Professional Documents
Culture Documents
EM1
ENGINE
ON-VEHICLE INSPECTION
1.
2.
Intelligent Tester
CAN VIM
DLC3
A087542E04
3.
Intelligent Tester
CAN VIM
DLC3
A087542E04
4.
INSPECT COMPRESSION
(a) Remove the windshield wiper link (see page WW13).
(b) Remove the front cowl top panel outer.
EM
EM2
EM
SST
(j)
A057119E02
Intelligent Tester
CAN VIM
DLC3
A087542E04
EM3
CO
Normal
Low
High
HC
High
High
High
INSPECT CO/HC
(a) Set the vehicle to inspection mode (see page IN34).
(b) Run the engine at 2,500 rpm for approximately 180
seconds.
(c) Insert a CO/HC meter testing probe at least 40 cm
(1.3 ft.) into the btailpipe during idling.
(d) Immediately check the CO/HC concentration at idle
and 2,500 rpm.
HINT:
When performing the 2 mode (2,500 rpm and idle)
test, check that the CO/HC concentration complies
with local regulations.
(e) If the CO/HC concentration does not comply with
regulations, troubleshoot in the order given below.
(1) Check the heated oxygen sensor operation
(see page ES-392).
(2) See the table below for possible causes, and
then inspect the applicable causes and repair it
if necessary.
Problems
Causes
Rough idle
1. Faulty ignition:
Incorrect timing
Plugs are contaminated, plugs are shorted or plug gaps are
incorrect
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Rough idle
(Fluctuating HC reading)
1. Vacuum leaks:
Ventilation hoses
Intake manifold
Throttle body
IAC valve
Brake booster line
2. Lean mixture causing misfire
Rough idle
(Black smoke from exhaust)
EM
EM4
DRIVE BELT
1NZ-FXE ENGINE MECHANICAL
ENGINE
COMPONENTS
DRIVE BELT
EM
x3
x2
A129334E01
EM5
ON-VEHICLE INSPECTION
1.
A087786E01
CORRECT
New belt
99 to 121 lbf
Used belt
55 to 77lbf
HINT:
After installing the drive belt, check that it fits
properly in the ribbed grooves. Check with your
hands to confirm that the belt has not slipped out
of the groove on the bottom of the crankshaft
pulley.
A "new belt" is a belt which has been used less
than 5 minutes on a running engine.
A "used belt" is a belt which has been used on a
running engine for 5 minutes or more.
After installing a new belt, run the engine for
approximately 5 minutes and then recheck the
tension.
INCORRECT
A122295E01
Idler Pulley
(b) Reference:
Check the drive belt deflection.
(1) When not using a belt tension gauge, measure
the belt deflection.
Pressing force: 98 N (10 kgf, 22 lbf)
Standard belt deflection
Item
Crankshaft
Pulley
Water Pump
Pulley
A093818E02
Specified Condition
Specified Condition
New belt
Used belt
NOTICE:
Check the drive belt deflection at the
specified point.
When installing a new belt, set its tension
value as specified.
When inspecting a belt which has been
used over 5 minutes, apply the
specification for "Used belt".
When reinstalling a belt which has been
used over 5 minutes, adjust its deflection
and tension to the intermediate value of
each specification for "Used belt".
Belt tension and deflection should be
checked after 2 revolutions of engine
cranking.
When using a belt tension gauge,
confirm the accuracy by using a master
gauge first.
EM
EM6
REMOVAL
1.
2.
3.
A086911E01
EM
A
B
A086912E01
EM7
INSTALLATION
1.
2.
3.
4.
5.
A086912E01
A086911E01
EM
EM7
VALVE CLEARANCE
ADJUSTMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
EM
EM8
Timing Mark
EM
A092837E01
IN
A081895E02
Exhaust
IN
A081896E02
Specified Condition
Intake
Specified Condition
Intake
Exhaust
EM9
Timing Mark
EM
A092837E01
Paint Mark
A092838E01
A037101E03
EM10
Plunger
Unlock
Stopper Plate
EM
A092839E01
Plunger
Stopper Plate
A092840E02
Plunger
Lock
Stopper Plate
A092841E01
EM11
(f)
Stopper Plate
EM
A092842E01
SST
A050157E01
(j)
1
A035760E02
A037148E01
EM12
(l)
1
A035766E02
(m) Hold the timing chain with one hand, and remove
the camshaft and the camshaft timing gear
assembly.
EM
A035767E01
A035227E01
A001082E01
Item
Thickness
Intake
Exhaust
(r)
EM13
EM
EM14
EM
A116733E01
EM15
EM
A116734E01
Thickness
Lifter No.
Thickness
Lifter No.
Thickness
06
30
54
08
32
56
EM16
Lifter No.
EM
Lifter No.
Thickness
Lifter No.
Thickness
10
34
58
12
36
60
14
38
62
16
40
64
18
42
66
20
44
68
22
46
70
24
48
72
26
50
74
28
52
EM17
EM
A130303E01
EM18
EM
A116736E01
Thickness
Lifter No.
Thickness
Lifter No.
Thickness
06
30
54
08
32
56
EM19
Thickness
Lifter No.
Thickness
Lifter No.
Thickness
10
34
58
12
36
60
14
38
62
16
40
64
18
42
66
20
44
68
22
46
70
24
48
72
26
50
74
28
52
Paint Mark
Timing Mark
A130317E01
A037107E02
EM
EM20
(w) Hold the timing chain, and align the timing mark on
the camshaft timing sprocket with the paint mark of
the timing chain.
Timing Mark
A092844E02
EM
A037148E01
SST
A050157E01
EM21
EM
A089861E01
(ae) Turn the crankshaft pulley until its timing notch and
timing mark 0 of the chain cover are aligned.
(af) Check that all the pairs of the timing marks are
aligned.
Timing Mark
A092837E01
Adhesive
A058128E03
EM22
EM
EM23
TIMING CHAIN
1NZ-FXE ENGINE MECHANICAL
ENGINE
COMPONENTS
x6
WIRE HARNESS
9.0 (92, 80 in.*lbf)
RADIATOR SUPPORT
OPENING COVER
5.5 (56, 49 in.*lbf)
EM
x2
3.0 (31, 27 in.*lbf)
CLAMP
WINDSHIELD WASHER
JAR ASSEMBLY
x2
5.5 (56, 49 in.*lbf)
x3
NO. 2 AIR
CLEANER INLET
RESERVOIR BRACKET
PURGE VSV
14 (143, 10)
x3
x2
ENGINE UNDER COVER RH
N*m (kgf*cm, ft.*lbf) : Specified torque
x4
A124494E01
EM24
21 (56, 16)
21 (56, 16)
x2
EM
COWL TOP VENTILATOR
LOUVER LH
COWL TOP
VENTILATOR
LOUVER RH
x5
WINDSHIELD
MOTOR WITH
WIPER LINK
ASSEMBLY
EM25
10 (102, 7.4)
10 (102, 7.4)
x4
10 (102, 7.4)
IGNITION COIL
10 (102, 7.4)
x4
x2
x7
x2
VENTILATION HOSE
EM
CYLINDER HEAD COVER
NO. 2 VENTILATION HOSE
GASKET
EM26
52 (530, 38)
52 (530, 38)
7.5 (76, 66 in.*lbf)
ENGINE MOUNTING
INSULATOR RH
EM
ENGINE MOUNTING
BRACKET
55 (560, 41)
52 (530, 38)
CRANKSHAFT
POSITION
SENSOR
24 (245, 18)
STUD BOLT
32 (326, 24)
7.5 (76, 66 in.*lbf)
24 (245, 18)
x2
11 (112, 8.1)
STRAIGHT PIN
x 11
CRANKSHAFT PULLEY
O-RING
11 (112, 8.1)
x3
GASKET
x2
DRIVE BELT
15 (153, 11)
WATER PUMP
11 (112, 8.1)
Non-reusable part
Grease application
A124496E01
EM27
EM
CHAIN
A124497E01
EM28
REMOVAL
EM
1.
2.
3.
4.
5.
6.
7.
8.
9.
A086911E01
EM29
A087334E01
EM
A087335E01
A087336E01
A087337E01
A087338E01
EM30
A087339E01
EM
A087340E01
A087341E01
A087343E01
EM31
A087344E01
(f)
EM
A066472E01
A087345E01
SST
A092650E01
SST
A092651E01
EM32
A087348E01
EM
A087349E01
A087350E01
A087351E01
EM33
Timing Mark
Timing Mark
EM
A093711E02
Plunger
Unlock
Stopper Plate
A092824E01
Stopper Plate
Lock
A092825E01
EM34
A089044E01
EM
A088883E02
A088884E01
A088885E01
INSPECTION
1.
Measuring Area
01234 5
16
A050062E01
INSPECT CHAIN
(a) Using a spring scale, pull the timing chain with a
force of 140 N (14.3 kgf, 31.5 lbf) and measure the
length of it.
Maximum chain elongation:
124.2 mm (4.890 in.)
If the elongation is greater than the maximum,
replace the chain.
EM35
HINT:
Perform the measurements at 3 or more random
places to obtain the average length.
2.
3.
4.
A011223E02
A037065E01
A037066E01
EM
EM36
INSTALLATION
1.
40q
Timing Mark
INSTALL CHAIN
(a) Set the position of the No. 1 cylinder to 20 ATDC.
NOTICE:
To prevent the pistons from hitting against
valves, the following procedures must be
performed in the order below.
(1) Set the crankshaft between 40 to 140 ATDC.
(2) Set the cams of the intake and exhaust timing
sprockets to 20 ATDC.
(3) Reset the crankshaft to 20 ATDC.
(b) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
EM
A092826E01
20 ATDC
Mark Plate
Timing Mark
Mark Plate
Timing Mark
30
A081877E03
A088883E02
EM37
Plunger
Unlock
Stopper Plate
A092824E01
EM
Stopper Plate
Lock
A092825E01
Plunger
Stopper Plate
A080976E02
HINT:
If the stopper plate is not completely lowered
and a 3.0 mm (0.118 in.) diameter bar cannot
be inserted, unlock and pull out the plunger
slightly. Then the stopper plate will be
completely lowered and a 3.0 mm (0.118 in.)
diameter bar can be inserted easily.
A087621E01
(f)
A089044E01
2.
3.
4.
EM38
5.
6.
7.
8.
9.
A087351E01
EM
A087350E01
A089869E01
SST
A092652E01
EM39
A087345E01
Seal Packing
11
A092514E01
10
1
8
2
6
A035756E02
A087344E01
EM
EM40
A087341E01
(f)
EM
A087340E01
A092653E01
A087337E01
EM41
A087336E02
EM
A087335E01
A087334E01
(c) Connect the No. 1 air inlet, and then tighten the
clamp.
20. INSTALL FRONT COWL TOP PANEL OUTER
21. INSTALL WINDSHIELD WIPER MOTOR AND WIPER
LINK ASSEMBLY (See page WW-16)
22. INSTALL COWL TOP VENTILATOR LOUVER RH
23. INSTALL COWL TOP VENTILATOR LOUVER LH
A086911E01
EM42
EM
EM43
CYLINDER HEAD
1NZ-FXE ENGINE MECHANICAL
ENGINE
COMPONENTS
x6
WIRE HARNESS
9.0 (92, 80 in.*lbf)
RADIATOR SUPPORT
OPENING COVER
EM
x2
3.0 (31, 27 in.*lbf)
WINDSHIELD WASHER
JAR ASSEMBLY
CLAMP
x2
5.5 (56, 49 in.*lbf)
x3
NO. 2 AIR
CLEANER INLET
RESERVOIR BRACKET
PURGE VSV
14 (143, 10)
x3
x2
ENGINE UNDER COVER RH
N*m (kgf*cm, ft.*lbf) : Specified torque
x4
A124494E02
EM44
21 (56, 16)
21 (56, 16)
x2
EM
COWL TOP VENTILATION
LOUVER LH
COWL TOP
VENTILATION
LOUVER RH
x5
WINDSHIELD
MOTOR WITH
WIPER LINK
ASSEMBLY
x 12
EM45
11 (112, 8.1)
INVERTER COVER
11 (112, 8.1)
EM
NO. 2 INVERTER COOLING HOSE
NO. 1 INVERTER
COOLING HOSE
EM46
EM
FRONT EXHAUST
PIPE ASSEMBLY
GASKET
A129335E01
EM47
EM
21 (214, 16)
21 (214, 16)
21 (214, 16)
EM48
10 (102, 7.4)
10 (102, 7.4)
x4
10 (102, 7.4)
IGNITION COIL
10 (102, 7.4)
x4
x2
x7
x2
VENTILATION HOSE
EM
CYLINDER HEAD COVER
NO. 2 VENTILATION HOSE
GASKET
EM49
52 (530, 38)
52 (530, 38)
ENGINE MOUNTING
INSULATOR RH
ENGINE MOUNTING
BRACKET
EM
55 (560, 41)
52 (530, 38)
CRANKSHAFT
POSITION
SENSOR
24 (245, 18)
STUD BOLT
32 (326, 24)
7.5 (76, 66 in.*lbf)
24 (245, 18)
x2
11 (112, 8.1)
STRAIGHT PIN
x 11
CRANKSHAFT PULLEY
O-RING
11 (112, 8.1)
x3
GASKET
x2
DRIVE BELT
15 (153, 11)
WATER PUMP
11 (112, 8.1)
Non-reusable part
Grease application
A124496E02
EM50
EM
CHAIN
A124497E03
EM51
23 (235, 17)
x3
NO. 1 CAMSHAFT
BEARING CAP
x 16
x8
13 (133, 10)
NO. 2 CAMSHAFT
BEARING CAP
NO. 2 CAMSHAFT
CAMSHAFT TIMING
SPROCKET
CAMSHAFT
64 (653, 47)
CAMSHAFT
TIMING GEAR
64 (653, 47)
1st: 29 (296, 21)
2nd: 90
3rd: 90
EM
x 10
CYLINDER HEAD
GASKET
EM52
O-RING
DELIVERY PIPE
SPACER
FUEL INJECTOR
EM
x4
INSULATOR
x3
x2
x2
27 (275, 20)
EXHAUST MANIFOLD
GASKET
GASKET
20 (204, 15)
x2
x3
GASKET
INTAKE MANIFOLD
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A129819E01
EM53
VALVE LIFTER
VALVE SPRING RETAINER LOCK
VALVE SPRING RETAINER
VALVE SPRING
VALVE STEM OIL SEAL
VALVE SPRING SEAT
EM
CAMSHAFT BEARING
CAP SETTING RING PIN
44 (449, 33)
GASKET
4.0 (41, 35 in.*lbf)
STUD BOLT
STUD BOLT
CYLINDER HEAD
GASKET
10 (102, 7)
STUD BOLT
30 (306, 22)
EXHAUST VALVE
EM54
REMOVAL
EM
A087632E01
1.
2.
PRECAUTION
CAUTION:
The hybrid system uses high voltage circuits, so
improper handling could cause an electric shock or
leakage. During service (e.g. installing or removing
the parts, inspection, replacing the parts), be sure to
follow the procedures (see page HV-519).
3.
4.
5.
6.
7.
8.
9.
EM55
EM
A087634E01
A087635E01
EM56
(b) Disconnect the fuel tube from the fuel delivery pipe.
NOTICE:
Even if the fuel tube is stuck and cannot be
disconnected, do not use any tools. Push and
pull the parts with the quick connector pinched
to disconnect the tube.
(c) Cover the disconnected fuel tube and fuel delivery
pipe with a plastic bag in order to prevent foreign
objects from entering them.
A087636E01
EM
A087637E01
A087638E01
A087639E01
A087641E01
10
EM57
4
A035286E02
DISASSEMBLY
1.
2.
3.
A088717E02
A038128E02
A088718E01
EM
EM58
4.
5.
6.
7.
SST
A037109E02
EM
A080961E01
A080962E01
8.
EM59
Front Side
EM
A092363E02
9.
A088720E01
EM60
INSPECTION
1.
Specified Condition
0.05 mm (0.0020 in.)
EM
Exhaust Manifold Side
A050931E01
2.
3.
A001071E01
Underhead Length
A098332E01
4.
EM61
EM
A037353E01
5.
EM02534E06
Z000052E01
Margin Thickness
EM00181E03
EM62
6.
7.
EM
EM00801E01
EM00281E01
EM63
8.
A001478E01
Specified Condition
Intake
Exhaust
Specified Condition
Intake
Exhaust
Width
A050036E01
45
20
A092365E01
EM
EM64
75
45
A092366E01
45
20
EM
A092365E01
75
45
A092366E01
P016860E01
A088724E01
EM65
Retard Side
Paths
Advance
Side Paths
Close
Open
Vinyl Tape
Open
Close
Rubber Piece
A051761E02
Retard
Side Path
Advance
Side Path
A051762E01
Retard
Side Path
Decompress
Advanced
Side Path
Hold Pressure
A051763E01
EM
EM66
EM
A037071E01
A037072E01
EM67
A037114E01
Specified Condition
No. 1 journal
Other journals
EM
EM68
Specified Condition
No. 1 journal
Other journals
EM
Plastigage
A001452E01
(f)
A001453E01
EM69
REPLACEMENT
1.
A001067E01
(b) Using SST and a hammer, tap out the guide bush.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
SST
EM
A037110E01
A001445E01
Specified Condition
STD
O/S 0.05
SST
9.0 to 9.4 mm
A080977E02
EM70
(f)
2.
A001447E01
EM
Bush size
Specified Condition
STD
O/S 0.05
EM71
REASSEMBLY
8.5 to 9.5 mm
A080980E03
1.
2.
EM
EM72
EM
D
B
Stud Bolt
A
43.5 mm
(1.713 in.)
Stud Bolt
C
13.0 mm (0.512 in.)
Stud Bolt
D
A117402E01
3.
Intake Side
Exhaust Side
Gray
Black
A092940E02
EM73
SST
A001063E01
4.
A001065E01
(b) Using SST, compress the valve spring and place the
2 retainer locks around the valve stem.
SST 09202-70020 (09202-00010)
SST
A037109E01
A007307E01
EM
EM74
Mesh
6.
7.
8.
A050664E01
EM
A088717E02
EM75
INSTALLATION
1.
2.
3.
4.
5.
6.
7.
Lot No.
8.
A092832E02
Cylinder Head
Diameter:
4.5 to 5.5 mm
Cylinder Head
Gasket
Cylinder Block
Seal Packing
A073748E02
10
7
A035286E03
EM
EM76
90
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by an additional
90 and then another 90, as shown in the
illustration.
(f) Check that the paint mark is now 180 opposite to
the front.
90
Front
Paint Mark
EM
A092833E01
9.
40q
Timing Mark
INSTALL CAMSHAFT
NOTICE:
If turning the camshaft with the chain removed, turn
the crankshaft counterclockwise by 40 from TDC/
compression.
(a) Apply engine oil to the cam and cylinder head
journals.
A092826E01
Timing Mark
A093712E01
A087642E01
EM77
A093713E01
A087638E01
A087637E01
EM
EM78
A087635E01
EM
A087634E01
EM79
EM
EM80
ENGINE ASSEMBLY
1NZ-FXE ENGINE MECHANICAL
ENGINE
COMPONENTS
WINDSHIELD WIPER ARM COVER
21 (56, 16)
21 (56, 16)
x2
EM
HOOD TO COWL TOP SEAL
COWL TOP
VENTILATOR
LOUVER RH
x5
WINDSHIELD WIPER
MOTOR AND LINK
ASSEMBLY
EM81
x 12
11 (112, 8.1)
EM
INVERTER COVER
11 (112, 8.1)
NO. 1 INVERTER
COOLING HOSE
ENGINE ROOM
MAIN WIRE
HARNESS
EM82
EM
21 (214, 16)
21 (214, 16)
21 (214, 16)
EM83
x6
INVERTER BRACKET
21 (214, 16)
20 (204, 15)
COOLER BRACKET
x5
EM
25 (255, 18)
x2
RADIATOR
SUPPORT
HOOD LOCK
CONTROL CABLE
HOOD LOCK
HORN CONNECTOR
x3
x4
A124482E01
EM84
WIRE HARNESS
FAN MOTOR CONNECTOR
EM
HOSE CLAMP
HOSE CLAMP
A124483E01
EM85
x4
RADIATOR SUPPORT
UPPER RH
RADIATOR SUPPORT
UPPER LH
RADIATOR FAN
TEMPERATURE
SWITCH
NO. 2 RADIATOR
ASSEMBLY
RADIATOR SUPPORT
LOWER LH
RADIATOR SUPPORT
LOWER LH
EM
EM86
EM
FRONT FLOOR CARPET
GASKET
COMPRESSION SPRING
43 (440, 32)
x2
GASKET
COMPRESSION SPRING
x2
FRONT EXHAUST PIPE
x4
43 (440, 32)
FRONT FLOOR
PANEL BRACE
30 (302, 22)
Non-reusable part
A124485E01
EM87
PURGE VSV
FUEL TUBE
FRONT
STABILIZER
LINK LH
CLIP
49 (500, 36)
x3
25 (255, 18)
35 (357, 26)
COOLER COMPRESSOR
WITH MOTOR ASSEMBLY
89 (908, 66)
NO. 3 INVERTER
COOLING HOSE
FRONT DRIVE SHAFT LH
FRONT AXLE
HUB NUT LH
Non-reusable part
A124486E01
EM
EM88
52 (530, 38)
x2
80 (816, 59)
EM
x2
52 (530, 38)
x2
x2
x2
x2
x2
56 (571, 41)
EM89
EM
ENGINE HANGER
CLAMP
40 (408, 30)
ENGINE HANGER
FLYWHEEL
40 (408, 30)
49 (500, 36)
STARTER HOLE
INSULATOR
32 (326, 24)
x6
TRANSMISSION
INPUT DAMPER
x6
20 (204, 15)
FLYWHEEL HOUSING
SIDE COVER
HYBRID VEHICLE
TRANSAXLE
ASSEMBLY
EM90
x2
EM
GASKET
OIL DIPSTICK
OIL DIPSTICK
GUIDE
9.0 (92, 80 in.*lbf)
O-RING
KNOCK SENSOR
20 (204, 15)
DRIVE BELT
40 (408, 30)
IDLER PULLEY
RADIATOR
OUTLET HOSE
20 (204, 15)
20 (204, 15)
x2
x3
GASKET
INTAKE MANIFOLD
EM91
x4
EM
IGNITION COIL
x4
x4
NOISE FILTER
27 (275, 20)
GASKET
GASKET
20 (204, 15)
ENGINE COOLANT
TEMPERATURE SENSOR
EXHAUST MANIFOLD
27 (275, 20)
EM92
REMOVAL
EM
1.
PRECAUTION
CAUTION:
The hybrid system uses high voltage circuits, so
improper handling could cause an electric shock or
leakage. During service (e.g. installing or removing
the parts, inspection, replacing the parts), be sure to
follow the procedures (see page HV-519).
2.
3.
4.
5.
6.
7.
8.
9.
EM93
A087644
A087645E01
A087646E01
A088023E01
EM
EM94
A088024E01
EM
A088025E01
(b) Disconnect the fuel tube from the fuel delivery pipe.
NOTICE:
Even if the fuel tube is stuck and cannot be
disconnected, do not use any tools. Push and
pull the part with the quick connector pinched to
disconnect the tube.
(c) Cover the disconnected fuel tube and fuel delivery
pipe with plastic bags in order to prevent foreign
objects from entering them.
A088026E01
A088027E01
A088028E01
EM95
EM
A088029E02
A088030E02
A088159E01
A088031E01
EM96
(c) Loosen the bolt on the column side (A) of the sliding
yoke.
(d) Remove the bolt on the gear side (B) of the sliding
yoke.
(e) Put paint marks on the sliding yoke and
intermediate shaft, and then disconnect the sliding
yoke.
Paint Mark
A093709E01
EM
A088033E01
EM97
A088034E01
EM
A088035E01
A088036E01
A088037E01
EM98
A088038E01
EM
A088039E01
A088040E01
SST
A089849E01
EM99
SST
A092534E01
EM
A088041E01
A088042E01
A088043E01
EM100
EM
A092817E01
A088163E01
A088048E01
A088051E02
EM101
A088050E01
A089055E02
INSPECTION
1.
2.
A130329
A130330
INSTALLATION
1.
A089055E02
EM
EM102
2.
3.
A088050E01
EM
3
A088052E02
A088048E01
4.
5.
6.
7.
A088163E01
A092817E01
EM103
8.
9.
A088045E01
A088043E01
A088042E01
A088041E01
EM
EM104
Adhesive
A004869E02
EM
SST
A092534E01
A089851E01
A089849E01
A088040E01
EM105
A088039E01
EM
A088038E01
A088037E01
A088035E01
EM106
EM
A088036E01
A
B
B
A089852E01
EM107
B
Paint Mark
EM
A093709E01
A088030E02
A088029E02
A088028E01
EM108
A088027E01
EM
A087643E01
A087635E01
A088024E01
A088023E01
EM109
A087646E01
EM
A087645E01
EM110
EM
EM111
ENGINE UNIT
1NZ-FXE ENGINE MECHANICAL
ENGINE
COMPONENTS
10 (102, 7)
x2
OIL FILLER CAP
OIL FILLER CAP GASKET
VENTILATION VALVE
x7
x2
EM
10 (102, 7)
SPARK PLUG
EM112
55 (561, 41)
32 (326, 24)
ENGINE MOUNTING
BRACKET RH
24 (245, 18)
x4
24 (245, 18)
CRANKSHAFT
POSITION
SENSOR
x2
EM
11 (112, 8)
x 11
7.5 (76, 66 in.*lbf)
x2
128 (1,305, 95)
CRANKSHAFT PULLEY
11 (112, 8)
STRAIGHT PIN
OIL PUMP SEAL
x3
GASKET
x2
WATER PUMP
15 (153, 11)
11 (112, 8)
CHAIN
x2
NO. 1 CHAIN
TENSIONER
Non-reusable part
Apply MP grease
EM113
23 (235, 17)
NO. 1 CAMSHAFT
BEARING CAP
x3
x 16
x8
13 (129, 9)
NO. 2 CAMSHAFT
BEARING CAP
EM
CAMSHAFT
64 (653, 47)
NO. 2 CAMSHAFT
CAMSHAFT TIMING GEAR
64 (653, 47)
EM114
CYLINDER HEAD
8.0 (82, 71 in.*lbf)
19 (194, 14)
O-RING
FUEL INJECTOR
x4
SPACER
O-RING
EM
THERMOSTAT
ENGINE REAR OIL SEAL
GASKET
O-RING
WATER INLET
x2
OIL PAN
OIL STRAINER
30 (306, 22)
GASKET
11 (112, 8)
OIL FILTER
x 13
x2
24 (245, 18)
GASKET
x9
x2
EM115
OIL RING
(EXPANDER)
CONNECTING ROD
OIL RING
(SIDE RAIL)
PISTON
EM
STRAIGHT PIN
35 (357, 26)
STRAIGHT PIN
CYLINDER BLOCK
WATER DRAIN COCK
TIGHT PLUG
STRAIGHT PIN
STRAIGHT PIN
STRAIGHT PIN
11 (112, 8)
UPPER MAIN
BEARING
STRAIGHT PIN
STRAIGHT PIN
5.0 (51, 44 in.*lbf)
CRANKSHAFT
CRANKSHAFT
BEARING CAP
LOWER MAIN
BEARING
EM116
DISASSEMBLY
1.
2.
3.
4.
5.
6.
EM
A065656E01
A088868E02
A088869E02
SST
A088870E01
7.
EM117
REMOVE THERMOSTAT
(a) Remove the 2 nuts and water inlet.
A088871E01
EM
A088872E01
8.
9.
A088874E02
SST
A088875E02
A088890E01
EM118
A088876E01
EM
A080963E03
A066472E01
Timing Mark
A092837E01
EM119
SST
SST
A088877E01
SST
A088878E01
A088879E01
A066477E01
EM
EM120
EM
A088880E01
A088881E01
A088882E01
Oil Jet
Timing Mark
A050142E05
EM121
Plunger
Unlock
Stopper Plate
A092824E01
EM
Stopper Plate
Lock
A092825E01
Plunger
Stopper Plate
A080976E02
HINT:
If the stopper plate is not completely lowered and a
3.0 mm (0.118 in.) diameter bar cannot be inserted,
unlock and pull out the plunger slightly. Then the
stopper plate will be completely lowered and a 3.0
mm (0.118 in.) diameter bar can be inserted easily.
A087621E01
A089044E01
EM122
A088883E02
EM
A088884E01
A088885E01
A088886E01
A088887E01
EM123
A088888E02
A037074E02
A064874E01
1
A037075E02
Flange Bolt
Do Not Remove
Straight Pin
A050060E02
EM
EM124
10
4
A035286E02
EM
A088892E02
A088893E01
SST
SST
A088894E02
(c) Insert the blade of SST between the oil pan and No.
2 oil pan, cut off the applied sealer and remove the
No. 2 oil pan.
SST 09032-00100
NOTICE:
Be careful not to damage the oil pan and No. 2
oil pan.
EM125
A084113E01
EM
A088895E01
A088896E01
A088897E01
EM126
A089042E01
EM
A089043E01
SST
A084166E01
(f)
Plastigage
EM127
A050668E01
Front Mark
A091905E01
(i)
SST
A084167E01
90
Paint Mark
Engine Front
(j) Mark the front of the connecting cap bolts with paint.
(k) Retighten the cap bolts by 90 as shown in the
illustration.
NOTICE:
Do not turn the crankshaft.
(l) Remove the 2 bolts, connecting rod cap and lower
bearing.
A050671E02
A037349E01
EM
EM128
Mark
1 , 2 or 3
Front Mark
A051826E01
Reference
Number Mark
EM
Oil Clearance
U/S 0.25
A001166E01
A084170E01
10
EM129
A084171E02
Upper Bearing
Oil Groove
Lower Bearing
Block Side
A
(d) Install the upper bearing with the oil groove onto the
cylinder block, and the lower bearing onto the
bearing cap.
NOTICE:
Do not apply engine oil to the contact surfaces
of the cylinder block or the backside of the
bearing.
HINT:
The mass production parts do not have claws as
marks. If reusing the mass production parts,
measure the clearance of both sides with the
bearing in the center of the bearing cap.
Standard clearance:
A - B = within 0.8 mm (0.032 in.)
(e) Install the crankshaft onto the cylinder block.
Cap Side
A
(f)
Plastigage
A050669E03
EM
EM130
Front
Mark
Number
No. 3
(g) Check the front marks and numbers and install the
bearing caps onto the cylinder block.
(h) Apply a light coat of engine oil to the threads of the
bearing cap bolts.
No. 1, 2, 4, 5
A091910E01
(i)
7
10
EM
A084171E05
90
Painted
Mark
Engine Front
(j) Mark the front of the bearing cap bolts with paint.
(k) Retighten the bearing cap bolts by 90 in the same
sequence.
(l) Check that the painted mark is now at a 90 angle to
the front.
NOTICE:
Do not turn the crankshaft.
(m) Remove the bearing cap.
A050671E04
A037352E03
EM131
HINT:
If the oil clearance is greater than the maximum,
select and replace the bearing. If necessary, use
an undersized bearing.
To select the correct bearing size, calculate the
bearing number by adding together the numbers
imprinted on the cylinder block and crank journal.
Example:
Imprinted number on the cylinder block is 3.
Imprinted number on the crank journal is 5. 3 + 5
= 8 Select the bearing with the bearing number 3.
Standard cylinder block diameter
Cylinder Block
Number
Bearing
Number
No. 1
No. 3
No. 5
No. 2
No. 4
A091934E01
Number
Specified Condition
Specified Condition
Reference
Cylinder Block Number +
Crank Journal Number
Bearing Number
Oil Clearance
0 to 2
3 to 5
Same as above
6 to 8
Same as above
9 to 11
Same as above
U/S 0.25
Same as above
EM
EM132
A084172E01
SST
EM
SST
SST
A084173E01
A084175E01
A084179E01
EM133
A088908E01
Front Side
Intake Side
EM
A092959E02
A084194E01
A084195E01
EM134
A037182E01
(c) Remove the 2 oil pan straight pins from the cylinder
block.
EM
A084196E01
A084197E01
EM135
INSPECTION
1.
2.
Thrust Direction
Axial Direction
Front
A
B
10 mm
(0.39 in.)
Center
A091907E02
3.
37 mm
A084180E02
A084198E01
EM
EM136
EM00227E01
EM
4.
5.
A001185E01
EM137
Z000065E01
6.
Specified Condition
No. 1 ring
No. 2 ring
Oil ring
A084181E01
110 mm
A037354E03
Standard
Maximum
No. 1 ring
No. 2 ring
Oil ring
EM
EM138
8.
9.
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.)
If the circle runout is greater than the maximum,
replace the crankshaft.
A001470E01
EM
A011241E01
A037157E01
ZF06928E01
A038171E01
EM139
A001194E01
EM
EM140
REPLACEMENT
1.
Wooden Block
EM
A035281E06
SST
Wooden
Block
A037153E02
Cut Position
A050694E02
SST
A066485E01
2.
Cut Position
EM141
A088160E02
SST
A088161E01
REASSEMBLY
Adhesive
1.
A054747E04
40q
40q
A098338E01
EM
EM142
2.
Adhesive
A058129E03
EM
SST
A037185E01
0.2 to 1.2 mm
A080981E02
3.
8 mm
20 mm
11.5 to 12.5
mm
A091911E02
EM143
18 mm
EM
A091912E02
8 mm
8.5 to 9.5 mm
18 mm
A091913E02
36 mm
18.5 to 19.5 mm
A091914E02
EM144
8 mm
3.5 to 4.5 mm
8 mm
EM
4.
5.
A091915E02
B
C
A (M6)
15 mm (0.61 in.)
18 mm (0.70 in.)
8 mm (0.31 in.)
C (M6)
47 mm
(1.85 in.)
12 mm (0.47 in.)
A037223E03
NOTICE:
Make sure that the bottom of the stud bolt
contacts the cylinder block, as shown in the
illustration.
(b) Install the stud bolt for the knock sensor to the
cylinder block.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
A088908E01
EM145
6.
7.
INSTALL CRANKSHAFT
(a) Install the upper bearing with the oil groove onto the
cylinder block, and the lower bearing onto the
bearing cap.
NOTICE:
Do not apply engine oil to the contact surface of
the cylinder block or the backside of the
bearing.
HINT:
Mass production parts do not have claws as marks.
If reusing the mass production parts, measure the
clearance of both sides with the bearing in the
center of the bearing cap.
Standard clearance:
A - B = within 0.8 mm (0.032 in.)
Align
A091917E01
Upper Bearing
Oil Groove
Lower Bearing
Block Side
A
Cap Side
A
A001191E04
EM
EM146
(d) Check the front marks and numbers and install the
bearing caps onto the cylinder block.
(e) Apply a light coat of engine oil to the threads of the
bearing cap bolts.
Front Mark
Number
No. 3
No. 1, 2, 4, 5
A050917E02
(f)
7
10
EM
A084171E05
(g) Mark the front of the bearing cap bolts with paint.
(h) Retighten the bearing cap bolts by 90 in the same
sequence.
(i) Check that the painted mark is now at a 90 angle to
the front.
Painted
Mark
90
Engine Front
A050671E04
8.
Front
Mark
A091919E01
SST
SST
SST
A037366E01
EM147
A089103E02
9.
Claw
A050672E01
A084172E01
Cord
Mark
Upward
Gap
Paint Color
Code Mark
Red
1R
Blue
2R
Oil ring
Paint Mark
A091920E01
(b) Position the piston rings so that the ring ends are as
shown in the illustration.
EM
EM148
Front
Mark
Piston Ring
Compressor
A091922E02
Front Mark
EM
A091905E01
(f)
SST
A084167E01
90
Painted
Mark
Engine Front
A050671E04
(g) Mark the front of the connecting cap bolts with paint.
(h) Retighten the cap bolts by 90 as shown.
(i) Check that the crankshaft turns smoothly.
EM149
13 mm
(0.51 in.)
22.5 mm
(0.89 in.)
16.5 mm
(0.65 in.)
27.5 mm
(1.08 in.)
Stud Bolt A
(M6)
Stud Bolt B
8 mm
(M6)
(0.31 in.)
9 mm
(0.31 in.)
A050686E02
9 mm
(0.35 in.)
11 mm
(0.43 in.)
Seal Packing
Seal Packing
4 mm
(0.16 in.)
4 mm
(0.16 in.)
A120012E01
A088897E01
EM
EM150
14 2
8 1 9
13
10
12
11
A037067E02
EM
A084113E01
A081876E03
A088893E01
EM151
A088892E02
SST
A088870E01
Lot No.
A092832E02
Cylinder Head
Diameter:
4.5 to 5.5 mm
Cylinder Head
Gasket
Cylinder Block
Seal Packing
A073748E02
EM
EM152
10
7
A035286E03
90
EM
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by an additional
90 and then another 90, as shown in the
illustration.
(f) Check that the painted mark is now at a 180 angle
to the front.
90
Front
Paint Mark
A092833E01
Straight Pin
Groove
A080974E04
EM153
A092826E01
A037103E03
A032167E01
EM
EM154
Seal Packing
Seal Packing
EM
A
A
C
Seal Packing
C
Seal Packing
Diameter:
A-A
1.5 to 2.0 mm
(0.059 to 0.078 in.)
2.5 mm
(0.098 in.)
B - B, C - C
(After Assembling)
B - B, C - C
1.5 mm
(0.059 in.)
2.5 mm
(0.098 in.)
Other Part
Seal Diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)
Diameter:
1.0 mm
(0.039 in.)
1.0 mm
(0.039 in.)
A117400E03
EM155
Seal packing:
Water pump part: Toyota Genuine Adhesive
1324, Three Bond 1324 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 within 3 minutes of
applying seal packing.
Do not expose the seal to engine oil for at
least 2 hours after installation.
Do not start the engine for at least 2 hours
after installation.
(d) Align the keyway of the oil pump drive rotor with the
rectangular portion of the crankshaft, and slide the
oil pump into place.
A035284E01
A
C
C
B
C
A037150E01
(e) Install the oil pump assembly with the 15 bolts and
nut. Uniformly tighten the bolts and nut in several
steps.
Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for bolt A
11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt
B
11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt
C
24 N*m (245 kgf*cm, 18 ft.*lbf) for nut D
24 N*m (245 kgf*cm, 18 ft.*lbf) for bolt E
NOTICE:
Be careful not to disturb the seal packing.
After installing the timing chain case, install
the mounting bracket and water pump within
15 minutes.
HINT:
Each bolt length is as follows:
30 mm (1.18 in.) for bolt A
35 mm (1.38 in.) for bolt B
20 mm (0.79 in.) for bolt C
20 to 14 mm (0.79 to 0.55 in.) for bolt E
EM
E M 1 5 6
A088879E01
EM
A088890E01
A088876
Insulator
O-Ring
A050145E01
Connector
Turn
EM157
Push
A
B
A089809E02
Seal Packing
11
A050172E01
10
1
8
2
6
A035756E02
EM
EM158
A080963E02
EM
SST
A086914E01
A088874E02
10 10
Jiggle Valve
A092977E01
A088871E01
EM159
A088868E02
EM