TOYOTA 2AZ FSE ENGINE REPAIR MANUAL

0108M−02 A54988 N m (kgf cm, ft lbf) Specified torque z Non−reusable part Camshaft Timing Tube Assy Camshaft Drive Gear Seal Washer z Camshaft Setting Oil Seal No 2 Camshaft, No 4 Camshaft Sub−assy Wa.

A54988

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

z Non−reusable part

Camshaft Timing Tube Assy

Camshaft Drive Gear

1 Diagnosis

2 Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting

3 Final Inspection

Adjusting”, but ”Final Inspection” is omitted

done in the practical situation

on the repairing condition Be sure to use SST and SSM when they are required and follow the workingprocedure properly A list of SST and SSM is in the Preparation section of this manual

to understand the fitting condition of the components

components drawing

Example:

what to do and where

Task heading: what to do

Detailed text: how to do task Set part No Component part No.

A59974

01−2

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INTRODUCTION HOW TO USE THIS ENGINE REPAIR MANUAL

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.

important points are described

placed using an illustration In the explanations, details of the operational method, standard value andnotice are placed

be different from the actual vehicle

proce-dure to look up your specifications The specifications are also found in the Service Specifications tion for a quick reference

7 SI UNIT

Sys-tem of Unit), and alternately expressed in the metric sysSys-tem and in the English SysSys-tem

Example:

Torque: 30 N×m (310 kgf×cm, 22 ft×lbf)

Z11554

Seal Lock Adhesive

MANUAL

REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL

PRECAUTION

causes functional failure of the engine

not pry out by screwdriver)

alumi-num bar

reas-sembly

mark

or direction

PARTS

with a seal lock adhesive at the factory

caused to move in any way, it must be recoated withthe specified adhesive

adhesive and dry with compressed air Then applythe specified seal lock adhesive to the bolt, nut orthreads

L1 L2

D02612

L2 L1

D01201

L2 L1

D01202

NOTICE:

Do the torque checking with the lower limit value of the torque tolerance.

it for a specified time until it hardens

When necessary, use a sealer on gaskets to prevent leaks

Carefully observe all specifications for bolt tightening torques Always use a torque wrench

of the torque wrench combined with SST or tool, ifyou tighten until the reading of the torque wrenchreached the specified torque value, the actualtorque becomes excessive

In case of using SST or extension tool, find the ing of the torque wrench by the formula

elec-tric motor or stove in the surroundings

places

and do not spray much water so as to prevent slipping

spark or high temperature.

PARTS

bad effect to the engine and turbo charger

close the opening of the removed inlet system parts andthe engine with a clean shop lag or gum tape

no mixing of a metal tip

portion and the clamp position to restore it surely

where it has a clamp track

to the arrow mark direction after the installation

TERMS FOR ENGINE REPAIR MANUAL

ABBREVIATIONS USED IN MANUAL

Abbreviations Meaning

Abbreviations Meaning

01−12

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INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL

GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE ommendations, as well as their TOYOTA equivalents

rec-SAE

TOYOTA TERMS ( )−−ABBREVIATIONS

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

Electrically Erasable Programmable Read Only Memory (EEPROM),

Erasable Programmable Read Only Memory (EPROM)

HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO 2 S)

Intake Vacuum

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

Electric Air Control Valve (EACV)

Diesel Particulate Trap (DPT)

Central Fuel Injection (Ci)

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INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL

Thermostatic Vacuum Switching Valve (TVSV)

Three−Way Catalytic (TWC) Manifold Converter

CYLINDER BLOCK ASSY(2AZ−FSE)

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

09201−10000 Valve Guide Bushing Remover &

Replacer Set

CYLINDER HEAD ASSY(2AZ−FSE)

(09201−01050) Valve Guide Bushing Remover &

Replacer 5

CYLINDER HEAD ASSY(2AZ−FSE)

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

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

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

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

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

09223−22010 Crankshaft Front Oil Seal

Replacer

PARTIAL ENGINE ASSY(2AZ−FSE)

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

−

PREPARATION ENGINE MECHANICAL

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

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

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

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

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

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

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

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

CYLINDER BLOCK ASSY(2AZ−FSE)

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

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

CYLINDER HEAD ASSY(2AZ−FSE) CYLINDER BLOCK ASSY(2AZ−FSE)

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

CYLINDER HEAD ASSY(2AZ−FSE) CYLINDER BLOCK ASSY(2AZ−FSE)

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

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

Recomended Tools

09031−00040 Pin Punch CYLINDER HEAD ASSY(2AZ−FSE)

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

(09043−20120) Socket Hexagon Wrench 12 PARTIAL ENGINE ASSY(2AZ−FSE)

09043−50100 Bi−hexagon Wrench 10 mm PARTIAL ENGINE ASSY(2AZ−FSE)

SSM

08833−00070 ”Adhesive 1324,”

THREE BOND 1324 or equivalent

CYLINDER BLOCK ASSY(2AZ−FSE)

09041−00020 Torx Driver T25 STARTER ASSY (2AZ−FSE)

Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt

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

Hexagon Nut Cold Forging Nut Cutting Processed Nut

ENGINE MECHANICAL

SERVICE DATA

Oil pump drive gear

Oil pump drive shaft gear

Crankshaft timing gear or sprocket

Chain tensioner slipper

Chain vibration damper No.1

Cylinder head set bolt

Maximum

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

Chain sub−assy

Camshaft timing gear or sprocket

Camshaft

Minimum Camshaft No.2

Minimum

No 1 journal diameter

Other journal diameter

0.03 mm (0.0012 in.) 45.510 to 45.610 mm (1.7917 to 1.7957 in.) 45.430 mm (1.7886 in.)

0.03 mm (0.0012 in.) 45.983 to 46.083 mm (1.8106 to 1.8143 in.) 45.900 mm (1.8071 in.)

35.971 to 35.985 mm (1.4162 to 1.4167 in.) 22.959 to 22.975 mm (0.9039 to 0.9045 in.)

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.)

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.) 0.040 to 0.079 mm (0.00157 to 0.00311 in.) 0.025 to 0.062 mm (0.00098 to 0.00244 in.) 0.07 mm (0.0028 in.)

Warpage

0.05 mm (0.0020 in.) 0.08 mm (0.0031 in.) 0.08 mm (0.0031 in.) Inner compression spring

Free length

45.7 mm (1.799 in.) 1.6 mm (0.063 in.) Intake valve

Minimum Valve stem diameter

Minimum

101.71 mm (4.0043in.) 101.21 mm (3.9846in.) 5.470 to 5.485 mm (0.2154 to 0.2159 in.) 1.05 to 1.45 mm (0.041 to 0.057 in.) 0.75 mm (0.030 in.)

101.15 mm (3.9823in.) 100.70 mm (3.9646 in.) 5.465 to 5.480 mm (0.2152 to 0.2157 in.) 1.2 to 1.6 mm (0.047 to 0.063 in.) 0.9 mm (0.035 in.)

Intake valve guide bush

Bushing inside diameter

Maximum Diameter

Protrusion height

5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.025 to 0.060 mm (0.00098 to 0.00236 in.) 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.) Exhaust valve guide bush

Bushing inside diameter

Maximum Diameter

Protrusion height

5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.030 to 0.065 mm (0.0012 to 0.0026 in.) 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.) Valve lifter

Lifter diameter

Lifter bore diameter

Maximum

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

Ring w/head pin

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.) 0.001 to 0.007 mm (0.00004 to 0.00028 in.) 0.05 mm (0.0020 in.)

0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) Cylinder block

0.05 mm (0.0020 in.) 88.500 to 88.513 mm (3.4842 to 3.3848 in.) Piston

Piston diameter

Maximum

88.439 to 88.449 mm (3.4818 to 3.4822 in.) 0.051 to 0.074 mm (0.0020 to 0.0029 in.) 0.1 mm (0.0039 in.)

Piston ring

No 2 Oil (side rail)

No 2 Oil (side rail) Maximum No 1

No 2 Oil (side rail)

0.030 to 0.080 mm (0.0012 to 0.0031 in.) 0.020 to 0.060 mm (0.0008 to 0.0024 in.) 0.020 to 0.070 mm (0.0008 to 0.0028 in.) 0.22 to 0.32 mm (0.0087 to 0.0126 in.) 0.50 to 0.60 mm (0.0197 to 0.0236 in.) 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 0.89 mm (0.0350 in.)

1.35 mm (0.0531 in.) 0.73 mm (0.0287 in.) Piston pin

Bushing inside diameter

Piston pin diameter

Maximum

22.005 to 22.014 mm (0.8663 to 0.8667 in.) 21.997 to 22.009 mm (0.8660 to 0.8665 in.) 0.001 to 0.007 mm (0.00004 to 0.00028 in.) 0.010 mm (0.0039 in.)

Connecting rod bolt

Minimum

7.2 to 7.3 mm (0.283 to 0.287 in.) 7.0 mm (0.276 in.)

Maximum Thrust washer thickness

Main journal diameter

Maximum

Crank pin diameter

0.040 to 0.240 mm (0.0016 to 0.0094 in.) 0.30 mm (0.0118 in.)

1.930 to 1.980 mm (0.0760 to 0.0780 in.) 0.03 mm (0.0012 in.)

54.988 to 55.000 mm (2.1648 to 2.06535 in.) 0.017 to 0.040 mm (0.0007 to 0.0016 in.) 0.050 mm (0.0020 in.)

0.003 mm (0.0001 in.) 47.990 to 48.000 mm (1.8894 to 1.8898 in.) Crankshaft bearing cap set bolt

Minimum

7.5 to 7.6 mm (0.295 to 0.299 in.) 7.2 mm (0.283 in.)

9.0 21 43 9.0

92 214 438 92

15 32

Bolt B Bolt C Nut

11 14 21 11

112 143 214 112

8 10 15 8

Bolt B Bolt C Bolt D

5.0 5.0 9.5 9.5

51 51 97 97

250 Turn 90_

18 Turn 90_

2nd

20 40

204 408

15 30

Stud bolt B Stud bolt C

5.0 10 5.0

51 102 51

44 in.×lbf 7

44 in.×lbf

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.)

STARTING & CHARGING

SERVICE DATA

Below 1 W Below 1.5 W

Below 1 W

10 kW or higher Starter armature assy

Maximum

Minimum

0.02 mm (0.0008 in.) 0.05 mm (0.0020 in.)

29 mm (1.142 in.)

28 mm (1.102 in.) Starter brush holder assy

Minimum

15.5 mm (0.610 in.) 9.0 mm (0.354 in.)

10 kW or higher Generator rotor assy

Minimum

1.8 to 2.8 W 15.3 to 15.5 mm (0.602 to 0.610 in.) 14.3 mm (0.561 in.)

Generator brush holder assy

Minimum

13.2 mm (0.520 in.) in new condition 6.0 mm (0.236 in.)

2.2 1.2

22 12

11 in.×lbf Generator rear end cover x Stator sub−assy generator w/ rectifier

Nut B Screw

19.5 12 2.4

199 122 24

14 9.0

21 in.×lbf

Cylinder Head Cover Sub−assy

Cylinder Head Cover Gasket

Camshaft Position Sensor

9.0 (92, 80 in.×lbf)

19 (194, 14)

Spark Plug

Crankshaft Position Sensor

Oil Filter Sub−assy

Water Pump Assy Water Pump Pulley

9.0 (92, 80 in.×lbf)

Crankshaft Pulley

25 (255, 18)

Oil Pan Drain Plug

Oil Pan Sub−assy

9.0 (92, 80 in.×lbf) 9.0 (92, 80 in.×lbf)

Oil Filter Union

PARTIAL ENGINE ASSY (2AZ−FSE)

COMPONENTS

Chain Sub−assy

Chain Vibration Damper No 1

Crankshaft Timing Sprocket

No 2 Chain Sub−assy

Timing Chain or Belt Cover Sub−assy

9.0 (92, 80 in.×lbf) 9.0 (92, 80 in.×lbf)

Chain Tensioner Assy No 1

No 3 Bearing Cap

Camshaft Camshaft Timing Gear Assy

Cylinder Head Sub−assy Camshaft Timing Sprocket

No 1 Bearing Cap

Camshaft Bearing No 1

No 2 Camshaft

1st: 79 (806, 58) 2nd: Turn 90_

Cylinder Head Bolt

54 (551, 39)

54 (551, 39)

Camshaft Bearing No 2

No 2 Bearing Cap

z O−ring

z Engine Rear Oil Seal

Oil Control Valve Filter

for Camshaft Timing

Stiffening Crankcase Assy

No 2 Balance Shaft

fil-ter union.

A77356

A77426

Groove Timing Marks Timing Marks

A77380

SST

14−6

−

ENGINE MECHANICAL PARTIAL ENGINE ASSY (2AZ−FSE)

mark 0 of the timing chain cover

sprockets are aligned with the timing marks of the No 1bearing cap, as shown in the illustration

pulley set bolt

Be sure not to operate the crankshaft without the chain tensioner.

cyl-inder block, and then remove the pump

ENGINE MECHANICAL PARTIAL ENGINE ASSY (2AZ−FSE)

pan Cut off applied sealer and remove the oil pan

tim-ing chain cover and cylinder head or cylinder block with

a screwdriver

NOTICE:

Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.

CASE OIL SEAL

the adjusting hole of the oil pump drive shaft gear with thegroove of the oil pump.

ENGINE MECHANICAL PARTIAL ENGINE ASSY (2AZ−FSE)

drive shaft gear to temporarily lock the gear in position.Remove the nut

and chain

bearing cap bolts in the sequence shown in the tion Then remove the 5 bearings

bearing cap bolts in the sequence shown in the tion Then remove the 5 bearings

A77413

Advance Angle Port

A31032

tim-ing sprocket

NOTICE:

Be careful not to damage the camshaft.

cam-shaft timing gear does not move

angle side, as shown in the illustration

of air pressure to the port on the advanced angle side

tim-ing gear can be turned by hand to the advanced angleside (counterclockwise), the direction of the arrow in theillustration

be difficult to release

10 5

1

14−12

−

ENGINE MECHANICAL PARTIAL ENGINE ASSY (2AZ−FSE)

NOTICE:

S Be sure not to remove the other 4 bolts.

S If planning to reuse the camshaft timing gear, release the straight pin lock first, and then install the gear.

10 bolts in the sequence shown in the illustration move the 10 cylinder head bolts and plate washers

Re-NOTICE:

S Be careful not to drop washers into the cylinder head.

remov-ing bolts in an incorrect order.

moving the balance shaft back and forth.

Standard thrust clearance:

0.050 to 0.090 mm (0.0020 to 0.0035 in.) Maximum thrust clearance: 0.090 mm (0.0035 in.)

If the thrust clearance is greater than the maximum, replace thebalance shaft housing and bearings If necessary, replace thebalance shaft

shown in the illustration

NOTICE:

Be careful not to damage the contact surfaces of the ance shaft housing and crankcase.

bal-HINT:

Keep the lower bearing and balance shaft housing together

HINT:

Keep the upper bearing with the crankcase

If a bearing or journal is damaged, replace the bearings If essary, replace the balance shaft

crank-case

the balance shaft housing

the heads of the balance shaft housing bolts