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• Jimmy Brian Kaifiti

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01–1 INTRODUCTION

–

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL 010B2–08

GENERAL INFORMATION 1. (a) (b)

(c)

(d)

ProCarManuals.com

2. (a) 3. (a)

4. (a) (b) (c)

GENERAL DESCRIPTION This manual is made in accordance with SAE J2008. Generally, repair operations can be separated in the following 3 main processes: 1. Diagnosis 2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting 3. Final Inspection This manual explains the 1st process of ”Diagnosis” (placed in the ”Diagnostics” section), the 2nd process of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting”, but the 3rd process of ”Final Inspection” is omitted. The following essential operations are not written in this manual. However, these operations must be done in the practical situation. (1) Operation with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check INDEX An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be repaired. PREPARATION Use of special service tools (SST) and special service materials (SSM) may be required, depending on the repairing condition. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual. REPAIR PROCEDURES Component drawing is placed under the title when necessary. Illustrations are placed as ”disassembled parts drawing” so that it enables you to understand the fitting condition of the components. Non–reusable parts, grease applied parts, precoated parts and tightening torque are specified in the components drawing. Example:

OVERHAUL

Camshaft, No. 3 Camshaft Sub–assy Camshaft Drive Gear

Camshaft Timing Tube Assy

7.5 (80, 66 in.·lbf)

Seal Washer

z Camshaft Setting Oil Seal

No. 2 Camshaft, No. 4 Camshaft Sub–assy

Camshaft Driven Main Gear

Screw Plug 78 (790, 58)

15 (150, 11)

Wave Washer

N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Camshaft Timing Gear Bolt Washer Camshaft Sub Gear Snap Ring A54988

01–2 INTRODUCTION

–

HOW TO USE THIS MANUAL

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

ProCarManuals.com

(d)

Illustration: what to do and where

Task heading: what to do

Set part No.

Component part No.

Detailed text: how to do task A59974

HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task heading can be read at a glance when necessary, and the text below provides detailed information. Important specifications and warnings always stand out in bold type. 5. (a)

SERVICE SPECIFICATIONS Specifications are presented in bold type throughout the manual. You never have to leave the procedure to look up your specifications. The specifications are also found in the Service Specifications section for a quick reference.

6.

TERMS DEFINITION

CAUTION NOTICE HINT

Indicates the possibility of injury to you or other people. Indicates the possibility of damage to the components being repaired. Provides additional information to help you to perform the repair efficiently.

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–3 INTRODUCTION

HOW TO USE THIS MANUAL

SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 NVm (310 kgfVcm, 22 ftVlbf)

ProCarManuals.com

7. (a)

–

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–4 INTRODUCTION

–

REPAIR INSTRUCTION

REPAIR INSTRUCTION 010L5–01

PRECAUTION 1. (a)

2. (a)

ProCarManuals.com

3. (a)

4. (a)

5. 6. 7. 8. 9.

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

(a)

Seal Lock Adhesive Z11554

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Precoated Parts: (1) Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (3) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.

01–5 INTRODUCTION

–

REPAIR INSTRUCTION

NOTICE: Do the torque checking with the lower limit value of the torque tolerance. (4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for a specified time until it hardens. (b) Gaskets: When necessary, use a sealer on gaskets to prevent leaks. (c) Bolts, Nuts and Screws: Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. (d) L1

Torque When Using Extension Tool with Torque Wrench: (1) In case of tightening by extending the entire length of the torque wrench combined with SST or tool, if you tighten until the reading of the torque wrench reached the specified torque value, the actual torque becomes excessive. (2) In this text, only the specified torque is described. In case of using SST or extension tool, find the reading of the torque wrench by the formula. (3) Formula T’=T x L2/(L1 + L2)

L2

ProCarManuals.com

D02612

L1

L2

T’

Reading of torque wrench {NVm (kgfVcm, ftVlbf)}

T

Torque {NVm (kgfVcm, ftVlbf)}

L1

Length of SST or tool (cm)

L2

Length of torque wrench (cm)

D01201

L1

L2

D01202

10. (a)

(b)

REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS Place for Removing and Installing Fuel System Parts: (1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, electric motor or stove in the surroundings. (2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those places. Removing and Installing of Fuel System Parts: (1) Prepare a fire extinguisher before starting the operation. (2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do not spray much water so as to prevent slipping.

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–6 INTRODUCTION

(3) (4) (5)

REPAIR INSTRUCTION

Never use any electric equipment like an electric motor or a working light as they may cause spark or high temperature. Never use an iron hammer as it may cause spark. Dispose the shop lag separately from any fuel deposit. 11. (a) (b)

(c) D01563

Flat Spring Clamp

ProCarManuals.com

–

12. (a) (b) (c) (d)

Clamp Track D25081

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS If any metal tip is mixed in the inlet pass, that may give a bad effect to the engine and turbo charger. When removing and installing of the inlet system parts, close the opening of the removed inlet system parts and the engine with a clean shop lag or gum tape. When installing the inlet system parts, check that there is no mixing of a metal tip. HANDLING OF HOSE CLAMPS Before removing the hose, check the depth of inserting portion and the clamp position to restore it surely. Change a deformed or dented into a new one. In case of reusing the hose, install the clamp on the hose where it has a clamp track. For a flat spring type clamp, make it adjust by adding force to the arrow mark direction after the installation.

01–7 INTRODUCTION

–

TERMS

TERMS 010B9–09

ABBREVIATIONS USED IN THIS MANUAL

ProCarManuals.com

Abbreviations

Meaning

ABS

Anti–Lock Brake System

A/C

Air Conditioner

AC

Alternating Current

ACC

Accessory

ACIS

Acoustic Control Induction System

ACSD

Automatic Cold Start Device

A.D.D.

Automatic Disconnecting Differential

A/F

Air–Fuel Ratio

AHC

Active Height Control Suspension

ALR

Automatic Locking Retractor

ALT

Alternator

AMP

Amplifier

ANT

Antenna

Approx.

Approximately

ASSY

Assembly

A/T, ATM

Automatic Transmission (Transaxle)

ATF

Automatic Transmission Fluid

AUTO

Automatic

AUX

Auxiliary

AVG

Average

AVS

Adaptive Variable Suspension

B+

Battery Voltage

BA

Brake Assist

BACS

Boost Altitude Compensation System

BAT

Battery

BDC

Bottom Dead Center

B/L

Bi–Level

B/S

Bore–Stroke Ratio

BTDC

Before Top Dead Center

BVSV

Bimetallic Vacuum Switching Valve

CB

Circuit Breaker

CCo

Catalytic Converter For Oxidation

CD

Compact Disc

CF

Cornering Force

CG

Center Of Gravity

CH

Channel

CKD

Complete Knock Down

COMB.

Combination

CPE

Coupe

CPS

Combustion Pressure Sensor

CPU

Central Processing Unit

CRS

Child Restraint System

CTR

Center

C/V

Check Valve

CV

Control Valve

CW

Curb Weight

DC

Direct Current

DEF

Defogger

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–8 INTRODUCTION

–

TERMS

ProCarManuals.com

Abbreviations

Meaning

DFL

Deflector

DIFF.

Differential

DIFF. LOCK

Differential Lock

D/INJ

Direct Injection

DLC

Data Link Connector

DLI

Distributorless Ignition

DOHC

Double Overhead Camshaft

DP

Dash Pot

DS

Dead Soak

DSP

Digital Signal Processor

DTC

Diagnostic Trouble Code

DVD

Digital Versatile Disc

EBD

Electric Brake Force Distribution

ECAM

Engine Control And Measurement System

ECD

Electronic Controlled Diesel

ECDY

Eddy Current Dynamometer

ECT

Electronic Control Transmission

ECU

Electronic Control Unit

ED

Electro–DepositedCoating

EDU

Electronic Driving Unit

EDIC

Electric Diesel Injection Control

EFI

Electronic Fuel Injection

E/G

Engine

EGR

Exhaust Gas Recirculation

EGR–VM

EGR–Vacuum Modulator

ELR

Emergency Locking Retractor

EMPS

Electric Motor Power Steering

ENG

Engine

ESA

Electronic Spark Advance

ETCS–i

Electronic Throttle Control System–intelligent

EVAP

Evaporative Emission Control

EVP

Evaporator

E–VRV

Electric Vacuum Regulating Valve

EX

Exhaust

FE

Fuel Economy

FF

Front–EngineFront–Wheel–Drive

F/G

Fuel Gauge

FIPG

Formed In Place Gasket

FL

Fusible Link

F/P

Fuel Pump

FPU

Fuel Pressure Up

Fr

Front

F/W

Flywheel

FW/D

Flywheel Damper

FWD

Front–Wheel–Drive

GAS

Gasoline

GND

Ground

GPS

Global Positioning System

HAC

High Altitude Compensator

H/B

Hatchback

H–FUSE

High Current Fuse

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–9 INTRODUCTION

–

TERMS

ProCarManuals.com

Abbreviations

Meaning

HI

High

HID

High Intensity Discharge (Head Lamp)

HSG

Housing

HT

Hard Top

HWS

Heated Windshield System

IC

Integrated Circuit

IDI

Indirect Diesel Injection

IFS

Independent Front Suspension

IG

Ignition

IIA

Integrated Ignition Assembly

IN

Intake (Manifold, Valve)

INT

Intermittent

I/P

Instrument Panel

IRS

Independent Rear Suspension

ISC

Idle Speed Control

J/B

Junction Block

J/C

Junction Connector

KD

Kick–Down

LAN

Local Area Network

LB

Liftback

LCD

Liquid Crystal Display

LED

Light Emitting Diode

LH

Left–Hand

LHD

Left–Hand Drive

L/H/W

Length, Height, Width

LLC

Long–Life Coolant

LNG

Liquified Natural Gas

LO

Low

LPG

Liquified Petroleum Gas

LSD

Limited Slip Differential

LSP & PV

Load Sensing Proportioning And Bypass Valve

LSPV

Load Sensing Proportioning Valve

MAP

Manifold Absolute Pressure

MAX.

Maximum

MIC

Microphone

MIL

Malfunction Indicator Lamp

MIN.

Minimum

MG1

Motor Generator No.1

MG2

Motor Generator No.2

MP

Multipurpose

MPI

Multipoint Electronic Injection

MPX

Multiplex Communication System

M/T, MTM

Manual Transmission (Transaxle)

MT

Mount

MTG

Mounting

N

Neutral

NA

Natural Aspiration

No.

Number

O2S

Oxygen Sensor

O/D

Overdrive

OEM

Original Equipment Manufacturing

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–10 INTRODUCTION

–

TERMS

ProCarManuals.com

Abbreviations

Meaning

OHC

Overhead Camshaft

OHV

Overhead Valve

OPT

Option

ORVR

On–board Refilling Vapor Recovery

O/S

Oversize

P & BV

Proportioning And Bypass Valve

PCS

Power Control System

PCV

Positive Crankcase Ventilation

PKB

Parking Brake

PPS

Progressive Power Steering

PTC

Positive Temperature Coefficient

PS

Power Steering

PTO

Power Take–Off

P/W

Power Window

R&P

Rack And Pinion

RAM

Random Access Memory

R/B

Relay Block

RBS

Recirculating Ball Type Steering

R/F

Reinforcement

RFS

Rigid Front Suspension

RH

Right–Hand

RHD

Right–Hand Drive

RLY

Relay

ROM

Read Only Memory

Rr

Rear

RRS

Rigid Rear Suspension

RWD

Rear–Wheel Drive

SDN

Sedan

SEN

Sensor

SICS

Starting Injection Control System

SOC

State Of Charge

SOHC

Single Overhead Camshaft

SPEC

Specification

SPI

Single Point Injection

SRS

Supplemental Restraint System

SSM

Special Service Materials

SST

Special Service Tools

STD

Standard

STJ

Cold–Start Fuel Injection

SW

Switch

SYS

System

T/A

Transaxle

TACH

Tachometer

TBI

Throttle Body Electronic Fuel Injection

TC

Turbocharger

TCCS

TOYOTA Computer–Controlled System

TCV

Timing Control Valve

TDC

Top Dead Center

TEMP.

Temperature

TEMS

TOYOTA Electronic Modulated Suspension

TFT

Toyota Free–Tronic

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–11 INTRODUCTION

–

TERMS

ProCarManuals.com

Abbreviations

Meaning

TIS

Total Information System For Vehicle Development

T/M

Transmission

TMC

TOYOTA Motor Corporation

TMMK

TOYOTA Motor Manufacturing Kentucky, Inc.

TRC

Traction Control System

TURBO

Turbocharge

TWC

Three–Way Catalyst

U/D

Underdrive

U/S

Undersize

VCV

Vacuum Control Valve

VENT

Ventilator

VIN

Vehicle Identification Number

VPS

Variable Power Steering

VSC

Vehicle Stability Control

VSV

Vacuum Switching Valve

VTV

Vacuum Transmitting Valve

VVT–i

Variable Valve Timing–intelligent

w/

With

WGN

Wagon

W/H

Wire Harness

w/o

Without

WU–TWC

Warm Up Three–way Catalytic Converter

WU–OC

Warm Up Oxidation Catalytic Converter

1st

First

2nd

Second

2WD

Two Wheel Drive Vehicle (4 x 2)

3rd

Third

4th

Fourth

4WD

Four Wheel Drive Vehicle (4 x 4)

4WS

Four Wheel Steering System

5th

Fifth

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

01–12 INTRODUCTION

–

TERMS 010BA–12

GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents.

ProCarManuals.com

SAE ABBREVIATIONS

TOYOTA TERMS ( )––ABBREVIATIONS

SAE TERMS

A/C

Air Conditioning

Air Conditioner

ACL

Air Cleaner

Air Cleaner, A/CL

AIR

Secondary Air Injection

Air Injection (AI)

AP

Accelerator Pedal

B+

Battery Positive Voltage

+B, Battery Voltage

BARO

Barometric Pressure

HAC

CAC

Charge Air Cooler

Intercooler

CARB

Carburetor

Carburetor

CFI

Continuous Fuel Injection

CKP

Crankshaft Position

Crank Angle

CL

Closed Loop

Closed Loop

CMP

Camshaft Position

Cam Angle

CPP

Clutch Pedal Position

–

CTOX

Continuous Trap Oxidizer

–

CTP

Closed Throttle Position

LL ON, Idle ON

DFI

Direct Fuel Injection (Diesel)

Direct Injection (DI/INJ)

DI

Distributor Ignition

DLC1 DLC2 DLC3

Data Link Connector 1 Data Link Connector 2 Data Link Connector 3

1: Check Connector 2: Total Diagnosis Communication Link (TDCL) 3: OBD II Diagnostic Connector

DTC

Diagnostic Trouble Code

Diagnostic Trouble Code

DTM

Diagnostic Test Mode

ECL

Engine Control Level

ECM

Engine Control Module

Engine ECU (Electronic Control Unit)

ECT

Engine Coolant Temperature

Coolant Temperature, Water Temperature (THW)

EEPROM

Electrically Erasable Programmable Read Only Memory

Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM)

EFE

Early Fuel Evaporation

Cold Mixture Heater (CMH), Heat Control Valve (HCV)

EGR

Exhaust Gas Recirculation

Exhaust Gas Recirculation (EGR)

EI

Electronic Ignition

Distributorless Ignition (DLI)

EM

Engine Modification

Engine Modification (EM)

EPROM

Erasable Programmable Read Only Memory

Programmable Read Only Memory (PROM)

EVAP

Evaporative Emission

Evaporative Emission Control (EVAP)

FC

Fan Control

–

FEEPROM

Flash Electrically Erasable Programmable Read Only Memory

–

FEPROM

Flash Erasable Programmable Read Only Memory

–

FF

Flexible Fuel

–

FP

Fuel Pump

Fuel Pump

GEN

Generator

Alternator

GND

Ground

Ground (GND)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

–

–

–

– –

01–13

ProCarManuals.com

INTRODUCTION

–

TERMS

HO2S

Heated Oxygen Sensor

Heated Oxygen Sensor (HO2S)

IAC

Idle Air Control

Idle Speed Control (ISC)

IAT

Intake Air Temperature

Intake or Inlet Air Temperature

ICM

Ignition Control Module

IFI

Indirect Fuel Injection

IFS

Inertia Fuel–Shutoff

–

ISC

Idle Speed Control

–

KS

Knock Sensor

Knock Sensor

MAF

Mass Air Flow

Air Flow Meter

MAP

Manifold Absolute Pressure

Manifold Pressure Intake Vacuum

MC

Mixture Control

Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV)

MDP

Manifold Differential Pressure

MFI

Multiport Fuel Injection

Electronic Fuel Injection (EFI)

MIL

Malfunction Indicator Lamp

Check Engine Lamp

MST

Manifold Surface Temperature

–

MVZ

Manifold Vacuum Zone

–

NVRAM

Non–Volatile Random Access Memory

–

O2S

Oxygen Sensor

Oxygen Sensor, O2 Sensor (O2S)

OBD

On–Board Diagnostic

On–Board Diagnostic System (OBD)

OC

Oxidation Catalytic Converter

Oxidation Catalyst Convert (OC), CCo

OP

Open Loop

Open Loop

PAIR

Pulsed Secondary Air Injection

Air Suction (AS)

PCM

Powertrain Control Module

–

PNP

Park/Neutral Position

–

PROM

Programmable Read Only Memory

–

PSP

Power Steering Pressure

–

PTOX

Periodic Trap Oxidizer

Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT)

RAM

Random Access Memory

Random Access Memory (RAM)

RM

Relay Module

ROM

Read Only Memory

Read Only Memory (ROM)

RPM

Engine Speed

Engine Speed

SC

Supercharger

Supercharger

SCB

Supercharger Bypass

E–ABV

SFI

Sequential Multiport Fuel Injection

Electronic Fuel Injection (EFI), Sequential Injection

SPL

Smoke Puff Limiter

–

SRI

Service Reminder Indicator

–

SRT

System Readiness Test

–

ST

Scan Tool

–

TB

Throttle Body

Throttle Body

TBI

Throttle Body Fuel Injection

Single Point Injection Central Fuel Injection (Ci)

TC

Turbocharger

Turbocharger

TCC

Torque Converter Clutch

Torque Converter

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

– Indirect Injection (IDL)

–

–

01–14 INTRODUCTION

–

TERMS

Transmission Control Module

Transmission ECU, ECT ECU

TP

Throttle Position

Throttle Position

TR

Transmission Range

TVV

Thermal Vacuum Valve

Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV)

TWC

Three–Way Catalytic Converter

Three–Way Catalytic (TWC) Manifold Converter CCRO

TWC+OC

Three–Way + Oxidation Catalytic Converter

CCR + CCo

VAF

Volume Air Flow

Air Flow Meter

VR

Voltage Regulator

Voltage Regulator

VSS

Vehicle Speed Sensor

Vehicle Speed Sensor

WOT

Wide Open Throttle

Full Throttle

WU–OC

Warm Up Oxidation Catalytic Converter

–

WU–TWC

Warm Up Three–Way Catalytic Converter

–

3GR

Third Gear

–

4GR

Fourth Gear

–

ProCarManuals.com

TCM

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

–

02–1 PREPARATION

–

ENGINE MECHANICAL

ENGINE MECHANICAL 022IW–01

PREPARATION

ProCarManuals.com

SST 09011–38121

12 mm Socket Wrench for 12 Pointed Head

CYLINDER BLOCK ASSY

09032–00100

Oil Pan Seal Cutter

PARTIAL ENGINE ASSY

09201–10000

Valve Guide Bushing Remover & Replacer Set

CYLINDER HEAD ASSY

(09201–01050)

Valve Guide Bushing Remover & Replacer 5

CYLINDER HEAD ASSY

09201–41020

Valve Stem Oil Seal Replacer

CYLINDER HEAD ASSY

09202–70020

Valve Spring Compressor

CYLINDER HEAD ASSY

Attachment

CYLINDER HEAD ASSY

Crankshaft Pulley Holding Tool

PARTIAL ENGINE ASSY

Bolt

PARTIAL ENGINE ASSY

09223–15030

Oil Seal & Bearing Replacer

PARTIAL ENGINE ASSY

09223–22010

Crankshaft Front Oil Seal Replacer

PARTIAL ENGINE ASSY

09228–06501

Oil Filter Wrench

PARTIAL ENGINE ASSY

(09202–00010)

09213–54015

(91651–60855)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

02–2

ProCarManuals.com

PREPARATION

–

ENGINE MECHANICAL

09309–37010

Transmission Bearing Replacer

PARTIAL ENGINE ASSY

09330–00021

Companion Flange Holding Tool

PARTIAL ENGINE ASSY

09950–50013

Puller C Set

PARTIAL ENGINE ASSY

(09951–05010)

Hanger 150

PARTIAL ENGINE ASSY

(09952–05010)

Slide Arm

PARTIAL ENGINE ASSY

(09953–05020)

Center Bolt 150

PARTIAL ENGINE ASSY

(09954–05021)

Claw No.2

PARTIAL ENGINE ASSY

09950–60010

Replacer Set

CYLINDER HEAD ASSY CYLINDER BLOCK ASSY

(09951–00180)

Replacer 18

CYLINDER HEAD ASSY

(09951–00200)

Replacer 20

CYLINDER BLOCK ASSY

09950–70010

Handle Set

CYLINDER HEAD ASSY CYLINDER BLOCK ASSY PARTIAL ENGINE ASSY

(09951–07100)

Handle 100

CYLINDER HEAD ASSY CYLINDER BLOCK ASSY PARTIAL ENGINE ASSY

Variable Pin Wrench Set

PARTIAL ENGINE ASSY

09960–10010

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

02–3 PREPARATION

–

ENGINE MECHANICAL

(09962–01000)

Variable Pin Wrench Arm Assy

PARTIAL ENGINE ASSY

(09963–00700)

Pin 7

PARTIAL ENGINE ASSY

Valve seal cutter set by BANZAI (J)

CYLINDER HEAD ASSY

Pin Punch .

CYLINDER HEAD ASSY

(09043–20060)

Socket Hexagon Wrench 6

PARTIAL ENGINE ASSY

(09043–20120)

Socket Hexagon Wrench 12

PARTIAL ENGINE ASSY

09043–50100

Bi–hexagon Wrench 10 mm

PARTIAL ENGINE ASSY

TB–524

Recomended Tools

ProCarManuals.com

09031–00040

Equipment Reamer piston ring compressor Micro meter Dial indicator Spring tension gauge Feeler gauge Cylinder gauge Straight edge Torque wrench Slide calipers V–block Sandpaper (#400) Piston heater Wooden block Plastigage Angle gauge

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

02–4 PREPARATION

–

LUBRICATION

LUBRICATION 022IX–01

PREPARATION SST 09011–12271

Equipment Feeler gauge Straight edge

ProCarManuals.com

Torque wrench

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Socket Wrench for 27 mm

OIL PUMP ASSY

02–5 PREPARATION

–

STARTING & CHARGING

STARTING & CHARGING 022KC–01

PREPARATION SST 09285–76010

Injection Pump Camshaft Bearing Cone Replacer

GENERATOR ASSY

09041–00020

Torx Driver T25

STARTER ASSY

09904–00010

Expander Set

STARTER ASSY

No. 4 Claw

STARTER ASSY

Recomended Tools

ProCarManuals.com

(09904–00050)

Equipment Dial indicator Ohmmeter Torque wrench Slide calipers V–block

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

03–1 SERVICE SPECIFICATIONS

–

STANDARD BOLT

STANDARD BOLT 030LK–05

HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt

Deep Recess Bolt

Stud Bolt

4

Class

4T No Mark

ProCarManuals.com

Weld Bolt

No Mark

No Mark

5

5T

6

6T w/ Washer

w/ Washer

7

7T

8

8T

9

9T

10

10T

11

11T

B06431

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

03–2 SERVICE SPECIFICATIONS

–

STANDARD BOLT 030LL–05

SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque

ProCarManuals.com

Class

Diameter mm

Pitch mm

Hexagon head bolt

Hexagon flange bolt

N·m

kgf·cm

ft·lbf

N·m

kgf·cm

ft·lbf

4T

6 8 10 12 14 16

1 1.25 1.25 1.25 1.5 1.5

5 12.5 26 47 74 115

55 130 260 480 760 1,150

48 in.·lbf 9 19 35 55 83

6 14 29 53 84 –

60 145 290 540 850 –

52 in.·lbf 10 21 39 61 –

5T

6 8 10 12 14 16

1 1.25 1.25 1.25 1.5 1.5

6.5 15.5 32 59 91 140

65 160 330 600 930 1,400

56 in.·lbf 12 24 43 67 101

7.5 17.5 36 65 100 –

75 175 360 670 1,050 –

65 in.·lbf 13 26 48 76 –

6T

6 8 10 12 14 16

1 1.25 1.25 1.25 1.5 1.5

8 19 39 71 110 170

80 195 400 730 1,100 1,750

69 in.·lbf 14 29 53 80 127

9 21 44 80 125 –

90 210 440 810 1,250 –

78 in.·lbf 15 32 59 90 –

7T

6 8 10 12 14 16

1 1.25 1.25 1.25 1.5 1.5

10.5 25 52 95 145 230

110 260 530 970 1,500 2,300

8 19 38 70 108 166

12 28 58 105 165 –

120 290 590 1,050 1,700 –

9 21 43 76 123 –

8T

8 10 12

1.25 1.25 1.25

29 61 110

300 620 1,100

22 45 80

33 68 120

330 690 1,250

24 50 90

9T

8 10 12

1.25 1.25 1.25

34 70 125

340 710 1,300

25 51 94

37 78 140

380 790 1,450

27 57 105

10T

8 10 12

1.25 1.25 1.25

38 78 140

390 800 1,450

28 58 105

42 88 155

430 890 1,600

31 64 116

11T

8 10 12

1.25 1.25 1.25

42 87 155

430 890 1,600

31 64 116

47 97 175

480 990 1,800

35 72 130

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

03–3 SERVICE SPECIFICATIONS

–

STANDARD BOLT 030LM–05

HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut

Old Standard Hexagon Nut Cold Forging Nut

Class

Cutting Processed Nut

4N No Mark

5N (4T) No Mark (w/ Washer)

No Mark (w/ Washer)

No Mark

6N

ProCarManuals.com

6N

7N (5T) *

8N 8N

10N (7T) 10N

No Mark

11N 11N

12N 12N

*: Nut with 1 or more marks on one side surface of the nut. B06432

HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

03–4 SERVICE SPECIFICATIONS

–

ENGINE MECHANICAL

ENGINE MECHANICAL 031FM–01

SERVICE DATA Oil pump drive gear Gear diameter (w/chain)

Minimum 48.2 mm (1.898 in.)

Oil pump drive shaft gear Gear diameter (w/chain)

Minimum 48.2 mm (1.898 in.)

Crankshaft timing gear or sprocket Gear diameter (w/chain)

Minimum 51.6 mm (2.031 in.)

Chain tensioner slipper Wear

Maximum 1.0 mm (0.039 in.)

Chain vibration damper No.1 Wear

Maximum 1.0 mm (0.039 in.)

ProCarManuals.com

Cylinder head set bolt Bolt length

Standard 161.3 to 162.7 mm (6.350 to 6.406 in.) Maximum 164.2 mm (6.465 in.)

Chain sub–assy Elongation

Maximum 115.4 mm (4.543 in.)

Camshaft timing gear or sprocket Sprocket diameter (w/chain)

Minimum 97.3 mm (3.831 in.)

Camshaft Circle runout Cam lobe height Camshaft No.2 Circle runout Cam lobe height No. 1 journal diameter Other journal diameter Thrust clearance Intake Exhaust Oil clearance Intake No. 1 journal bearing mark 1 Intake No. 1 journal bearing mark 2 Intake No. 1 journal bearing mark 3 Exhaust No. 1 journal Other journals Intake No. 1 journal Other journals Valve clearance Intake Exhaust

Maximum 0.05 mm (0.0020 in.) Standard 45.510 to 45.610 mm (1.7917 to 1.7957 in.) Minimum 45.400 mm (1.7874 in.) Maximum 0.05 mm (0.0020 in.) Standard 45.983 to 46.083 mm (1.8104 to 1.8143 in.) Minimum 45.873 mm (1.8060 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 22.959 to 22.975 mm (0.9040 to 0.9045 in.) Standard Maximum Standard Maximum

0.040 to 0.095 mm (0.0016 to 0.0037 in.) 0.11 mm (0.0043 in.) 0.080 to 0.135 mm (0.0032 to 0.0053 in.) 0.15 mm (0.0059 in.)

Standard Standard Standard Standard Standard Maximum Maximum

0.007 to 0.038 mm (0.0028 to 0.00150 in.) 0.008 to 0.038 mm (0.0031 to 0.00150 in.) 0.008 to 0.038 mm (0.0031 to 0.00150 in.) 0.015 to 0.054 mm (0.0006 to 0.0021 in.) 0.025 to 0.062 mm (0.00098 to 0.00244 in.) 0.07 mm (0.0028 in.) 0.10 mm (0.0039 in.)

(Cold) 0.19 to 0.29 mm (0.007 to 0.0114 in.) 0.30 to 0.40 mm (0.012 to 0.0160 in.)

Cylinder head Warpage Cylinder block side Intake manifold side Exhaust manifold side

Maximum 0.05 mm (0.0020 in.) Maximum 0.08 mm (0.0031 in.) Maximum 0.08 mm (0.0031 in.)

Inner compression spring Free length Deviation Angle (reference)

45.7 mm (1.799 in.) Maximum 1.6 mm (0.063 in.) Maximum 2_

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

03–5 SERVICE SPECIFICATIONS Intake valve Overall length

ENGINE MECHANICAL

Standard 101.71 mm (4.0043in.) Minimum 101.21 mm (3.9846in.) 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Standard 1.05 to 1.45 mm (0.041 to 0.057 in.) Minimum 0.5 mm (0.020 in.)

Valve stem diameter Margin thickness Exhaust valve Overall length

Standard 101.15 mm (3.9823in.) Minimum 100.70 mm (3.9646 in.) 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Standard 1.2 to 1.6 mm (0.047 to 0.063 in.) Minimum 0.75 mm (0.030 in.)

Valve stem diameter Margin thickness Intake valve guide bush Bushing inside diameter Oil clearance

5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard 0.025 to 0.060 mm (0.00098 to 0.00236 in.) Maximum 0.08 mm (0.0031 in.) 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 9.6 to 10.0 mm (0.3779 to 0.3937 in.)

Diameter Protrusion height Exhaust valve guide bush Bushing inside diameter Oil clearance

5.510 to 5.530 mm (0.2169 to 0.2177 in.) Standard 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum 0.10 mm (0.0039 in.) 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 9.6 to 10.0 mm (0.3779 to 0.3937 in.)

Diameter Protrusion height

ProCarManuals.com

–

Valve lifter Lifter diameter Lifter bore diameter Oil clearance

30.966 to 30.976 mm (1.2191 to 1.2195 in.) 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum 0.08 mm (0.0032 in.)

Ring w/head pin Protrusion height Connecting rod Thrust clearance Oil clearance Bushing inside diameter Oil clearance Out–of–alignment Rod twist

3.0 to 5.5 mm (0.118 to 0.217 in.) Standard Maximum Standard Maximum

0.160 to 0.362 mm (0.0063 to 0.0143 in.) 0.362 mm (0.0143 in.) 0.024 to 0.048 mm (0.0009 to 0.0019 in.) 0.08 mm (0.0031 in.) 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Standard 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum 0.05 mm (0.0020 in.) Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.) Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)

Cylinder block Warpage Bore diameter Piston Piston diameter Piston oil clearance Piston ring Ring groove clearance

End gap

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Maximum 0.05 mm (0.0020 in.) Standard 86.000 to 86.013 mm (3.3858 to 3.3863 in.) 85.927 to 85.937 mm (3.3829 to 3.3833 in.) Standard 0.063 to 0.086 mm (0.0025 to 0.0034 in.) Maximum 0.1 mm (0.0039 in.) No. 1 No. 2 Oil (side rail) Standard No. 1 No. 2 Oil (side rail) Maximum No. 1 No. 2 Oil (side rail)

0.020 to 0.070 mm (0.0008 to 0.0028 in.) 0.020 to 0.060 mm (0.0008 to 0.0024 in.) 0.070 to 0.150 mm (0.0028 to 0.0059 in.) 0.30 to 0.40 mm (0.0118 to 0.0157 in.) 0.47 to 0.62 mm (0.0185 to 0.0244 in.) 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 0.89 mm (0.0350 in.) 1.37 mm (0.0539 in.) 0.73 mm (0.0287 in.)

03–6 SERVICE SPECIFICATIONS Piston pin Bushing inside diameter Piston pin diameter Oil clearance Connecting rod bolt Diameter Crankshaft Thrust clearance Thrust washer thickness Circle runout Main journal diameter Oil clearance Crank pin taper and out– of –round Crank pin diameter

ProCarManuals.com

Crankshaft bearing cap set bolt Diameter

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

–

ENGINE MECHANICAL

22.005 to 22.014 mm (0.8663 to 0.8667 in.) 21.997 to 22.006 mm (0.8660 to 0.8664 in.) Standard 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum 0.005 mm (0.0020 in.) Standard 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum 7.0 mm (0.276 in.) Standard 0.040 to 0.240 mm (0.0016 to 0.0094 in.) Maximum 0.30 mm (0.0118 in.) 1.930 to 1.980 mm (0.0760 to 0.0780 in.) Maximum 0.03 mm (0.0012 in.) 54.988 to 55.000 (2.1648 to 2.06535 in.) Standard 0.017 to 0.040 mm (0.0007 to 0.0016 in.) Maximum 0.07 mm (0.0028 in.) Maximum 0.003 mm (0.0001 in.) 47.990 to 48.000 mm (1.8894 to 1.8898 in.) Standard 7.5 to 7.6 mm (0.295 to 0.299 in.) Minimum 7.2 mm (0.283 in.)

03–7 SERVICE SPECIFICATIONS

–

ENGINE MECHANICAL 031FN–01

TORQUE SPECIFICATION Part Tightened

NVm

kgfVcm

ftVlbf

Stiffening crankcase assy x Cylinder block

33

332

24

Oil control valve filter x Cylinder block

30

306

22

Cylinder block water drain cock x Stiffening crankcase assy

25

255

18

79 Turn 90_

806 Turn 90_

58 Turn 90_

Camshaft timing gear assy x Camshaft

54

551

40

Camshaft timing sprocket x Camshaft

54

551

40

Camshaft bearing cap No. 1 x Cylinder head

30

301

22

Camshaft bearing cap No. 2 x Cylinder head

30

301

22

Camshaft bearing cap No. 3 x Cylinder head

9.0

92

80 in.Vlbf

Oil pump assy x Stiffening crankcase assy

19

194

14

Chain tensioner plate x Stiffening crankcase assy

12

122

9

Oil pump drive sprocket x Oil pump

30

301

22

Chain vibration damper No. 1 x Cylinder head

9.0

92

80 in.Vlbf

Chain vibration damper No. 1 x Cylinder block

9.0

92

80 in.Vlbf

Chain tensioner slipper x Cylinder block

19

194

14

Timing chain guide x Crankshaft bearing cap No. 1

9.0

92

80 in.Vlbf

9.0 21 43 9.0

92 214 438 92

80 in.Vlbf 15 32 80 in.Vlbf

Cylinder head x Cylinder block

ProCarManuals.com

Timing chain cover (See page 14–5)

1st 2nd

Bolt A Bolt B Bolt C Nut

Oil pan x Stiffening crankcase assy

9.0

92

80 in.Vlbf

Oil pan drain plug x Oil pan

25

250

18

Water pump assy x Cylinder block

9.0

92

80 in.Vlbf

Water pump pulley x Water pump assy

26

265

19

Crankshaft position sensor x Timing chain cover

9.0

92

80 in.Vlbf

Crankshaft pulley x Crankshaft

170

1,733

125

Chain tensioner assy No. 1 x Timing chain cover

9.0

92

80 in.Vlbf

9.0

92

80 in.Vlbf

11 14 21 11

112 143 214 112

8 10 15 8

Oil filter union x Stiffening crankcase assy

30

306

22

Spark plug x Cylinder head

19

194

14

19

194

14

5 5 9.5 9.5

51 51 97 97

44 in.Vlbf 44 in.Vlbf 84 in.Vlbf 84 in.Vlbf

Camshaft position sensor x Cylinder head Cylinder head cover x Cylinder head (See page 14–5)

Bolt A Bolt B Bolt C Nut

Ventilation valve x Cylinder head cover Stud bolt x Cylinder head (See page 14–39)

Bolt A Bolt B Bolt C Bolt D

Connecting rod cap x Connecting rod

1st 2nd

25 Turn 90_

250 Turn 90_

18 Turn 90_

Crankshaft bearing cap x Cylinder block

1st 2nd

20 40

204 408

15 29

Stud bolt A Stud bolt B Stud bolt C

5.0 10 5.0

51 97 51

44 in.Vlbf 84 in.Vlbf 44 in.Vlbf

Stud bolt x Cyllinder block (See page 14–53)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

03–8 SERVICE SPECIFICATIONS

–

LUBRICATION

LUBRICATION 031FK–01

SERVICE DATA Oil pump Side clearance Tip clearance

ProCarManuals.com

Body clearance

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Standard Maximum Standard Maximum Standard Maximum

0.030 to 0.085 mm (0.0012 to 0.0033 in.) 0.16 mm (0.0063 in.) 0.080 to 0.160 mm (0.0031 to 0.0063 in.) 0.35 mm (0.0138 in.) 0.100 to 0.170 mm (0.00394 to 0.00669 in.) 0.325 mm (0.01280 in.)

03–9 SERVICE SPECIFICATIONS

–

LUBRICATION 031FL–01

TORQUE SPECIFICATION Part Tightened

NVm

kgfVcm

ftVlbf

8.8

90

80 in.Vlbf

Oil pump x Oil pump relief valve plug

49

500

35

ProCarManuals.com

Oil pump x Oil pump cover

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

03–10 SERVICE SPECIFICATIONS

–

STARTING & CHARGING

STARTING & CHARGING 031E6–02

SERVICE DATA Starter armature assy Circle runout Commutator length Starter brush holder assy Brush length Generator rotor assy Slip ring resistance Slip ring diameter

ProCarManuals.com

Generator brush holder assy Exposed brush length

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Standard Maximum Standard Minimum

0.02 mm (0.0008 in.) 0.05 mm (0.0020 in.) 29 mm (1.142 in.) 28 mm (1.102 in.)

Standard 15.5 mm (0.610 in.) Minimum 9.0 mm (0.354 in.) at 20_C (68_F) 2.27 to 2.53 W Standard 15.3 to 15.5 mm (0.602 to 0.610 in.) Minimum 14.3 mm (0.561 in.) Standard 11.0 to 13.6 mm (0.433 to 0.535 in.) Minimum 1.5 mm (0.059 in.)

03–11 SERVICE SPECIFICATIONS

–

STARTING & CHARGING 031E7–02

TORQUE SPECIFICATION Part Tightened

NVm

kgfVcm

ftVlbf

Starter commutator end frame assy x Starter drive housing assy

6.0

61

53 in.Vlbf

Starter drive housing assy x Repair service starter kit

2.3

24

21 in.Vlbf

Lead wire x Repair service starter kit

6.0

61

53 in.Vlbf

Generator pulley x Generator rotor assy

65

663

48

Stator sub–assy generator w/ rectifire x Drive end frame

3.5

36

31 in.Vlbf

w/ washer w/o washer

2.2 1.2

22 12

19 in.Vlbf 11 in.Vlbf

Nur A Nut B Screw

19.5 12 2.4

199 122 24

14 9.0 21 in.Vlbf

Regulator rear end cover x Stator sub–assy generator w/ rectifire

ProCarManuals.com

Generator rear end cover x Stator sub–assy generator w/ rectifire (See page 19–9)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–1 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

PARTIAL ENGINE ASSY 141BX–01

COMPONENTS Oil Filler Cap Sub–assy Oil Filler Cap Gasket

14 (143, 10)

11 (112, 8.0) 11 (112, 8.0)

Ventilation Valve 19 (194, 14)

Cylinder Head Cover Sub–assy

Cylinder Head Cover Gasket Camshaft Position Sensor

Spark Plug

ProCarManuals.com

19 (194, 14) 9.0 (92, 80 in.Vlbf)

Water Pump Assy Crankshaft Position Sensor

Water Pump Pulley

Oil Filter Union 26 (265, 19)

9.0 (92, 80 in.Vlbf)

30 (306, 22)

Oil Filter Sub–assy 170 (1,733, 125)

Crankshaft Pulley Oil Pan Sub–assy z Gasket Oil Pan Drain Plug 25 (255, 18) 9.0 (92, 80 in.Vlbf) 9.0 (92, 80 in.Vlbf)

N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

A77363

14–2 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

Chain Sub–assy Chain Vibration Damper No. 1 Chain Tensioner Slipper

Crankshaft Timing Sproket No. 2 Chain Sub–assy

19 (194, 14)

Spring Camshaft Timing Gear Sprocket

Crankshaft Sensor Plate No. 1

Chain Tensioner

ProCarManuals.com

9.0 (92, 80 in.Vlbf)

30 (301, 22) 9.0 (92, 80 in.Vlbf)

z Gasket

12 (122, 9.0)

Timing Chain Guide Oil Pump Assy

19 (194, 14)

9.0 (92, 80 in.Vlbf) 9.0 (92, 80 in.Vlbf)

Chain Tensioner Assy No. 1 z Gasket

43 (438, 32) 43 (438, 32) 9.0 (92, 80 in.Vlbf)

z Timing Gear Case or Timing Chain Case Oil Seal 21 (214, 15)

Timing Chain or Belt Cover Sub–assy

N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

A77364

14–3 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

9.0 (92, 80 in.Vlbf) 30 (301, 22)

No. 1 Bearing Cap

Camshaft Bearing No. 1

No. 3 Bearing Cap

No. 2 Bearing Cap Camshaft

Crankshaft Timing Gear Assy

54 (551, 49)

No. 2 Camshaft

Cylinder Head Set Bolt

54 (551, 49)

79 (806, 58)

ProCarManuals.com

Camshaft Timing Gear Or Sprocket Camshaft Bearing No. 2

Cylinder Head Sub–assy

z Cylinder Head Gasket

N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

A77365

14–4 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

z Gasket Plug 30 (306, 22)

Oil Control Valve Filter

ProCarManuals.com

z Engine Rear Oil Seal

z O–ring

Stiffening Crankcase Assy

33 (332, 24)

33 (332, 24)

N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

A77362

14–5 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY 141BY–01

OVERHAUL

1.

REMOVE OIL FILLER CAP SUB–ASSY

2.

REMOVE OIL FILLER CAP GASKET

3.

REMOVE VENTILATION VALVE SUB–ASSY

4. (a)

REMOVE SPARK PLUG Using a 16 mm plug wrench, remove the spark plugs.

ProCarManuals.com

A77358

A77361

A77357

16 mm Plug Wrench

A77236

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–6 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

5. (a)

REMOVE OIL FILTER SUB–ASSY Using SST, remove the oil filter. SST 09228–06501

6. (a)

REMOVE OIL FILTER UNION Using a 12 mm socket hexagon wrench, remove the oil filter union.

7. (a) (b)

REMOVE CYLINDER HEAD COVER SUB–ASSY Remove 9 bolts and 2 nuts from the cylinder head cover. Remove the cylinder head cover.

SST A77425

12 mm Hexagon Wrench

ProCarManuals.com

A77239

A64640

8.

REMOVE CYLINDER HEAD COVER GASKET

9. (a)

A77356

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

REMOVE CAMSHAFT POSITION SENSOR Remove the bolt and the camshaft position sensor.

14–7 ENGINE MECHANICAL

REMOVE CRANKSHAFT PULLEY Set No. 1 cylinder to TDC/ compression. (1) Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. (2) Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360_) and align the mark as above.

Timing Marks

A77426

(b) SST

ProCarManuals.com

PARTIAL ENGINE ASSY

10. (a)

Timing Marks

Groove

–

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

A77380

(2)

Using the pulley set bolt and SST, remove the crankshaft pulley. SST 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05021) SST

A77381

11. REMOVE CHAIN TENSIONER ASSY NO.1 NOTICE: Do not turn the crankshaft. (a) Separate a clamp. 12. (a)

A77359

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

REMOVE CRANKSHAFT POSITION SENSOR Remove the 2 bolts and the crankshaft position sensor.

14–8 ENGINE MECHANICAL

13. (a)

–

PARTIAL ENGINE ASSY

REMOVE WATER PUMP PULLEY Using SST, remove the 4 bolts and the water pump pulley. SST 09960–10010 (09962–01000, 09963–00700)

͓͓͔ A77427

14. (a) (b)

REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts and clamp. Using a screw driver, pry between the water pump and cylinder block, and then remove the water pump. NOTICE: Be careful not to damage the contact surface of the water pump and cylinder block. Pry

ProCarManuals.com

A64711

15.

REMOVE OIL PAN DRAIN PLUG

16. (a)

REMOVE OIL PAN SUB–ASSY Remove the 12 bolts and 2 nuts.

A77360

A64641

(b)

Insert the blade of SST between the crank case, timing chain cover and oil pan, cut off applied sealer and remove the oil pan. SST 09032–00100 NOTICE: Be careful not to damage the contact surface of the timing chain cover, crank case and oil pan. A00019

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–9 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

17.

REMOVE TIMING CHAIN OR BELT COVER SUB–ASSY (a) Remove the 14 bolts and 2 nuts. (b) Using a screwdriver, pry between the timing chain cover and cylinder head or cylinder block. (c) Remove the timing chain cover. NOTICE: Be careful not to damage the contact surface of the timing chain cover, cylinder head and cylinder block.

Pry

ProCarManuals.com

A64642

18. (a)

REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver and a hammer, tap out the oil seal.

A77242

19. 20. (a)

REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and chain tensioner slipper.

21. (a)

A77355

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

REMOVE CHAIN VIBRATION DAMPER NO.1 Remove the 2 bolts and the chain vibration damper No. 1.

14–10 ENGINE MECHANICAL

22. (a)

–

PARTIAL ENGINE ASSY

REMOVE TIMING CHAIN GUIDE Remove the bolt and the timing chain guide.

A77243

23. 24.

REMOVE CHAIN SUB–ASSY REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

90_

25. (a)

REMOVE NO.2 CHAIN SUB–ASSY Turn the crankshaft counterclockwise 90_, and align adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.

(b)

Insert a 4 mm diameter bar in the adjusting hole drive shaft gear to lock in position, and remove the nut.

(c) (d)

Remove the bolt, chain tensioner and spring. Remove the oil pump drive shaft gear and chain No.2.

ProCarManuals.com

Groove

A77382

Groove A77383

A66833

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–11 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

26. (a)

REMOVE OIL PUMP ASSY Remove the 3 bolts, the remove then oil pump and gasket.

27. (a)

REMOVE NO.2 CAMSHAFT Remove the No. 2 and No. 3 camshaft bearing caps in the sequence shown in the illustration. Remove the No. 2 camshaft.

A77354

1

3

5

4

2

(b)

ProCarManuals.com

A77428

28. (a) (b)

1

29.

3

5

4

2

REMOVE CAMSHAFT Remove the No. 1 and No. 3 camshaft bearing caps in the sequence shown in the illustration. Remove the camshaft.

A77429

REMOVE CAMSHAFT BEARING NO.1

30. (a)

REMOVE CAMSHAFT TIMING GEAR OR SPROCKET Clamp the No. 2 camshaft in a vise, and remove the camshaft timing gear. NOTICE: Be careful not to damage the No. 2 camshaft.

A64874

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–12 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

31. (a)

REMOVE CAMSHAFT TIMING GEAR ASSY Clamp the camshaft in a vise, and make sure the camshaft timing gear assembly does not move. NOTICE: Be careful not to damage the camshaft. (b) Cover all the oil ports with vinyl tape expect the advance angle port as shown in the illustration.

Advance Angle Port

A77413

Put air pressure into the oil port with 150 kPa (1.5 kgf/cm2 21 psi), and turn the camshaft timing gear assembly to the advance direction (counterclockwise) by force. NOTICE: Some oil spraying will occur. Be prepared to catch the spray with a shop rag. HINT: Depending on the pressure, the VVT timing sprocket may turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, it might be difficult to get the lock–pin to release.

(c)

ProCarManuals.com

A31032

(d)

Remove the flange bolt from the camshaft timing gear assembly. NOTICE: S Be sure not to remove the other 4 bolts. S In case of reusing the camshaft timing gear assembly, release the straight pin lock first, and then install the gear.

Straight Pin

Flange Bolt A32639

32.

A32664

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

REMOVE CAMSHAFT BEARING NO.2

14–13 ENGINE MECHANICAL

33.

–

PARTIAL ENGINE ASSY

REMOVE CAMSHAFT HOUSING PLUG

ProCarManuals.com

A64712

35. 36. 37. (a)

3

7

9

6

2

1

5

10

8

4

A77430

34. (a)

REMOVE CYLINDER HEAD SUB–ASSY Using several steps, loosen the 10 cylinder head bolts with a 10 mm bi–hexagon wrench uniformly in the sequence shown. (b) Remove 10 cylinder head bolts and plate washers. NOTICE: S Be careful not to drop washers into the cylinder head. S Head warpage or cracking could result from removing bolts in an incorrect order.

REMOVE CYLINDER HEAD GASKET REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB–ASSY REMOVE OIL CONTROL VALVE FILTER Using a 12 mm hexagon wrench, remove the plug, gasket and oil control valve filter. 38. (a) (b)

Tape

Cut Position

REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver with the tip wrapped in tape, pry out the oil seal. NOTICE: After the removal, check the crankshaft is not damaged. If it is damaged, smooth the surface with 400 grit sand paper.

A77244

3

4

7 9 10

5

1

8

6

2

11

39. (a)

A77431

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

REMOVE STIFFENING CRANKCASE ASSY Loosen and remove the 11 bolts uniformly in several steps, in the sequence shown. (b) Using a screw driver, remove the crankcase by prying the between the crankcase and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. (c) Remove the O–ring from the cylinder block.

14–14 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

40. (a) (b)

EM2378

ProCarManuals.com

A53036

EM2378

INSPECT OIL PUMP DRIVE GEAR Wrap the chain around the drive gear. Using vernier calipers, measure the drive gear diameter with the chain wrapped. NOTICE: Vernier calipers must contact the chain rollers for the measuring. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) If the diameter is less than minimum, replace the chain and drive gear. 41. INSPECT OIL PUMP DRIVE SHAFT GEAR (a) Wrap the chain around the drive shaft gear. (b) Using vernier calipers, measure the drive shaft gear diameter with the chain wrapped. NOTICE: Vernier calipers must contact the chain rollers for the measuring. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) If the diameter is less than minimum, replace the chain and drive shaft gear. 42. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET (a) Wrap the chain around the timing gear. (b) Using vernier calipers, measure the timing gear diameter with the chain wrapped. NOTICE: Vernier calipers must contact the chain rollers for the measuring. Minimum gear diameter (w/chain): 51.6 mm (2.031 in.) If the diameter is less than minimum, replace the chain and timing gear.

43. (a)

INSPECT CHAIN TENSIONER SLIPPER Measure the chain tensioner slipper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the chain tensioner slipper.

A33838

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–15 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

44. (a)

INSPECT CHAIN VIBRATION DAMPER NO.1 Measure the chain vibration damper No. 1 wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the chain vibration damper No. 1

A36686

45. (a)

INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the length of head bolts from the seat to the end. Standard bolt length: 161.3 to 162.7 mm (6.350 to 6.406 in.) Maximum bolt length: 164.2 mm (6.465 in.) If the length is greater than maximum, replace the bolt.

Overall Length

ProCarManuals.com

A77407

46. (a)

Raise Move Lock

(b)

INSPECT CHAIN TENSIONER ASSY NO.1 Check the plunger moves smoothly when the ratchet pawl is raised, and when the ratchet pawl is released, the plunger is locked in place. Replace the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushing with your finger.

A77432

47. (a)

INSPECT CHAIN SUB–ASSY Using vernier calipers, measure length of the 15 links with the chain dully stretched. Maximum chain elongation: 115.4 mm (4.543 in.) If the elongation is greater than maximum, replace the chain. NOTICE: Make the same measurements pulling at 3 or more random places to obtain an average length.

115.4 mm (4.543 in.)

15 Links A57478

48. (a) (b)

INSPECT CAMSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing sprocket. Using vernier calipers, measure the timing sprocket diameter with the chain wrapped. Minimum sprocket diameter (w/ chain): 97.3 mm (3.831 in.) If the diameter is less than minimum, replace the chain and timing sprocket. A30206

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–16 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

NOTICE: Vernier calipers must contact the chain rollers for the measuring.

49. (a)

INSPECT CAMSHAFT 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: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, replace the camshaft. EM1628

ProCarManuals.com

(b)

Inspect cam lobe height. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 45.510 to 45.610 mm (1.7917 to 1.7957 in.) Minimum cam lobe height: 45.400 mm (1.7874 in.) If the cam lobe height is less than minimum, replace the camshaft. A36687

(c)

Inspect camshaft journals. (1) Using a micrometer, measure the journal diameter. Journal diameter: No. 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Others 22.959 to 22.975 mm (0.9040 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance. A36688

50. (a)

INSPECT NO.2 CAMSHAFT Inspect the No. 2 camshaft for runout. (1) Place the No. 2 camshaft on V–blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, replace the No. 2 camshaft. EM1628

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–17 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

(b)

Inspect cam lobe height. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 45.983 to 46.083 mm (1.8106 to 1.8143 in.) Minimum cam lobe height: 45.873 mm (1.8060 in.) If the cam lobe height is less than minimum, replace the No. 2 camshaft. A36687

(c)

Inspect camshaft journals. (1) Using a micrometer, measure the journal diameter. Journal diameter: No. 1 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Others 22.959 to 22.975 mm (0.9040 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance.

ProCarManuals.com

A36688

51. (a)

INSTALL STIFFENING CRANKCASE ASSY Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing on the places shown in the illustration. Seal Packing: Part No. 08826 – 00080 or equivalent NOTICE: S Remove any oil from the contact surface. S Install the crankcase within 3 minutes after applying seal packing. S Do not start the engine within 2 hours after installing.

Seal packing

(mm)

A77245

(b)

A37779

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Install a new O–ring to the place shown in the illustration.

14–18 ENGINE MECHANICAL

9

8

5 3 2

7

11

4

6

10

1

ProCarManuals.com

SST

(c)

–

PARTIAL ENGINE ASSY

Tighten the 11 bolts in several steps in the sequence shown in the illustration. Torque: 33 NVm (332 kgfVcm, 24 ftVlbf)

A77433

A77434

52. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free of foreign material. (b) Using SST and a hammer, equally tap the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223–15030, 09950–70010 (09951–07100) NOTICE: Wipe off extra grease on the crankshaft. 53. (a) (b)

Mesh Part

INSTALL OIL CONTROL VALVE FILTER Check that no foreign material on the mesh part of the filter. Using a 6 mm socket hexagon wrench, install the oil control valve filter with a new gasket. Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)

A77435

54. (a)

45_

45_ A77436

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB–ASSY Install the water drain cock sub assembly within the range shown in the illustration. Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)

14–19 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

55. (a)

INSTALL CYLINDER HEAD GASKET Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE: S Remove any oil from contact surface. S Be careful of the installation direction. S Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

Lot No.

ProCarManuals.com

A77408

Cylinder Head f 2.5 to 3 mm

Cylinder Head Gasket

12.5 to 1.5 mm Cylinder Block

Seal Packing

A77437

56. INSTALL CYLINDER HEAD SUB–ASSY HINT: The cylinder head bolts are tightened in 2 successive steps. (a) Apply a continuous bead (Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)) of seal packing on the places as shown in the illustration. Seal Packing: Part No. 08826 – 00080, or equivalent. NOTICE: S Remove any oil from the contact surface. S Install the cylinder head within 3 minutes after applying seal packing. S Do not start the engine within 2 hours after installing. (b) Apply a light coat of engine oil on the threads of the cylinder head bolts. (c) Install the bolts and plate washers to the cylinder head. NOTICE: Do not drop the washers into the cylinder head.

(d)

9

3

2

6

8

7

5

1

4

10

A77438

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Using several steps tighten each bolt with a 10 mm bi– hexagon wrench uniformly in the sequence shown in the illustration. Torque: 79 NVm (806 kgfVcm, 58 ftVlbf)

14–20 ENGINE MECHANICAL

(e) 90_

(f)

Engine Front

(g)

–

PARTIAL ENGINE ASSY

Mark each cylinder head bolt head on the front side with paint. Retighten the cylinder head bolts by 90_ in the same sequence shown as step (b). Check that each painted mark is now at a 90_ angle to the front.

Paint Mark A77411

A00976

57. (a)

ProCarManuals.com

Flange

INSTALL CAMSHAFT HOUSING PLUG Apply engine oil to a new O–ring, and install the camshaft housing plug. NOTICE: S Install the plug with its flange portions faced the manifold. S Insert the plug into the cylinder head until its flange portions reach the installation surface of the cylinder head.

A77247

58.

INSTALL CAMSHAFT BEARING NO.2

59. (a)

Straight Pin

Key Groove

A77248

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSTALL CAMSHAFT TIMING GEAR ASSY Align the key groove of the camshaft timing gear with the straight pin located on the camshaft, then fit the timing gear into place. (b) Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove. CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle). (c) Check that there is no clearance between the gear’s fringe and the camshaft. (d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 NVm (551 kgfVcm, 49 ftVlbf)

14–21 ENGINE MECHANICAL

(e)

–

PARTIAL ENGINE ASSY

Check that the camshaft timing gear assembly can move to the retard angle side (the right direction), and is locked at the most retarded position.

60. (a)

INSTALL CAMSHAFT TIMING GEAR OR SPROCKET Clamp the camshaft No. 2 in a vise, and install the camshaft No. 2 timing gear. Torque: 54 NVm (551 kgfVcm, 40 ftVlbf) NOTICE: Be careful not to damage the No. 2 camshaft.

A64874

ProCarManuals.com

61.

INSTALL CAMSHAFT BEARING NO.1

62. (a)

5

3

1

2

INSTALL CAMSHAFT Place the camshaft on the cylinder head as shown in the illustration. (b) Tighten the camshaft bearing cap No. 1 and No. 3 in the sequence shown in the illustration. Torque: Bearing cap No. 1 30 NVm (301 kgfVcm, 22 ftVlbf) Bearing cap No. 3 9 NVm (92 kgfVcm, 80 in.Vlbf) NOTICE: S Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 1. S Install the camshaft with its timing mark of camshaft timing gear upward.

4

No. 1 cylinder

A77439

63. (a)

INSTALL NO.2 CAMSHAFT Place the No. 2 camshaft on the cylinder head as shown in the illustration. (b) Tighten the camshaft bearing cap No. 2 and No. 3 in the sequence shown in the illustration. Torque: Bearing cap No. 2 30 NVm (301 kgfVcm, 22 ftVlbf) Bearing cap No. 3 9 NVm (92 kgfVcm, 80 in.Vlbf) NOTICE: S Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 2. S Install the camshaft with its timing mark of camshaft timing gear upward.

No. 1 cylinder

5

3

1

2

4

A77440

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–22 ENGINE MECHANICAL

64. (a)

–

PARTIAL ENGINE ASSY

INSTALL OIL PUMP ASSY Install the oil pump assembly with the 3 bolts and a new gasket. Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)

65. (a) (b)

INSTALL NO.2 CHAIN SUB–ASSY Set the crankshaft key in the left side position. Turn the flat portion of the drive shaft upward.

(c)

Align the mark links (yellow colored links) with the timing marks of the gears as shown in the illustration. With the chain wrapped, insert the gears to the crankshaft and oil pump shaft. Temporarily secure the oil pump drive shaft gear with a nut.

B11424

Mark Link

ProCarManuals.com

Timing Mark

(d) (e)

Timing Mark Mark Link

A77384

(f)

Groove

A77385

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Insert the damper spring into the adjusting hole of the cylinder block, and install the chain tensioner plate with the bolt. Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)

14–23 ENGINE MECHANICAL

(g) (h)

–

PARTIAL ENGINE ASSY

Align the adjusting hole of the sprocket with the groove of the oil pump. Put a 4 mm diameter bar into the adjusting hole to lock in position, and assemble the nut. Torque: 30 NVm (301 kgfVcm, 22 ftVlbf)

Groove A77386

(i) 90_

Rotate the crankshaft 90_ clockwise, and position the key of the crankshaft upward.

ProCarManuals.com

A77387

66.

INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

67. (a)

Timing Marks

INSTALL CHAIN SUB–ASSY Set No. 1 cylinder to TDC/ compression. (1) Align the timing marks of the camshaft timing sprockets with the timing marks located on the No. 1 bearing caps.

Timing Marks A77441

(2)

A52505

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Using the crankshaft pulley bolt, turn the crankshaft and set the key on the crankshaft upward.

14–24 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

(b)

Align the mark link (blue or orange colored link) with the timing mark located on the crankshaft timing gear.

(c)

Using SST, install the sprocket. SST 09309–37010

(d)

Align the mark links (gold or yellow colored links) with each timing mark located on the camshaft timing gear, and on the timing sprocket to install the chain.

Timing Mark Mark Link

A77442

SST

ProCarManuals.com

A77443

Mark Links Timing Marks

Timing Mark

A77389

68. 69. 70.

INSTALL TIMING CHAIN GUIDE Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) INSTALL CHAIN TENSIONER SLIPPER Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)

71. (a)

A32629

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 Install the crankshaft position sensor plate with the ”F” mark facing forward.

14–25 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

72.

INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09223–22010 (b) Apply a light coat of MP grease to the lip of a new oil seal. NOTICE: Keep the lip free of foreign material.

͓͓͔

A77444

Seal Packing

ProCarManuals.com

A77445

73. INSTALL TIMING CHAIN OR BELT COVER SUB–ASSY NOTICE: S Remove any oil from the contact surface. S Install the chain cover within 3 minutes after applying seal packing. S Do not start the engine within 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of seal packing as shown in the illustration. Seal packing: Part No. 08826 – 00080 or equivalent

(c) Seal Packing

4mm

A A

2.5 mm f 3 to 4 mm A A A77391

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Apply a continuous bead (Diameter 3 to 4 mm (0.118 to 0.157 in.)) of seal packing as shown in the illustration. Seal packing: Part No. 08826 – 00080 or equivalent

14–26 ENGINE MECHANICAL

(d) Nut

Nut

C C

C

C

PARTIAL ENGINE ASSY

Install the timing chain cover with the 14 bolts and 2 nuts. Torque: Bolt A 9.0 NVm (92 kgfVcm, 80 in.Vlbf) Bolt B 21 NVm (214 kgfVcm, 15 ftVlbf) Bolt C 43 NVm (438 kgfVcm, 32 ftVlbf) Nut 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

C

A

B

–

B

B B B

B

B B

ProCarManuals.com

A77251

74. INSTALL OIL PAN SUB–ASSY NOTICE: S Remove any oil from the contact surface. S Install the oil pan within 3 minutes after applying seal packing. S Do not start the engine within 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan. (b) Apply a continuous bead (Diameter 3 mm to 4 mm (0.079 to 0.118 in.)) of seal packing as shown in the illustration, and install the oil pan. Seal packing: Part No. 08826 – 00080 or equivalent

6mm

Seal Packing A77392

(c)

Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

A64641

75. (a)

INSTALL OIL PAN DRAIN PLUG Install the oil pan drain plug and a new gasket. Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–27 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

76. (a) (b)

Seal Width 2.2 to 2.5 mm A77446

INSTALL WATER PUMP ASSY Clean the contact surface of the cylinder block. Apply a continuous bead (Diameter 2.2 to 2.5 mm(0.087 to 0.098in.)) of seal packing to the outside edge of the water pump. Seal packing: Part No. 08826 – 00100 or equivalent NOTICE: S Remove any oil from the contact surface. S Install the water pump within 5 minutes after applying seal packing. S Do not start the engine within 2 hours after installing.

Install the clamp and the water pump assembly with the 4 bolts and 2 nuts. Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) NOTICE: Tighten the outside bolts and nuts.

ProCarManuals.com

(c)

A64722

77. (a)

INSTALL WATER PUMP PULLEY Using SST, install the water pump pulley with the 4 bolts. SST 09960–10010 (09962–01000, 09963–00700) Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)

78. (a) (b)

INSTALL CRANKSHAFT POSITION SENSOR Apply a light coat of engine oil to the O–ring. Install the crankshaft position sensor with the bolt. Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) Confirm the wire harness of the crankshaft position sensor is placed as shown in the illustration.

͓͓͔ A77447

Wire Harness

(c) Clamp Rib A77448

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–28 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

79. (a)

INSTALL CRANKSHAFT PULLEY Using SST, tighten the set bolt. SST 09213–54015 (91651–60855), 09330–00021 Torque: 170 NVm (1,733 kgfVcm, 125 ftVlbf)

80. (a)

INSTALL CHAIN TENSIONER ASSY NO.1 Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger is locked in the position.

SST

A77393

Raise

Push

Pin

Hook

ProCarManuals.com

A77394

(b)

Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) NOTICE: If the hook is disengaged while installing, re–apply the hook and then insert the chain tensioner.

Engine Front

A77395

(c)

Disconnect

Pin Hook

Turn A77396

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Turn the crankshaft pulley counterclockwise, and check that the plunger knock pin is free from the hook.

14–29 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

(d)

Turn the crankshaft clockwise, and check that the plunger is extended.

81. (a)

INSPECT VALVE CLEARANCE Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks located on the No. 1 bearing cap as shown in the illustration.

Plunger

Push

Turn

A77397

Timing Marks

(b)

ProCarManuals.com

Timing Marks

Groove

A77449

(c)

No. 1 Cylinder TDC/Compression IN

EX A77378

(d)

(e)

No. 4 Cylinder TDC/Compression IN

EX A77379

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Check only the valve indicated as shown in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and the camshaft. (2) Record the our–of–specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Valve clearance (cold): Intake 0.19 to 0.29 mm (0.007 to 0.011 in.) Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.) Turn the crankshaft 1 revolution (360_) clockwise, and set the No. 4 cylinder to TDC/compression.

Check only the valve indicated as shown in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and the camshaft. (2) Record the out–of–specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Valve clearance (cold): Intake 0.19 to 0.29 mm (0.007 to 0.011 in.) Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.)

14–30 ENGINE MECHANICAL

Paint Mark

Paint Mark

Timing Mark Groove

Timing Mark

–

PARTIAL ENGINE ASSY

82. ADJUST VALVE CLEARANCE NOTICE: Do not turn the crankshaft without the chain tensioner. (a) Turn the crankshaft 1 revolution (360_) clockwise, and set the No. 1 cylinder to TDC/compression. (b) Place matchmarks on the timing chain and camshaft timing gear. (c) Remove the 2 bolts and the chain tensioner.

A77450

Loosen

Hold

(d)

Fix the camshaft with a wrench, then loosen the camshaft timing gear set bolt. NOTICE: Be careful not to damage the valve lifter.

ProCarManuals.com

A77412

1

3

5

4

2

(e)

Using several steps, loosen the camshaft bearing cap bolts on the No. 2 camshaft in the sequence shown in the illustration, and then remove the bearing caps.

(f) (g)

Raising the No. 2 camshaft, remove the set bolt. Remove the timing chain sprocket from the No. 2 camshaft with the timing chain assembled. Remove the timing chain sprocket from the timing chain.

A77451

(h)

A52473

1

3

5

4

(i)

2

(j)

A77452

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Using several steps, loosen the camshaft bearing cap bolts on the camshaft in the sequence shown in the illustration, then remove the bearing caps. Remove the intake camshaft.

14–31 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

(k)

Tie the timing chain with a string.

(l)

Using a micrometer, measure the thickness of the removed lifter. Calculate the thickness of a new lifter so that the valve clearance comes within the specified valve.

A32556

(m)

Thickness of the new lifter

B

Thickness of the used lifter

C

Measured valve clearance

Valve clearance: Intake A = B + (C – 0.24 mm (0.0094 in.)) Exhaust A = B + (C – 0.35 mm (0.0138 in.))

A01082

ProCarManuals.com

A

EXAMPLE: (Intake) Measure valve clearance = 0.44 mm (0.0173 in.) 0.44 mm (0.0173 in.) – 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.) (Measured – Specification = Excess clearance) Used shim measurement = 5.30 mm (0.2087 in.) 0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.) (Excess clearance + Used shim = Ideal new shim) Closest new shim = 5.50 mm (0.2165 in.) = Shim No. ”50”

HINT: S S

S

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Select a new lifter with a thickness as close as possible to the calculated values. Lifter 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.) Refer to new Lifter Thickness table on the following 2 pages.

14–32

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Valve Lifter Selection Chart (Intake)

–

ProCarManuals.com

ENGINE MECHANICAL

A77296

Intake valve clearance (Cold): 0.19 to 0.29 mm (0.008 to 0.011 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter.

mm (in.)

Thickness

Lifter No.

Thickness

30

5.300 (0.2087)

54

5.540 (0.2181)

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)

Lifter No.

Thickness

Lifter No.

06

5.060 (0.1992)

08

PARTIAL ENGINE ASSY

New Lifter Thickness

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Valve Lifter Selection Chart (Exhaust)

–

ProCarManuals.com

ENGINE MECHANICAL mm (in.)

Lifter Thickness

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

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)

No.

No.

Thickness

5.660 (0.2228)

14–33

A77297

Exhaust valve clearance (Cold): 0.30 to 0.40 mm (0.0118 to 0.0157 in.) EXAMPLE: The 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. 44 lifter.

Lifter

PARTIAL ENGINE ASSY

New lifter thickness Lifter

14–34 ENGINE MECHANICAL

Paint Mark

–

PARTIAL ENGINE ASSY

(n)

Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing sprockets.

(o)

Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration. Torque: Bearing cap No. 1 30 NVm (301 kgfVcm, 22 ftVlbf) Bearing cap No. 3 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

(p)

Put the camshaft No. 2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets.

(q)

Raising the No. 2 camshaft, tighten the set bolt temporarily.

(r)

Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration. Torque: Bearing cap No. 2 30 NVm (301 kgfVcm, 22 ftVlbf) Bearing cap No. 3 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

Timing Mark A77254

5

3

1

ProCarManuals.com

Bearing Cap No. 1

2

4

Bearing Cap No. 3 A77415

Paint Mark

Timing Mark

A77453

A52473

Bearing Cap No. 2 Bearing Cap No. 3

5

3

1

2

4

A77416

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–35 ENGINE MECHANICAL

Tighten

Hold

–

PARTIAL ENGINE ASSY

(s)

Fix the camshaft with a wrench, then tighten the camshaft timing gear set bolt. Torque: 54 NVm (551 kgfVcm, 40 ftVlbf) NOTICE: Be careful not to damage the valve lifter.

A77417

(t)

HINT: There are 7 links between the two paint marks.

7 Links

ProCarManuals.com

Paint Mark

Check that each pair of the matchmarks are aligning as shown in the illustration.

Paint Mark

Timing Marks

Timing Mark Groove A77454

(u) Raise

Install the chain tensioner. (1) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger is locked in the position.

Push

Pin

Hook A77394

(2)

Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) NOTICE: If the hook is disengaged from the pin, re–apply the hook then resume installation.

Engine Front

A77395

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–36 ENGINE MECHANICAL

–

PARTIAL ENGINE ASSY

(3)

Turn the crankshaft counterclockwise, and disengage the hook from the pin to free the plunger.

(4)

Turn the crankshaft clockwise, and check that the plunger is pushed by the slipper.

Disconnect

Pin Hook

Turn A77396

Plunger

ProCarManuals.com

Push

83.

Turn

A77510

INSTALL CAMSHAFT POSITION SENSOR Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) INSTALL CYLINDER HEAD COVER GASKET 85. INSTALL CYLINDER HEAD COVER SUB–ASSY (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the 2 locations shown in the illustraSeal Packing tion. Seal packing: Part No. 08826–00080 or equivalent NOTICE: S Remove any oil from the contact surface. S Install the cylinder head cover within 5 minutes after applying seal packing. S Do not expose seal packing to engine oil 2 hours after installing. A77399

84.

(c) A

A

C B

A Nut

86. (a)

C

A

B

A

Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: Bolt A 11 NVm (112 kgfVcm, 8 ftVlbf) Bolt B 14 NVm (143 kgfVcm, 10 ftVlbf) Bolt C 21 NVm (214 kgfVcm, 15 ftVlbf) Nut 11 NVm (112 kgfVcm, 8 ftVlbf)

Nut A77346

INSTALL OIL FILTER UNION Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–37 ENGINE MECHANICAL

87. (a) (b) (c) (d) SST

–

PARTIAL ENGINE ASSY

INSTALL OIL FILTER SUB–ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it an additional 3/4 turn. SST 09228–06501

A77425

88. 89. (a)

ProCarManuals.com

90. 91.

INSTALL SPARK PLUG Torque: 19 NVm (194 kgfVcm, 14 ftVlbf) INSTALL VENTILATION VALVE SUB–ASSY Apply adhesive on the threads of the ventilation valve. Torque: 15 NVm (153 kgfVcm, 11 ftVlbf) Adhesive: Part No. 08833–00070 THREE BOND 1324 or equivalent INSTALL OIL FILLER CAP GASKET INSTALL OIL FILLER CAP SUB–ASSY

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–38 ENGINE MECHANICAL

–

CYLINDER HEAD ASSY

CYLINDER HEAD ASSY 141BV–01

COMPONENTS

Valve Lifter Valve Retainer Lock Retainer Inner Compression Spring Intake Valve Guide Bush

z Valve Stem Oil O Seal or Ring Valve Spring Seat

ProCarManuals.com

Exhaust Valve Guide Bush

Stud Bolt

Ring w/ Head Pin Cylinder Head Assy

Exhaust Valve Intake Valve

z Non–reusable part

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

A77366

14–39 ENGINE MECHANICAL

–

CYLINDER HEAD ASSY 141BW–01

OVERHAUL 1. REMOVE VALVE LIFTER HINT: Store the valve liters in correct order, so that they can be returned to the original locations when re–assembling.

2. (a)

SST

(b)

ProCarManuals.com

Wooden Blocks

A77455

(b)

Wooden Blocks A77456

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Retainer

2

Valve spring

3

Intake valve

REMOVE EXHAUST VALVE Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202–70020 (09202–00010) Remove the parts below from the cylinder head. 1

Retainer

2

Valve spring

3

Intake valve

HINT: Store the removed parts in correct order, so that they can be returned to the original locations when re–assembling.

4. (a)

A14202

1

HINT: Store the removed parts in correct order, so that they can be returned to the original locations when re–assembling.

3. (a)

SST

REMOVE INTAKE VALVE Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202–70020 (09202–00010) Remove the parts below from the cylinder head.

REMOVE VALVE STEM OIL O SEAL OR RING Using needle–nose pliers, remove the oil seals.

14–40 ENGINE MECHANICAL

5. (a)

–

CYLINDER HEAD ASSY

REMOVE VALVE SPRING SEAT Using compressed air and a magnetic finger, remove the spring seat by blowing air.

HINT: Store the removed parts in correct order, so that they can be returned to the original locations when re–assembling.

A14192

6.

REMOVE STUD BOLT

ProCarManuals.com

7. (a)

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

Intake Manifold Side

Exhaust Manifold Side

A77255

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–41 ENGINE MECHANICAL

8. (a)

–

CYLINDER HEAD ASSY

INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks.

A14180

9. (a)

Width

ProCarManuals.com

A77457

INSPECT VALVE SEATS Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve against the seat. (c) Check the valve face and seat according to 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 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 mm (0.039 to 0.055 in.). 10. REPAIR VALVE SEATS NOTICE: Releasing the seat–cutter pressure gradually helps to make smoother valve seat faces. (a) Using a 45_ cutter, cut valve face of the cylinder head a little wider than the specified valve seating width. (b) Confirm that the valve fits the valve seat center portion. If not, re–cut the valve face with the 45_ cutter. (c) Adjust valve face with a 30_ or 60_ cutter to accurately fit the valve seat center portion. (1)

45_ 30_

1.0 to 1.4mm

A77502

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

If the seating is too high on the valve face, use 30_ and 45_ cutters to correct the seat.

14–42 ENGINE MECHANICAL

CYLINDER HEAD ASSY

(2)

75_ 45_

(d) (e)

1.0 to1.4mm

–

If the seating is too low on the valve face, use 75_ and 45_ cutters to correct the seat. Hand–lap the valve and valve seat with an abrasive compound. Recheck the valve seating position.

A77503

11. (a) (b)

ProCarManuals.com

A36626

(c)

12. (a) (b) (c)

INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: Intake 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Exhaust 0.080 to 0.135 m (0.0032 to 0.0053 in.) Maximum thrust clearance: Intake 0.11 mm (0.0043 in.) Exhaust 0.15 mm (0.0059 in.) If the thrust clearance is greater than maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal.

A36627

(d)

Install the bearing caps. Torque: No. 1 30 NVm (301 kgfVcm, 22 ftVlbf) No. 2 30 NVm (301 kgfVcm, 22 ftVlbf) No. 3 9 NVm (92 kgfVcm, 80 in.Vlbf) NOTICE: Do not turn the camshaft. A32645

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–43 ENGINE MECHANICAL

–

CYLINDER HEAD ASSY

(e)

ProCarManuals.com

A36628

Remove the bearing cap, and measure the Plastigage at its widest point. Standard oil clearance: Intake No. 1 journal bearing mark 1 0.007 to 0.038 mm (0.0028 to 0.00150 in.) Intake No. 1 journal bearing mark 2 0.008 to 0.038 mm (0.0031 to 0.00150 in.) Intake No. 1 journal bearing mark 3 0.008 to 0.038 mm (0.0031 to 0.00150 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.) Exhaust No. 1 journal 0.015 to 0.054 mm (0.0006 to 0.0021 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.) Maximum oil clearance: Intake No. 1 journal 0.07 mm (0.0028 in.) Other journals 0.10 mm (0.0039 in.) NOTICE: Completely remove the Plastigage after the inspection. (f) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the cylinder head.

(g)

If the oil clearance on No. 1 journal is greater than maximum, replace the bearing.

HINT: Cylinder head journal bore diameter: Number Mark

Mark ”1”

40.000 to 40.008 mm (1.57480 to 1.57511 in.)

Mark ”2”

40.009 to 40.017 mm (1.57515 to 1.57547 in.)

Mark ”3”

40.018 to 40.025 mm (0.57551 to 1.57578 in.)

Standard bearing center wall thickness: Number Mark

A77460

Mark ”1”

2.000 to 2.004 mm (0.07874 to 0.07890 in.)

Mark ”2”

2.005 to 2.008 mm (0.07894 to 0.07905 in.)

Mark ”3”

2.009 to 2.012 mm (0.07909 to 0.07921 in.)

Camshaft journal diameter: 35.971 to 35.985 mm (1.41648 to 1.41673 in.)

13. (a)

EM0801

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSPECT INNER COMPRESSION SPRING Check the free length. (1) Using vernier calipers, measure the free length of the valve spring. Free length: 45.7 mm (1.799 in.)

14–44 ENGINE MECHANICAL

–

CYLINDER HEAD ASSY

(b)

Check the deviation. (1) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2_

14. (a)

INSPECT INTAKE VALVE Check the valve overall length. (1) Using vernier calipers, measure the valve overall length. Standard overall length: 101.71 mm (4.0043 in.) Minimum overall length: 101.21 mm (3.9846 in.)

(b)

Check the diameter of the valve stem. (1) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.)

(c)

Check the valve head margin thickness. (1) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.05 to 1.45 mm (0.041 to 0.057 in.) Minimum margin thickness: 0.75 mm (0.030 in.)

15. (a)

INSPECT EXHAUST VALVE Check the valve overall length. (1) Using vernier calipers, measure the valve overall length. Standard overall length: 101.15 mm (3.9823 in.) Minimum overall length: 100.70 mm (3.9646 in.)

Deviation

A77461

ProCarManuals.com

EM2534

A32770

Margin Thickness A77462

EM2534

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–45 ENGINE MECHANICAL

–

CYLINDER HEAD ASSY

(b)

Check the diameter of the valve stem. (1) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 in.)

(c)

Check the valve head margin thickness. (1) Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.2 to 1.6 mm (0.047 to 0.063 in.) Minimum margin thickness: 0.9 mm (0.035 in.)

16. (a)

INSPECT INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the inside diameter of the guide bushing diameter. Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement from the guide bushing. Standard oil clearance: 0.025 to 0.060 mm (0.00098 to 0.00236 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) INSPECT EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the inside diameter of the guide bushing diameter. Bushing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) REMOVE INTAKE VALVE GUIDE BUSH Gradually heat the cylinder head to 80 to 100_C (176 to 212_F).

Z00052

Margin Thickness

ProCarManuals.com

A77462

(b)

A13367

17. (a)

(b)

A13367

18. (a)

A13100

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–46 ENGINE MECHANICAL

–

CYLINDER HEAD ASSY

(b)

Using SST and a hammer, tap out the guide bushing. SST 09201–10000 (09201–01050), 09950–70010 (09951–07100)

19. (a)

REMOVE EXHAUST VALVE GUIDE BUSH Gradually heat the cylinder head to 80 to 100_C (176 to 212_F).

(b)

Using SST and a hammer, tap out the guide bushing. SST 09201–10000 (09201–01050), 09950–70010 (09951–07100) INSTALL INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Install the STD bushing if the diameter is within specified diameter.

SST

A77463

ProCarManuals.com

A13100

SST

20. (a)

(b) A77464

HINT: STD

(c)

SST

(d) A77465

21. (a)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

10.333 to 10.344 mm (0.4068 to 0.4072 in.)

Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937 in.) SST 09201–10000 (09201–01050), 09950–70010 (09951–07100), 23801 Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.00098 to 0.00236 in.) INSTALL EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

14–47 ENGINE MECHANICAL

(b)

–

CYLINDER HEAD ASSY

Install the STD bushing if the diameter is within specified diameter.

HINT: STD

(c) SST

(d)

ProCarManuals.com

A77466

10.333 to 10.344 mm (0.4068 to 0.4072 in.)

Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937 in.) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem. SST 09201–10000 (09201–01050), 09950–70010 (09951–07100), 23801 Standard oil clearance: 0.030 to 0.065 mm (0.00118 to 0.00256 in.)

22. (a)

INSPECT VALVE LIFTER Check the lifter diameter. (1) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.)

(b)

Check the valve lifter oil clearance. (1) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.08 mm (0.0032 in.)

P16860

(c)

A13374

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–48 ENGINE MECHANICAL

Upper Side

–

CYLINDER HEAD ASSY

23. (a)

INSTALL RING W/HEAD PIN Using a plastic–faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 5.5 mm (0.217 in.)

24. (a)

INSTALL RING PIN Using a plastic–faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 6.5 mm (0.256 in.)

25. (a)

INSTALL TIGHT PLUG Apply seal packing to the cylinder head as shown in the illustration. Using SST, tap in plug to the specified protrusion height. SST 09950–60010 (09951–00180), 09950–70010 (09951–07100) Protrusion height: 1.5 to 2.5 mm (0.059 to 0.098 in.)

5.5

[mm]

A77256

ProCarManuals.com

Upper Side

[mm] A77257

(b)

Exhaust Manifold Side

1.5 – 2.5 (0.059 – 0.098)

{mm (in.)} Seal Packing

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

A77258

14–49 ENGINE MECHANICAL

26.

Front

–

CYLINDER HEAD ASSY

INSTALL STUD BOLT Torque: Bolt A 5.0 NVm (51 kgfVcm, 44 Bolt B 5.0 NVm (51 kgfVcm, 44 Bolt C 9.5 NVm (97 kgfVcm, 84 Bolt D 9.5 NVm (97 kgfVcm, 84

in.Vlbf) in.Vlbf) in.Vlbf) in.Vlbf)

Upper

ProCarManuals.com

Intake Manifold Side Exhaust Manifold Side

[mm]

A77259

27.

INSTALL VALVE SPRING SEAT

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–50 ENGINE MECHANICAL

Intake Side

Exhaust Side Gray Black

A77467

–

CYLINDER HEAD ASSY

28. INSTALL VALVE STEM OIL O SEAL OR RING (a) Apply a light coat of engine oil on new valve stem seals. NOTICE: Pay much attention assembling the oil seal for intake and exhaust. Installing the wrong one may cause improper installation. HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black. (b)

Using SST, push in the oil seal. SST 09201–41020

29. (a)

INSTALL INTAKE VALVE Install the parts below to the cylinder head.

SST

ProCarManuals.com

A77468

SST

1

(b)

Wooden Blocks

Intake valve

2

Spring

3

Retainer

Using SST and wooden blocks, compress and install 2 valve spring retainer locks. SST 09202–70020 (09202–00010)

A77455

(c)

Wrap the tip of a discarded valve with vinyl tape, place the discarded valve tip on the installed valve. Using a plastic– faced hammer, lightly tap the discarded valve head to ensure proper fitting of the installed valve. NOTICE: Be careful not to damage the valve stem tip.

Vinyl Tape

Valve Stem

A77469

30. (a)

SST

(b) Wooden Blocks A77456

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSTALL EXHAUST VALVE Install the parts below to the cylinder head. 1

Exhaust valve

2

Spring

3

Retainer

Using SST and wooden blocks, compress and install 2 valve spring retainer locks. SST 09202–70020 (09202–00010)

14–51 ENGINE MECHANICAL

(c)

CYLINDER HEAD ASSY

Wrap the tip of a discarded valve with vinyl tape, place the discarded valve tip on the installed valve. Using a plastic– faced hammer, lightly tap the discarded valve head to ensure proper fitting of the installed valve. NOTICE: Be careful not to damage the valve stem tip.

Vinyl Tape

Valve Stem

–

A77469

ProCarManuals.com

31. INSTALL VALVE LIFTER (a) Apply a light coat of engine oil on the valve lifter. NOTICE: Install the valve lifters to the original locations.

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–52 ENGINE MECHANICAL

–

CYLINDER BLOCK ASSY

CYLINDER BLOCK ASSY 141BT–01

COMPONENTS Piston Ring Set

Snap Ring Piston Piston Pin

Connecting Rod

ProCarManuals.com

Connecting Rod Bearing

Cylinder Block Assy

Crankshaft Thrust Washer

Crankshaft Bearing

Crankshaft

Connecting Rod Bearing

Connecting Rod Bearing

Crankshaft Bearing Ring Pin

Crankshaft Bearing Cap Bolt

A77367

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–53 ENGINE MECHANICAL

–

CYLINDER BLOCK ASSY 141BU–01

OVERHAUL

1. (a)

(b)

ProCarManuals.com

A13845

INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. INSPECT CONNECTING ROD OIL CLEARANCE

2. HINT: The connecting rod cap bolts are tightened in 2 successive steps. (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (b) Using a 12 mm socket wrench, remove the 2 connecting rod cap bolts. SST 09011–38121 (c) Clean the crank pin and bearing. (d) Check the crank pin and bearing for pitting and scratches. (e) Lay a strip of Plastigage on the crank pin. Plastigage

A77271

(f) Front Mark

(g) (h)

A77272

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Check that the front mark of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil on the threads of the connecting rod cap bolts. Using a 12 mm socket wrench, tighten the bolts in several steps with the specified torque. SST 09011–38121 Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)

14–54 ENGINE MECHANICAL

90_

Paint Mark

Engine Front

–

CYLINDER BLOCK ASSY

(i)

Place the front mark on each connecting rod cap bolt head with paint. (j) Retighten the cap bolts by 90_ as shown in the illustration. NOTICE: Do not turn the crankshaft. (k) Remove the 2 bolts, connecting rod cap and lower bearing.

A77470

(l)

Measure the Plastigage at its widest point. Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) NOTICE: Completely remove the Plastigage.

ProCarManuals.com

A38162

(m)

Mark 1, 2 or 3

Mark 1, 2 or 3

If replacing the bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked ”1”, ”2” and ”3” accordingly.

HINT: Standard bearing center wall thickness.

A77471

3. (a) (b)

Mark 1

1.485 to 1.488 mm (0.0585 to 0.0586 in.)

Mark 2

1.488 to 1.491 mm (0.0586 to 0.0587 in.)

Mark 3

1.491 to 1.494 mm (0.0587 to 0.0588 in.)

REMOVE PISTON SUB–ASSY W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT: S S A13469

4.

REMOVE CONNECTING ROD BEARING

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Keep the bearing, connecting rod and cap together. Store the piston and connecting rod assemblies in correct order so they can be returned to the original locations when re–installing.

14–55 ENGINE MECHANICAL

5. (a)

–

CYLINDER BLOCK ASSY

(b)

REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand.

6. (a)

REMOVE PISTON Using a small screwdriver, pry out the 2 snap rings.

(b)

Gradually heat the piston to 80 to 90 _C (176 to 194 _F).

(c)

Using a plastic–faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

A14289

ProCarManuals.com

A13861

A01178

HINT: S S

The piston and pin are a matched set. Store the pistons, pins, rings, connecting rods and bearings in correct order so that they can be returned to the original locations when re–assembling.

7. (a)

INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.040 to 0.240 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 1.930 to 1.980 mm (0.0760 to 0.0780 in.)

A01179

(b) A13851

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–56 ENGINE MECHANICAL

7

3

1

5

8. (a)

9

(b)

8

4

2

6

–

CYLINDER BLOCK ASSY

REMOVE CRANKSHAFT Using several steps, loosen and remove the 10 bearing cap sub–assembly bolts uniformly in the sequence shown. Remove the bearing cap and the crankshaft.

10

ProCarManuals.com

A77475

9. REMOVE CRANKSHAFT THRUST WASHER UPPER 10. REMOVE CRANKSHAFT BEARING NOTICE: Store the bearings in correct order so they can be returned to the original locations when re–assembling. 11. REMOVE CRANKSHAFT BEARING NO.2 NOTICE: Store the bearings in correct order so they can be returned to the original locations when re–assembling. 12. REMOVE STUD BOLT

13. (a)

A38165

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.)

14–57 ENGINE MECHANICAL

–

CYLINDER BLOCK ASSY

14. (a)

INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 86.000 to 86.013 mm (3.3858 to 3.3863 in.) Maximum diameter: 86.013 mm (3.3863 in.) If the diameter is greater than maximum, replace the cylinder block. Thrust Direction Front Axial Direction A

ProCarManuals.com

B

10 mm (0.39 in.)A77472

15. (a)

INSPECT PISTON DIAMETER Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.4 mm (1.1968 in.) from the piston head. Piston diameter: 85.927 to 85.937 mm (3.3829 to 3.3833 in.)

30.4 mm (1.1968 in.) A78295

16. (a)

(b)

INSPECT PISTON CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.063 to 0.086 mm (0.0025 to 0.0034 in.) Maximum oil clearance: 0.1 mm (0.0039 in.) If the clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.

17. (a)

A36650

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove. Ring groove clearance: Piston Ring

mm (in.)

No. 1

0.020 to 0.007 (0.0008 to 0.0028)

No. 2

0.020 to 0.006 (0.0008 to 0.0024)

Oil ring (Side rail)

0.070 to 0.150 (0.0028 to 0.0059)

14–58 ENGINE MECHANICAL

–

CYLINDER BLOCK ASSY

18. (a)

INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 4.5 mm (1.77 in.) from the top of the cylinder block.

(b)

Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.) No. 2 0.47 to 0.62 mm (0.0185 to 0.0244 in.) Oil (side rail) 0.10 to 0.35 mm (0.0039 to 0.0138 in.) Maximum end gap: No. 1 0.89 mm (0.0350 in.) No. 2 1.37 mm (0.0539 in.) Oil (side rail) 0.73 mm (0.0287 in.)

19. (a)

INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston bushing. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.)

(b)

Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.009 mm (0.8660 to 0.8665 in.)

(c)

Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.)

4.5 mm (1.77 in.)

Piston Ring A77473

ProCarManuals.com

EM2552

A13490

EM0227

(d)

A01185

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–59 ENGINE MECHANICAL

(e)

Piston Bushing Inside Diameter Mark

(f)

Front Mark

(g)

–

CYLINDER BLOCK ASSY

If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.

Front Mark

Connecting Rod Bushing Inside Diameter Mark

ProCarManuals.com

A77474

20. (a)

(b)

INSPECT CONNECTING ROD SUB–ASSY 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 out–of alignment is greater than maximum, replace the connecting rod assembly.

Z00064

(c)

(1) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly.

Z00065

21. (a)

(b)

A01470

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSPECT CONNECTING ROD BOLT Using a vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than minimum, replace the bolt.

14–60 ENGINE MECHANICAL

–

CYLINDER BLOCK ASSY

22. (a)

INSPECT CRANKSHAFT 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.)

(b)

Using a micrometer, measure the diameter of each main journal. Diameter: 54.988 to 55.000 (2.1648 to 2.06535 in.) Check each main journal for taper and out–of–round as shown. Maximum taper and out –of– round: 0.003 mm (0.0001 in.)

A13859

(c)

ProCarManuals.com

HINT: Mark

mm (in.)

0

54.998 to 55.000 (2.16528 to 2.16535)

1

54.996 to 54.998 (2.16520 to 2.16528)

2

54.994 to 54.996 (2.16512 to 2.16520)

3

54.992 to 54.994 (2.16504 to 2.16512)

4

54.990 to 54.992 (2.16496 to 2.16504)

5

54.988 to 54.990 (2.16490 to 2.16496)

A38182

(d)

(e)

Using a micrometer, measure the diameter of each crank pin. Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.) Check each crank pin for taper and out–of–round as shown. Maximum taper and out–of–round: 0.003 mm (0.0001 in.)

ZF6928

23. (a)

INSPECT CRANKSHAFT BEARING CAP SET BOLT Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.) Minimum diameter: 7.2 mm (0.283 in.) If the diameter is less than minimum, replace the bolt.

EM6347

A15065

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–61 ENGINE MECHANICAL

24. (a)

Upper Side

–

CYLINDER BLOCK ASSY

INSTALL RING PIN Using a plastic–faced hammer, tap into the ring pin. Standard protrusion: Ring pin A 6 mm (0.236 in.) Ring pin B 5 mm (0.197 in.) Bottom Side

ProCarManuals.com

6 (Ring Pin A) 5 (Ring Pin B)

{mm} A77273

A53029

25. INSPECT CRANKSHAFT OIL CLEARANCE NOTICE: S Clean the backside of the bearing and the bearing surface of the bearing cap and keep them free of oils. S The bearing cap bolts are tightened in 2 progressive steps. (a) Clean each main journal and bearing. (b) Install the upper bearing with an oil groove on cylinder block. (c) Install the lower bearing on the bearing cap sub assembly. (d) Place the crankshaft on the cylinder block.

(e)

Plastigage

A77274

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Lay a strip of Plastigage across each journal. SST 09011–38121

14–62 ENGINE MECHANICAL

(f) (g)

–

CYLINDER BLOCK ASSY

Examine the front marks and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads and under the bearing cap bolts.

Front Mark and Journal Number A77275

̷

̳

̱

̵

(h)

̹

(i)

̸

̴

̲

̶

Using several steps, tighten the bolts with the specified torque in the sequence shown in the illustration. Torque: 20 NVm (204 kgfVcm, 15 ftVlbf) Retighten the bolts in the same way as above with the specified torque. Torque: 40 NVm (408 kgfVcm, 29 ftVlbf)

10

ProCarManuals.com

A77475

90_

Paint Mark

Engine Front

A77470

(j)

Place the front mark on each bearing cap bolt head with paint. (k) Retighten the bearing cap bolts by 90_ in the same sequence as step (h). (l) Check that each painted mark is now at a 90_ angle to the front. NOTICE: Do not turn the crankshaft. (m) Remove the bearing caps. (n)

Measure the Plastigage at its widest point. Standard oil clearance: 0.017 to 0.040 mm (0.0007 to 0.0016 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) NOTICE: Completely remove the Plastigage.

A13855

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–63 ENGINE MECHANICAL

(o)

Mark

ProCarManuals.com

A77276

–

CYLINDER BLOCK ASSY

If using a standard bearing, replace it with one having the same number as old one. If the number of the bearing cannot be determined, select a proper bearing by putting together the numbers imprinted on the cylinder block and the crankshaft. The total number of this will determine an applicable bearing among the 4 standard bearings, marked ”1”, ”2”, ”3” and ”4”. For the details about selection, refer to the table and hint below.

Cylinder block + Crankshaft

0 to 2

3 to 5

6 to 8

9 to 11

Replacement bearing number

”1”

”2”

”3”

”4”

HINT: EXAMPLE Cylinder block with imprinted number ”4” Crankshaft with imprinted number ”3” ”4” + ”3” = ”7” Select the bearing with marked ”3”

Reference: Item

Mark

mm (in.)

Cylinder block main journal bore diameter (A)

0 1 2 3 4 5 6

59.000 to 59.002 (2.08683 to 2.32291) 59.003 to 59.004 (2.08694 to 2.32299) 59.005 to 59.006 (2.08701 to 2.32307) 59.007 to 59.009 (2.08708 to 2.32318) 59.010 to 59.011 (2.08718 to 2.32326) 59.012 to 59.013 (2.08725 to 2.32334) 59.014 to 59.016 (2.08733 to 2.32346)

Crankshaft main journal diameter (B)

0 1 2 3 4 5

54.998 to 55.000 (1.94528 to 2.16535) 54.996 to 54.998 (1.94521 to 2.16527) 54.994 to 54.996 (1.94514 to 2.16519) 54.992 to 54.994 (1.94507 to 2.16511) 54.990 to 54.992 (1.94500 to 2.16504) 54.988 to 54.990 (1.94493 to 2.16496)

Standard bearing center wall thickness

1 2 3 4

1.993 to 1.996 (0.07846 to 0.07858) 1.996 to 1.999 (0.07858 to 0.07870) 1.999 to 2.002 (0.07870 to 0.07882) 2.002 to 2.005 (0.07882 to 0.07894)

26. (a)

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSTALL TIGHT PLUG Apply adhesive around tight plugs. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent.

14–64 ENGINE MECHANICAL

(b)

–

CYLINDER BLOCK ASSY

Using SST, push in the tight plugs as shown in the illustration. SST 09950–60010 (09951–00200), 09950–70010 (09951–07100) Standard depth: Engine front 1.7 to 2.7 mm (0.067 to 0.106 in.) Engine rear 2.2 to 3.2 mm (0.087 to 0.126 in.)

Engine Rear

ProCarManuals.com

Engine Front

A77484

27. (a)

INSTALL STUD BOLT Install the stud bolts as shown in the illustration. Torque: Stud bolt A 5.0 NVm (51 kgfVcm, 44 in.Vlbf) Stud bolt B 10NVm (97 kgfVcm, 84 in.Vlbf) Stud bolt C 5.0NVm (51 kgfVcm, 44 in.Vlbf)

Front Side

C

Exhaust Side

A A

16

B

84

18

14 31.5

9 A (M16)

27.5 20 B (M10)

9 C (M6) A77476

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–65 ENGINE MECHANICAL

28. (a)

Back Side

–

CYLINDER BLOCK ASSY

INSTALL STRAIGHT PIN Using a plastic–faced hammer, tap into the straight pin. Standard protrusion Pin A 7.5 mm (0.295 in.) Pin B 12 mm (0.472 in.) Bottom Side

Front Side A A

B

A

B

A

10 8

ProCarManuals.com

7.5 (Pin A) 12 (Pin B) 22

15 A

B A77477

29. (a) (b)

INSTALL PISTON Using a small screwdriver, install a new snap ring at one end of the piston pin hole. Gradually heat the piston to 80 to 90_C (176 to 194_F).

A13857

(c) Front Mark

(d)

Front Mark

A77478

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Align the front mark of the piston with the front mark located on the connecting rod, and push in the piston with your thumb. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.

14–66 ENGINE MECHANICAL

–

CYLINDER BLOCK ASSY

30. (a) (b)

INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the painted mark facing right side. NOTICE: Install the compression ring No. 2 with the code mark (2T) upward.

Upward No. 1 Painted Mark No. 2 Code Mark (2T)

ProCarManuals.com

A77479

No. 1 and Expander

(c) Side Rail Lower

Position the piston rings so that the ring ends are as shown.

Front

Side Rail Upper

No. 2 Compression A77480

31. (a)

INSTALL CRANKSHAFT BEARING Install the upper bearing with an oil groove on cylinder block. NOTICE: Clean the back side of the bearing and the bearing surface of the cylinder block and keep them free of oils.

A53029

32. INSTALL CRANKSHAFT BEARING NO.2 (a) Install the lower bearing on bearing cap. NOTICE: Clean the back side of the bearing and the bearing surface of the cylinder block and keep them free of oils.

A33379

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

14–67 ENGINE MECHANICAL

33. (a)

34. (a) (b)

–

CYLINDER BLOCK ASSY

INSTALL CRANKSHAFT THRUST WASHER UPPER Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward. INSTALL CRANKSHAFT Apply engine oil on the upper bearing and install the crankshaft on the cylinder block. Apply engine oil on the lower bearing.

A13501

(c) (d)

Examine the front marks and install the bearing caps to the cylinder block. Apply a light coat of engine oil on the threads of the bearing cap bolts.

Front Mark and Journal Number

ProCarManuals.com

A77275

̷

̳

̱

̵

(e)

̹

(f)

̸

̴

̲

̶

Using several steps, tighten the bolts with the specified torque in the sequence shown in the illustration. Torque: 20 NVm (204 kgfVcm, 15 ftVlbf) Retighten the bolts in the same way as above with the specified torque. Torque: 40 NVm (408 kgfVcm, 29 ftVlbf)

10 A77475

Paint Mark

90_ Engine Front

(g) (h) (i) (j)

Place the front mark on each bearing cap bolt head with paint. Retighten the bearing cap bolts by 90_ in the same sequence as step (e). Check that each painted mark is now at a 90_ angle to the front. Check that the crankshaft turns smoothly.

A77470

35. (a)

Claw

A77481

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSTALL CONNECTING ROD BEARING 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 bearing cap and keep them free of oils. 36. INSTALL PISTON SUB–ASSY W/CONNECTING ROD NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps.

14–68 ENGINE MECHANICAL

(a) (b)

–

CYLINDER BLOCK ASSY

Apply engine oil on the cylinder walls, the pistons, and the surfaces of connecting rod bearings. Check the position of the piston ring ends.

(c)

Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod.

Front Mark

Front

A77482

(d) Front Mark

ProCarManuals.com

(e) (f)

A77483

90_

Paint Mark

Engine Front

(g) (h) (i) (j)

A77470

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Check that the protrusion of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil on the threads of the connecting rod cap bolts. Using a 12 mm socket wrench, tighten the bolts in several steps with the specified torque. Torque: 25 NVm (250 kgfVcm, 18 ftVlbf) SST 09011–38121 Place the front mark on each connecting cap bolt head with paint. Retighten the cap bolts by 90_ as shown in the illustration. Check that each painted mark is at a 90_ angle to the front. Check that the crankshaft turns smoothly.

16–1 COOLING

–

WATER PUMP ASSY

WATER PUMP ASSY 160MB–01

INSPECTION 1. (a) (b)

INSPECT WATER PUMP ASSY Visually check the drain hole coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump.

ProCarManuals.com

A36661

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

17–1 LUBRICATION

–

OIL PUMP ASSY

OIL PUMP ASSY 170FL–01

COMPONENTS

8.8 (90, 80 in.Vlbf)

ProCarManuals.com

Oil Pump Relief Valve Plug 49 (500, 35)

Oil Pump Relief Valve Spring Oil Pump Relief Valve

Drive Rotor

Oil Pump Cover

Driven Rotor

Oil Pump Body

A77235

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

17–2 LUBRICATION

–

OIL PUMP ASSY 170FM–01

OVERHAUL 1. (a) 2. 3.

REMOVE OIL PUMP RELIEF VALVE PLUG Using a 27 mm socket wrench, remove the oil pump relief plug. SST 09011–12271 REMOVE OIL PUMP RELIEF VALVE SPRING REMOVE OIL PUMP RELIEF VALVE

4. (a) (b)

INSPECT OIL PUMP RELIEF VALVE Coat the oil pump relief valve with engine oil. Check that it falls smoothly into the oil pump relief valve hole by its own weight. If it does not, replace the oil pump relief valve. If necessary, replace the oil pump assembly.

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A77229

5. (a)

REMOVE OIL PUMP COVER Remove 7 bolts and the oil pump cover.

6. (a)

INSPECT OIL PUMP ROTOR SET Place the drive and driven rotors into the oil pump body with the marks facing the oil pump cover.

A77233

Mark

A77230

7. (a)

INSPECT ROTOR TIP CLEARANCE Using a feeler gauge, measure the clearance between the drive and driven rotor tip. Standard tip clearance: 0.080 to 0.160 mm (0.0031 to 0.0063 in.) Maximum tip clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than maximum, replace the rotors as a set. A77231

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

17–3 LUBRICATION

–

OIL PUMP ASSY

8. (a)

INSPECT ROTOR BODY CLEARANCE Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.100 to 0.170 mm (0.0039 to 0.067 in.) Maximum body clearance: 0.325 mm (0.0128 in.) If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. A77232

9. (a)

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A38022

10.

INSPECT ROTOR SIDE CLEARANCE Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 to 0.085 mm (0.0012 to 0.0033 in.) Maximum side clearance: 0.16 mm (0.0063 in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.

REMOVE OIL PUMP ROTOR SET

11. (a) (b)

INSTALL OIL PUMP ROTOR SET Coat the drive rotor and driven rotor with engine oil. Place the drive rotor and driven rotor into the pump body with marks facing the pump body cover.

Marks

A77234

12. 13. (a)

INSTALL OIL PUMP COVER Torque: 8.8 NVm (90 kgfVcm, 80 in.Vlbf) INSTALL OIL PUMP RELIEF VALVE Coat the oil pump relief valve with engine oil, and insert the oil pump relief valve into oil pump body hole.

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

17–4 LUBRICATION

OIL PUMP ASSY

INSTALL OIL PUMP RELIEF VALVE SPRING INSTALL OIL PUMP RELIEF VALVE PLUG Using a 27 mm socket wrench, install the oil pump relief valve plug. Torque: 49 NVm (500 kgfVcm, 35 ftVlbf) SST 09011–12271

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14. 15. (a)

–

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–1 STARTING & CHARGING

–

STARTER ASSY

STARTER ASSY 190OH–01

COMPONENTS

Repair Service Starter Kit

2.3 (24, 21 in.Vlbf)

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Planet Gear

Starter Yoke Assy 6.0 (61, 53 in.Vlbf)

Starter Brush Holder Assy

Repair Service Starter Kit

6.0 (61, 53 in.Vlbf)

Starter Armature Plate Starter Armature Assy

6.0 (61, 53 in.Vlbf)

Starter Commutator End Frame Assy N·m (kgf·cm, ft·lbf) : Specified torque A81554

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–2 STARTING & CHARGING

–

STARTER ASSY 190OI–01

OVERHAUL

1. (a)

REMOVE REPAIR SERVICE STARTER KIT Remove the nut, and disconnect the lead wire from the repair service starter kit.

(b)

Remove the 3 nuts holding the repair service starter kit to the starter housing. Remove the repair service starter kit. Remove the return spring and plunger.

A81555

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(c) (d)

A82635

2. (a)

REMOVE STARTER YOKE ASSY Using a torx driver T25, remove the 2 through bolts and pull out the starter yoke together with the starter commutator end frame.

(b)

Remove the starter yoke from the starter commutator end frame.

A82636

A82637

3. (a)

REMOVE STARTER ARMATURE ASSY Remove the starter armature assy from the starter yoke assy.

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–3 STARTING & CHARGING

–

STARTER ASSY

4. (a)

REMOVE STARTER ARMATURE PLATE Remove the armature plate from the starter yoke.

5. (a)

REMOVE STARTER BRUSH HOLDER ASSY Remove the 2 screws and brush holder assy from the commutator end frame.

6. (a)

REMOVE PLANET GEAR Remove the 3 planet gears from the repair service starter kit.

A79722

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A82638

A82639

7. (a)

INSPECT REPAIR SERVICE STARTER KIT Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If necessary, replace the repair service starter kit.

A82640

(b)

Check the pull–in coil for open circuit. (1) Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the repair service starter kit.

Terminal C

Continuity Terminal 50 A82641

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–4 STARTING & CHARGING

–

STARTER ASSY

(c)

Check if the hold–in coil has an open circuit. (1) Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the repair service kit. Continuity Terminal 50 A82642

8. (a)

INSPECT STARTER ARMATURE ASSY Check the commutator for open circuit. (1) Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segments, replace the armature.

Continuity

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A82643

(b)

Check the commutator for ground. (1) Using an ohmmeter, check that there is no continuity between the commutator and the armature coil core. If there is continuity, replace the armature.

No Continuity

A82644

A82645

(c) Check the commutator for dirty or burned surface. If the surface is dirty or burnt, smooth the surface with 400–grit sandpaper. (d) Check for the commutator circuit runout. (1) Place the commutator on V–blocks. (2) Using a dial indicator, measure the circle runout. Standard runout: 0.02 mm (0.0008 in.) Maximum runout: 0.05 mm (0.0020 in.) If the runout is greater than maximum, replace the armature. (e)

Using vernier calipers, measure the commutator diameter. Standard length: 29 mm (1.142 in.) Minimum length: 28 mm (1.102 in.) If the diameter is less than minimum, replace the armature.

29mm

A82646

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–5 STARTING & CHARGING

–

STARTER ASSY

9. (a)

INSPECT STARTER BRUSH HOLDER ASSY Using vernier calipers, measure the brush length. Standard length: 15.5 mm (0.610 in.) Minimum length: 9.0 mm (0.354 in.) If the length is less than minimum, replace the starter brush holder assy.

Length

A82647

(b)

Check the brush holder. (1) Using an ohmmeter, check that there is no continuity between the positive (+) and negative (–) brush holders. If there is continuity, repair or replace the starter commutator end frame assy.

No Continuity

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A82648

10. (a)

INSPECT REPAIR SERVICE STARTER KIT Check the starter clutch. (1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. If necessary, replace the repair service starter kit.

Lock

Free A82649

11. (a) (b)

INSTALL PLANET GEAR Apply grease to the planet gears and pin parts of the planetary shaft. Install the 3 planet gears.

12. (a)

INSTALL STARTER BRUSH HOLDER ASSY Install the brush holder to the starter armature assy.

Apply Grease

A82650

A82651

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–6 STARTING & CHARGING

13. (a)

–

STARTER ASSY

INSTALL STARTER COMMUTATOR END FRAME ASSY Install the commutator end frame with the 2 screws.

A82652

14. (a) (b)

INSTALL STARTER ARMATURE ASSY Align the rubber with the convex cutout of starter yoke. Install starter armature with the brush holder to the starter yoke.

15. (a) (b)

INSTALL STARTER ARMATURE PLATE Insert the starter armature plate to the starter yoke. Align the keyway of the starter plate with the key inside the starter yoke, and install the starter plate.

16. (a)

INSTALL STARTER YOKE ASSY Align the key of the starter yoke with the keyway located on the starter drive housing.

(b)

Using a torx driver T25, install the starter yoke with the 2 through bolts. Torque: 6.0 NVm (61 kgfVcm, 53 in.Vlbf) INSTALL REPAIR SERVICE STARTER KIT Apply grease to the plunger and hook. Set the plunger and hook of the repair service starter kit to the drive lever. Install the plunger and return spring.

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A82653

Key Keyway

A82654

Key Keyway

A81586

17. (a) (b) (c) A82636

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–7 STARTING & CHARGING

–

STARTER ASSY

(d)

Install the repair service starter kit with the 3 nuts. Torque: 2.3 NVm (24 kgfVcm, 21 in.Vlbf)

(e)

Connect the lead wire to the repair service starter kit and then fasten it with the nut. Torque: 6.0 NVm (61 kgfVcm, 53 in.Vlbf)

A82635

ProCarManuals.com

A81555

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

19–8 STARTING & CHARGING

–

GENERATOR ASSY

GENERATOR ASSY 190OJ–01

COMPONENTS

Pully

Drive End Frame

65 (663, 48)

Bearing Retainer

Fitting Ring

Spring Washer Spacer Ring

z Front Bearing

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Generator Rotor Assy z Rear Bearing 3.5 (36, 31 in.Vlbf)

2.2 (22, 19 in.Vlbf)

19.5 (199, 14)

Terminal Cover Stator Sub–assy Generator W/ Rectifire 2.4 (24, 21 in.Vlbf)

Regulator Sub–assy Generator W/ Brush

1.2 (12, 11 in.Vlbf) 12 (122, 9)

Generator Rear End Cover N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

B09747

19–9 STARTING & CHARGING

–

GENERATOR ASSY

OVERHAUL

190OK–01

1. (a)

REMOVE GENERATOR REAR END COVER Remove the 2 terminal covers by turning them counterclockwise.

(b)

Remove the screw and 2 nuts, and then detach the generator rear end cover.

2.

REMOVE REGULATOR SUB–ASSY GENERATOR W/BRUSH Remove the 3 screws and the regulator sub–assy generator w/ brush.

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A80108

B09748

(a)

B09749

3. (a)

B09750

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

REMOVE STATOR W/RECTIFIRE Remove the 4 bolts.

SUB–ASSY

GENERATOR

19–10 STARTING & CHARGING

(b) 4.

–

GENERATOR ASSY

Using a screwdriver, pry out the stator sub–assy generator w/rectifire. REMOVE BEARING SET GENERATOR

B10446

5. REMOVE PULLEY SET GENERATOR (a) Clamp the swivel arm in a vise. NOTICE: Be careful not to damage the fan. (b) Using an impact wrench or internal serration on rotor shaft end together with a torque wrench,remove the nut and spring washer, then detach the pulley.

ProCarManuals.com

B10014

6. (a)

REMOVE GENERATOR ROTOR ASSY Using a press, press out the generator rotor assy and spacer ring.

B10015

Ohmmeter

Continuity

7. (a)

INSPECT GENERATOR ROTOR ASSY Inspect the generator rotor assy for open circuit. (1) Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.27 to 2.53 W at 20_C (68_F) If there is no continuity, replace the generator rotor assy.

B10452

Ohmmeter

No Continuity

B10453

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

(b)

Inspect the generator rotor assy for ground. (1) Using an ohmmeter, check that there is no continuity between the slip ring and the generator rotor assy. If there is continuity, replace the generator rotor assy.

19–11 STARTING & CHARGING

–

GENERATOR ASSY

(c)

B00896

Positive (+) Terminal Rectifier Terminal Ohmmeter

No Continuity

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B09842

Negative (–) Terminal Rectifier Terminal Ohmmeter

No Continuity

B09843

Rectifier Terminal Ohmmeter

Continuity B09844

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

Inspect the slip rings. (1) Check that the slip rings are not rough or scored. If rough or scored, replace the generator rotor assy. (2) Using vernier calipers, measure the slip ring diameter. Standard diameter: 15.3 to 15.5 mm (0.602 to 0.610 in.) Minimum diameter: 14.3 mm (0.561 in.) If the diameter is less than minimum, replace the generator rotor assy. 8.

INSPECT STATOR SUB–ASSY GENERATOR W/RECTIFIRE (a) Inspect the positive (+) rectifier. (1) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (1). (3) Check that one shows continuity and the other shows no continuity. If result is not as specified, replace the stator sub–assy generator w/ rectifire.

(b)

Inspect the negative (–) rectifier. (1) Using an ohmmeter, connect one tester probe to each negative (–) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (1). (3) Check that one shows continuity and the other shows no continuity. If result is not as specified replace the stator sub–assy generator w/ rectifire. (c) Inspect the stator for open circuit. Using an ohmmeter, check that there is continuity between the rectifier terminals. If there is no continuity, replace the stator sub–assy generator w/ rectifire.

19–12 STARTING & CHARGING

–

GENERATOR ASSY

9. (a)

INSPECT BRUSH Using vernier calipers, measure the brush length. Standard exposed length: 11.0 to 13.6 mm (0.433 to 0.535 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the expose length is less than minimum, replace the voltage regulator and the brush assembly.

Length

B09845

10. (a)

INSTALL GENERATOR ROTOR ASSY Using SST and a press, press in the generator rotor assy. SST 09285–76010 NOTICE: Avoid misalignment during pressing

SST

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B10019

11. (a) (b)

INSTALL PULLEY SET GENERATOR Clamp the rotor in a soft jaw vise. Install the pulley with the spring washer and nut. Torque: 65 NVm (663 kgfVcm, 48 ftVlbf)

12. (a)

INSTALL BEARING SET GENERATOR Insert the fitting ring into in the position shown in the illustration. Align the key of the fitting ring with the keyway of the stator sub–assy generator w/ rectifire. Install the bearing.

B10014

(b) (c)

B09847

13. (a) (b)

B09750

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

INSTALL STATOR SUB–ASSY GENERATOR W/RECTIFIRE Align the key of the drive end frame with the keyway of the stator sub–assy generator w/ rectifire. Install the stator sub–assy generator w/ rectifire with the 4 bolts. Torque: 3.5 NVm (36 kgfVcm, 31 in.Vlbf)

19–13 STARTING & CHARGING

14. (a)

–

GENERATOR ASSY

INSTALL REGULATOR SUB–ASSY GENERATOR W/BRUSH Attach the brushes and the terminals to the rectifier end frame of the regulator sub–assy generator w/ brush.

B09848

(b)

with Washer

Install the regulator sub–assy generator w/ brush with the 3 screws.

HINT: Install the screw with the plate washer to the position shown in the illustration. Torque: 2.2 NVm (22 kgfVcm, 19 in.Vlbf) for without washer 1.2 NVm (12 kgfVcm, 11 in.Vlbf) for with washer

without Washer

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B10021

Nut A

Screw

15. (a)

INSTALL GENERATOR REAR END COVER Install the generator rear end cover with the 2 nuts and the screw. Torque: 19.5 NVm (199 kgfVcm, 14 ftVlbf) for nut A 12 NVm (122 kgfVcm, 9 ftVlbf) for nut B 2.4 NVm (24 kgfVcm, 21 in.Vlbf) for screw

(b)

Install the 2 terminal covers by turning them clockwise.

Nut B

B09748

A80108

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)