install the drain plug with a new gasket. Torque: 38 N*m (382 kgf*cm, 28 ft.*lbf) 20. INSTALL OIL FILTER UNION (a) Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 21. INSTALL OIL FILTER SUB-ASSEMBLY (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. (c) Gently screw the oil filter into place, and tighten it A079679E01 until the gasket comes into contact with the seat., EM–190 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(d) Using SST, tighten it an additional 3/4 turn. SST 09228-06501 HINT: When using a torque wrench, tighten it to the specified torque. Torque: 13 N*m (133 kgf*cm, 9.5 ft.*lbf)

SST

A038018E02 22. INSTALL CYLINDER HEAD GASKET Lot No. (a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward. NOTICE: • Remove any oil from the contact surface. • Pay attention to the mounting orientation of the cylinder head gasket. • Place the cylinder head on the cylinder head gently in order not to damage the gasket. A011249E05 23. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: The cylinder head bolts are tightened in 2 successive steps. (a) Apply a light coat of engine oil to the threads of the892cylinder head bolts.4 5 (b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) (c) Mark the front of the cylinder head bolt with paint. 106137A035288E03, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–191

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(d) Retighten the cylinder head bolts by 90° and then an additional 90° as shown in the illustration. (e) Check that the paint mark is now at a 180° angle from the front. 90 90 Paint Mark42589

E

107613A116959E01 (f) Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as shown in the illustration. Cylinder Head Seal Packing: Toyota Genuine Seal Packing Black, Three Diameter: Bond 1207B or Equivalent 4.5 to 5.5 mm NOTICE: • Remove any oil from the contact surface. Cylinder Head • Install the oil pump assembly within 3 Gasket minutes and tighten the bolts within 15 minutes of applying seal packing. Cylinder Block 24. INSTALL ENGINE REAR OIL SEAL Seal Packing (a) Apply MP grease to a new oil seal lip. NOTICE: A073748E02 Keep the seal lip free of foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 NOTICE: • Do not tap the oil seal at an angle. • Wipe any extra grease off the crankshaft. 25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY NOTICE: SST Install the camshaft timing gear assembly onto the A050928E01 camshaft with the lock pin of the camshaft timing gear assembly released., EM–192 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(a) Put the camshaft timing gear assembly and camshaft together with the straight pin of the Straight Pin groove. (b) Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits into the groove, push to ensure a good fit. NOTICE: Groove Do not turn the camshaft timing gear in the A116230E01 retard direction (clockwise). (c) Check that there is no clearance between the gear fringe and the camshaft. (d) Tighten the flange bolt with the camshaft timing gear fixed. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: • Do not lock the camshaft timing gear assembly when tightening the bolt. • Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position. • Tightening the bolts with the lock pin locked could cause breakage of the lock pin. (e) Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position. 26. INSTALL CAMSHAFT (a) Apply a light coat of engine oil to the camshaft journals. (b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (c) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the camshaft level. 3124A037103E04, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–193

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27. INSTALL CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vice. (b) Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: Do not damage the camshaft. 28. INSTALL NO. 2 CAMSHAFT A032167E01 (a) Apply a light coat of engine oil to the camshaft journals. (b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (c) Examine the front marks and numbers on camshaftE3124bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration. 5 Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 2 23 N*m (235 kgf*cm, 17 ft.*lbf) for bearing cap No. 1 NOTICE: Tighten each bolt uniformly while keeping the camshaft level. Bearing Cap No. 1 Bearing Cap No. 2 A116223E01 29. INSTALL CAMSHAFT POSITION SENSOR (a) Apply engine oil to the O-ring. NOTICE: If the O-ring is damaged, replace the camshaft position sensor. (b) Install the camshaft position sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A080958E01, EM–194 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

30. INSTALL CHAIN SUB-ASSEMBLY TDC: (a) Make sure that all the timing marks are in the positions (TDC) shown in the illustration. Timing Marks HINT: The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring. Timing Mark A116571E01 (b) Set the timing mark of the crankshaft in a position Timing Mark between 40 and 140°ATDC, as illustrated. 40° to 140° ATDC A116573E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–195

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(c) Set the camshaft timing gear and the camshaft 20° ATDC: timing sprocket in the positions (20°ATDC) shown in Timing Marks the illustration. (d) Set the crankshaft in the position (20°ATDC) shown in the illustration.

E

30° Timing Mark A116574E01 (e) Install chain vibration damper No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116576, EM–196 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(f) Align the timing marks of the camshaft with the mark Mark Plates plates of the timing chain and install the timing chain. HINT: Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench. Timing Marks Mark Plate Timing Mark A116577E01 31. INSTALL CHAIN TENSIONER SLIPPER (a) Install the chain tensioner slipper. A116569 32. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 (a) Install chain tensioner assembly No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Remove the bar from chain tensioner assembly No. 1. A116568 33. INSTALL OIL PUMP SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. Wooden SST 09950-60010 (09951-00250, 09951-00380, Block SST 09952-06010), 09950-70010 (09951-07100) NOTICE: • Do not tap the oil seal at an angle. • Keep the seal lip free of foreign matter. (b) Apply MP grease to the oil seal lip. A037153E03, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–197

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34. INSTALL OIL PUMP ASSEMBLY (a) Install 2 new O-rings in the 2 locations shown in the illustration. A116556

E

,

EM–198 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

(b) Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.

B B A A

Seal Packing

C

Seal Packing C 4.5 to 5.5 (0.177 to 0.217) A-A 1.5 to 2.0 (0.059 to 0.079) 2.5 (0.098) 1.5 Seal Width (Other Part) (0.059) 3.5 to 4.5 (0.138 to 0.177) 5.0 1.5 (0.197) (0.059) 1.5 to 2.0 B-B, C-C (0.059 to 0.079) Seal Width (Water Pump Part) 2.5 (0.098) 3.5 to 4.5 (0.138 to 0.177) 2.5 1.0 (0.098) (0.039) 1.5 to 2.0 3.5 to 4.5 (0.059 to 0.079) (0.138 to 0.177) 1.0 (0.039) mm (in.) A116557E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–199

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Seal packing: Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other part Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the oil pump assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying the the seal packing. • Do not expose the seal to engine oil for at least 2 hours after the installation. (c) Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft, and slide the oil pump into place. E A116558 (d) Install the oil pump assembly with the 15 bolts and nut. Tighten the bolts and nut uniformly in several

D

steps. Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for boltAAE11 N*m (112 kgf*cm, 8.1 ft.*lbf) for boltBCA11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt C

C

24 N*m (245 kgf*cm, 18 ft.*lbf) for nutDCC24 N*m (245 kgf*cm, 18 ft.*lbf) for boltECNOTICE: Install the mounting bracket and water pumpCBwithin 15 minutes of installing the oil pump assembly. C C HINT: Each bolt length is as follows. C C A: 30 mm (1.181 in.)C A116554E01 B: 35 mm (1.378 in.) C: 20 mm (0.787 in.) E: 20 to 14 mm (0.787 to 0.551 in.) Double ended bolt, EM–200 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

35. INSTALL WATER PUMP ASSEMBLY (a) Install the water pump and a new gasket with the 3 bolts and 2 nuts. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) A116192 36. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (a) Install the transverse engine mounting bracket with the 4 bolts. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 37. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Align the pin hole in the crankshaft damper with the pin position and install the crankshaft damper sub- assembly. A080957E01 (b) Provisionally install the bolt. (c) Using 2 SSTs, tighten the bolt while holding the crankshaft damper sub-assembly. SST SST 09213-14010 (91651-60865), 09330-00021 Torque: 128 N*m (1305 kgf*cm, 95 ft.*lbf) NOTICE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly. A117461E01 38. INSTALL WATER PUMP PULLEY (a) Using SST, install the pump pulley with the 3 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

SST

A116191E01 39. INSPECT VALVE CLEARANCE (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–201

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(2) Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01 (b) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for intake: E 0.15 to 0.25 mm (0.006 to 0.010 in.) for exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) Record any out-of-specification valve clearance A116201 measurements. They will be used later to determine the required replacement adjusting shim. (c) Turn the crankshaft 1 complete revolution (360°) and align its timing notch with timing mark "0" of the oil pump. (d) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) for Exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) Record any out-of-specification valve clearance A116202 measurements. They will be used later to determine the required replacement adjusting shim. 40. ADJUST VALVE CLEARANCE Matchmark NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves. A116206E01, EM–202 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper, and align its timing notch with timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E04 (b) Put paint marks on the chain in the places where the Paint Marks timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Timing Marks A116207E01 (c) Using an 8 mm hexagon wrench, remove the screw plug. G100163, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–203

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(d) Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward. Stopper Plate A116209E01 E (e) Using a wrench, rotate the No. 2 camshaft clockwise to push in the plunger of the chain tensioner. Plunger A116210E01 (f) Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and inserta3mm (0.12 in.) diameter bar into the holes to hold the stopper plate. HINT: • Fix the stopper plate using the bar while rotating the camshaft right and left slightly. • Hold the bar with tape so that it does not come out. A116212, EM–204 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(g) Using a wrench, hold the hexagonal lobe of No. 2 camshaft and remove the flange bolt. A116213 (h) Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown13542in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. A116214E01 (i) Remove the flange bolt and remove the camshaft timing sprocket. A116215 (j) Remove the No. 2 camshaft. A116216 (k) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2. NOTICE: Loosen the bolts uniformly while keeping the camshaft level. 2431A116217E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–205

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(l) Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly. A116218 (m) Tie the chain with a piece of string as shown in the illustration. (n) Remove the valve lifters.

E

A035227E01 (o) Using a micrometer, measure the thickness of the removed lifter. (p) Calculate the thickness of the new lifter so that the valve clearance comes to within the specified values. A Thickness of new lifter B Thickness of used lifter C Measured valve clearance A001082E01 Valve clearance: Intake A = B + (C - 0.20 mm (0.008 in.)) Exhaust A = B + (C - 0.30 mm (0.012 in.)) (q) Select a new lifter with a thickness as close to the calculated values as possible. HINT: Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.)., EM–206 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

A117457, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–207

M Intake valve clearance (cold):

0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE: A 5.250 mm (0.2067 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) E 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173), EM–208 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

A117458, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–209

M Exhaust valve clearance (cold):

0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE: A 5.340 mm (0.2102 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) E 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) (r) Install the selected valve lifter. (s) Apply a light coat of engine oil to the camshaft and camshaft journals. (t) Install the chain onto the camshaft timing gear with Paint Mark the paint mark and the timing mark aligned, as shown in the illustration. Timing Mark A116220E01 (u) Examine the front marks and the numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.

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

camshaft level. 3124A116222E01, EM–210 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(v) Install camshaft No. 2. A116216 (w) Hold the chain, and align the timing mark on the Paint Mark camshaft timing sprocket with the paint mark of the chain. (x) Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft. Timing Mark Pin A116224E01 (y) Provisionally install the flange bolt. A116215 (z) Examine the front marks and the numbers of3124camshaft bearing cap No. 1 and camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the 5 illustration. Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 2 23 N*m (235 kgf*cm, 17 ft.*lbf) for bearing cap No. 1 NOTICE: Tighten the bolts uniformly while keeping the Bearing Cap No. 1 Bearing Cap No. 2 camshaft level. A116223E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–211

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(aa) Using a wrench, hold the hexagonal lobe of camshaft No. 2, and install the flange bolt. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) SST 09023-38400 (ab) Remove the bar from the timing chain tensioner. A116225 (ac) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.

E

Timing Notch A116203E01 (ad) Check that all the pairs of timing marks are aligned. Paint Marks (ae) Apply adhesive to the end 2 or 3 threads of the screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Timing Marks A116207E01 (af) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) G100163 41. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE

ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring, and install it onto the camshaft timing oil control valve. (b) Install the camshaft timing oil control valve with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Do not twist the O-ring. A064872E01, EM–212 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

42. INSTALL FUEL INJECTOR ASSEMBLY (a) Apply a light coat of gasoline or spindle oil to new O- rings, then install one onto each fuel injector. (b) Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the O- ring of the fuel injector. O-Ring A115499E01 (c) While turning the fuel injector left and right, install it onto the fuel delivery pipe. Turn NOTICE: • Do not twist the O-ring. • After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring Push with a new one. A115500E01 43. INSTALL INJECTOR VIBRATION INSULATOR (a) Install 4 new injector vibration insulators onto the cylinder head. A115497 44. INSTALL DELIVERY PIPE NO. 1 SPACER (a) Install the 2 delivery pipe No. 1 spacers onto the cylinder head. NOTICE: Install delivery pipe No. 1 spacer in the correct direction. A115501 45. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Provisionally install the fuel delivery pipe sub- assembly and 4 fuel injectors with the 3 bolts. NOTICE: • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub- assembly. A115494, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–213

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(b) Tighten the 3 bolts to the specified torque. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A

A

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

A B

A115494E01 46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (a) Install the gasket onto the cylinder head cover. (b) Apply seal packing to the cylinder head, as shown in the illustration. Seal Packing: E Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. Seal Packing A115503E01 • Install the cylinder head cover sub-assembly within 3 minutes of applying the seal packing. • Do not start engine for at least 2 hours after the installation. (c) Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers. (d) Tighten the 9 bolts and 2 nuts in the sequence 11957shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7.0 ft.*lbf) 1012364A035756E01 47. INSTALL VENTILATION VALVE SUB-ASSEMBLY (a) Install the ventilation valve onto the cylinder head cover. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 48. INSTALL OIL LEVEL GAUGE GUIDE (a) Apply engine oil to a new O-ring. (b) Install the oil level gauge guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A080963E01 49. INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring on the crankshaft position sensor. NOTICE: If the O-ring is damaged, replace the crankshaft position sensor. (b) Install the crankshaft position sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf), EM–214 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

50. INSTALL OIL FILLER CAP GASKET (a) Install the oil filler cap gasket onto the oil filler cap. 51. INSTALL OIL FILLER CAP SUB-ASSEMBLY (a) Install the oil filler cap onto the cylinder head cover. 52. INSTALL THERMOSTAT (a) Install a new gasket onto the thermostat. (b) Install the thermostat with the jiggle valve facing upward. 10 10 HINT: The jiggle valve may be set within 10°either side as shown in the illustration. A116188E01 53. INSTALL WATER INLET (a) Install the water inlet with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 54. INSTALL ENGINE COOLANT TEMPERATURE

SENSOR

(a) Provisionally install the engine coolant temperature sensor through a new gasket. A080960E01 (b) Using SST, tighten the engine coolant temperature sensor. SST SST 09817-33190 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) A117464E01 55. INSTALL ENGINE OIL PRESSURE SWITCH

ASSEMBLY

Adhesive (a) Apply adhesive to the end 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent A050082E13, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–215

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(b) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A117463 56. INSTALL KNOCK SENSOR (a) Install the knock sensor with the nut as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) E +- 30° A090881E01 57. INSTALL SPARK PLUG (a) Using a spark plug wrench, install the spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) A080968E01, 1NZ-FE ENGINE MECHANICAL – ENGINE EM–1

M ENGINE ON-VEHICLE INSPECTION

1. INSPECT ENGINE COOLANT (See page CO-1) 2. INSPECT ENGINE OIL (See page LU-1) 3. INSPECT BATTERY (See page CH-4) 4. INSPECT AIR CLEANER FILTER ELEMENT SUB-

ASSEMBLY

(a) Remove the air cleaner filter element sub-assembly. (b) Visually check that there is no dirt, blockage, or damage to the air cleaner filter element. HINT: • If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air. E • If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it. 5. INSPECT SPARK PLUG (See page IG-5) 6. INSPECT IGNITION TIMING (a) When using an intelligent tester: (1) Warm up and stop the engine. (2) Connect the intelligent tester to the DLC3. Intelligent Tester (3) Turn the ignition switch ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ ACTIVE TEST / TC (TE1) / ON. HINT: DLC3 Refer to the intelligent tester operator's manual CAN VIM for further details. (5) Inspect the ignition timing during idling. A125658E01 Ignition timing: 8 to 12 degrees BTDC NOTICE: • Turn all the electrical systems and the A/ C off. • Inspect the ignition timing with the cooling fan off. • When checking the ignition timing, shift the transmission to the neutral position. (6) Select the following menu items: TC (TE1) / OFF. (7) Turn the ignition switch OFF. (8) Disconnect the intelligent tester from the DLC3. (b) When not using an intelligent tester: (1) Remove cylinder head cover No. 2 (see page IG-9)., EM–2 1NZ-FE ENGINE MECHANICAL – ENGINE

EM

(2) Pull out the wire harness (brown) shown in the illustration. NOTICE: After checking, wrap the wire harness with tape. (3) Warm up and stop the engine. (4) Connect the clip of the timing light to the wire harness. NOTICE: A116196 Use a timing light that detects the first signal. (5) Turn the ignition switch ON. (6) Using SST, connect terminals 13 (TC) and 4 DLC3 (CG) of the DLC3. CG SST 09843-18040 NOTICE: Examine the terminal numbers before12345678connecting them. Connecting the wrong terminals could damage the engine. 9 10111213141516 (7) Inspect the ignition timing during idling. Ignition timing:

TC

A082779E23 8 to 12 degrees BTDC NOTICE: • Turn all the electrical systems and the A/ C off. • Inspect the ignition timing with the cooling fan off. • When checking the ignition timing, shift the transmission to the neutral position. (8) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (9) Turn the ignition switch OFF. (10) Remove the timing light. (11) Install cylinder head cover No. 2 (see page IG- 10). 7. INSPECT ENGINE IDLING SPEED (a) When using an intelligent tester: (1) Warm up and stop the engine. (2) Connect the intelligent tester to the DLC3. Intelligent Tester (3) Turn the ignition switch ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ DATA LIST / PRIMARY / ENGINE SPD. HINT: DLC3 Refer to the intelligent tester operator's manual CAN VIM for further details. (5) Inspect the engine idling speed. A125658E01 Idling speed: 550 to 650 rpm for manual transaxle 650 to 750 rpm for automatic transaxle NOTICE: • Turn all the electrical systems and the A/ C off., 1NZ-FE ENGINE MECHANICAL – ENGINE EM–3

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• Inspect the idling speed with the cooling fan off. • When checking the idling speed, shift the transmission to either the neutral position or the parking position. (6) Turn the ignition switch OFF. (7) Disconnect the intelligent tester from the DLC3. (b) When not using an intelligent tester. (1) Warm up and stop the engine. (2) Install SST to terminal 9 (TAC) of the DLC3, then connect a tachometer. DLC3 SST 09843-18040 NOTICE: Examine the terminal numbers before12345678connecting them. Connecting the wrong terminals could damage the engine. E 9 10111213141516 (3) Turn the ignition switch ON. (4) Inspect the engine idling speed.

TAC

A082779E24 Idling speed: 550 to 650 rpm for manual transaxle 650 to 750 rpm for automatic transaxle (5) Turn the ignition switch OFF. (6) Disconnect the tachometer. (7) Remove SST from terminal 9 (TAC). 8. INSPECT COMPRESSION (a) Warm up and stop the engine. (b) Remove cylinder head cover No. 2 (see page IG-9). (c) Remove the 4 ignition coils (see page IG-9). (d) Remove the 4 spark plugs. (e) Disconnect the 4 fuel injector connectors. (f) Inspect the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression: 1,471kPa (15.0 kgf/cm2, 213 psi) Minimum pressure: A116195 1,079 kPa (11.0 kgf/cm2, 156 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less NOTICE: • Use a fully-charged battery so the engine speed can be increased to 250 rpm or more. • Inspect the other cylinders in the same way. • Measure the compression in as short a time as possible., EM–4 1NZ-FE ENGINE MECHANICAL – ENGINE

EM

(4) If the cylinder compression is low, pour a light coat of engine oil into the cylinder through the spark plug hole, then inspect it again. HINT: • If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. • If the pressure stays low, the valve may be stuck or seated improperly, or there may be leakage from the gasket. (g) Connect the 4 fuel injector connectors. (h) Install the 4 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) (i) Install the 4 ignition coils (see page IG-9). (j) Install cylinder head cover No. 2 (see page IG-10). 9. INSPECT CO/HC (a) Start the engine. (b) Run the engine at 2,500 rpm for approximately 180 seconds. (c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe while idling. (d) Check the CO/HC concentration during idling and when running at 2,500 rpm. HINT: When doing the 2 mode (with the engine idling/ running at 2,500 rpm) test, the measuring procedures are determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below. (1) Check the heated oxygen sensor operation (see page ES-276). (2) See the table below for possible causes, then inspect the applicable parts and repair them if necessary. CO HC Problems Possible Causes Normal High Rough idling 1. Faulty ignition: – Incorrect timing – Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leakage from intake and exhaust valves 4. Leakage from cylinders Low High Rough idling 1. Vacuum leaks: (Fluctuating HC reading) – PCV hoses – Intake manifold – Throttle body – Brake booster line 2. Lean mixture causing misfire High High Rough idling 1. Restricted air cleaner filter element (Black smoke from exhaust) 2. Plugged PCV valve 3. Faulty EFI systems: – Faulty pressure regulator – Faulty engine coolant temperature sensor – Faulty mass air flow meter – Faulty ECM – Faulty injectors – Throttle body, 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–5

M DE1NZG-IFNEE ENGINRE MECHANICIAL VE BELT COMPONENTS E

ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115143E01,

EM–6 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM

19 (189, 14) 54 (551, 40) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A116199E01, 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–7

M REMOVAL

1. REMOVE ENGINE UNDER COVER RH 2. REMOVE FAN AND GENERATOR V BELT (a) Loosen bolts A and B. A (b) Release the fan and generator V belt tension and remove the fan and generator V belt.

B

A116197E01

INSPECTION

1. INSPECT FAN AND GENERATOR V BELT E (a) Visually check the belt for excessive wear, frayed cords etc. If any defects are found, replace the belt. HINT: • If any defects are found, replace the belt. • Cracks on the rib side of a belt are considered acceptable. If the belt has pieces missing from the ribs, it should be replaced. B000543, EM–8 1NZ-FE ENGINE MECHANICAL – DRIVE BELT

EM INSTALLATION

1. INSTALL FAN AND GENERATOR V BELT (a) Provisionally install the fan and generator V belt onto each pulley. NOTICE: Make sure that the V-belt is securely fitted into the rib groove of the pulley. 2. ADJUST FAN AND GENERATOR V BELT (a) Insert an adjusting bar between the engine

NG

mounting bracket and generator assembly. Push the adjusting bar toward the vehicle front to adjust the generator V belt tension. OK NOTICE: Do not insert the adjusting bar between the camshaft timing oil control valve assembly and generator assembly. It could damage the A116198E01 camshaft timing oil control valve assembly. (b) First tighten bolt A, then tighten bolt B. Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) for boltAA54 N*m (551 kgf*cm, 40 ft.*lbf) for bolt B

B

A116197E01 3. INSPECT FAN AND GENERATOR V BELT w/o Air Conditioner (a) Check the V belt deflection and tension. Deflection Item Specified Condition New belt 7.0 to 8.5 mm (0.28 to 0.33 in) Used belt 11 to 13 mm (0.43 to 0.51 in) Tension Item Specified Condition New belt 539 to 637 N (55 to 65 kg, 121 to 143 ld) w/ Air Conditioner Used belt 245 to 392 N (25 to 40 kg, 55 to 88 ld) If the belt deflection is not as specified, adjust it. HINT: • Check the V belt deflection at the specified point. • Check the drive belt deflection at the specified point. • When installing a new belt, set its tension to the specified value. • When inspecting a belt which has been used for A116200E01 over 5 minutes, apply the used belt specifications., 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–9

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• When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the intermediate values of each used belt specification. • V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking. • When using a belt tension gauge, confirm its accuracy by using a master gauge first. 4. INSTALL ENGINE UNDER COVER RH

E

, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–9

M VALVE CLEARANCE ADJUSTMENT

1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

2. REMOVE ENGINE UNDER COVER RH 3. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 4. REMOVE IGNITION COIL NO. 1 (See page IG-9) 5. DISCONNECT VENTILATION HOSE (See page FU-13) 6. DISCONNECT VENTILATION HOSE NO. 2 (See page FU-13) E 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) 8. INSPECT VALVE CLEARANCE HINT: Inspect the valve clearance when the engine is cold. (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01 (b) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) for exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) A116201, EM–10 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

EM

(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. (c) Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark "0" of the oil pump. (d) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) for exhaust: 0.25 to0.35 mm (0.010 to 0.014 in.) (2) Record any out-of-specification valve clearance A116202 measurements. They will be used later to determine the required replacement adjusting shim. 9. ADJUST VALVE CLEARANCE Matchmark NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves. (a) Remove the fan and generator V belt (See page A116206E01 EM-7). (b) Remove the engine mounting insulator sub- assembly RH (See page LU-17). (c) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–11

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(d) Place paint marks on the chain in the places where Paint Marks the timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Timing Marks A116207E01 (e) Using an 8 mm hexagon wrench, remove the screw plug.

E

G100163 (f) Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward. Stopper Plate A116209E01 (g) Using a wrench, rotate camshaft No. 2 clockwise to push in the plunger of the chain tensioner. Plunger A116210E01, EM–12 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

EM

(h) Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and inserta3mm (0.12 in.) diameter bar into the holes to hold the stopper plate. HINT: • Fix the stopper plate using the bar while rotating the camshaft right and left slightly. • Hold the bar with tape so that the bar does not come off. A116212 (i) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and remove the fringe bolt. A116213 (j) Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown13542in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. A116214E01 (k) Remove the fringe bolt and remove the camshaft timing sprocket. A116215, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–13

M

(l) Remove camshaft No. 2. A116216 (m) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2. NOTICE: E Loosen each bolt uniformly while keeping the camshaft level. 2431A116217E01 (n) Hold the chain by hand and remove the camshaft and the camshaft timing gear assembly. A116218 (o) Tie the chain with a piece of string as shown in the illustration. (p) Remove the 16 valve lifters. A035227E01 (q) Using a micrometer, measure the thickness of the removed lifter. (r) Calculate the thickness of a new lifter so that the valve clearance comes to within the specified values. A Thickness of new lifter B Thickness of used lifter C Measured valve clearance A001082, EM–14 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

EM

Valve clearance: Intake A = B + (C - 0.20 mm (0.008 in.)) Exhaust A = B + (C - 0.30 mm (0.012 in.)) (s) Select a new lifter with a thickness as close to the calculated values as possible. HINT: Lifters are available in 35 sizes in increments of 0.020mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.)., 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–15

M E

A117457,

EM–16 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM Intake valve clearance (cold):

0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE: A 5.250 mm (0.2067 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700(0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173), 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–17

M E

A117458,

EM–18 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE: A 5.340 mm (0.2102 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) (t) Install the selected valve lifter. (u) Apply a light coat of engine oil to the camshaft and camshaft journals. (v) Install the chain onto the camshaft timing gear with Paint Mark the paint mark and the timing mark aligned as shown in the illustration. Timing Mark A116220E01 (w) Examine the front marks and the numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.

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

camshaft level. 3124A116222E01, 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–19

M

(x) Install camshaft No. 2. A116216 (y) Hold the chain, and align the timing mark on the Paint Mark camshaft timing sprocket with the paint mark of the chain. (z) Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and E install the sprocket onto the camshaft. Timing Mark Pin A116224E01 (aa) Provisionally install the flange bolt. A116215 (ab) Examine the front marks and the numbers of3124camshaft bearing cap No. 1 and camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps, in the sequence shown in the 5 illustration. Torque: for bearing cap No. 2 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the Bearing Cap No. 1 Bearing Cap No. 2 camshaft level. A116223E01, EM–20 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE

EM

(ac) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and install the flange bolt. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) SST 09023-38400 (ad) Remove the bar from the timing chain tensioner.

SST

A116225E01 (ae) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (af) Check that all the pairs of timing marks are aligned. Paint Marks (ag) Apply adhesive to the 2 or 3 threads of the screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Timing Marks A116207E01 (ah) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) (ai) Install the engine mounting insulator sub-assembly RH (See page LU-26). (for Hatchback) (aj) Install the engine mounting insulator sub-assembly RH (See page LU-26). (for Sedan) (ak) Install the fan and generator V belt (See page EM- 7). G100163 (al) Adjust the fan and generator V belt (See page EM- 7). (am)Inspect the fan and generator V belt (See page EM- 8). 10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 11. CONNECT VENTILATION HOSE NO. 2 (See page FU- 20) 12. CONNECT VENTILATION HOSE (See page FU-20) 13. INSTALL IGNITION COIL NO. 1 (See page IG-9), 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–21

M

14. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 15. CHECK FOR ENGINE OIL LEAKAGE 16. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 17. INSTALL ENGINE UNDER COVER RH

E

,

EM–22 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

E1TNZG-IFNEE ENGIINE MMECHANICAL ING CHAIN

COMPONENTS

ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115143E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–23

M

7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2 7.0 (71, 62 in.*lbf)

E

N*m (kgf*cm, ft.*lbf) : Specified torque A115136E01,

EM–24 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

19 (189, 14) 54 (551, 40) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A116199E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–25

M

for Hatchback: 11 (112, 8.1) FAN BELT ADJUSTING BAR 19 (189, 14) 54 (551, 40) 52 (530, 38) GENERATOR x2 ASSEMBLY E 45 (459, 33) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft.*lbf) : Specified torque A116193E06,

EM–26 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

for Sedan: 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR 54 (551, 40) 52 (530, 38) GENERATOR x2

ASSEMBLY

52 (530, 38) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR 52 (530, 38) SUB-ASSEMBLY RH N*m (kgf*cm, ft*lbf) : Specified torque A133594E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–27

M

9.0 (92, 80 in.*lbf)

E

IGNITION COIL NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A115486E01,

EM–28 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

13 (133, 9.6) WIRE HARNESS BRACKET 10 (102, 7.0) SEAL WASHER 10 (102, 7.0) x7 10 (102, 7.0) 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY VENTILATION HOSE NO. 2 VENTILATION HOSE CYLINDER HEAD COVER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A115504E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–29

M E GASKET

11 (112, 8.1) x2 x3 x3 WATER PUMP ASSEMBLY 15 (153, 11) 11 (112, 8.1) WATER PUMP PULLEY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116194E01,

EM–30 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

CAMSHAFT TIMING OIL O-RING CONTROL VALVE ASSEMBLY 7.5 (76, 66 in.*lbf) 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116180E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–31

M

TRANSVERSE ENGINE ENGINE MOUNTING BRACKET x4 55 (561, 41)

E

24 (245, 18) 32 (326, 24) x2 24 (245, 18) x11 11 (112, 8.1) OIL PUMP ASSEMBLY 7.5 (76, 66 in.*lbf) 11 (112, 8.1)

CRANKSHAFT

POSITION SENSOR 128 (1305, 95) OIL PUMP SEAL CRANKSHAFT DAMPER SUB-ASSEMBLY CRANKSHAFT STRAIGHT PIN O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A116559E01,

EM–32 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM

CHAIN TENSIONER ASSEMBLY NO. 1 9.0 (92, 80 in.*lbf) CHAIN SUB-ASSEMBLY CHAIN TENSIONER

SLIPPER

9.0 (92, 80 in.*lbf) CHAIN VIBRATION DAMPER NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A116579E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–33

M REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

2. REMOVE FRONT WHEEL RH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE OIL 5. DRAIN ENGINE COOLANT (See page CO-8) 6. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 7. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 8. REMOVE GENERATOR ASSEMBLY (See page CH-10) E 9. REMOVE IGNITION COIL NO. 1 (See page IG-9) 10. DISCONNECT VENTILATION HOSE (See page FU-13) 11. DISCONNECT VENTILATION HOSE NO. 2 (See page FU-13) 12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) 13. REMOVE ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-17) 14. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-18) 15. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-403) 16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-396) 17. REMOVE WATER PUMP PULLEY (See page CO-15) 18. REMOVE WATER PUMP ASSEMBLY (See page CO- 15) 19. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page LU-18) 20. REMOVE OIL PUMP ASSEMBLY (See page LU-19) 21. REMOVE OIL PUMP SEAL (See page LU-21) 22. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 NOTICE: • Do not rotate the crankshaft with the chain tensioner removed. • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first., EM–34 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM

(a) Pull up the stopper plate and hold it with its lock released. Stopper Plate A116564E01 (b) Unlock the plunger of the tensioner and push it in to the end. Plunger A116565E01 (c) Pull down the stopper plate with the plunger pushed to the end and lock the plunger. Stopper Plate A116566E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–35

M

(d) Inserta3mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger. A116567 E (e) Remove the 2 bolts and remove chain tensioner assembly No. 1. A116568 23. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the chain tensioner slipper. A116569 24. REMOVE CHAIN VIBRATION DAMPER NO. 1 (a) Remove the 2 bolts and remove chain vibration damper No. 1. 25. REMOVE CHAIN SUB-ASSEMBLY A116570, EM–36 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM INSPECTION

1. INSPECT CHAIN SUB-ASSEMBLY (a) Using a spring scale, apply 140 N (14.3 kgf, 31.5 lb) to the timing chain and measure its length. Maximum chain elongation: 123.2 mm (4.850 in.) If the elongation is greater than the maximum, replace the chain. HINT: A050062 Perform the same measurement at 3 or more random places and calculate the average length.

INSTALLATION

TDC: 1. INSTALL CHAIN SUB-ASSEMBLY Timing Marks (a) Make sure that all the timing marks are in the positions (TDC) shown in the illustration. HINT: The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring. Timing Mark A116571E01 (b) Set the timing mark of the crankshaft in a position Timing Mark between 40 and 140°ATDC as illustrated. 40° to 140° ATDC A116573E01, 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–37

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(c) Set the camshaft timing gear and the camshaft 20° ATDC: timing sprocket in the positions ( 20°ATDC) shown Timing Marks in the illustration. (d) Set the crankshaft in the position ( 20°ATDC) shown in the illustration.

E

30° Timing Mark A116574E01 (e) Install chain vibration damper No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116576, EM–38 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN

EM

(f) Align the timing marks of the camshaft with the mark Mark Plates plates of the timing chain and install the timing chain. HINT: Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench. Timing Marks Mark Plate Timing Mark A116577E01 2. INSTALL CHAIN TENSIONER SLIPPER (a) Install the chain tensioner slipper. A116569 3. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 (a) Install chain tensioner assembly No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Remove the bar from chain tensioner assembly No. 1. 4. INSTALL OIL PUMP SEAL (See page LU-21) 5. INSTALL OIL PUMP ASSEMBLY (See page LU-22) A116568 6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page LU-26) 7. INSTALL WATER PUMP ASSEMBLY (See page CO- 16) 8. INSTALL WATER PUMP PULLEY (See page CO-16) 9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-397) 10. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-403), 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–39

M

11. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-26) 12. INSTALL ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-26) 13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 14. CONNECT VENTILATION HOSE NO. 2 (See page FU- 20) 15. CONNECT VENTILATION HOSE (See page FU-20) 16. INSTALL IGNITION COIL NO. 1 (See page IG-9) 17. INSTALL GENERATOR ASSEMBLY (See page CH-17) 18. INSTALL FAN AND GENERATOR V BELT (See page EM-7) E 19. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 20. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 21. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 22. ADD ENGINE OIL 23. ADD ENGINE COOLANT (See page CO-8) 24. CHECK ENGINE OIL LEVEL (See page LU-1) 25. CHECK FOR ENGINE OIL LEAKAGE 26. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-1) 27. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 28. INSTALL ENGINE UNDER COVER RH 29. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf),

EM–40 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

E1CNZG-IFNEE ENGINAE MECHANICMAL SHAFT

COMPONENTS ENGINE UNDER COVER RH

5.0 (51, 44 in.*lbf)

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

A115143E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–41

M

7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2 7.0 (71, 62 in.*lbf)

E

N*m (kgf*cm, ft.*lbf) : Specified torque A115136E01,

EM–42 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

for Hatchback: 52 (530, 38) x2 45 (459, 33) 45 (459, 33) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft.*lbf) : Specified torque A116232E04, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–43

M

for Sedan: 52 (530, 38) x2 52 (530, 38) 52 (530, 38) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

E

52 (530, 38) N*m (kgf*cm, ft*lbf) : Specified torque A133595E01,

EM–44 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

9.0 (92, 80 in.*lbf) IGNITION COIL NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A115486E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–45

M

13 (133, 9.6) WIRE HARNESS BRACKET 10 (102, 7.0) SEAL WASHER

E

10 (102, 7.0) x7 10 (102, 7.0) 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY VENTILATION HOSE NO. 2 VENTILATION HOSE CYLINDER HEAD COVER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A115504E01,

EM–46 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM

x16 13 (129, 9.4) 23 (235, 17) CAMSHAFT BEARING CAP NO. 2 CAMSHAFT BEARING CAP NO. 1 x8 CAMSHAFT TIMING NO. 2 CAMSHAFT

SPROCKET CAMSHAFT

64 (653, 47) 64 (653, 47) CAMSHAFT TIMING GEAR ASSEMBLY 15 (153, 11) N*m (kgf*cm, ft.*lbf) : Specified torque A116233E02, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–47

M REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

2. REMOVE ENGINE UNDER COVER RH 3. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 4. REMOVE IGNITION COIL NO. 1 (See page IG-9) 5. DISCONNECT VENTILATION HOSE (See page FU-13) 6. DISCONNECT VENTILATION HOSE NO. 2 (See page FU-13) 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) E 8. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 9. REMOVE ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-17) 10. REMOVE NO. 2 CAMSHAFT Matchmark NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40 ° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves. A116206E01 (a) Set the No. 1 cylinder to TDC / compression. (1) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that the timing marks on both the camshaft timing sprocket and the camshaft timing gear are facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01, EM–48 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(b) Place paint marks on the chain in the places where Paint Marks the timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Timing Marks A116207E01 (c) Using an 8 mm hexagon wrench, remove the screw plug. G100163 (d) Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward. Stopper Plate A116209E01 (e) Using a wrench, rotate camshaft No. 2 clockwise to push in the plunger of the chain tensioner. Plunger A116210E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–49

M

(f) Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and inserta3mm (0.12 in.) diameter bar into the holes to hold the stopper plate. HINT: • Fix the stopper plate using the bar while rotating the camshaft right and left slightly. • Hold the bar with tape so that it does not come off. A116212 E (g) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and remove the flange bolt. A116213 (h) Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown13542in the illustration, then remove camshaft bearing caps No. 1 and No. 2. NOTICE: Loosen the bolts uniformly while keeping the camshaft level. A116214E01 (i) Remove the flange bolt and remove the camshaft timing sprocket. A116215, EM–50 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(j) Remove camshaft No. 2. A116216 11. REMOVE CAMSHAFT (a) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the2431camshaft level. A116217E01 (b) Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly. A116218 (c) Tie the chain with a piece of string as shown in the illustration. 12. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (a) Clamp the camshaft in a vise and confirm that it is locked. NOTICE: Do not damage the camshaft. A035227E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–51

M

(b) Cover the 4 oil paths of the cam journal with tape as Retard Side shown in the illustration. Paths HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil Advance paths. Plug one of the oil paths for each groove with Side Paths a piece of rubber before wrapping the cam journal with the tape. (c) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed E Open Vinyl Tape Rubber Piece A116226E04 (d) Apply air at about 150 kPa (1.5 kgf*cm2) pressure Retard Advance into the 2 broken paths (the advance side path and Side Path Side Path the retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02 (e) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. HINT: Retard Advance Side Path Side Path The lock pin is released, and the camshaft timing gear revolves in the advance direction. (f) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. NOTICE: The camshaft timing gear assembly Decompress Hold Pressure occasionally shifts to the retard side abruptly, if the air pressure on the advance side path is released first. This often results in breakage of A116228E02 the lock pin., EM–52 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(g) Remove the flange bolt and remove the camshaft timing gear assembly. NOTICE: • Do not remove the other 4 bolts. • When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first. Flange Bolt A116229E01, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–53

M INSPECTION

1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Check the lock of camshaft timing gear. (1) Clamp the camshaft in a vice, and check that the camshaft timing gear is locked. NOTICE: Do not damage the camshaft. (b) Release the lock pin. Retard Side (1) Cover the 4 oil paths of the cam journal with Paths tape as shown in the illustration. HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and Advance the other is for advancing cam timing (lower). Side Paths Each groove has 2 oil paths. Plug one of the oil E paths for each groove with a piece of rubber before wrapping the cam journal with the tape. (2) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed Open Vinyl Tape Rubber Piece A116226E05 (3) Apply air at about 150 kPa (1.5kgf*cm2) Retard Advance pressure into the 2 broken paths (the advance Side Path Side Path side path and the retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02, EM–54 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(4) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. Retard Advance Side Path Side Path HINT: The lock pin is released and the camshaft timing gear revolves in the advance direction. (5) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. Decompress Hold Pressure NOTICE: Camshaft timing gear assembly occasionally shifts to the retard side A116228E02 abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock pin. (c) Check the revolution. (1) Rotate the valve timing assembly back and forth several times, except where the lock pin meets it at the most retarded angle. Check the movable range and that it rotates smoothly. Standard: Smooth movable range is about 22.5° NOTICE: Perform this check by hand, instead of using air pressure. (d) Check that the gear locks in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked in the most retarded position., 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–55

M INSTALLATION

1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY NOTICE: Install the camshaft timing gear assembly onto the camshaft with the lock pin of the camshaft timing gear assembly released. (a) Put the camshaft timing gear assembly and camshaft together with the straight pin of the Straight Pin groove. (b) Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits the groove, push to ensure a good fit. NOTICE: Do not turn the camshaft timing gear in the Groove retard direction (clockwise). E A116230E01 (c) Check that there is no clearance between the gear flange and the camshaft. (d) Tighten the flange bolt with the camshaft timing gear fixed. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: • Do not lock the camshaft timing gear assembly when tightening the bolt. • Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position. • Tightening the bolts with the lock pin locked could cause breakage of the lock pin. (e) Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position. 2. INSTALL CAMSHAFT (a) Apply a light coat of engine oil to the camshaft and camshaft journals. (b) Install the chain onto the camshaft timing gear with Paint Mark the paint mark and the timing mark aligned as shown in the illustration. Timing Mark A116220E01, EM–56 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(c) Examine the front marks and numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the camshaft level. 3124A116222E01 3. INSTALL NO. 2 CAMSHAFT (a) Install camshaft No. 2. A116216 (b) Hold the chain and align the timing mark on the Paint Mark camshaft timing sprocket with the paint mark of the chain. (c) Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft. Timing Mark Pin A116224E01 (d) Provisionally install the flange bolt. A116215, 1NZ-FE ENGINE MECHANICAL – CAMSHAFT EM–57

M

(e) Examine the front marks and numbers on camshaft3124bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration. 5 Torque: for bearing cap No. 2 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the camshaft level. Bearing Cap No. 1 Bearing Cap No. 2 A116223E01 E (f) Using a wrench, hold the hexagonal lobe of camshaft No. 2 and install the flange bolt. SST 09023-38400 Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) (g) Remove the bar from the timing chain tensioner.

SST

A116225E01 (h) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01 (i) Check that all the pairs of timing marks are aligned. Paint Marks (j) Apply adhesive to the end 2 or 3 threads of the screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Timing Marks A116207E01, EM–58 1NZ-FE ENGINE MECHANICAL – CAMSHAFT

EM

(k) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 4. INSPECT VALVE CLEARANCE (See page EM-9) 5. ADJUST VALVE CLEARANCE (See page EM-10) 6. INSTALL ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-26) G100163 7. INSTALL FAN AND GENERATOR V BELT (See page EM-7) 8. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 9. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 11. CONNECT VENTILATION HOSE NO. 2 (See page FU- 20) 12. CONNECT VENTILATION HOSE (See page FU-20) 13. INSTALL IGNITION COIL NO. 1 (See page IG-9) 14. CONNECT CABLE TO NEGATIVE BATTERY

TERMINAL

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 15. CHECK FOR ENGINE OIL LEAKAGE 16. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 17. INSTALL ENGINE UNDER COVER RH, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–57

M CE1NZG-IFNEE ENGINYE MECHANILCAL INDER HEAD COMPONENTS

for Hatchback: FRONT WIPER ARM HEAD CAP FRONT WIPER ARM AND BLADE ASSEMBLY LH FRONT WIPER ARM HEAD CAP 26 (265, 19) FRONT WIPER ARM AND BLADE ASSEMBLY RH 26 (265, 19) COWL TOP VENTILATOR LOUVER CENTER NO. 1 E

CLIP

COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

CLIP CLIP

HOOD TO COWL TOP SEAL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 COWL TOP VENTILATOR LOUVER LH 6.5 (66, 58 in.*lbf) FRONT WIPER MOTOR AND LINK x9 5.5 (56, 49 in.*lbf) COWL TOP PANEL OUTER N*m (kgf*cm, ft*lbf) : Specified torque A118803E10,

EM–58 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

for Sedan: FRONT WIPER FRONT WIPER ARM AND ARM HEAD CAP BLADE ASSEMBLY LH FRONT WIPER ARM AND BLADE ASSEMBLY RH FRONT WIPER ARM HEAD CAP COWL SIDE VENTILATOR SUB-ASSEMBLY RH 26 (265, 19) 26 (265, 19) X3

CLIP

COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY FRONT AIR SHUTTER SEAL COWL SIDE VENTILATOR 5.5 (56, 49 in.*lbf) SUB-ASSEMBLY LH X2 WINDSHIELD WIPER MOTOR AND LINK X8 6.5 (66, 58 in.*lbf) COWL TOP PANEL OUTER 6.5 (66, 58 in.*lbf) CENTER BRACKET COWL TOP PANEL OUTER N*m (kgf*cm, ft.*lbf) : Specified torque A133320E03, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–59

M E

ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115143E01,

EM–60 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2 7.0 (71, 62 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A115136E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–61

M

VENTILATION HOSE NO. 2 FUEL VAPOR FEED HOSE NO. 1 FUEL VAPOR FEED HOSE NO. 2

E

AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 A133592E01,

EM–62 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

19 (189, 14) 54 (551, 40) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A116199E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–63

M

BATTERY CLAMP SUB-ASSEMBLY

BATTERY E

BATTERY TRAY HEATED OXYGEN SENSOR BRACKET BOOSTER VACUUM TUBE FUEL TUBE SUB-ASSEMBLY WATER FILLER SUB-ASSEMBLY FUEL TUBE SUB-ASSEMBLY 7.5 (76, 66 in.*lbf) x2 x3 44 (449, 33) RADIATOR HOSE NO. 3 MANIFOLD SUPPORT BRACKET RESERVE TANK HOSE x2 43 (438, 32) GASKET EXHAUST PIPE ASSEMBLY FRONT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116961E01,

EM–64 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

for Hatchback: 11 (112, 8.1) FAN BELT ADJUSTING BAR 19 (189, 14) 54 (551, 40) 52 (530, 38) GENERATOR x2

ASSEMBLY

45 (459, 33) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft.*lbf) : Specified torque A116193E06, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–65

M

for Sedan: 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR 54 (551, 40) 52 (530, 38) GENERATOR x2 E

ASSEMBLY

52 (530, 38) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR 52 (530, 38) SUB-ASSEMBLY RH N*m (kgf*cm, ft*lbf) : Specified torque A133594E01,

EM–66 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

9.0 (92, 80 in.*lbf) IGNITION COIL NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A115486E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–67

M

13 (133, 9.6) WIRE HARNESS BRACKET 10 (102, 7.0) SEAL WASHER

E

10 (102, 7.0) x7 10 (102, 7.0) 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY VENTILATION HOSE NO. 2 VENTILATION HOSE CYLINDER HEAD COVER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A115504E01,

EM–68 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM GASKET

11 (112, 8.1) x2 x3 x3 WATER PUMP ASSEMBLY 15 (153, 11) 11 (112, 8.1) WATER PUMP PULLEY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116194E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–69

M

CAMSHAFT TIMING OIL O-RING CONTROL VALVE ASSEMBLY

E

7.5 (76, 66 in.*lbf) 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116180E01,

EM–70 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

TRANSVERSE ENGINE ENGINE MOUNTING BRACKET x4 55 (561, 41) 24 (245, 18) 32 (326, 24) x2 24 (245, 18) x11 11 (112, 8.1) OIL PUMP ASSEMBLY 7.5 (76, 66 in.*lbf) 11 (112, 8.1)

CRANKSHAFT

POSITION SENSOR 128 (1305, 95) OIL PUMP SEAL CRANKSHAFT DAMPER SUB-ASSEMBLY CRANKSHAFT STRAIGHT PIN O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A116559E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–71

M

CHAIN TENSIONER ASSEMBLY NO. 1 9.0 (92, 80 in.*lbf)

E

CHAIN SUB-ASSEMBLY CHAIN TENSIONER

SLIPPER

9.0 (92, 80 in.*lbf) CHAIN VIBRATION DAMPER NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A116579E01,

EM–72 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

UNION TO CONNECTOR TUBE HOSE 30 (306, 22) x3 VENTILATION HOSE INTAKE MANIFOLD TO HEAD GASKET NO. 1 WATER BY-PASS INTAKE MANIFOLD HOSE 30 (306, 22) x2 WATER BY-PASS HOSE NO. 2 OIL LEVEL GAUGE SUB-ASSEMBLY OIL LEVEL GAUGE GUIDE 9.0 (92, 80 in.*lbf) O-RING N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A121463E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–73

M

x16 x3 13 (129, 9.4) 23 (235, 17) CAMSHAFT BEARING CAP NO. 2 CAMSHAFT BEARING CAP NO. 1 NO. 2 CAMSHAFT

CAMSHAFT E

1st: 29 (300, 22) x10 2nd: Turn 90° PLATE WASHER 3rd: Turn 90° HEATER WATER INLET HOSE A CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET 9.0 (92, 80 in.*lbf) WATER BY-PASS PIPE NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116963E01,

EM–74 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

x4 8.0 (82, 71 in.*lbf) EXHAUST MANIFOLD HEAT INSULATOR NO. 1 EXHAUST MANIFOLD TO HEAD GASKET EXHAUST MANIFOLD x3 27 (275, 20) x2 27 (275, 20) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116967E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–75

M

19 (194, 14) x2 DELIVERY PIPE NO. 1 SPACER x2 FUEL DELIVERY PIPE SUB-ASSEMBLY 9.0 (92, 80 in.*lbf)

E

O-RING BOOSTER VACUUM TUBE FUEL INJECTOR ASSEMBLY x4 INJECTOR VIBRATION INSULATOR 9.0 (92, 80 in.*lbf) HARNESS BRACKET 13 (131, 9.5)

GASKET

13 (131, 9.5) 20 (204, 15) HARNESS BRACKET ENGINE COOLANT TEMPERATURE SENSOR WATER BY-PASS HOSE CAMSHAFT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 8.0 (82, 71 in.*lbf) A116965E01,

EM–76 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM

x8 x8 VALVE LIFTER x8 x8 RETAINER LOCK x8 x8

RETAINER

x8 x8 VALVE SPRING VALVE STEM OIL SEAL x8 x8 x8 x8 VALVE SPRING SEAT x8 x8 INTAKE VALVE GUIDE BUSH EXHAUST VALVE GUIDE

BUSH

44 (449, 33) WITH HEAD TAPER SCREW PLUG NO. 1 CAMSHAFT BEARING CAP RING PIN GASKET 4.0 (41, 35in.*lbf) STUD BOLT 9.0 (92, 80in.*lbf) STUD BOLT 10 (102, 7.4) STUD BOLT 10 (102, 7.4) STUD BOLT OIL CONTROL VALVE FILTER

GASKET

30 (306, 22) WITH HEAD TAPER SCREW PLUG NO. 2 INTAKE VALVE EXHAUST VALVE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117451E03, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–77

M REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE (See Page FU-1) 2. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINAL

3. REMOVE FRONT WIPER ARM HEAD CAP (for Hatchback) (See page WW-17) 4. REMOVE FRONT WIPER ARM HEAD CAP (for Sedan) (See page WW-9) 5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) (See page WW-17) 6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) (See page WW-9) E 7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) (See page WW-17) 8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) (See page WW-9) 9. REMOVE HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-18) 10. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-18) 11. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-18) 12. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-10) 13. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-10) 14. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Sedan) (See page WW-10) 15. REMOVE FRONT WIPER MOTOR AND LINK (for Hatchback) (See page WW-19) 16. REMOVE FRONT WIPER MOTOR AND LINK (for Sedan) (See page WW-10) 17. REMOVE COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (See page EM-122) 18. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan) (See page ES-432) 19. REMOVE COWL TOP PANEL OUTER (for Hatchback) (See page EM-123) 20. REMOVE COWL TOP PANEL OUTER (for Sedan) (See page ES-432) 21. REMOVE BATTERY 22. REMOVE BATTERY TRAY 23. REMOVE FRONT WHEEL RH, EM–78 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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24. REMOVE ENGINE UNDER COVER RH 25. DRAIN ENGINE OIL 26. DRAIN ENGINE COOLANT (See page CO-8) 27. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 (See page ES-410) 29. DISCONNECT RADIATOR HOSE NO. 3 (a) Disconnect radiator hose No. 3. A116580 30. DISCONNECT RESERVE TANK HOSE (a) Disconnect the reserve tank hose. A116581 31. REMOVE WATER FILLER SUB-ASSEMBLY (a) Separate radiator hose No. 1 from the cylinder head. (b) Remove the 2 nuts and remove the water filler sub- assembly. A116739 32. DISCONNECT WATER BY-PASS HOSE NO. 2 (a) Disconnect water by-pass hose No. 2. A116740, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–79

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33. DISCONNECT WATER BY-PASS HOSE (a) Disconnect the water by-pass hose. A116741 34. DISCONNECT THROTTLE WITH MOTOR BODY

CONNECTOR

(a) Separate the wire harness clamp. (b) Remove the nut and separate the throttle with motor body connector. E A116742 35. DISCONNECT VENTILATION HOSE (a) Disconnect the ventilation hose. A116973 36. DISCONNECT UNION TO CONNECTOR TUBE HOSE (a) Disconnect the union to connector tube hose. 37. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY A116744 38. REMOVE INTAKE MANIFOLD (a) Separate the 3 wire harness clamps shown in the illustration. A116745, EM–80 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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(b) Remove the 3 bolts and 2 nuts and remove the intake manifold. A116746 39. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the wire harness clamp and the bolt and remove the oil level gauge guide. 40. DISCONNECT FUEL TUBE SUB-ASSEMBLY (See page FU-14) A116747 41. DISCONNECT BOOSTER VACUUM TUBE (a) Disconnect the booster vacuum tube. A116748 42. DISCONNECT CAMSHAFT POSITION SENSOR

CONNECTOR

(a) Disconnect the camshaft position sensor connector. A116749 43. DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR (a) Disconnect the engine coolant temperature sensor connector. A116750, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–81

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44. DISCONNECT HEATED OXYGEN SENSOR

CONNECTOR

(a) Remove the bolts and separate the sensor bracket. (b) Disconnect the heated oxygen sensor connector. A116751 45. DISCONNECT HEATER WATER INLET HOSE A (a) Disconnect heater water inlet hose A.

E

A116752 46. SEPARATE WATER BY-PASS PIPE NO. 1 (a) Remove the bolt and separate water by-pass pipe No. 1. A116753 47. DISCONNECT WIRE HARNESS (a) Remove the 2 bolts and disconnect the wire harness. A116755 48. SEPARATE EXHAUST PIPE ASSEMBLY FRONT (a) Remove the 2 bolts and 2 compression springs and separate the exhaust pipe assembly front. A116756, EM–82 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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49. REMOVE MANIFOLD SUPPORT BRACKET (a) Remove the 3 bolts and remove the manifold support bracket. 50. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 51. REMOVE GENERATOR ASSEMBLY (See page CH-10) 52. REMOVE IGNITION COIL NO. 1 (See page IG-9) A116757 53. REMOVE VENTILATION HOSE (See page FU-13) 54. REMOVE VENTILATION HOSE NO. 2 (See page FU- 13) 55. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) 56. REMOVE ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-17) 57. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-18) 58. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-403) 59. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-396) 60. REMOVE WATER PUMP PULLEY (See page CO-15) 61. REMOVE WATER PUMP ASSEMBLY (See page CO- 15) 62. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page LU-17) 63. REMOVE OIL PUMP ASSEMBLY (See page LU-19) 64. REMOVE OIL PUMP SEAL (See page LU-21) 65. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 (See page EM-33) 66. REMOVE CHAIN TENSIONER SLIPPER (See page EM-35) 67. REMOVE CHAIN VIBRATION DAMPER NO. 1 (See page EM-35) 68. REMOVE CHAIN SUB-ASSEMBLY 69. REMOVE CAMSHAFT NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first., 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–83

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(a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration, and then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. (b) Remove the camshaft and camshaft No. 2. A035758E01 70. REMOVE CYLINDER HEAD SUB-ASSEMBLY (a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 plate washers. E NOTICE: • Do not drop the washers into the cylinder head. • Head warpage or cracking could result from A035286 removing the bolts in the wrong order. 71. REMOVE CYLINDER HEAD GASKET (a) Remove the cylinder head gasket. A116758 72. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (a) Remove the 4 bolts and remove exhaust manifold heat insulator No. 1. A116759 73. REMOVE EXHAUST MANIFOLD (a) Remove the 3 bolts and 2 nuts and remove the exhaust manifold. A116761, EM–84 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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74. REMOVE HARNESS BRACKET (a) Remove the bolt and remove the harness bracket. A116762 75. REMOVE BOOSTER VACUUM TUBE (a) Remove the 2 bolts and remove the booster vacuum tube. A116763 76. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and remove the camshaft position sensor. A116764 77. REMOVE ENGINE COOLANT TEMPERATURE

SENSOR

(a) Using SST, remove the engine coolant temperature sensor connector. SST 09817-33190

SST

A116765E01 78. REMOVE WATER BY-PASS HOSE (a) Remove the water by-pass hose. A116766, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–85

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79. REMOVE HARNESS BRACKET (a) Remove the bolt and remove the harness bracket. A116767 80. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors. NOTICE: Do not drop the fuel injectors when removing E the fuel delivery pipe sub-assembly. 81. REMOVE FUEL INJECTOR ASSEMMBLY (See page FU-16) A116768 82. REMOVE DELIVERY PIPE NO. 1 SPACER (a) Remove the 2 delivery pipe No. 1 spacers. A116955 83. REMOVE INJECTOR VIBRATION INSULATOR (a) Remove the 4 injector vibration insulators. A116956

DISASSEMBLY

1. REMOVE WITH HEAD TAPER SCREW PLUG NO. 1 (a) Using a 10 mm socket hexagon wrench, remove the taper screw plug and the gasket. 2. REMOVE VALVE LIFTER HINT: Keep the valve lifters in the correct order so that they can be returned to their original locations when reassembled. A062890E01, EM–86 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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3. REMOVE WITH HEAD TAPER SCREW PLUG NO. 2 (a) Using an 8 mm hexagon wrench, remove the taper screw plug. 4. REMOVE OIL CONTROL VALVE FILTER A038128E01 5. REMOVE INTAKE VALVE (a) Using SST, compress the valve spring and remove SST the 2 retainer locks, retainer and valve spring. SST 09202-70020 (09202-00010) HINT: Keep the valves, valve springs, spring seats and spring retainers in the correct order so that they can be returned to their original locations when reassembled. A037109E03 6. REMOVE EXHAUST VALVE (a) Using SST, compress the valve spring and remove the 2 retainer locks, retainer and valve spring. SST 09202-70020 (09202-00010) HINT: Keep the valves, valve springs, spring seats and spring retainers in the correct order so that they can be returned to their original locations when reassembled. 7. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seal. A080961E01 8. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seats. 9. REMOVE STUD BOLT (a) Using "Torx" socket wrenches E5 and E7, remove the 7 stud bolts. 10. REMOVE CAMSHAFT BEARING CAP SETTING RING

PIN

A080962E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–87

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1. INSPECT CYLINDER HEAD FOR WARPAGE (a) Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder block and the manifolds. Maximum warpage Surface Specified Condition Cylinder Block Side Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.10 mm (0.0039 in.) Exhaust manifold side 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace Intake Manifold Side the cylinder head.

E

Exhaust Manifold Side A050931E01 2. INSPECT CYLINDER HEAD FOR CRACKS (a) Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. A001071E01 3. INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the length of the Underhead Length head bolts from the seat to the end. Standard length: 142.8 to 144.2 mm (5.622 to 5.677 in.) Maximum length: 147.1 mm (5.791 in.) If the length is greater than the maximum, replace the bolt. A098332E01 4. INSPECT INTAKE VALVE (a) Check the overall valve length. Standard overall length: 89.25 mm (3.5138 in.) Minimum overall length: 88.75 mm (3.4941 in.) If the overall length is less than the minimum, replace the valve. EM02534E06, EM–88 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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(b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.970 to 4.985 mm (0.1957 to 0.1963 in.) Z000052E01 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, Margin Thickness replace the valve. 5. INSPECT EXHAUST VALVE (a) Check the overall valve length. EM00181E03 Standard overall length: 87.90 mm (3.4606 in.) Minimum overall length: 87.40 mm (3.4409 in.) If the overall length is less than the minimum, replace the valve. (b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.965 to 4.980 mm (0.1955 to 0.1961 in.) (c) Check the valve head margin thickness. Standard margin thickness: 1.15 mm (0.045 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. 6. INSPECT VALVE SPRING (a) Using vernier calipers, measure the free length of the valve spring. Standard free length: 45.05 to 45.15 mm (1.774 to 1.778 in.) If the free length is not as specified, replace the spring. EM00801E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–89

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(b) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring. EM00988E01 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Standard installed tension: 149 to 165 N (15.2 to 16.8 kgf, 33.5 to 37.1 lbf) at 32.5 mm (1.280 in.) E Maximum working tension: 286 to 316 N (29.1 to 32.2 kgf, 64.2 to 71.0 lbf) at 23.9 mm (0.941 in.) If the installed tension is not as specified, replace EM00281E01 the valve spring. 7. INSPECT VALVE GUIDE BUSH OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.010 to 5.030 mm (0.1972 to 0.1980 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement to calculate the oil clearance. Standard oil clearance A001478E02 Guide Bush Specified Condition Intake 0.025 to 0.060 mm(0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm(0.0012 to 0.0026 in.) Maximum oil clearance Guide Bush Specified Condition Intake 0.08 mm (0.0032 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see page EM- 92). 8. INSPECT INTAKE VALVE SEAT (a) Apply a light coat of prussian blue to the valve face. (b) Lightly press the valve against the seat., EM–90 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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(c) Check the valve face and seat in accordance with the following procedure. (1) If blue appears 360° around the face, the valve is concentric. If not, replace the valve. (2) If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface Width the seat. (3) Check that the seat contact is in the middle of the valve face with the width between 1.0 to 1.4 A050036E01 mm (0.039 to 0.055 in.). 9. INSPECT VALVE LIFTER (a) Using a micrometer, measure the lifter diameter. Standard lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) P016860E01 10. INSPECT VALVE LIFTER OIL CLEARANCE (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Standard lifter bore diameter: 31.000 to 31.025 mm (1.2205 to 1.2215 in.) (b) Subtract the lifter diameter measurement from the lifter bore diameter measurement to calculate the oil clearance. Standard oil clearance: A001080E01 0.024 to 0.059 mm (0.0009 to 0.0023 in.) Maximum oil clearance: 0.1 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 11. INSPECT CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. EM01628E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–91

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(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 44.617 to 44.717 mm (1.7566 to 1.7605 in.) Minimum cam lobe height: 43.16 mm (1.6992 in.) If the cam lobe height is less than the minimum, replace the camshaft. A037113E01 (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition E No. 1 journal 34.449 to 34.465 mm(1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm(0.9035 to 0.9041 in.) A037114E01 If the journal diameter is not as specified, check the oil clearance. 12. INSPECT NO. 2 CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 44.666 to 44.766 (1.7585 to 1.7624 in.) Minimum cam lobe height: 44.52 mm (1.7528 in.) If the cam lobe height is less than the minimum, replace the camshaft. (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition No. 1 journal 34.449 to 34.465 mm(1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm(0.9035 to 0.9041 in.) If the journal diameter is not as specified, check the oil clearance., EM–92 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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13. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshafts. (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head together. A001455E01 14. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps and the camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the Plastigage camshaft journals. (d) Install the bearing caps (see page EM-97). NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. A001452E01 (f) Measure the Plastigage at its widest point. Standard oil clearance: 0.035 to 0.072 mm (0.0014 to 0.0028 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head together. NOTICE: A001453E01 Completely remove the Plastigage after the measurement. 80 to 100°C (176 to 212°F) REPLACEMENT 1. REMOVE INTAKE VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). A001067E02, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–93

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(b) Using SST and a hammer, tap out the guide SST bushing. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 2. REMOVE EXHAUST VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Using SST and a hammer, tap out the guide bushing. A037110E02 SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 3. INSTALL INTAKE VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Inside Diameter: E 9.685 to 9.706 mm (0.3813 to 0.3821 in.) If the bushing bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bushing bore to the dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). A001445E01 Bushing bore diameter mm (in.) Bushing size 9.685 to 9.706 (0.3813 to 0.3821) STD 9.735 to 9.755 (0.3833 to 0.3841) O/S 0.05 (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Using SST and a hammer, tap a new guide bushing in to the specified protrusion height. SST SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) 9.0 to 9.4 mm A080977E02 (d) Using a sharp 5 mm reamer, ream the guide Reamer bushing to obtain the standard oil clearance between the guide bushing and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) 4. INSTALL EXHAUST VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Inside Diameter: A001447E02 9.685 to 9.706 mm (0.3813 to 0.3821 in.), EM–94 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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If the bushing bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bushing bore to the dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). Bushing bore diameter mm (in.) Bushing size 9.685 to 9.706 (0.3813 to 0.3821) STD 9.735 to 9.755 (0.3833 to 0.3841) O/S 0.05 (b) Heat the cylinder head to 80 to 100°C (176 to 212°F). (c) Using SST and a hammer, tap a new guide bushing in to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) (d) Using a sharp 5 mm reamer, ream the guide bushing to obtain the standard oil clearance between the guide bushing and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

REASSEMBLY

1. INSTALL CAMSHAFT BEARING CAP SETTING RING

PIN

(a) Using a plastic-faced hammer, tap a new ring pin in to the specified protrusion height. Protrusion height: 8.5 to 9.5 mm (0.335 to 0.374 in.) 2. INSTALL STUD BOLT (a) Using "Torx" socket wrenches E5 and E7, install the 7 stud bolts. 8.5 to 9.5 mm Torque: Stud bolt A: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) Stud bolt B: A080980E02 4.0 N*m (41 kgf*cm, 35 in.*lbf) Stud bolt C: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) Stud bolt D: 9.0 N*m (92 kgf*cm, 80 in.*lbf), 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–95

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28.5 19.5 26.5 22.5 43.5 38.5 49.5 37.5 12 12 13 13 Stud Bolt A Stud Bolt B Stud Bolt C Stud Bolt D [mm] A050180E03 3. INSTALL VALVE STEM OIL SEAL (a) Apply a light coat of engine oil to new valve stem oil Intake Exhaust seals. NOTICE: Gray Installing the oil seals for the intake and exhaust onto the opposite valve guide bush as may Black cause failures. HINT: The intake valve oil seal is gray and the exhaust A050182E02 valve oil seal is black. (b) Using SST, push in the oil seals. SST 09201-41020

SST

A001063E02, EM–96 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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4. INSTALL INTAKE VALVE (a) Install the valve, spring seat, valve spring, and spring retainer. NOTICE: Install the parts in their original locations in the original order. A001065E01 (b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem. SST SST 09202-70020 (09202-00010) A037109E03 (c) Using a plastic-faced hammer and the valve stem (not in use) with its tip wrapped in tape, gently tap the valve stem tip to ensure a proper fit. NOTICE: Do not damage the valve stem tip. 5. INSTALL EXHAUST VALVE (a) Install the valve, spring seat, valve spring, and spring retainer. (b) Using SST, compress the valve spring and place the A007307E01 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) (c) Using a plastic-faced hammer and the valve stem (not in use) with its tip wrapped in tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Do not damage the valve stem tip. 6. INSTALL OIL CONTROL VALVE FILTER (a) Install the oil control valve filter. 7. INSTALL WITH HEAD TAPER SCREW PLUG NO. 2 (a) Using an 8 mm hexagon wrench, install the taper screw plug and a new gasket. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 8. INSTALL VALVE LIFTER (a) Apply a light coat of engine oil to the 16 valve lifters. (b) Install the 16 valve lifters. (c) Check that the valve lifters rotate smoothly by hand. A038128E01, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–97

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9. INSTALL WITH HEAD TAPER SCREW PLUG NO. 1 (a) Using a 10 mm socket hexagon wrench, install the taper screw plug with a new gasket. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A062890E01

INSTALLATION

1. INSTALL INJECTOR VIBRATION INSULATOR (a) Install 4 new injector vibration insulators onto the cylinder head. E A116956 2. INSTALL DELIVERY PIPE NO. 1 SPACER (a) Install the 2 delivery pipe No. 1 spacers onto the cylinder head. NOTICE: Install the delivery pipe No. 1 spacer in the correct direction. 3. INSTALL FUEL INJECTOR ASSEMBLY (See page FU- 17) A116957 4. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Provisionally install the fuel delivery pipe sub- assembly with the 4 fuel injectors using the 3 bolts. NOTICE: • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub- assembly. A116768 (b) Tighten the 3 bolts to the specified torque. A Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for boltAA9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt B

B

A116768E01, EM–98 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

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5. INSTALL HARNESS BRACKET (a) Install the harness bracket with the bolt. Torque: 13 N*m (131 kgf*cm, 9.5 ft.*lbf) A116767 6. INSTALL WATER BY-PASS HOSE (a) Install the water by-pass hose. A116766 7. INSTALL ENGINE COOLANT TEMPERATURE

SENSOR

(a) Provisionally install the engine coolant temperature sensor through a new gasket. (b) Using SST, tighten the engine coolant temperature sensor. SST 09817-33190 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

SST

A116765E01 8. INSTALL CAMSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring on the camshaft position sensor. (b) Install the camshaft position sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Do not twist the O-ring. A116764 9. INSTALL BOOSTER VACUUM TUBE (a) Install the booster vacuum tube with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116763, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–99

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10. INSTALL HARNESS BRACKET (a) Install the harness bracket with the bolt. Torque: 13 N*m (131 kgf*cm, 9.5 ft.*lbf) A116762 11. INSTALL EXHAUST MANIFOLD (a) Using several steps, install a new exhaust manifold 1 gasket and the exhaust manifold with the 3 bolts45and 2 nuts in the sequence shown in the illustration. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) E A116761E01 12. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (a) Install exhaust manifold heat insulator No. 1 with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A116759 13. INSTALL CYLINDER HEAD GASKET Lot No. (a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward. NOTICE: • Remove any oil from the contact surfaces. • Check the mounting orientation of the cylinder head gasket. • Place the cylinder head on the cylinder head gently in order not to damage the gasket. A117469E01 14. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: The cylinder head bolts are tightened in 2 successive steps. (a) Apply a light coat of engine oil to the threads of the cylinder head bolts., EM–100 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

(b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench, in the sequence shown in the illustration. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) (c) Mark the front of the cylinder head bolt with paint. A035288 (d) Retighten the cylinder head bolts 90° and then an additional by 90° as shown in the illustration. (e) Check that the paint mark is now at a 180° angle from the front. 90 90 Paint Mark42589107613A116959E01 (f) Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as shown in the illustration. Cylinder Head Seal Packing: Toyota Genuine Seal Packing Black, Three Diameter: Bond 1207B or Equivalent 4.5 to 5.5 mm NOTICE: • Remove any oil from the contact surfaces. Cylinder Head • Install the oil pump assembly within 3 Gasket minutes and tighten the bolts within 15 minutes of applying the seal packing. Cylinder Block Seal Packing A073748E02, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–101

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15. INSTALL CAMSHAFT (a) Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then provisionally tighten the 19 bolts. A117473 E (b) Uniformly tighten the bolts in several steps in the sequence shown in the illustration and install53124camshaft bearing cap No. 1 and camshaft bearing cap No. 2. Torque: Camshaft bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf) Camshaft bearing cap No. 2 13 N*m (129 kgf*cm, 9.4 ft.*lbf) NOTICE: 3124Tighten each bolt uniformly while keeping the camshaft level. 16. INSTALL CHAIN SUB-ASSEMBLY (See page EM-36) 17. INSTALL CHAIN TENSIONER SLIPPER (See page Bearing Cap No. 2 EM-38) 18. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 (See page EM-38) 19. INSTALL OIL PUMP SEAL (See page LU-21) 20. INSTALL OIL PUMP ASSEMBLY (See page LU-22) 21. INSTALL TRANSVERSE ENGINE ENGINE Bearing Cap Bearing Cap No. 2 MOUNTING BRACKET (See page LU-26) No. 1 22. INSTALL WATER PUMP ASSEMBLY (See page CO- 16) A117472E01 23. INSTALL WATER PUMP PULLEY (See page CO-16) 24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-397) 25. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-403) 26. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (See page LU-26) 27. INSTALL ENGINE MOUNTING INSULATOR SUB- ASSEMBLY RH (See page LU-26), EM–102 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

28. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-19) 29. INSTALL VENTILATION HOSE NO. 2 (See page FU- 20) 30. INSTALL VENTILATION HOSE (See page FU-20) 31. INSTALL IGNITION COIL NO. 1 (See page IG-9) 32. INSTALL GENERATOR ASSEMBLY (See page CH-17) 33. INSTALL FAN AND GENERATOR V BELT (See page EM-7) 34. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 35. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 36. INSTALL MANIFOLD SUPPORT BRACKET (a) Install the manifold support bracket with the 3 bolts. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A116757 37. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Using vernier calipers, measure the free length of the compression spring. Minimum length: 40.5 mm (1.594 in.) If the length is not as specified, replace the compression spring. A104634 (b) Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold. NOTICE: Wooden • Install the exhaust pipe gasket in the correct Block direction. • Do not damage the outer surface of the exhaust pipe gasket. Gasket • Do not reuse the exhaust pipe gasket. A104635E01 • Do not push in the gasket with the exhaust pipe when installing., 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–103

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(c) Install the exhaust front pipe assembly with the 2 compression springs and 2 bolts. Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) A116756 38. CONNECT WIRE HARNESS (a) Connect the wire harness with the 2 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)

E

A116755 39. INSTALL WATER BY-PASS HOSE NO. 1 (a) Install water by-pass pipe No. 1 with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116753 40. CONNECT HEATER WATER INLET HOSE A (a) Connect heater water inlet hose A. A116752 41. CONNECT HEATED OXYGEN SENSOR CONNECTOR (a) Connect the heated oxygen sensor connector. (b) Install the sensor bracket with the bolt. A116751, EM–104 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

42. CONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR (a) Connect the engine coolant temperature sensor connector. A116750 43. CONNECT CAMSHAFT POSITION SENSOR

CONNECTOR

(a) Connect the camshaft position sensor connector. A116749 44. CONNECT BOOSTER VACUUM TUBE (a) Connect the booster vacuum tube. 45. CONNECT FUEL TUBE SUB-ASSEMBLY (See page FU-18) A116748 46. INSTALL OIL LEVEL GAUGE GUIDE (a) Apply engine oil to a new O-ring. (b) Install the oil level gauge guide with the bolt through a new O-ring. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install the wire harness. 47. INSTALL INTAKE MANIFOLD (a) Install a new gasket onto the intake manifold. A116747 (b) Install the intake manifold with the 3 bolts and 2 nuts. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) A116746, 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–105

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(c) Connect the 3 wire harness clamps shown in the illustration. 48. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY A116745 49. CONNECT UNION TO CONNECTOR TUBE HOSE (a) Connect the union to connector tube hose.

E

A116744 50. CONNECT VENTILATION HOSE (a) Connect the ventilation hose. A116973 51. CONNECT THROTTLE WITH MOTOR BODY

CONNECTOR

(a) Install the throttle with motor body connector bracket with the nut. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Connect the throttle with motor body connector. (c) Connect the wire harness clamp. A116742 52. CONNECT WATER BY-PASS HOSE (a) Connect the water by-pass hose. A116741, EM–106 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM

53. CONNECT WATER BY-PASS HOSE NO. 2 (a) Connect water by-pass hose No. 2. A116740 54. INSTALL WATER FILLER SUB-ASSEMBLY (a) Install the water filler sub-assembly with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (b) Connect radiator hose No. 1 to the cylinder head. A116739 55. CONNECT RESERVE TANK HOSE (a) Connect the reserve tank hose. A116581 56. CONNECT RADIATOR HOSE NO. 3 (a) Connect radiator hose No. 3. 57. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 (See page ES-414) 58. INSTALL BATTERY TRAY 59. INSTALL BATTERY 60. ADD ENGINE OIL A116580 61. ADD ENGINE COOLANT (See page CO-8) 62. CHECK ENGINE OIL LEVEL (See page LU-1) 63. CHECK FOR ENGINE OIL LEAKAGE 64. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-1) 65. CHECK FOR EXHAUST GAS LEAKAGE 66. CHECK FOR FUEL LEAKAGE (See page FU-7) 67. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10), 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–107

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68. INSTALL ENGINE UNDER COVER RH 69. INSTALL FRONT WHEEL RH 70. INSTALL COWL TOP PANEL OUTER (for Hatchback) (See page EM-146) 71. INSTALL COWL TOP PANEL OUTER (for Sedan) (See page ES-434) 72. INSTALL COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (See page EM-147) 73. INSTALL FRONT AIR SHUTTER SEAL RH (for Sedan) (See page ES-435) 74. INSTALL FRONT WIPER MOTOR AND LINK (for Hatchback) (See page WW-21) 75. INSTALL FRONT WIPER MOTOR AND LINK (for E Sedan) (See page WW-12) 76. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-21) 77. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-21) 78. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Sedan) (See page WW-12) 79. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-13) 80. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-13) 81. INSTALL HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-22) 82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) (See page WW-22) 83. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) (See page WW-13) 84. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) (See page WW-23) 85. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) (See page WW-14) 86. INSTALL FRONT WIPER ARM HEAD CAP (for Hatchback) (See page WW-23) 87. INSTALL FRONT WIPER ARM HEAD CAP (for Sedan) (See page WW-15), EM–108 1NZ-FE ENGINE MECHANICAL – CYLINDER HEAD

EM REPAIR

45° 1. REPAIR INTAKE VALVE (a) Repair the intake valve seat. 20° NOTICE: Releasing the seat-cutter pressure gradually helps to make the valve seat face smoother. (b) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. 1.0 to 1.4 mm A067983E01 (c) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. 75° (d) Hand-lap the valve and valve seat with an abrasive compound. 45° (e) Recheck the valve seating position. 2. REPAIR EXHAUST VALVE NOTICE: Releasing the seat-cutter pressure gradually helps 1.0 to 1.4 mm to make the valve seat face smoother. A080979E04 (a) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. (b) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (c) Hand-lap the valve and valve seat with an abrasive compound. (d) Recheck the valve seating position., 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–109

M EE1NZG-IFNEE ENGINNE MECHANIGCAL INE ASSEMBLY COMPONENTS

for Hatchback: FRONT WIPER ARM HEAD CAP FRONT WIPER FRONT WIPER ARM RH ARM HEAD CAP26 (265, 19) 26 (265, 19) COWL TOP VENTILATOR LOUVER CONTER NO. 1 E FRONT WIPER CLIP ARM LH COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

CLIP CLIP

HOOD TO COWL TOP SEAL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 COWL TOP VENTILATOR LOUVER LH 6.5 (66, 58 in.*lbf) x2 FRONT WIPER MOTOR AND LINK x9 5.5 (56, 49 in.*lbf) COWL TOP PANEL OUTER N*m (kgf*cm, ft*lbf) : Specified torque A118803E11,

EM–110 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM

for Sedan: FRONT WIPER ARM HEAD CAP FRONT WIPER ARM LH FRONT WIPER ARM RH FRONT WIPER ARM HEAD CAP COWL SIDE 26 (265, 19) 26 (265, 19)

VENTILATOR

SUB-ASSEMBLY RH CLIP x2 COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY COWL SIDE VENTILATOR SUB-ASSEMBLY LH FRONT AIR 5.5 (56, 49 in.*lbf)

SHUTTER

SEAL RH x2 FRONT WIPER MOTOR AND LINK 6.5 (66, 58 in.*lbf) x8 COWL TOP x2 COWL TOP TO COWL PANEL OUTER INNER BRACE 6.5 (66, 58 in.*lbf) N*m (kgf*cm, ft*lbf) : Specified torque A133320E11, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–111

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7.0 (71, 62 in.*lbf) 7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO. 2

E

3.5 (36, 31 in.*lbf) AIR CLEANER HOSE NO. 1 BATTERY CLAMP AIR CLEANER ASSEMBLY

BATTERY

7.8 (80, 69 in.*lbf) BATTERY TRAY AIR CLEANER INLET NO. 1 17 (175, 13) 19 (194, 14) x5 BATTERY CARRIER 5.0 (51, 44 in.*lbf) AIR CLEANER BRACKET 5.0 (51, 44 in.*lbf) ENGINE UNDER COVER RH ENGINE UNDER COVER LH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A108442E08, EM–112 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

UNION TO CHECK VALVE HOSE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) HEATER WATER INLET HOSE A FUEL TUBE SUB-ASSEMBLY FUEL PIPE CLAMP NO. 1 RADIATOR RESERVOIR TANK HOSE RADIATOR HOSE NO. 3 RADIATOR HOSE NO. 2 A108443E08, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–113

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for Hatchback: SHIFT LEVER KNOB SUB-ASSEMBLY (for FAN AND GENERATOR V BELT Manual Transaxle) CONSOLE BOX SHIFTING HOLE COVER REAR COVER SUB-ASSEMBLY (for Manual Transaxle) 52 (530, 38) 45 (459, 33) 5.0 (51, 44 in.*lbf) 45 (459, 33) E ENGINE MOUNTING INSULATOR RH 52 (530, 38) 28 (290, 21)

CLIP

CONSOLE BOX ASSEMBLY REAR STEERING SLIDING YOKE SUB-ASSEMBLY 52 (530, 38) ENGINE MOUNTING INSULATOR LH COLUMN HOLE COVER SILENCER SHEET WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque A108444E13, EM–114 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

for Sedan: CONSOLE UPPER REAR PANEL SUB-ASSEMBLY FAN AND GENERATOR V BELT SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE BOX (for Manual Transaxle) CARPET SHIFTING HOLE COVER SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY 52 (530, 38) 52 (530, 38) INSTRUMENT PANEL FINISH PANEL END LH CONSOLE BOX ASSEMBLY REAR ENGINE MOUNTING INSULATOR RH INSTRUMENT PANEL FINISH PANEL LOWER CLIP CENTER STEERING SLIDING YOKE SUB-ASSEMBLY

INSTRUMENT

PAD LOWER LH 28 (290, 21) COLUMN HOLE COVER 52 (530, 38) SILENCER SHEET ENGINE MOUNTING INSULATOR LH WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) 25 (255, 18) N*m (kgf*cm, ft*lbf) : Specified torque A128444E03, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–115

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29 (300, 21) SPEED SENSOR FRONT LH (w/ ABS) 8.0 (82, 71 in.*lbf) E 74 (755, 55) COTTER PIN 49 (500, 36) TIE ROD END SUB-ASSEMBLY LH 216 (2,203, 160) FRONT AXLE HUB LH NUT FRONT STABILIZER CLIP LINK ASSEMBLY LH 98 (999, 72) FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A108449E06,

EM–116 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM GASKET

43 (438, 32) 43 (438, 32) EXHAUST PIPE GASKET ASSEMBLY FRONT 43 (438, 32) 44 (449, 33) 43 (438, 32) HEATED OXYGEN SENSOR N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A136509E01, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–117

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FRONT SUSPENSION

CROSSMEMBER

SUB-ASSEMBLY STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1 E 120 (1,224, 89) x2 (for Automatic Transaxle) 95 (969, 70) x2 70 (714, 52) x2 160 (1,631, 118) 120 (1,224, 89) (for Manual Transaxel) N*m (kgf*cm, ft.*lbf) : Specified torque A108445E05,

EM–118 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM

for Automatic Transaxle: FRONT DRIVE SHAFT ASSEMBLY RH 18 (183, 13) DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY LH 30 (301, 22) x5 DRIVE PLATE SPACER FR

CLIP

TRANSMISSION CONTROL x6 88 (900, 65) CABLE ASSEMBLY x6 27 (275, 20) DRIVE PLATE SPACER RR x2 DRIVE PLATE AND 30 (301, 22) TORQUE CONVERTER DRIVE PLATE AND RING CLUTCH SETTING BOLT GEAR SUB-ASSEMBLY 12 (122, 9) FLYWHEEL HOUSING 9.8 (100, 87 in.*lbf) UNDER COVER OIL COOLER OUTLET HOSE 37 (378, 27) STARTER ASSEMBLY AUTOMATIC TRANSAXLE 37 (378, 27) OIL COOLER INLET HOSE ASSEMBLY FLYWHEEL HOUSING SIDE COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117318E08, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–119

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for Manual Transaxle: 18 (183, 13) DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY RH FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY LH

E

33 (336, 24)

CLIP

1st: 49 (500, 38) CLIP 2nd: Turn 90° PLATE

WASHER CLIP

PLATE WASHER CLIP x5 TRANSMISSION CONTROL CABLE ASSEMBLY x6 33 (336, 24) 19 (195, 14) 25 (250, 18) FLYWHEEL SUB-ASSEMBLY x6 x2 CLUTCH DISC 9.8 (100, 87 in.*lbf)

ASSEMBLY

CONTROL CABLE

BRACKET

37 (378, 27) 37 (378, 27) STARTER ASSEMBLY MANUAL TRANSAXLE FLYWHEEL HOUSING ASSEMBLY12 (122, 8.9) SIDE COVER x2 CLUTCH COVER ASSEMBLY CLUTCH RELEASE CYLINDER ASSEMBLY 12 (120, 9) N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part A117354E09,

EM–120 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM

FUEL TUBE SUB-ASSEMBLY FUEL PIPE CLAMP NO. 2 VENTILATION HOSE RADIO SETTING CONDENSER

VENTILATION

40 (408, 30) 60 (612, 44) HOSE NO. 2 FAN BELT ADJUSTING

SLIDER

OXYGEN SENSOR WIRING BRACKET 11 (408, 30) BOOSTER VACUUM TUBE 19 (194, 14) 9.0 (92, 80 in.*lbf) 54 (551, 40) 9.8 (100, 87 in.*lbf) HEATER WATER INLET HOSE A GENERATOR ASSEMBLY 10 (102, 89 in.*lbf) 7.5 (76, 66 in.*lbf) WATER FILLER SUB-ASSEMBLY WIRE HARNESS CLAMP BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque A117343E02, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–121

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8.0 (82, 71 in.*lbf) 9.0 (92, 80 in.*lbf) x4 EXHAUST MANIFOLD HEAT INSULATOR NO. 1 27 (275, 20) IGNITION COIL NO. 1 x3 x2 EXHAUST MANIFOLD EXHAUST MANIFOLD GASKET E 44 (449, 33) MANIFOLD SUPPORT BRACKET OIL LEVEL GAUGE SUB-ASSEMBLY INTAKE MANIFOLD GASKET 30 (306, 22) 9.0 (92, 80 in.*lbf) x3 9.0 (92, 80 in.*lbf) WATER BY-PASS PIPE NO. 1 x2 30 (306, 22) INTAKE MANIFOLD 9.0 (92, 80 in.*lbf) WATER BY-PASS PIPE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A108468E05, EM–122 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE 2. REMOVE BATTERY (a) Disconnect the cable from the battery terminal. (b) Loosen the nut and remove the battery clamp. (c) Remove the battery. 3. REMOVE BATTERY TRAY 4. REMOVE FRONT WHEELS 5. REMOVE ENGINE UNDER COVER LH 6. REMOVE ENGINE UNDER COVER RH 7. DRAIN ENGINE COOLANT (See page CO-8) 8. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-158) 9. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-26) 10. REMOVE FRONT WIPER ARM HEAD CAP (See page WW-9) 11. REMOVE FRONT WIPER ARM LH (See page WW-9) 12. REMOVE FRONT WIPER ARM RH (See page WW-9) 13. REMOVE HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-18) 14. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-18) 15. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-18) 16. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-10) 17. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-10) 18. REMOVE COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Sedan) (See page WW-10) 19. REMOVE FRONT WIPER MOTOR AND LINK (See page WW-19) 20. REMOVE COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (a) Disengage the claw and remove cowl to register duct sub-assembly No. 2. A108437, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–123

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21. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan) (a) Disengage the 3 claws and remove the front air shutter seal RH. A133324 E 22. REMOVE COWL TOP PANEL OUTER (for Hatchback) (a) Disengage the wire harness clamp. A108438 (b) Remove the 9 bolts and remove the cowl top panel outer. A115392 23. REMOVE COWL TOP PANEL OUTER (for Sedan) (a) Disengage the wire harness clamp. A128446, EM–124 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

(b) Remove the 2 bolts and remove the cowl top to cowl inner brace. A128447 (c) Remove the 8 bolts and remove the cowl top panel outer. A128448 24. REMOVE AIR CLEANER ASSEMBLY (a) Separate the intake air flow meter connector and the wire harness clamp. (b) Separate the fuel vapor feed hose and fuel vapor feed hose No. 1 from the vacuum switching valve assembly. (c) Separate the vacuum switching valve connector and the wire harness clamp. (d) Separate the ventilation hose from the air cleaner hose. (e) Release the air cleaner cap sub-assembly with air cleaner hose No. 1. (f) Loosen the air cleaner hose clamp on the throttle body side and remove the air cleaner cap and the air cleaner hose. A117355 (g) Remove the air cleaner element. (h) Separate the wire harness clamp from the air cleaner case. (i) Remove the 2 bolts and remove the air cleaner case with air cleaner inlet No. 1. A104895, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–125

M

25. REMOVE AIR CLEANER BRACKET (a) Separate the wire harness clamp from the air cleaner bracket. (b) Remove the 2 bolts and remove the air cleaner bracket. A117308 26. REMOVE BATTERY CARRIER (a) Separate the wire harness clamp from the battery carrier. (b) Remove the 5 bolts and remove the battery carrier. E A117309 27. DISCONNECT RADIATOR HOSE NO. 3 (a) Disconnect radiator hose No. 3 from the water filler. A117310 28. DISCONNECT RADIATOR RESERVOIR TANK HOSE (a) Disconnect the radiator reservoir tank hose from the water filler. A117356 29. DISCONNECT RADIATOR HOSE NO. 2 (a) Disconnect radiator hose No. 2 from the water inlet. A104893, EM–126 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

EM

30. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) (a) Loosen the clip and disconnect the oil cooler outlet hose. A117306 31. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) (a) Loosen the clip and disconnect the oil cooler inlet hose. 32. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 33. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) (See page AX- A117307 106) 34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) (See page MX-27) 35. DISCONNECT UNION TO CHECK VALVE HOSE (a) Disconnect the union to check valve hose from the booster vacuum tube. 36. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) (a) Disconnect heater water outlet hose A from the heater unit. I100777 37. DISCONNECT HEATER WATER INLET HOSE A (a) Disconnect heater water inlet hose A from the heater unit. I100779, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–127

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38. DISCONNECT FUEL TUBE SUB-ASSEMBLY (a) Remove fuel pipe clamp No. 1. A105667 (b) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe. NOTICE: • Remove any dirt and foreign matter from the fuel tube connector before performing this E work. • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the A117321 pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube. • If the fuel tube connector and pipe are stuck, push and pull to release them. 39. REMOVE FAN AND GENERATOR V BELT (See page EM-7) 40. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) (a) Disconnect the connector. (b) Remove the 4 bolts and separate the with pulley compressor assembly. HINT: Remove the compressor assembly together with the low and high pressure hoses, then suspend them from the body with a piece of rope. 41. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) (See page MX-27), EM–128 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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42. DISCONNECT ENGINE WIRE (a) Pull up the lever and disconnect the connector of the engine control computer. A107314 (b) Remove the 2 connectors and the clamp from the engine room junction block and disconnect the wire harness. A104339 (c) Remove the bolt and separate the earth wire of the engine room wire harness. (d) Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine. 43. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page PS-74) 44. SEPARATE STEERING SLIDING YOKE SUB- A108450 ASSEMBLY (See page PS-74) 45. REMOVE STEERING COLUMN HOLE COVER SUB- ASSEMBLY NO. 1 (See page PS-75) 46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) 47. REMOVE SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle) (See page PB-6) 48. REMOVE CONSOLE BOX REAR COVER (for Hatchback) (See page PB-6) 49. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (for Sedan) (See page ME-138) 50. REMOVE INSTRUMENT PANEL FINISH PANEL END LH (for Sedan) (See page ME-138) 51. REMOVE INSTRUMENT PAD LOWER LH (for Sedan) (See page IP-44) 52. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for Sedan) (See page IP-84) 53. REMOVE CONSOLE UPPER REAR PANEL SUB- ASSEMBLY (for Sedan) (See page IP-84), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–129

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54. REMOVE CONSOLE BOX CARPET (for Sedan) (See page PB-7) 55. REMOVE REAR CONSOLE BOX ASSEMBLY (See page PB-8) 56. REMOVE HEATED OXYGEN SENSOR (See page EC- 22) 57. REMOVE EXHAUST PIPE ASSEMBLY FRONT (See page EX-5) 58. REMOVE FRONT AXLE HUB LH NUT (See page DS- 3) 59. REMOVE FRONT AXLE HUB RH NUT (See page AX- 159) 60. SEPARATE SPEED SENSOR FRONT LH (w/ ABS) E (See page DS-3) 61. SEPARATE SPEED SENSOR FRONT RH (w/ ABS) (See page AX-159) 62. SEPARATE TIE ROD END SUB-ASSEMBLY LH (See page DS-3) 63. SEPARATE TIE ROD END SUB-ASSEMBLY RH (See page AX-160) 64. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-4) 65. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH (See page AX-160) 66. SEPARATE FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 LH (See page DS-4) 67. SEPARATE FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 RH (See page AX-160) 68. SEPARATE FRONT AXLE ASSEMBLY LH (See page DS-4) 69. SEPARATE FRONT AXLE ASSEMBLY RH (See page MX-29) 70. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-5) 71. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-5) 72. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle), EM–130 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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73. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) (a) Remove the 6 torque converter set bolts. A117323 74. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine lifter. G100156 (b) Remove the 5 bolts and the nut and remove the engine mounting insulator RH. G100143 (c) Remove the through bolt and the nut and separate the engine mounting insulator LH. G100158 (d) Remove the 6 bolts, and remove the engine assembly with transaxle and the front suspension crossmember from the vehicle. 75. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Remove the bolt and remove the radio setting condenser. (b) Remove the bolt and remove the oxygen sensor wiring bracket. G100157, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–131

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(c) Install the engine hangers with the bolts, as shown Front Rear in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) Part No.: 12281-21010 for engine hanger 91642-81025 for bolt (d) Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember. A070012E01 (e) Remove the through bolt from the engine moving control rod and remove the front suspension crossmember. 76. REMOVE VENTILATION HOSE (a) Loosen the 2 clips and remove the ventilation hose. 77. REMOVE VENTILATION HOSE NO. 2 E (a) Loosen the clips and remove ventilation hose No. 2. 78. REMOVE FUEL TUBE SUB-ASSEMBLY (a) Disengage the claw and remove fuel pipe clamp No. 2. A107342 (b) Pinch the fuel tube connector retainer from both sides, disconnect the fuel tube connector and separate the fuel tube from the pipe. NOTICE: • Remove any dirt and foreign matter from the fuel tube connector before performing this work. • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel A107343 tube connector has the O-rings that seal the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube. • If the fuel tube connector and pipe are stuck, push and pull to release them. 79. REMOVE WATER FILLER SUB-ASSEMBLY (a) Disconnect radiator hose No. 1 from the cylinder head. (b) Remove the 2 nuts and remove the water filler sub- assembly., EM–132 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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80. REMOVE HEATER WATER INLET HOSE A (a) Disconnect heater water inlet hose A from the cylinder head. 81. REMOVE FLYWHEEL HOUSING SIDE COVER (See page ST-9) 82. REMOVE STARTER ASSEMBLY (See page ST-9) 83. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) (a) Remove the 7 bolts and remove the automatic transaxle with torque converter. C118504 84. REMOVE DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (for Automatic Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Remove the 6 bolts, drive plate spacer FR, drive plate and ring gear sub-assembly and drive plate spacer RR. 85. REMOVE CONTROL CABLE BRACKET (for Manual SST Transaxle) (See page MX-28) A107285E01 86. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) (See page MX-30) 87. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-15) 88. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 89. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Remove the 6 bolts and flywheel. 90. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 91. REMOVE IGNITION COIL NO. 1 SST (a) Disconnect the connectors of the ignition coils. A107285E01 (b) Remove the bolt and remove all the ignition coils. 92. REMOVE GENERATOR ASSEMBLY (See page CH-10), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–133

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93. REMOVE INTAKE MANIFOLD (a) Disconnect the union to connector tube hose from the booster vacuum tube. (b) Disconnect the engine wire from the intake manifold. A117312 (c) Disconnect the water by-pass hose from the cylinder head.

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A117313 (d) Disconnect the water by-pass hose from water bypass pipe No. 1. (e) Disconnect the throttle with motor body assembly connector. A117314 (f) Remove the 3 bolts and 2 nuts in the order shown in the illustration and remove the intake manifold. (g) Remove the gasket from the intake manifold. 4351A035213E01 94. REMOVE WATER BY-PASS PIPE NO. 1 (a) Remove the 2 bolts and 2 nuts and remove water by-pass pipe No. 1. A117315, EM–134 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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95. REMOVE BOOSTER VACUUM TUBE (a) Remove the 2 bolts and remove the booster vacuum tube. 96. REMOVE ENGINE WIRE (a) Disconnect all the sensor connectors and wire harness clamps from the engine assembly and remove the engine wire harness. A117316 97. REMOVE WIRE HARNESS CLAMP BRACKET (a) Remove the 2 bolts and remove the 2 wire harness clamp brackets. 98. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (a) Remove the 4 bolts and remove the exhaust manifold heat insulator. 99. REMOVE MANIFOLD SUPPORT BRACKET A107284 (a) Remove the 3 bolts and remove the manifold support bracket. 100.REMOVE EXHAUST MANIFOLD (a) Remove the 3 bolts and 2 nuts and remove the exhaust manifold. 101.REMOVE DRIVE SHAFT HEAT INSULATOR SUB-

ASSEMBLY

(a) Remove the bolt and nut and remove the drive shaft heat insulator. A117317

INSTALLATION

1. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-

ASSEMBLY

(a) Install the drive shaft heat insulator sub-assembly with the bolt and nut. Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf) A117317, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–135

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2. INSTALL EXHAUST MANIFOLD (a) Tighten the exhaust manifold nuts and bolts, in the415order shown in the illustration, through a new gasket. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 3. INSTALL MANIFOLD SUPPORT BRACKET23(a) Install the manifold bracket with the 3 bolts. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A067694E01 4. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (a) Install the exhaust manifold insulator with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 5. INSTALL WIRE HARNESS CLAMP BRACKET (a) Install the 2 wire harness clamp brackets with the2Ebolts. Torque: 10 N*m (102 kgf*cm, 89 in.*lbf) 6. INSTALL ENGINE WIRE (a) Connect all the sensor connectors and wire harness clamps to the engine assembly and install the engine wire harness. A107284 7. INSTALL BOOSTER VACUUM TUBE (a) Install the booster vacuum tube with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A117316 8. INSTALL WATER BY-PASS PIPE NO. 1 (a) Install water by-pass pipe No. 1 through a new gasket with the 2 bolts and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 9. INSTALL INTAKE MANIFOLD (a) Install a new gasket onto the intake manifold. A117315, EM–136 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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(b) Provisionally tighten the intake manifold nuts and bolts in the order shown in the illustration, and then tighten them to the specified torque. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) (c) Connect the engine wire to the intake manifold. 2315A035197E01 (d) Connect the water by-pass hose to water bypass pipe No. 1. A117314 (e) Connect the water by-pass hose to the cylinder head. (f) Connect the union to connector tube hose to the booster vacuum tube. (g) Connect the throttle with motor body assembly connector. 10. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY 11. INSTALL GENERATOR ASSEMBLY (See page CH-17) A117313 12. INSTALL IGNITION COIL NO.1 (See page IG-9) 13. INSTALL DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (for Automatic Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Clean the 6 bolts and their holes.

SST

A107285E01 (c) Apply adhesive to the end 2 or 3 threads of the Adhesive bolts. Adhesive: Part No. 08833-0070, three bond 1324 or the equivalent. (d) Install the drive plate spacer RR, drive plate and ring gear sub-assembly and drive plate spacer FR. A057108E01, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–137

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(e) Install and uniformly tighten the 6 bolts in several steps, in the sequence shown in the illustration. 1 Torque: 88 N*m (900 kgf*cm, 65 ft.*lbf) 6 NOTICE:4 Do not start the engine for at least 1 hour after performing the installation. 2 3 A050929E02 14. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) (a) Make sure that the knock pin is installed on the engine side. (b) Install the automatic transaxle with torque converter E with the 7 bolts. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) CAUTION: Make sure that the torque converter rotates. C118504 15. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (a) Hold the crankshaft with SST. SST 09960-10010 (09962-01000, 09963-01000) (b) Clean the 6 bolts and their holes.

SST

A107285E01 (c) Apply adhesive to the end 2 or 3 threads of new Adhesive bolts. Adhesive: Part No. 08833-0070, three bond 1324 or the equivalent. A057108E01 (d) Install the flywheel with the 6 bolts in the order shown in the illustration. 1 Torque: 49 N*m (500 kgf*cm, 38 ft.*lbf) 6 (e) Mark a paint mark on each bolt head on the engine 4 upper side. 2 3 A050929E02, EM–138 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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(f) Tighten the bolts 90° in the sequence shown in the illustration. NOTICE: Do not start the engine for at least 1 hour after 90° performing the installation. 16. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See page CL-16) 17. INSTALL CLUTCH COVER ASSEMBLY (for Manual A068530E01 Transaxle) (See page CL-17) 18. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See page CL-17) 19. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) (See page MX-30) 20. INSTALL CONTROL CABLE BRACKET (for Manual Transaxle) (See page MX-32) 21. INSTALL STARTER ASSEMBLY (See page ST-17) 22. INSTALL FLYWHEEL HOUSING SIDE COVER (See page ST-17) 23. CONNECT HEATER WATER INLET HOSE A (a) Connect heater water inlet hose A to the cylinder head. 24. INSTALL WATER FILLER SUB-ASSEMBLY (a) Connect radiator hose No. 1 to the cylinder head. (b) Install the water filler sub-assembly with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (c) Connect radiator hose No. 1 to the water filler. 25. INSTALL FUEL TUBE SUB-ASSEMBLY (a) Connect the fuel tube connector and pipe and install fuel pipe clamp No. 2. CAUTION: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the the tip of the pipe. After connecting, pull the pipe and A107342 connector to make sure that they are securely connected. 26. INSTALL VENTILATION HOSE NO. 2 (a) Install ventilation hose No. 2 with the clip. 27. INSTALL VENTILATION HOSE (a) Install the ventilation hose with the clip. 28. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Install the engine moving control rod with the through bolt. Torque: 120 N*m (1,224 kgf*cm, 89 ft.*lbf) (b) Remove the 2 bolts and remove the 2 engine hangers., 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–139

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(c) Install the oxygen sensor wiring bracket with the bolt. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) (d) Install the radio setting condenser with the bolt. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (for Hatchback) (a) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter. (b) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed. G100156 E (c) Install the engine mounting insulator LH with the through bolt and nut. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) G100158 (d) Install the engine mounting insulator RH with the5AAbolts and nut. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) for Bolt A 52 N*m (530 kgf*cm, 38 ft.*lbf) for Bolt B 52 N*m (530 kgf*cm, 38 ft.*lbf) for Nut C (e) Operate the engine lifter and provisionally install the B front suspension crossmember onto the vehicle with the 6 bolts. ABCG100143E02 (f) Insert SST into the datum holes in the front suspension crossmembers RH and LH alternately and tighten bolts A, B and C on both sides in several sequences. Bolt A SST 09670-00010Bolt A Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for Bolt A Bolt B 160 N*m (1,631 kgf*cm, 118 ft.*lbf) for Bolt B Bolt B Bolt C Bolt C 95 N*m (969 kgf*cm, 70 ft.*lbf) for Bolt C G100157E01 CAUTION: • Insert SST into the datum hole vertically. • If impossible to insert SST vertically, loosen all the bolts and then insert SST again., EM–140 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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Front Datum Hole Bolt A Bolt A Bolt B Bolt B Bolt C Bolt C OK NG OK NG A117079E01 30. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (for Sedan) (a) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter. (b) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed. G100156 (c) Install the engine mounting insulator LH with the through bolt and nut. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) G100158 (d) Install the engine mounting insulator RH with the 5 bolts and nut. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) G100143, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–141

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(e) Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts. Bolt A (f) Insert SST into the datum holes of the front Bolt A suspension crossmembers RH and LH alternately Bolt B and tighten bolts A, B and C on both sides in several Bolt B sequences. Bolt C Bolt C SST 09670-00010 G100157E01 Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for Bolt A 160 N*m (1,631 kgf*cm, 118 ft.*lbf) for Bolt B 95 N*m (969 kgf*cm, 70 ft.*lbf) for Bolt C CAUTION: • Insert SST into the datum hole vertically. • If impossible to insert SST vertically, loosen E all the bolts and then insert SST again. Front Datum Hole Bolt A Bolt A Bolt B Bolt B Bolt C Bolt C OK NG OK NG A117079E01 31. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) (a) Tighten the 6 torque converter set bolts. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 32. INSTALL FLYWHEEL HOUSING UNDER COVER 33. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-13) 34. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See A117323 page DS-14) 35. INSTALL FRONT AXLE ASSEMBLY LH (See page DS- 14) 36. INSTALL FRONT AXLE ASSEMBLY RH (See page DS-14), EM–142 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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37. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-14) 38. INSTALL FRONT STABILIZER LINK ASSEMBLY RH (See page MX-31) 39. INSTALL FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 LH (See page DS-14) 40. INSTALL FRONT SUSPENSION ARM SUB- ASSEMBLY LOWER NO. 1 RH (See page MX-31) 41. INSTALL TIE ROD END SUB-ASSEMBLY LH (See page DS-15) 42. INSTALL TIE ROD END SUB-ASSEMBLY RH (See page MX-31) 43. INSTALL SPEED SENSOR FRONT LH (w/ ABS) (See page DS-15) 44. INSTALL SPEED SENSOR FRONT RH (w/ ABS) (See page MX-31) 45. INSTALL FRONT AXLE HUB LH NUT (See page DS- 15) 46. INSTALL FRONT AXLE HUB RH NUT (See page MX- 31) 47. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See page EX-8) 48. INSTALL HEATED OXYGEN SENSOR (See page EC- 23) 49. INSTALL CONSOLE BOX ASSEMBLY REAR (See page PB-10) 50. INSTALL CONSOLE BOX REAR COVER (for Hatchback) (See page PB-11) 51. INSTALL SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle) (See page PB-12) 52. INSTALL CONSOLE BOX CARPET (for Sedan) (See page PB-11) 53. INSTALL CONSOLE UPPER REAR PANEL SUB- ASSEMBLY (for Sedan) (See page IP-89) 54. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for Sedan) (See page IP-89) 55. INSTALL INSTRUMENT PAD LOWER LH (for Sedan) (See page IP-55) 56. INSTALL INSTRUMENT PANEL FINISH PANEL END LH (for Sedan) (See page ME-141) 57. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (for Sedan) (See page ME-142) 58. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–143

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59. INSTALL STEERING COLUMN HOLE COVER SUB- ASSEMBLY NO. 1 (See page PS-79) 60. INSTALL STEERING SLIDING YOKE SUB- ASSEMBLY (See page PS-79) 61. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page PS-79) 62. CONNECT ENGINE WIRE (a) Install the earth wire of the engine room wire harness with the bolt.

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A108450 (b) Connect the 2 engine wire harness connectors and wire harness clamp to the engine room junction block. A104339 (c) Connect the engine wire harness connector to the ECM. 63. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) (See page MX-32) 64. INSTALL WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) (See page AC-209) 65. INSTALL FAN AND GENERATOR V BELT (See page EM-7) A107314 66. ADJUST FAN AND GENERATOR V BELT (See page EM-7) 67. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Connect the fuel tube connector and fuel pipe, and install fuel pipe clamp No. 1. CAUTION: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the the tip of the pipe. After connecting, pull the pipe and A105667 connector to make sure that they are securely connected., EM–144 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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68. CONNECT HEATER WATER INLET HOSE A (a) Connect heater water inlet hose A to the heater unit. I100779 69. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) (a) Connect heater water outlet hose A to the heater unit. 70. CONNECT UNION TO CHECK VALVE HOSE (a) Connect the union to check valve hose to the booster vacuum tube. 71. INSTALL TRANSMISSION CONTROL CABLE I100777 ASSEMBLY (for Automatic Transaxle) (See page AX- 109) 72. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) (See page MX-32) 73. INSTALL CYLINDER HEAD COVER NO. 2 (See page IG-10) 74. CONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) (a) Connect the oil cooler inlet hose with the clip. A117307 75. CONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) (a) Connect the oil cooler outlet hose with the clip. A117306, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–145

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76. CONNECT RADIATOR HOSE NO. 2 (a) Connect radiator hose No. 2 to the water inlet. A104893 77. CONNECT RADIATOR RESERVOIR TANK HOSE (a) Connect the radiator reservoir tank hose to the water filler.

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A117356 78. CONNECT RADIATOR HOSE NO. 3 (a) Connect radiator hose No. 3 to the water filler. A117310 79. INSTALL BATTERY CARRIER (a) Install the battery carrier with the 5 bolts. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) (b) Install the clamp. A117309 80. INSTALL AIR CLEANER BRACKET (a) Install the air cleaner bracket with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) (b) Connect the wire harness clamp to the air cleaner bracket. A117308, EM–146 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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81. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner case with air cleaner inlet No. 1 with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) (b) Connect the wire harness to the air cleaner case. (c) Install the air cleaner element. A104895 (d) Install and lock the air cleaner cap and the air cleaner hose and then tighten the air cleaner hose clamp. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (e) Connect the ventilation hose to the air cleaner hose. (f) Connect the vacuum switching valve connector and the wire harness clamp. (g) Connect the fuel vapor feed hose and fuel vapor feed hose No. 1 to the vacuum switching valve assembly. (h) Connect the intake air flow meter connector and the wire harness clamp. A117355 82. INSTALL COWL TOP PANEL OUTER (for Hatchback) (a) Install the cowl top panel with the 9 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 ft.*lbf) A115392 (b) Connect the wire harness clamp. A108438, 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–147

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83. INSTALL COWL TOP PANEL OUTER (for Sedan) (a) Install the cowl top panel outer with the 8 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) A128448 (b) Install the cowl top to cowl inner brace with the 2 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf)

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A128447 (c) Connect the wire harness clamp. A128446 84. INSTALL COWL TO REGISTER DUCT SUB- ASSEMBLY NO. 2 (for Hatchback) (a) Engage the claw and install cowl to register duct No. 2. A108437, EM–148 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

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85. INSTALL FRONT AIR SHUTTER SEAL RH (for Sedan) (a) Engage the 3 claws to install the front air shutter seal RH. 86. INSTALL FRONT WIPER MOTOR AND LINK (See page WW-21) 87. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback) (See page WW-21) 88. INSTALL COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY (for Hatchback) (See page WW-21) 89. INSTALL HOOD TO COWL TOP SEAL (for Hatchback) (See page WW-22) 90. INSTALL COWL TOP VENTILATOR LOUVER SUB- A133324 ASSEMBLY (for Sedan) (See page WW-12) 91. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) (See page WW-13) 92. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) (See page WW-13) 93. INSTALL FRONT WIPER ARM LH (See page WW-22) 94. INSTALL FRONT WIPER ARM RH (See page WW-23) 95. INSTALL FRONT WIPER ARM HEAD CAP (See page WW-23) 96. INSTALL BATTERY TRAY 97. INSTALL BATTERY (a) Install the battery onto the vehicle with the battery clamp. Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) (b) Connect the cable to the battery terminal. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 98. ADD ENGINE COOLANT (See page CO-8) 99. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-169) 100. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See page AX-93) 101.ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) 102. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) (See page MX-2) 103. INSPECT FAN AND GENERATOR V BELT (See page EM-8) 104.CHECK FOR FUEL LEAKAGE (See page FU-7) 105.CHECK FOR ENGINE OIL LEAKAGE 106.CHECK FOR EXHAUST GAS LEAKAGE 107.CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-1), 1NZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–149

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108. INSTALL ENGINE UNDER COVER RH 109. INSTALL ENGINE UNDER COVER LH 110. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 111. INSPECT IGNITION TIMING (See page EM-1) 112. INSPECT ENGINE IDLING SPEED (See page EM-2) 113. INSPECT CO/HC (See page EM-4) 114. INSPECT FRONT WHEEL ALIGNMENT 115. INSPECT ABS SENSOR SIGNAL (w/ ABS)

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EM–150 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

E1ENZG-IFNEE ENGINNE MECHANIGCAL INE UNIT

COMPONENTS

9.0 (92, 80 in.*lbf) x2 19 (194, 14) O-RING FUEL DELIVERY PIPE SUB-ASSEMBLY FUEL INJECTOR ASSEMBLY x4 INJECTOR VIBRATION INSULATOR x2 DELIVERY PIPE NO. 1 SPACER 20 (204, 15) SPARK PLUG ENGINE COOLANT TEMPERATURE SENSOR 18 (184, 13) GASKET x4 8.0 (82, 71 in.*lbf) CAMSHAFT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117466E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–151

M E

20 (204, 15) 7.5 (76, 66 in.*lbf) KNOCK SENSOR 15 (153, 11) CRANKSHAFT POSITION SENSOR ENGINE OIL PRESSURE SWITCH ASSEMBLY O-RING CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 7.5 (76, 66 in.*lbf) OIL LEVEL GAUGE GUIDE 9.0 (92, 80 in.*lbf) O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A117467E01,

EM–152 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

TRANSVERSE ENGINE ENGINE MOUNTING BRACKET x4 55 (561, 41) 24 (245, 18) OIL PUMP ASSEMBLY 32 (326, 24) x2 24 (245, 18) x11 11 (112, 8.1) 11 (112, 8.1) 128 (1,305, 95) OIL PUMP SEAL CRANKSHAFT DAMPER SUB-ASSEMBLY CRANKSHAFT STRAIGHT PIN O-RING 11 (112, 8.1) WATER PUMP PULLEY GASKET x2 x3 WATER PUMP ASSEMBLY 15 (153, 11) x3 11 (112, 8.1) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A117447E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–153

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CHAIN TENSIONER ASSEMBLY NO. 1 9.0 (92, 80 in.*lbf)

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CHAIN TENSIONER SLIPPER CHAIN SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) CHAIN VIBRATION DAMPER NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque A117448E01,

EM–154 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

10 (102, 7.0) OIL FILLER CAP SUB-ASSEMBLY SEAL WASHER 10 (102, 7.0) OIL FILLER CAP x7 27 (275, 20)

GASKET

VENTILATION VALVE SUB-ASSEMBLY 10 (102, 7.0) CYLINDER HEAD COVER SUB-ASSEMBLY CYLINDER HEAD COVER GASKET x3 23 (235, 17) x16 13 (129, 9.4) CAMSHAFT BEARING CAP NO. 2 CAMSHAFT BEARING CAP NO. 1 x4 NO. 2 CAMSHAFT CAMSHAFT TIMING

SPROCKET CAMSHAFT

64 (653, 47) 64 (653, 47) CAMSHAFT TIMING GEAR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A117449E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–155

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1st: 29 (300, 22) 2nd: turn 90° x10 3rd: turn 90° CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET

E THERMOSTAT GASKET

WATER INLET x2 O-RING 9.0 (92, 80 in.*lbf) CYLINDER BLOCK SUB-ASSEMBLY ENGINE REAR OIL SEAL OIL PAN SUB-ASSEMBLY 30 (306, 22) OIL FILTER UNION OIL FILTER SUB-ASSEMBLY x13 24 (245, 18) 5.0 (51, 44 in.*lbf) STUD BOLT 5.0 (51, 44 in.*lbf) GASKET STUD BOLT OIL STRAINER SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) 11 (112, 8.1) x9 38 (382, 28) 11 (112, 8.1) GASKET OIL PAN SUB-ASSEMBLY NO. 2 9.0 (92, 80 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease A117468E01,

EM–156 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

35 (357, 26) 5.0 (51, 44in.*lbf) CYLINDER BLOCK WATER DRAIN COCK STUD BOLT STRAIGHT PIN STRAIGHT PIN STRAIGHT PIN x2 OIL PUMP SET RING PIN 11 (112, 8.1) STUD BOLT STRAIGHT PIN 5.0 (51, 44in.*lbf) STUD BOLT OIL PUMP SET RING PIN 5.0 (51, 44in.*lbf) STRAIGHT PIN x2 STUD BOLT CRANKSHAFT THRUST CRANKSHAFT BEARING WASHER UPPER

CRANKSHAFT

CRANKSHAFT BEARING 1st: 22 (224, 16) 2nd: turn 90° CRANKSHAFT BEARING N*m (kgf*cm, ft.*lbf) : Specified torque CAP SET BOLT A117453E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–157

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PISTON RING SET WITH PIN PISTON SUB-ASSEMBLY E CONNECTING ROD SUB-ASSEMBLY

CONNECTING

ROD BEARING 1st: 15 (153, 11) 2nd: turn 90° CONNECTING ROD

BOLT

N*m (kgf*cm, ft.*lbf) : Specified torque A117452E03, EM–158 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM DISASSEMBLY

1. REMOVE SPARK PLUG (a) Using a spark plug wrench, remove the 4 spark plugs. A080968E01 2. REMOVE KNOCK SENSOR (a) Remove the nut and remove the knock sensor. A117462 3. REMOVE ENGINE OIL PRESSURE SWITCH

ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the oil pressure switch. A117463 4. REMOVE ENGINE COOLANT TEMPERATURE

SENSOR

SST (a) Using SST, remove the engine coolant temperature sensor. SST 09817-33190 A117464E01 5. REMOVE WATER INLET (a) Remove the 2 nuts and remove the water inlet. A080960E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–159

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6. REMOVE THERMOSTAT (a) Remove the thermostat. (b) Remove the gasket from the thermostat. A116187 7. REMOVE OIL FILLER CAP SUB-ASSEMBLY (a) Remove the oil filler cap from the cylinder head cover.

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A080967E01 8. REMOVE OIL FILLER CAP GASKET (a) Using a screwdriver, remove the gasket from the oil filler cap. 9. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and the crankshaft position sensor. A065656E01 10. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Remove the ventilation valve from the cylinder head cover. A080963E01 11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly. 12. REMOVE CYLINDER HEAD COVER GASKET (a) Remove the gasket from the cylinder head cover. A066472E01, EM–160 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE

ASSEMBLY

(a) Remove the bolt and the camshaft timing oil control valve. 14. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the bolt and the oil level gauge guide. A064872E01 15. REMOVE WATER PUMP PULLEY (a) Using SST, hold the pump pulley. SST 09960-10010 (09962-01000, 09963-00700) (b) Remove the 3 bolts and the pump pulley.

SST

A116191E01 16. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Set cylinder No. 1 to TDC/compression. (1) Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that the timing marks on the camshaft timing sprocket and the camshaft timing gear are all facing upward, as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01 (b) Using 2 SSTs, loosen the bolt while holding the crankshaft damper sub-assembly. SST SST 09213-14010 (91651-60865), 09330-00021 NOTICE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly. (c) Remove the SSTs and the bolt. A117461E01 (d) Remove the crankshaft damper sub-assembly., 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–161

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17. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (a) Remove the 4 bolts and remove the transverse engine mounting bracket. A080957E01 18. REMOVE WATER PUMP ASSEMBLY (a) Remove the 3 bolts and the 2 nuts and remove the water pump and the gasket.

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A116192 19. REMOVE OIL PUMP ASSEMBLY (a) Remove the 15 bolts and the nut. A116554 (b) Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it. NOTICE: Do not damage the contact surface of the oil pump assembly and oil pan sub-assembly. Tape A050903E01, EM–162 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(c) Remove the 2 O-rings from the cylinder block and oil pan sub-assembly. A116556 20. REMOVE OIL PUMP SEAL Wooden Blocks (a) Using a screwdriver with its tip wrapped in tape, remove the oil seal. 21. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 NOTICE: • Do not rotate the crankshaft with the chain tensioner removed. • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise A035281E04 40° from the TDC first. (a) Pull up the stopper plate and hold it with its lock released. Stopper Plate A116564E01 (b) Unlock the plunger of the tensioner and push it in to the end. Plunger A116565E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–163

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(c) Pull down the stopper plate with the plunger pushed to the end and lock the plunger. Stopper Plate A116566E01 E (d) Inserta3mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger. A116567 (e) Remove the 2 bolts and remove chain tensioner assembly No. 1. A116568 22. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the chain tensioner slipper. A116569, EM–164 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

23. REMOVE CHAIN VIBRATION DAMPER NO. 1 (a) Remove the 2 bolts and remove chain vibration damper No. 1. 24. REMOVE CHAIN SUB-ASSEMBLY A116570 25. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors. NOTICE: Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly. A115494 26. REMOVE DELIVERY PIPE NO. 1 SPACER (a) Remove the 2 delivery pipe No. 1 spacers. A115496 27. REMOVE INJECTOR VIBRATION INSULATOR (a) Remove the 4 injector vibration insulators. A115497 28. REMOVE FUEL INJECTOR ASSEMBLY Pull (a) Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly. A115498E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–165

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29. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and the camshaft position sensor. 30. REMOVE NO. 2 CAMSHAFT NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. A080958E01 (a) Using several steps, uniformly loosen and remove13542the 11 bearing cap bolts in the sequence shown in the illustration, then remove camshaft bearing cap No. 1, camshaft bearing cap No. 2 and camshaft No. 2. E NOTICE: Loosen each bolt uniformly while keeping the camshaft level. A037074E01 31. REMOVE CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vice. (b) Remove the flange bolt and the camshaft timing sprocket. NOTICE: Do not damage the camshaft. A064874E01 32. REMOVE CAMSHAFT (a) Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, then remove camshaft bearing cap No. 2 and the camshaft. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. 243133. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY A037075E01 (a) Clamp the camshaft in a vise, and confirm that it is locked. NOTICE: Do not damage the camshaft., EM–166 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(b) Cover the 4 oil paths of the cam journal with tape as Retard Side shown in the illustration. Paths HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil Advance paths. Plug one of the oil paths for each groove with Side Paths a piece of rubber before wrapping the cam journal with the tape. (c) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed Open Vinyl Tape Rubber Piece A116226E04 (d) Apply about 150 kPa (1.5 kgf*cm2) air pressure into Retard Advance the 2 broken paths (the advance side path and the Side Path Side Path retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02 (e) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. HINT: Retard Advance Side Path Side Path The lock pin is released and the camshaft timing gear revolves in the advance direction. (f) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. NOTICE: Camshaft timing gear assembly occasionally Decompress Hold Pressure shifts to the retard side abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock A116228E02 pin., 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–167

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(g) Remove the flange bolt and remove the camshaft timing gear assembly. NOTICE: • Do not remove the other 4 bolts. • When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first. Flange Bolt A116229E01 34. REMOVE CYLINDER HEAD SUB-ASSEMBLY392(a) Using several steps, uniformly loosen and remove76the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and the plate E washers. NOTICE: • Do not drop the washers into the cylinder151084head. A035286E01 • Head warpage or cracking could result from removing bolts in the wrong order. 35. REMOVE CYLINDER HEAD GASKET 36. REMOVE OIL FILTER SUB-ASSEMBLY (a) Using SST, remove the oil filter. SST 09228-06501

SST

A038018E02 37. REMOVE OIL FILTER UNION (a) Using a 12 mm hexagon wrench, remove the oil filter union. A079679E01, EM–168 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

38. REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal. NOTICE: After removal, check the crankshaft for any damage. If damaged, smooth the surface with 400-grit sandpaper. 39. REMOVE OIL PAN SUB-ASSEMBLY NO. 2 A051764E01 (a) Remove the oil pan drain plug and gasket. (b) Remove the 9 bolts and 2 nuts. A079680E01 (c) Insert the blade of SST between oil pan No. 1 and oil pan No. 2, and cut off the applied sealer and remove oil pan No. 2. SST 09032-00100 NOTICE: Do not damage oil pan No. 1 or oil pan No. 2. 40. REMOVE OIL STRAINER SUB-ASSEMBLY (a) Remove the bolt and 2 nuts. (b) Remove the oil strainer and the gasket. A001456E01 41. REMOVE OIL PAN SUB-ASSEMBLY (a) Loosen and remove the 13 bolts uniformly in several steps. A050902E01 (b) Using a screwdriver, remove oil pan No. 1 by prying between the cylinder block and oil pan No. 1. NOTICE: Do not damage the contact surfaces of oil pan No. 1 or the cylinder block. (c) Remove the 2 O-rings from the cylinder block. A011272E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–169

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42. REMOVE STUD BOLT (a) Remove the 4 stud bolts. A117459 43. REMOVE PISTON SUB-ASSEMBLY WITH 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 E upper bearing down through the top of the cylinder block to remove them. HINT: • Keep the bearing, connecting rod and cap A001166E01 together. • Keep the piston and the connecting rod assemblies in the correct order so that they can be returned to their original locations when reassembled. 44. REMOVE CONNECTING ROD BEARING 45. REMOVE CRANKSHAFT (a) Using several steps, loosen and remove the 10 bearing cap sub-assembly bolts uniformly with SST15973in the sequence shown in the illustration. SST 09011-38121 (b) Remove the bearing cap and the crankshaft. 46. REMOVE CRANKSHAFT BEARING26108447. REMOVE CRANKSHAFT THRUST WASHER UPPER A037365E02 48. REMOVE PISTON RING SET NOTICE: Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when reassembled. (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and the oil ring by hand. A037363E01, EM–170 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

49. REMOVE WITH PIN PISTON SUB-ASSEMBLY (a) Using SST, press the piston pin out of the piston. SST 09221-25026 (09221-00021, 09221-00030, SST 09221-00090, 09221-00150, 09221-00100) NOTICE: SST Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembled. 50. REMOVE CYLINDER BLOCK WATER DRAIN COCK SST SUB-ASSEMBLY SST 51. REMOVE STUD BOLT (a) Using "Torx" socket wrench E5, remove the 7 stud Connecting Piston Pin bolts. Rod 52. REMOVE RING PIN 53. REMOVE STRAIGHT PIN Piston

SST

A092172E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–171

M INSPECTION

1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Check the lock of camshaft timing gear. (1) Clamp the camshaft in a vice, and check that the camshaft timing gear is locked. NOTICE: Do not damage the camshaft. (b) Release the lock pin. Retard Side (1) Cover the 4 oil paths of the cam journal with Paths tape as shown in the illustration. HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and Advance the other is for advancing cam timing (lower). Side Paths Each groove has 2 oil paths. Plug one of the oil E paths for each groove with a piece of rubber before wrapping the cam journal with the tape. (2) Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path. Open Closed Closed Open Vinyl Tape Rubber Piece A116226E04 (3) Apply air at about 150 kPa (1.5 kgf*cm2) Retard Advance pressure into the 2 broken paths (the advance Side Path Side Path side path and the retard side path). NOTICE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes. A116227E02, EM–172 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(4) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced. Retard Advance Side Path Side Path HINT: The lock pin is released and the camshaft timing gear revolves in the advance direction. (5) When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path. Decompress Hold Pressure NOTICE: Camshaft timing gear assembly occasionally shifts to the retard side A116228E02 abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock pin. (c) Check that the revolution is smooth. (1) Rotate the valve timing assembly back and forth several times, except where the lock pin meets it at the most retarded angle. Check the movable range and that it rotates smoothly. Standard: Smooth movable range is about 22.5° NOTICE: Perform this check by hand, instead of using air pressure. (d) Check that the gear locks in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked in the most retarded position. 2. INSPECT CHAIN SUB-ASSEMBLY (a) Using a spring scale, apply 140 N (14.3 kgf, 31.5 lb) to the timing chain and measure its length. Maximum chain elongation: 123.2 mm (4.850 in.) Measuring Area If the elongation is greater than the maximum, replace the chain. HINT: 01234516 Perform the same measurement at 3 or more A032117E01 random places and calculate the average length. 3. INSPECT CHAIN TENSIONER ASSEMBLY NO. 1 (a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. (b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. A011223E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–173

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4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Wrap the chain around the timing sprocket. (b) Using vernier calipers, measure the diameter of the timing gear with the chain. Minimum gear diameter (with chain): 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the camshaft timing gear. NOTICE: A037071E01 Make sure that the vernier calipers are in contact with the chain link when measuring. 5. INSPECT CAMSHAFT TIMING SPROCKET (a) Wrap the chain around the timing sprocket. (b) Using vernier calipers, measure the diameter of the timing gear with the chain. Minimum gear diameter (with chain): E 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the camshaft timing sprocket. NOTICE: A037072E01 Make sure that the vernier calipers are in contact with the chain link when measuring. 6. INSPECT CHAIN TENSIONER SLIPPER (a) Check the chain tensioner slipper. Minimum thickness: 1.0 mm (0.039 in.) If the thickness is less than the minimum, replace the chain tensioner slipper. A037065E01 7. INSPECT CHAIN VIBRATION DAMPER NO. 1 (a) Check the vibration damper. Minimum thickness: 1.0 mm (0.039 in.) If the thickness is less than the minimum, replace the chain vibration damper. A037066E01, EM–174 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

8. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.16 to 0.36 mm (0.0063 to 0.0142 in.) Maximum thrust clearance: 0.36 mm (0.0142 in.) 9. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod A037347E01 and cap are aligned to ensure correct reassembly. (b) Using SST, remove the 2 connecting rod cap bolts. SST 09205-16010 SST (c) Clean the crank pin and bearing. (d) Check the crank pin and bearing for pitting and scratches. A037361E02 (e) Lay a strip of Plastigage across the crank pin. Plastigage A050668E03 (f) Make sure that the connecting rod and its cap are in Front the correct combination and that the front mark of Mark the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod. (g) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. A050673E02 (h) Using SST, tighten the bolts in several steps to the specified torque.

SST

SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A037360E03, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–175

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(i) Mark the front of the connecting cap bolts with paint. (j) Retighten the cap bolts by 90° as shown in the Front illustration. NOTICE: Do not turn the crankshaft. (k) Remove the 2 bolts, connecting rod cap and lower bearing. Paint Mark A065715E02 (l) Measure the Plastigage at its widest point. Plastigage Standard oil clearance: 0.012 to 0.038 mm (0.00047 to 0.00015 in.) Maximum oil clearance: 0.058 mm (0.0028in.) E NOTICE: Completely remove the Plastigage after the measurement. A037349E02 (m) When replacing a bearing, replace it with one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly. Standard bearing center wall thickness Mark mm (in.) 1 1.491 to 1.494 (0.0587 to 0.0588) 2 1.494 to 1.497 (0.0588 to 0.0589) Mark 1 , 2 or 3 Front Mark 3 1.497 to 1.500 (0.0589 to 0.0591) A051826E02 10. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.09 to 0.19 mm (0.0035 to 0.0075 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, A037350E01 replace the thrust washers as a set. Check the crankshaft and block for wear. Repair or replace the parts if necessary. HINT: Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.976 in.), EM–176 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

11. INSPECT CYLINDER BLOCK FOR WARPAGE (a) Using a precision straight edge and feeler gauge, Straight Edge measure the warpage of the surface which is in contact with the cylinder head gasket. Maximum warpage: 0.05 mm (0.0020 in.) A037353E02 12. INSPECT CYLINDER BORE (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both the thrust and axial directions. Standard Inside diameter: 75.000 to 75.013 mm (2.9528 to 2.9533 in.) (b) Calculate the difference between the maximum diameter and the minimum diameter of the 4 measured values. Difference limit: 0.10 mm (0.0039 in.) Thrust Direction If the difference is greater than the limit, replace the Front cylinder block. Axial Direction 10 mm A (0.39 in.) B Center A081899E02 13. INSPECT WITH PIN PISTON SUB-ASSEMBLY (a) Using a micrometer, measure the piston diameter at a right angle to the piston pin center line, and at the position 27.6 to 27.8 mm (1.0866 to 1.0945 in.) from the top of the piston head. Piston diameter: 74.935 to 74.945 mm (2.9502 to 2.9506 in.) 27.6 to 27.8 mm (1,0866 to 1,0945 in.) A050666E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–177

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(b) Using a caliper gauge, measure the piston pin hole diameter. Piston pin hole diameter: 18.013 to 18.016 mm (0.7092 to 0.7093 in.) at 20°C (68°F) (c) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 18.001 to 18.004 mm (0.7087 to 0.7088 in.) (d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement to calculate the oil clearance. Standard oil clearance: 0.009 to 0.015 mm (0.0004 to 0.0006 in.) EM00227 Maximum oil clearance: 0.050 mm (0.0020 in.) E If necessary, replace the piston and piston pin together. 14. INSPECT PISTON CLEARANCE (a) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.045 to 0.068 mm (0.0018 to 0.0027 in.) Maximum oil clearance: 0.08 mm (0.0032 in.) 15. INSPECT CONNECTING ROD SUB-ASSEMBLY (a) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the misalignment is greater than the maximum, replace the connecting rod assembly. Z000064E01 (2) Check for twist. Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z000065E01, EM–178 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

16. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance: No. 1: 0.03 to 0.07 mm (0.0012 to 0.0028 in.) No. 2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.) A001171E01 17. INSPECT PISTON RING END GAP (a) Using a piston, push the piston ring, a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. 110 mm (4.33 in.) A037354E02 (b) Using a feeler gauge, measure the end gap. Standard end gap: No. 1: 0.25 to 0.35 mm (0.0098 to 0.0138 in.) No. 2: 0.35 to 0.50 mm (0.0138 to 0.0197 in.) Oil (Side Rail): 0.10 to 0.35 mm (0.0039 to 0.0138 in.) Maximum end gap: EM07639 No. 1: 0.91 mm (0.0358 in.) No. 2: 1.06 mm (0.0417 in.) Oil (Side Rail): 0.82 mm (0.323 in.) 18. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the diameter of the bolt at the elongated portion. Standard diameter: 6.6 to 6.7 mm (0.260 to 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than the minimum, replace the bolt. A001470, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–179

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19. INSPECT CRANKSHAFT (a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) A011241E01 (b) Using a micrometer, measure the diameter of each main journal. Outside diameter: 45.988 to 46.000 mm (1.8106 to 1.8110 in.) (c) Check each main journal for taper and out-of- E roundness as shown. Maximum taper and out-of-roundness: 0.02 mm (0.0008 in.) A037157E01 (d) Using a micrometer, measure the diameter of each crank pin. Outside diameter: 39.992 to 40.000 mm (1.5745 to 1.5748 in.) (e) Check each crank pin for taper and out-of- roundness as shown. Maximum taper and out-of-roundness: 0.02 mm (0.0008 in.) ZF06928E01 (f) Wrap the chain around the timing sprocket. (g) Using vernier calipers, measure the timing sprocket diameter with the chain. Standard sprocket diameter (with chain): 51.72 mm (2.0362 in.) Minimum sprocket diameter (with chain): 50.5 mm (1.988 in.) NOTICE: Make sure that the vernier calipers are in A038171E01 contact with the chain rollers when measuring. 20. INSPECT CRANKSHAFT BEARING CAP SET BOLT (a) Using vernier calipers, measure the tension portion diameter of the elongated portion. Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter: 7.2 mm (0.283 in.) If the diameter is less than the minimum, replace the bolt. A015065E03, EM–180 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

21. INSPECT CRANKSHAFT OIL CLEARANCE (a) Clean each main journal and bearing. (b) Install the bearing onto the cylinder block and bearing cap. (See page EM-183) (c) Place the crankshaft onto the cylinder block. (d) Lay a strip of Plastigage across each journal. Plastigage A050669E02 (e) Examine the front marks and numbers and install Bearriing Cap Bearing Cap the bearing cap onto the cylinder block. CNaop. 3N:o. 3: No. 1, 2, 4, 5: (f) Apply a light coat of engine oil to the threads of the bearing cap bolts. Numberr FrFornotn Mt Marakrk Frrontt Marrkk and Nanudm Nbeurmber A118660E01 (g) Using SST, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration. (*1) 95137SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 106248A037364E07 (h) Mark the front of the bearing cap bolts with paint. (i) Retighten the bearing cap bolts by 90° in the same Front sequence as step (*1). (j) Check that the painted mark is now at a 90° angle from the front. NOTICE: Do not turn the crankshaft. (k) Remove the bearing cap sub-assembly. Paint Mark A065715E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–181

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(l) Measure the Plastigage at its widest point. Plastigage Standard oil clearance: 0.01 to 0.023 mm (0.0004 to 0.0009 in.)

Maximum oil clearance:

0.07 mm (0.0028 in.)

NOTICE: Completely remove the Plastigage after the

mesurement. A037352E02 (m) When replacing a standard bearing, replace it with one with the same number. If the number of the bearing cannot be found, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then select the E bearing with the same number as the total. There are 4 sizes of standard bearings, marked 1, 2, 3 and No. 1 No. 2 4 accordingly. No. 3 EXAMPLE: Cylinder Block 4 (A) + Crankshaft 3 No. 4 (B) = Total 7 (Use Bearing 3)No. 5 Cylinder Block (A) + 0 to23to56to89to 11 Crankshaft (B) No. 1 No. 3 No. 5 Use Bearing1234Mark No. 2 No. 4 A010463E02 Item Mark mm (in.) 0 50.000 to 50.003 (1.96850 to 1.96862) 1 50.003 to 50.005 (1.96862 to 1.96870) 2 50.005 to 50.007 (1.96870 to 1.96878) Cylinder block main journal bore diameter (A) 3 50.007 to 50.010 (1.96878 to 1.96890) 4 50.010 to 50.012 (1.96890 to 1.96898) 5 50.012 to 50.014 (1.96898 to 1.96906) 6 50.014 to 50.016 (1.96906 to 1.96913) 0 45.998 to 46.000 (1.81094 to 1.81102) 1 45.996 to 45.998 (1.81087 to 1.81094) Crankshaft main journal diameter (B) 2 45.994 to 45.996 (1.81079 to 1.81087)3 45.992 to 45.994 (1.81071 to 1.81079) 4 45.990 to 45.992 (1.81063 to 1.81071) 5 45.988 to 45.990 (1.81055 to 1.81063) 1 1.992 to 1.995 (0.07843 to 0.07854) Standard bearing center wall thickness 2 1.995 to 1.998 (0.07854 to 0.07866)3 1.998 to 2.001 (0.07866 to 0.07878) 4 2.001 to 2.004 (0.07878 to 0.07890), EM–182 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM REASSEMBLY

1. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Apply adhesive to the end 2 or 3 threads of the drain union and install the water drain cock within 3 minutes of applying the adhesive. (b) After applying the specified torque, rotate the drain union clockwise until its drain port faces downward. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) NOTICE: • Do not add coolant within 1 hour of installation. • Do not rotate the drain union more than 360° in step (b), and never loosen it after setting 40 40 the union correctly. A064756E01 2. INSTALL STRAIGHT PIN Upper Side Front Side

A A C

Lower Side Rear Side

D B

18.5 to 11.5 to 8.5 to 8.5 to 19.5 mm 12.5 mm 9.5 mm 9.5 mm Pin A ( 8) Pin B ( 8) Pin D ( 10) Pin C ( 10) A107304E02 (a) Using a plastic-faced hammer, tap in the straight pin. Standard protrusion: Pin A:, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–183

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8.5 to 9.5 mm (0.335 to 0.374 in.) Pin B: 8.5 to 9.5 mm (0.335 to 0.374 in.) Pin C: 18.5 to 19.5 mm (0.728 to 0.768 in.) Pin D: 11.5 to 12.5 mm (0.453 to 0.492 in.) 3. INSTALL OIL PUMP SET RING PIN Front Side (a) Using a plastic-faced hammer, tap in a new ring pin. Standard protrusion: 3.5 to 4.5 mm (0.138 to 0.177 in.) 4. INSTALL STUD BOLT

E

3.5 to 4.5 mm A107305E01BC

D A

12 48 43.5 29 8.5 10 8 129 A (M6) B (M6) C (M12) D (M6) [mm] A107306E01 (a) Using "Torx" socket wrench E5, install the 7 stud bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (for Stud bolt A, B and D) 11 N*m (112 kgf*cm, 8.1 ft.*lbf) (for Stud bolt C) NOTICE: The lower threads of the bolt are installed into the cylinder block., EM–184 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

5. INSTALL CRANKSHAFT BEARING (a) Align the crankshaft bearing (upper) with the oil hole of the cylinder block and install the bearing. NOTICE: Do not apply engine oil to the bearing or its contact surface. NG OK A117086E01 (b) Align the crankshaft bearing (lower) with the bearing cap and install the crankshaft bearing cap. NOTICE: A • Install the bearing cap so that the gap between A and B is less than 0.7 mm (0.028 in.). • Do not apply engine oil to the bearing or its B contact surface. A117087E01 6. INSTALL CRANKSHAFT THRUST WASHER UPPER (a) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward. (b) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block. A001191E03 7. INSTALL CRANKSHAFT Bearriing Cap Bearing Cap (a) Examine the front marks and numbers and install CNaop. 3N:o. 3: No. 1, 2, 4, 5: the bearing caps onto the cylinder block. (b) Apply a light coat of engine oil to the threads of the bearing cap bolts. Numberr FrFornotn Mt Marakrk Frrontt Marrkk and Nanudm Nbeurmber A118660E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–185

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(c) Using SST, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration (*1). 95137SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) NOTICE: Check that the crankshaft turns smoothly. 106248A037364E07 (d) Mark the front of the bearing cap bolts with paint. (e) Retighten the bearing cap bolts by 90° in the same Paint Mark 90° sequence as step (*1). (f) Check that the painted mark is now at a 90° angle from the front. E 8. INSPECT CRANKSHAFT THRUST CLEARANCE (See Engine Front page EM-174) 9. INSPECT CRANKSHAFT OIL CLEARANCE (See page A050671E03 EM-179) 10. INSTALL WITH PIN PISTON SUB-ASSEMBLY (a) Coat the piston pin and pin holes in the piston with engine oil. Front (b) Align the cavity of the piston with the protruding Mark portion on the connecting rod. A050053E01, EM–186 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(c) Using SST, press in the piston pin. SST 09221-25026 (09221-00021, 09221-00030, 09221-00090, 09221-00150, 09221-00100)

SST

SST NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they SST can be returned to the original locations when reassembled.

SST SST

Piston Pin Connecting Piston Rod A130429E01 11. INSTALL CONNECTING ROD BEARING Claw (a) Align the bearing claw with the groove of the connecting rod or connecting cap. NOTICE: Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oil. A050672E03 12. INSTALL PISTON RING SET HINT: When reusing the piston rings, install them onto the No. 2 matched pistons with the surfaces facing correctly. (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings. A012128E02, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–187

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(c) Position the piston rings so that the ring ends are as No. 1 Compression Lower shown. and Expander Side Rail 13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. (b) Check the position of the piston ring ends. Front Upper Side Rail No. 2 Compression A118663E01 E (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston Front facing forward. Mark NOTICE: • Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oil. • Match the numbered connecting rod cap with A001205E02 the connecting rod. (d) Make sure that the connecting rod and its cap are in Front the correct combination and that the front mark of Mark the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod. (e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. A050673E02 (f) Using SST, tighten the bolts in several steps to the specified torque. SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A037360E01, EM–188 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(g) Mark the front of the connecting cap bolts with paint. (h) Retighten the cap bolts by 90° as shown. Paint Mark 90° (i) Check that the crankshaft turns smoothly. 14. INSPECT CONNECTING ROD THRUST CLEARANCE (See page EM-173) Engine Front 15. INSPECT CONNECTING ROD OIL CLEARANCE (See page EM-173) 16. INSTALL STUD BOLT A050671E03 (a) Using "Torx" socket wrench E5, install the 4 stud bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 22.5 (0.51) (0.886) 8.0 (0.32) A Stud Bolt A

B

16.5 B (0.650) 27.5 (1.083) 9.0 (0.35)

A

Stud Bolt B mm (in.) A117460E01 17. INSTALL OIL PAN SUB-ASSEMBLY (a) Remove any old packing material from the contact surface. (b) Apply a continuous bead of seal packing (Diameter Seal Packing 2.0 mm to 3.0 mm (0.079 to 0.118 in.)) to the oil pan 9 mm 4 mm mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. 4 mm • Install the oil pan within 3 minutes of applying 11 mm Seal Packing A050687E04 the seal packing. • Do not expose the seal to engine oil for at least within 2 hours after the installation. (c) Install 2 new O-rings onto the cylinder block., 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–189

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(d) Using several steps, install and tighten the 13 bolts 15 14 uniformly in the sequence shown in the illustration. 543213 12 Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) HINT: Each bolt length is as follows: ABCBolt A 49 mm (1.93 in.) B Bolt B 88 mm (3.47 in.) Bolt C 144 mm (5.67 in.) 678110 18. INSTALL OIL STRAINER SUB-ASSEMBLY 9 A037067E03 (a) Install a new gasket and the oil strainer with the 2 nuts and the bolt. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) 19. INSTALL OIL PAN SUB-ASSEMBLY NO. 2 (a) Remove any old packing material from the contact surface. E (b) Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying Seal Width 2.5 to 3.5 mm A081876E02 the seal packing. • Do not expose the seal to engine oil for at least 2 hours after the installation. • Do not start the engine for at least 2 hours after the installation. (c) Install oil pan No. 2 with the 9 bolts and the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (d) Install the drain plug with a new gasket. Torque: 38 N*m (382 kgf*cm, 28 ft.*lbf) 20. INSTALL OIL FILTER UNION (a) Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 21. INSTALL OIL FILTER SUB-ASSEMBLY (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. (c) Gently screw the oil filter into place, and tighten it A079679E01 until the gasket comes into contact with the seat., EM–190 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(d) Using SST, tighten it an additional 3/4 turn. SST 09228-06501 HINT: When using a torque wrench, tighten it to the specified torque. Torque: 13 N*m (133 kgf*cm, 9.5 ft.*lbf)

SST

A038018E02 22. INSTALL CYLINDER HEAD GASKET Lot No. (a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward. NOTICE: • Remove any oil from the contact surface. • Pay attention to the mounting orientation of the cylinder head gasket. • Place the cylinder head on the cylinder head gently in order not to damage the gasket. A011249E05 23. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: The cylinder head bolts are tightened in 2 successive steps. (a) Apply a light coat of engine oil to the threads of the892cylinder head bolts.4 5 (b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) (c) Mark the front of the cylinder head bolt with paint. 106137A035288E03, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–191

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(d) Retighten the cylinder head bolts by 90° and then an additional 90° as shown in the illustration. (e) Check that the paint mark is now at a 180° angle from the front. 90 90 Paint Mark42589

E

107613A116959E01 (f) Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as shown in the illustration. Cylinder Head Seal Packing: Toyota Genuine Seal Packing Black, Three Diameter: Bond 1207B or Equivalent 4.5 to 5.5 mm NOTICE: • Remove any oil from the contact surface. Cylinder Head • Install the oil pump assembly within 3 Gasket minutes and tighten the bolts within 15 minutes of applying seal packing. Cylinder Block 24. INSTALL ENGINE REAR OIL SEAL Seal Packing (a) Apply MP grease to a new oil seal lip. NOTICE: A073748E02 Keep the seal lip free of foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 NOTICE: • Do not tap the oil seal at an angle. • Wipe any extra grease off the crankshaft. 25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY NOTICE: SST Install the camshaft timing gear assembly onto the A050928E01 camshaft with the lock pin of the camshaft timing gear assembly released., EM–192 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(a) Put the camshaft timing gear assembly and camshaft together with the straight pin of the Straight Pin groove. (b) Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits into the groove, push to ensure a good fit. NOTICE: Groove Do not turn the camshaft timing gear in the A116230E01 retard direction (clockwise). (c) Check that there is no clearance between the gear fringe and the camshaft. (d) Tighten the flange bolt with the camshaft timing gear fixed. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: • Do not lock the camshaft timing gear assembly when tightening the bolt. • Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position. • Tightening the bolts with the lock pin locked could cause breakage of the lock pin. (e) Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position. 26. INSTALL CAMSHAFT (a) Apply a light coat of engine oil to the camshaft journals. (b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (c) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) NOTICE: Tighten each bolt uniformly while keeping the camshaft level. 3124A037103E04, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–193

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27. INSTALL CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vice. (b) Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: Do not damage the camshaft. 28. INSTALL NO. 2 CAMSHAFT A032167E01 (a) Apply a light coat of engine oil to the camshaft journals. (b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (c) Examine the front marks and numbers on camshaftE3124bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration. 5 Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 2 23 N*m (235 kgf*cm, 17 ft.*lbf) for bearing cap No. 1 NOTICE: Tighten each bolt uniformly while keeping the camshaft level. Bearing Cap No. 1 Bearing Cap No. 2 A116223E01 29. INSTALL CAMSHAFT POSITION SENSOR (a) Apply engine oil to the O-ring. NOTICE: If the O-ring is damaged, replace the camshaft position sensor. (b) Install the camshaft position sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A080958E01, EM–194 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

30. INSTALL CHAIN SUB-ASSEMBLY TDC: (a) Make sure that all the timing marks are in the positions (TDC) shown in the illustration. Timing Marks HINT: The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring. Timing Mark A116571E01 (b) Set the timing mark of the crankshaft in a position Timing Mark between 40 and 140°ATDC, as illustrated. 40° to 140° ATDC A116573E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–195

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(c) Set the camshaft timing gear and the camshaft 20° ATDC: timing sprocket in the positions (20°ATDC) shown in Timing Marks the illustration. (d) Set the crankshaft in the position (20°ATDC) shown in the illustration.

E

30° Timing Mark A116574E01 (e) Install chain vibration damper No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A116576, EM–196 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(f) Align the timing marks of the camshaft with the mark Mark Plates plates of the timing chain and install the timing chain. HINT: Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench. Timing Marks Mark Plate Timing Mark A116577E01 31. INSTALL CHAIN TENSIONER SLIPPER (a) Install the chain tensioner slipper. A116569 32. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 (a) Install chain tensioner assembly No. 1 with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Remove the bar from chain tensioner assembly No. 1. A116568 33. INSTALL OIL PUMP SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. Wooden SST 09950-60010 (09951-00250, 09951-00380, Block SST 09952-06010), 09950-70010 (09951-07100) NOTICE: • Do not tap the oil seal at an angle. • Keep the seal lip free of foreign matter. (b) Apply MP grease to the oil seal lip. A037153E03, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–197

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34. INSTALL OIL PUMP ASSEMBLY (a) Install 2 new O-rings in the 2 locations shown in the illustration. A116556

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,

EM–198 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM

(b) Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.

B B A A

Seal Packing

C

Seal Packing C 4.5 to 5.5 (0.177 to 0.217) A-A 1.5 to 2.0 (0.059 to 0.079) 2.5 (0.098) 1.5 Seal Width (Other Part) (0.059) 3.5 to 4.5 (0.138 to 0.177) 5.0 1.5 (0.197) (0.059) 1.5 to 2.0 B-B, C-C (0.059 to 0.079) Seal Width (Water Pump Part) 2.5 (0.098) 3.5 to 4.5 (0.138 to 0.177) 2.5 1.0 (0.098) (0.039) 1.5 to 2.0 3.5 to 4.5 (0.059 to 0.079) (0.138 to 0.177) 1.0 (0.039) mm (in.) A116557E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–199

M

Seal packing: Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other part Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the oil pump assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying the the seal packing. • Do not expose the seal to engine oil for at least 2 hours after the installation. (c) Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft, and slide the oil pump into place. E A116558 (d) Install the oil pump assembly with the 15 bolts and nut. Tighten the bolts and nut uniformly in several

D

steps. Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for boltAAE11 N*m (112 kgf*cm, 8.1 ft.*lbf) for boltBCA11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt C

C

24 N*m (245 kgf*cm, 18 ft.*lbf) for nutDCC24 N*m (245 kgf*cm, 18 ft.*lbf) for boltECNOTICE: Install the mounting bracket and water pumpCBwithin 15 minutes of installing the oil pump assembly. C C HINT: Each bolt length is as follows. C C A: 30 mm (1.181 in.)C A116554E01 B: 35 mm (1.378 in.) C: 20 mm (0.787 in.) E: 20 to 14 mm (0.787 to 0.551 in.) Double ended bolt, EM–200 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

35. INSTALL WATER PUMP ASSEMBLY (a) Install the water pump and a new gasket with the 3 bolts and 2 nuts. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) A116192 36. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (a) Install the transverse engine mounting bracket with the 4 bolts. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 37. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Align the pin hole in the crankshaft damper with the pin position and install the crankshaft damper sub- assembly. A080957E01 (b) Provisionally install the bolt. (c) Using 2 SSTs, tighten the bolt while holding the crankshaft damper sub-assembly. SST SST 09213-14010 (91651-60865), 09330-00021 Torque: 128 N*m (1305 kgf*cm, 95 ft.*lbf) NOTICE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly. A117461E01 38. INSTALL WATER PUMP PULLEY (a) Using SST, install the pump pulley with the 3 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

SST

A116191E01 39. INSPECT VALVE CLEARANCE (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump. Timing Notch A116203E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–201

M

(2) Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E01 (b) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for intake: E 0.15 to 0.25 mm (0.006 to 0.010 in.) for exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) Record any out-of-specification valve clearance A116201 measurements. They will be used later to determine the required replacement adjusting shim. (c) Turn the crankshaft 1 complete revolution (360°) and align its timing notch with timing mark "0" of the oil pump. (d) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) for Exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) Record any out-of-specification valve clearance A116202 measurements. They will be used later to determine the required replacement adjusting shim. 40. ADJUST VALVE CLEARANCE Matchmark NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves. A116206E01, EM–202 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper, and align its timing notch with timing mark "0" of the oil pump. Timing Notch A116203E01 (2) Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Marks A116204E04 (b) Put paint marks on the chain in the places where the Paint Marks timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Timing Marks A116207E01 (c) Using an 8 mm hexagon wrench, remove the screw plug. G100163, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–203

M

(d) Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward. Stopper Plate A116209E01 E (e) Using a wrench, rotate the No. 2 camshaft clockwise to push in the plunger of the chain tensioner. Plunger A116210E01 (f) Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and inserta3mm (0.12 in.) diameter bar into the holes to hold the stopper plate. HINT: • Fix the stopper plate using the bar while rotating the camshaft right and left slightly. • Hold the bar with tape so that it does not come out. A116212, EM–204 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(g) Using a wrench, hold the hexagonal lobe of No. 2 camshaft and remove the flange bolt. A116213 (h) Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown13542in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2. NOTICE: Loosen each bolt uniformly while keeping the camshaft level. A116214E01 (i) Remove the flange bolt and remove the camshaft timing sprocket. A116215 (j) Remove the No. 2 camshaft. A116216 (k) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2. NOTICE: Loosen the bolts uniformly while keeping the camshaft level. 2431A116217E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–205

M

(l) Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly. A116218 (m) Tie the chain with a piece of string as shown in the illustration. (n) Remove the valve lifters.

E

A035227E01 (o) Using a micrometer, measure the thickness of the removed lifter. (p) Calculate the thickness of the new lifter so that the valve clearance comes to within the specified values. A Thickness of new lifter B Thickness of used lifter C Measured valve clearance A001082E01 Valve clearance: Intake A = B + (C - 0.20 mm (0.008 in.)) Exhaust A = B + (C - 0.30 mm (0.012 in.)) (q) Select a new lifter with a thickness as close to the calculated values as possible. HINT: Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.)., EM–206 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

A117457, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–207

M Intake valve clearance (cold):

0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE: A 5.250 mm (0.2067 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) E 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173), EM–208 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

A117458, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–209

M Exhaust valve clearance (cold):

0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE: A 5.340 mm (0.2102 in.) lifter is installed, and

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

New Shim Thickness

Shim No. Thickness Shim No. Thickness Shim No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) E 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) (r) Install the selected valve lifter. (s) Apply a light coat of engine oil to the camshaft and camshaft journals. (t) Install the chain onto the camshaft timing gear with Paint Mark the paint mark and the timing mark aligned, as shown in the illustration. Timing Mark A116220E01 (u) Examine the front marks and the numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.

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

camshaft level. 3124A116222E01, EM–210 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

(v) Install camshaft No. 2. A116216 (w) Hold the chain, and align the timing mark on the Paint Mark camshaft timing sprocket with the paint mark of the chain. (x) Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft. Timing Mark Pin A116224E01 (y) Provisionally install the flange bolt. A116215 (z) Examine the front marks and the numbers of3124camshaft bearing cap No. 1 and camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the 5 illustration. Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 2 23 N*m (235 kgf*cm, 17 ft.*lbf) for bearing cap No. 1 NOTICE: Tighten the bolts uniformly while keeping the Bearing Cap No. 1 Bearing Cap No. 2 camshaft level. A116223E01, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–211

M

(aa) Using a wrench, hold the hexagonal lobe of camshaft No. 2, and install the flange bolt. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) SST 09023-38400 (ab) Remove the bar from the timing chain tensioner. A116225 (ac) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.

E

Timing Notch A116203E01 (ad) Check that all the pairs of timing marks are aligned. Paint Marks (ae) Apply adhesive to the end 2 or 3 threads of the screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Timing Marks A116207E01 (af) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) G100163 41. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE

ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring, and install it onto the camshaft timing oil control valve. (b) Install the camshaft timing oil control valve with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Do not twist the O-ring. A064872E01, EM–212 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

42. INSTALL FUEL INJECTOR ASSEMBLY (a) Apply a light coat of gasoline or spindle oil to new O- rings, then install one onto each fuel injector. (b) Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the O- ring of the fuel injector. O-Ring A115499E01 (c) While turning the fuel injector left and right, install it onto the fuel delivery pipe. Turn NOTICE: • Do not twist the O-ring. • After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring Push with a new one. A115500E01 43. INSTALL INJECTOR VIBRATION INSULATOR (a) Install 4 new injector vibration insulators onto the cylinder head. A115497 44. INSTALL DELIVERY PIPE NO. 1 SPACER (a) Install the 2 delivery pipe No. 1 spacers onto the cylinder head. NOTICE: Install delivery pipe No. 1 spacer in the correct direction. A115501 45. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Provisionally install the fuel delivery pipe sub- assembly and 4 fuel injectors with the 3 bolts. NOTICE: • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub- assembly. A115494, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–213

M

(b) Tighten the 3 bolts to the specified torque. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A

A

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

A B

A115494E01 46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (a) Install the gasket onto the cylinder head cover. (b) Apply seal packing to the cylinder head, as shown in the illustration. Seal Packing: E Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. Seal Packing A115503E01 • Install the cylinder head cover sub-assembly within 3 minutes of applying the seal packing. • Do not start engine for at least 2 hours after the installation. (c) Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers. (d) Tighten the 9 bolts and 2 nuts in the sequence 11957shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7.0 ft.*lbf) 1012364A035756E01 47. INSTALL VENTILATION VALVE SUB-ASSEMBLY (a) Install the ventilation valve onto the cylinder head cover. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 48. INSTALL OIL LEVEL GAUGE GUIDE (a) Apply engine oil to a new O-ring. (b) Install the oil level gauge guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A080963E01 49. INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring on the crankshaft position sensor. NOTICE: If the O-ring is damaged, replace the crankshaft position sensor. (b) Install the crankshaft position sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf), EM–214 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT

EM

50. INSTALL OIL FILLER CAP GASKET (a) Install the oil filler cap gasket onto the oil filler cap. 51. INSTALL OIL FILLER CAP SUB-ASSEMBLY (a) Install the oil filler cap onto the cylinder head cover. 52. INSTALL THERMOSTAT (a) Install a new gasket onto the thermostat. (b) Install the thermostat with the jiggle valve facing upward. 10 10 HINT: The jiggle valve may be set within 10°either side as shown in the illustration. A116188E01 53. INSTALL WATER INLET (a) Install the water inlet with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 54. INSTALL ENGINE COOLANT TEMPERATURE

SENSOR

(a) Provisionally install the engine coolant temperature sensor through a new gasket. A080960E01 (b) Using SST, tighten the engine coolant temperature sensor. SST SST 09817-33190 Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) A117464E01 55. INSTALL ENGINE OIL PRESSURE SWITCH

ASSEMBLY

Adhesive (a) Apply adhesive to the end 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent A050082E13, 1NZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–215

M

(b) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A117463 56. INSTALL KNOCK SENSOR (a) Install the knock sensor with the nut as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) E +- 30° A090881E01 57. INSTALL SPARK PLUG (a) Using a spark plug wrench, install the spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) A080968E01]
15

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DISCRETE SEMICONDUCTORS DATA SHEET 1N5059 to 1N5062 Controlled avalanche rectifiers Product specification 1996 Jun 20 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, 2 columns M3D116 1N5059 to 1N5062 Controlled avalanche rectifiers Product specification 1996 Jun 20 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION This package is hermetically sealed and fatigue free as coeffic
DISCRETE SEMICONDUCTORS DATA SHEET 1N4728A to 1N4749A Voltage regulator diodes Product specification 1996 Apr 26 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D130 1N4728A to 1N4749A Voltage regulator diodes Product specification 1996 Apr 26 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Total power dissipation: Low voltage regulator diodes in hermetical
DISCRETE SEMICONDUCTORS DATA SHEET 1N4531; 1N4532 High-speed diodes Product specification 1996 Apr 03 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D050 1N4531; 1N4532 High-speed diodes Product specification 1996 Apr 03 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Hermetically sealed leaded glass The 1N4531, 1N4532 are high-speed switching d
DISCRETE SEMICONDUCTORS DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET M3D176 1N4150; 1N4151; 1N4153 High-speed diodes Product specification 1996 Apr 19 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Hermetically sealed leaded glass The 1N4150, 1N4151, 1N4153 are high-speed switching diod
DISCRETE SEMICONDUCTORS DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET M3D176 1N4148; 1N4446; 1N4448 High-speed diodes Product specification 1996 Apr 15 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Hermetically sealed leaded glass The 1N4148, 1N4446, 1N4448 are high-speed switching diod
DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET handbook, 2 columns M3D116 1N4001G to 1N4007G Rectifiers Product specification 1996 May 24 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION This package is hermetically sealed and fatigue free as coefficients of • Glass pa
DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D119 1N4001ID to 1N4007ID Rectifiers Product specification 1996 Jun 10 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION This package is hermetically sealed and fatigue free as coefficients of • Glass p
Small-signal Transistors Selection guide
Philips Semiconductors Small-signal Transistors Selection guide LEADED DEVICES (continued) NPN HIGH-VOLTAGE MEDIUM-POWER TRANSISTORSVIPfTYPE CEO C tothhTPNP PACKAGE max. max. max. FE FE min. PAGE NUMBER min. max. COMPL. (V) (mA) (mW) (MHz) BF420 TO-92 300 50 830 50 >50 60 BF421 534 BF422 TO-92 250 5
Small-signal Transistors Selection guide
Philips Semiconductors Small-signal Transistors Selection guide LEADED DEVICES (continued) NPN HIGH-VOLTAGE LOW-POWER TRANSISTORS V TYPE CEO IC Ptot fhhTPNP PACKAGE max. max. max. FE FE min. PAGE NUMBER min. max. COMPL. (V) (mA) (mW) (MHz) 2N5550 TO-92 140 300 630 60 >60 100 2N5400 184 2N5551 TO-92