1NZ-FXE ENGINE MECHANICAL – ENGINE EM–1 ENGINE ON-VEHICLE INSPECTION 1. INSPECT AIR CLEANER FILTER ELEMENT (a) Remove the air filter. (b) Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter. 2. INSPECT IGNITION TIMING (a) Set the vehicle to inspection mode (see page IN34). (b) Warm up the engine. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Select the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / IGN ADVANCE Standard ignition timing: 8 to 12° @ BTDC NOTICE: • Turn all the electrical systems OFF. • Inspect the engine idle speed with the cooling fan OFF. HINT: Refer to the intelligent tester operator's manual if you need help selecting the DATA LIST. (f) Check that the ignition timing advances immediately when the engine speed is increased. Intelligent Tester CAN VIM DLC3 A087542E04 3. INSPECT ENGINE IDLE SPEED (a) Set the vehicle to inspection mode (see page IN34). (b) Warm up the engine. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Select the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD Standard idle speed: 950 to 1,050 rpm (P range) NOTICE: • Turn all the electrical systems OFF. • Inspect the engine idle speed with the cooling fan OFF. HINT: Refer to the intelligent tester operator's manual if you need help selecting the DATA LIST. Intelligent Tester CAN VIM DLC3 A087542E04 4. INSPECT COMPRESSION (a) Remove the windshield wiper link (see page WW13). (b) Remove the front cowl top panel outer. EM EM–2 1NZ-FXE ENGINE MECHANICAL – ENGINE (c) Set the vehicle to inspection mode (see page IN34). (d) Warm up the engine. (e) Remove the air cleaner assembly. (f) Disconnect all the fuel injector connectors. (g) Disconnect the 4 ignition coil connectors and remove the 4 bolts. Then remove the 4 ignition coils. NOTICE: If inspecting the compression with the ignition coil connector disconnected, a DTC will be detected. After the inspection, check the DTC. (h) Remove all the spark plugs. (i) EM SST (j) Connect SST (attachment) to a compression gauge. SST 09992-00500 Install the compression gauge with SST into the spark plug hole. A057119E02 Intelligent Tester CAN VIM DLC3 A087542E04 (k) Connect the intelligent tester to the DLC3. (l) Turn the power switch ON (IG). (m) Select the following items: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST / COMPRESS TEST (n) Turn the power switch ON (IG) while depressing the brake pedal. Then, measure the compression pressure of each cylinder. Standard compression pressure: 882 kPa (9.0 kgf/cm2, 128 psi) Minimum pressure: 686 kPa (7.0 kgf/cm2, 99 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less NOTICE: • Measure the compression pressure as quickly as possible. • After performing all the procedures, be sure to clear DTCs stored in the memory. Then check that the normal code is output. If the compression pressure is low, pour a light coat of engine oil into the cylinder block, and then measure the compression pressure again. HINT: • If the compression increases after pouring engine oil, the piston ring may be damaged. • If the compression does not change after pouring engine oil, defects may be occurring around the valve. (o) Install all the spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) EM–3 1NZ-FXE ENGINE MECHANICAL – ENGINE (p) Install the 4 ignition coil connectors. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (q) Connect the 4 ignition coil connectors. (r) Connect all the fuel injector connectors. (s) Install the air cleaner assembly. (t) Install the front cowl top panel outer. (u) Install the windshield wiper link (see page WW-15). 5. CO Normal Low High HC High High High INSPECT CO/HC (a) Set the vehicle to inspection mode (see page IN34). (b) Run the engine at 2,500 rpm for approximately 180 seconds. (c) Insert a CO/HC meter testing probe at least 40 cm (1.3 ft.) into the btailpipe during idling. (d) Immediately check the CO/HC concentration at idle and 2,500 rpm. HINT: When performing the 2 mode (2,500 rpm and idle) test, check that the CO/HC concentration complies with local regulations. (e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check the heated oxygen sensor operation (see page ES-392). (2) See the table below for possible causes, and then inspect the applicable causes and repair it if necessary. Problems Causes Rough idle 1. Faulty ignition: – Incorrect timing – Plugs are contaminated, plugs are shorted or plug gaps are incorrect 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders Rough idle (Fluctuating HC reading) 1. Vacuum leaks: – Ventilation hoses – Intake manifold – Throttle body – IAC valve – Brake booster line 2. Lean mixture causing misfire Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Plugged ventilation valve 3. Faulty SFI system: – Faulty pressure regulator – Defective ECT sensor – Defective mass air flow meter – Faulty ECM – Faulty injectors – Faulty throttle position sensor EM EM–4 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT DRIVE BELT 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS NO. 1 AIR CLEANER INLET DRIVE BELT EM ENGINE UNDER COVER RH x3 x2 A129334E01 EM–5 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT ON-VEHICLE INSPECTION 1. CHECK DRIVE BELT TENSION (a) Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Standard drive belt tension Item A087786E01 CORRECT New belt 99 to 121 lbf Used belt 55 to 77lbf HINT: • After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hands to confirm that the belt has not slipped out of the groove on the bottom of the crankshaft pulley. • A "new belt" is a belt which has been used less than 5 minutes on a running engine. • A "used belt" is a belt which has been used on a running engine for 5 minutes or more. • After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension. INCORRECT A122295E01 Measure Point for Belt Deflection Idler Pulley (b) Reference: Check the drive belt deflection. (1) When not using a belt tension gauge, measure the belt deflection. Pressing force: 98 N (10 kgf, 22 lbf) Standard belt deflection Item Crankshaft Pulley Water Pump Pulley A093818E02 Specified Condition Specified Condition New belt 9.0 to 12.0 mm (0.35 to 0.47 in.) Used belt 11 to 15 mm (0.43 to 0.59 in.) NOTICE: • Check the drive belt deflection at the specified point. • When installing a new belt, set its tension value as specified. • When inspecting a belt which has been used over 5 minutes, apply the specification for "Used belt". • When reinstalling a belt which has been used over 5 minutes, adjust its deflection and tension to the intermediate value of each specification for "Used belt". • Belt tension and deflection should be checked after 2 revolutions of engine cranking. • When using a belt tension gauge, confirm the accuracy by using a master gauge first. EM EM–6 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT REMOVAL 1. REMOVE ENGINE UNDER COVER RH 2. REMOVE NO. 1 AIR CLEANER INLET (a) Loosen the clamp, and disconnect the air cleaner inlet from the air cleaner case. 3. REMOVE DRIVE BELT (a) Loosen nut A. (b) Turn adjust bolt B, and then release the belt tension. (c) Remove the belt. A086911E01 EM A B A086912E01 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT EM–7 INSTALLATION A 1. INSTALL DRIVE BELT (a) Temporarily install the belt on each pulley. 2. ADJUST DRIVE BELT TENSION (a) Turn adjust bolt B to adjust the belt tension. (b) Tighten nut A. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 3. CHECK DRIVE BELT TENSION (See page EM-5) 4. CONNECT NO. 1 AIR CLEANER INLET (a) Connect the air cleaner inlet to the air cleaner case and tighten the clamp. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 5. INSTALL ENGINE UNDER COVER RH B A086912E01 A086911E01 EM 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–7 VALVE CLEARANCE ADJUSTMENT 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE ENGINE UNDER COVER RH 6. REMOVE WIPER ARM HEAD CAP 7. REMOVE FRONT WIPER ARM LH (See page WW-13) 8. REMOVE FRONT WIPER ARM RH (See page WW-13) 9. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 10. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 11. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 12. REMOVE WINDSHIELD WIPER LINK ASSEMBLY (See page WW-13) 13. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 14. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 15. REMOVE AIR CLEANER ASSEMBLY (See page EM28) 16. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR (See page EM-29) 17. REMOVE RESERVOIR BRACKET (See page EM-29) 18. REMOVE CYLINDER HEAD COVER (See page EM30) 19. INSPECT VALVE CLEARANCE HINT: Inspect and adjust the valve clearance when the engine is cold. EM EM–8 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (2) Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Mark EM A092837E01 No. 1 Cylinder TDC/Compression EX (b) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (Cold) Item IN A081895E02 No. 4 Cylinder TDC/Compression EX 0.17 to 0.23 mm (0.007 to 0.009 in.) Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) (2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. (c) Turn the crankshaft 1 complete revolution until its timing notch and timing mark 0 of the chain cover are aligned. (d) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (Cold) Item IN A081896E02 Specified Condition Intake Specified Condition Intake 0.17 to 0.23 mm (0.007 to 0.009 in.) Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) (2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–9 20. ADJUST VALVE CLEARANCE (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (2) Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Mark EM A092837E01 (3) Put paint marks on the timing chain where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Paint Mark A092838E01 (b) Using an 8 mm hexagon wrench, remove the screw plug. A037101E03 EM–10 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (c) Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner at an upward position. HINT: Lifting up the stopper plate of the chain tensioner unlocks the plunger. Plunger Unlock Stopper Plate EM A092839E01 (d) Keeping the stopper plate of the chain tensioner lifted, slightly rotate the hexagonal lobe of the No. 2 camshaft to the right with an adjustable wrench so the plunger of the chain tensioner is pushed. HINT: When the camshaft No. 2 is slightly rotated to the right, the plunger is pushed. Plunger Stopper Plate A092840E02 (e) Keeping the adjustable wrench installed, remove the screwdriver with the plunger pushed. NOTICE: Do not move the adjustable wrench. HINT: Removing the screwdriver lowers the stopper plate and locks the plunger. Plunger Lock Stopper Plate A092841E01 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–11 (f) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the stopper plate of the chain tensioner lowered and locked. HINT: If a 3.0 mm (0.118 in.) diameter bar cannot be inserted into the hole of the stopper plate, rotate the No. 2 camshaft slightly to the left and right. Then a 3.0 mm (0.118 in.) diameter bar can be inserted easily. (g) Secure the 3.0 mm (0.118 in.) diameter bar with tape. Stopper Plate EM A092842E01 (h) Hold the hexagonal lobe of the camshaft No. 2 with the adjustable wrench. (i) Using SST, loosen the bolt. SST 09023-38400 SST A050157E01 (j) 1 3 5 4 2 Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. A035760E02 (k) Remove the flange bolt with the No. 2 camshaft lifted up. Then detach the No. 2 camshaft and the camshaft timing sprocket. A037148E01 EM–12 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (l) 2 4 3 Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. Then remove the 4 bearing caps. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. 1 A035766E02 (m) Hold the timing chain with one hand, and remove the camshaft and the camshaft timing gear assembly. EM A035767E01 (n) Tie the timing chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. A035227E01 (o) Remove the valve lifters. (p) Using a micrometer, measure the thickness of the removed lifter. (q) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. A New lifter thickness B Used lifter thickness C Measured valve clearance New lifter thickness A001082E01 Item Thickness Intake A = B + (C - 0.20 mm (0.008 in.)) Exhaust A = B + (C - 0.30 mm (0.012 in.)) (r) Select a new lifter with the thickness as close to the calculated values as possible. EXAMPLE: (Intake) Measured valve clearance = 0.40 mm (0.0158 in.) 0.40 mm (0.0158 in.) - 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.) (Measured - Specification = Excess clearance) Used lifter measurement = 5.25 mm (0.2067 in.) 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–13 0.20 mm (0.0079 in.) + 5.25 mm (0.2067 in.) = 5.45 mm (0.2146 in.) (Excess clearance + Used lifter = Ideal new lifter) Closest new lifter = 5.45 mm (0.2146 in.) Select No. 46 lifter (5.46 mm (0.2150 in.)) HINT: • Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). • Refer to the New lifter thickness table below. EM EM–14 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (1) Valve lifter selection chart (intake) Measured Clearance mm (in.) Installed Lifter Thickness mm (in.) EM A116733E01 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–15 (2) Valve lifter selection chart (intake) (continued). Measured Clearance mm (in.) Installed Lifter Clearance mm (in.) EM A116734E01 New lifter thickness Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.) 08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.) EM–16 Lifter No. EM 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE Thickness Lifter No. Thickness Lifter No. Thickness 10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.) 12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.) 14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.) 16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.) 18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.) 20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.) 22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.) 24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.) 26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.) 28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - - Standard intake valve clearance (Cold): 0.17 to 0.23 mm (0.007 to 0.009 in.) EXAMPLE: A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter. 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–17 (3) Valve lifter selection chart (exhaust). Measured Clearance mm (in.) Installed Lifter Thickness mm (in.) EM A130303E01 EM–18 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (4) Valve selection chart (exhaust) (continued). Measured Clearance mm (in.) Installed Lifter Clearance mm (in.) EM A116736E01 New lifter thickness Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.) 08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.) EM–19 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.) 12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.) 14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.) 16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.) 18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.) 20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.) 22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.) 24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.) 26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.) 28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - - Standard exhaust valve clearance (Cold): 0.27 to 0.33 mm (0.011 to 0.013 in.) EXAMPLE: A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter. (s) Reinstall the selected valve lifters. (t) Apply a light coat of engine oil to the camshaft journals. Paint Mark (u) Install the timing chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration. Timing Mark A130317E01 (v) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (130 kgf*cm, 9.6 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. 3 1 2 4 A037107E02 EM EM–20 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE Paint Mark (w) Hold the timing chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the timing chain. Timing Mark A092844E02 (x) Align the alignment pin hole on the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket into the camshaft. (y) Temporarily install the timing sprocket bolt. EM A037148E01 5 3 1 2 (z) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. (aa) Install the No. 1 bearing cap. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 4 No. 1 Bearing Cap A092845E02 (ab) Hold the hexagonal lobe of the No. 2 camshaft with the adjustable wrench. (ac) Using SST, tighten the bolt. SST 09023-38400 Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) SST A050157E01 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–21 (ad) Remove the bar from the timing chain tensioner. EM A089861E01 (ae) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (af) Check that all the pairs of the timing marks are aligned. Timing Mark A092837E01 (ag) Apply seal packing to 2 or 3 threads of the screw plug end. Seal packing: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Adhesive A058128E03 (ah) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 21. INSTALL CYLINDER HEAD COVER (See page EM-39) 22. INSTALL RESERVOIR BRACKET (See page EM-40) 23. INSTALL BRAKE MASTER CYLINDER RESERVOIR (See page EM-40) A037101E03 24. INSTALL AIR CLEANER ASSEMBLY (See page EM41) EM–22 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE 25. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 26. INSTALL WINDSHIELD WIPER LINK ASSEMBLY (See page WW-16) 27. INSTALL COWL TOP VENTILATOR LOUVER RH 28. INSTALL COWL TOP VENTILATOR LOUVER LH 29. INSTALL HOOD TO COWL TOP SEAL 30. INSTALL FRONT WIPER ARM LH (See page WW-16) 31. INSTALL FRONT WIPER ARM RH (See page WW-16) 32. INSTALL WIPER ARM HEAD CAP EM 33. CHECK ENGINE OIL LEAKS 34. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 35. REMOVE ENGINE UNDER COVER RH 36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 37. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 38. INSTALL REAR DECK FLOOR BOX (See page CH-8) 39. INSTALL NO. 2 REAR FLOOR BOARD (See page CH8) 40. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EM–23 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN TIMING CHAIN 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS x6 AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) WIRE HARNESS 9.0 (92, 80 in.*lbf) RADIATOR SUPPORT OPENING COVER 5.5 (56, 49 in.*lbf) EM x2 3.0 (31, 27 in.*lbf) CLAMP WINDSHIELD WASHER JAR ASSEMBLY x2 5.5 (56, 49 in.*lbf) 7.5 (76, 66 in.*lbf) x3 NO. 2 AIR CLEANER INLET BRAKE MASTER CYLINDER RESERVOIR COVER BRAKE MASTER CYLINDER RESERVOIR 8.5 (87, 75 in.*lbf) RESERVOIR BRACKET 4.9 (50, 43 in.*lbf) PURGE VSV 14 (143, 10) x3 x2 ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE UNDER COVER LH x3 x2 x4 A124494E01 EM–24 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN WINDSHIELD WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL EM COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) WINDSHIELD MOTOR WITH WIPER LINK ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E05 EM–25 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 10 (102, 7.4) 10 (102, 7.4) x4 10 (102, 7.4) IGNITION COIL 10 (102, 7.4) x4 x2 x7 x2 VENTILATION HOSE EM CYLINDER HEAD COVER NO. 2 VENTILATION HOSE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A124495E01 EM–26 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 52 (530, 38) 52 (530, 38) 7.5 (76, 66 in.*lbf) ENGINE MOUNTING INSULATOR RH EM CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ENGINE MOUNTING BRACKET 55 (560, 41) 52 (530, 38) CRANKSHAFT POSITION SENSOR 24 (245, 18) STUD BOLT 32 (326, 24) 7.5 (76, 66 in.*lbf) 24 (245, 18) x2 11 (112, 8.1) STRAIGHT PIN x 11 128 (1,305, 95) OIL PUMP SEAL CRANKSHAFT PULLEY O-RING 11 (112, 8.1) TIMING CHAIN COVER 11 (112, 8.1) x3 GASKET x2 DRIVE BELT 15 (153, 11) N*m (kgf*cm, ft.*lbf) : Specified torque WATER PUMP 11 (112, 8.1) WATER PUMP PULLEY Non-reusable part Grease application A124496E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–27 NO. 1 CHAIN TENSIONER CHAIN TENSIONER SLIPPER EM 9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf) CHAIN NO. 1 CHAIN VIBRATION DAMPER N*m (kgf*cm, ft.*lbf) : Specified torque A124497E01 EM–28 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN REMOVAL EM 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER 6. REMOVE FRONT WHEELS 7. REMOVE NO. 3 ENGINE UNDER COVER 8. REMOVE NO. 4 CENTER ENGINE UNDER COVER 9. DRAIN ENGINE COOLANT (See page CO-6) 10. DRAIN ENGINE OIL (See page LU-4) 11. REMOVE WIPER ARM HEAD CAP 12. REMOVE FRONT WIPER ARM LH (See page WW-13) 13. REMOVE FRONT WIPER ARM RH (See page WW-13) 14. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 15. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 16. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 17. REMOVE WINDSHIELD MOTOR WITH WIPER LINK ASSEMBLY (See page WW-13) 18. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 19. REMOVE AIR CLEANER ASSEMBLY (a) Loosen the clamp, then disconnect the No. 1 air cleaner inlet from the air cleaner case. A086911E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–29 (b) Disconnect the intake air flow meter connector, then remove the wire harness clamp. (c) Loosen the clamp, then remove the 2 bolts and air cleaner assembly. A087334E01 20. REMOVE NO. 2 AIR CLEANER INLET (a) Remove the clip and No. 2 air cleaner inlet. EM A087335E01 A087336E01 21. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR (a) Disconnect the connector. (b) Remove the 2 bolts. (c) Separate the claw fitting, then suspend the brake master cylinder reservoir with rope. NOTICE: Be careful of the angle of the brake master cylinder reservoir when suspending to prevent air from coming into the hose. 22. REMOVE RESERVOIR BRACKET (a) Disconnect the hose from the brake master cylinder reservoir bracket. (b) Remove the 3 bolts and wire harness clamp, then remove the brake master cylinder reservoir bracket. A087337E01 23. REMOVE WINDSHIELD WASHER JAR ASSEMBLY (a) Loosen the bolt which holds the headlight RH. (b) Disconnect the connector and remove the wire harness clamp. (c) Remove the bolt and bracket. A087338E01 EM–30 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN (d) Remove the nut. (e) Slightly lift the headlight RH and separate the claw fitting, then remove the washer jar assembly. (f) Disconnect the hose from the washer jar assembly. A087339E01 24. REMOVE CYLINDER HEAD COVER (a) Disconnect the fuel injector connector and ignition coil connector. (b) Remove the 3 bolts and wire harness clamp, then disconnect the wire harness. EM A087340E01 (c) Remove the brake master cylinder reservoir cover. A087341E01 (d) Disconnect the ventilation hose and ventilation hose No. 2. A087343E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–31 (e) Remove the bolt and ignition coil. A087344E01 (f) Remove the 9 bolts and 2 nuts, then remove the cylinder head cover. EM A066472E01 25. REMOVE PURGE VSV (a) Disconnect the connector and hose. (b) Remove the bolt and purge VSV. 26. REMOVE DRIVE BELT (See page EM-6) 27. REMOVE WATER PUMP (See page CO-11) A087345E01 28. REMOVE CRANKSHAFT PULLEY (a) Using SST, hold the crankshaft pulley and loosen the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. SST A092650E01 (b) Loosen the crankshaft bolt until 2 to 3 threads of the bolt are tightened to the crankshaft. (c) Using SST, remove the crankshaft damper. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) (d) Remove the crankshaft bolt. SST A092651E01 EM–32 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 29. REMOVE ENGINE MOUNTING INSULATOR RH (a) Put a wooden block on a jack. Support the oil pan with the jack. A087348E01 (b) Remove the 3 bolts and 4 nuts, then remove the engine mounting insulator RH. EM A087349E01 30. REMOVE ENGINE MOUNTING SPACER (a) Remove the 2 bolts and engine mounting spacer. A087350E01 31. REMOVE ENGINE MOUNTING BRACKET (a) Remove the 4 bolts and engine mounting bracket. A087351E01 32. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and camshaft timing oil control valve assembly. 33. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-443) 34. REMOVE TIMING CHAIN COVER (See page LU-15) A087352E01 35. REMOVE OIL PUMP SEAL (See page EM-138) 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–33 36. SET NO. 1 CYLINDER TO TDC / COMPRESSION (a) Install the washer to the crankshaft bolt, then install the bolt to the crankshaft. (b) Turn the crankshaft clockwise so it is positioned as illustrated. Timing Mark Timing Mark EM A093711E02 37. REMOVE NO. 1 CHAIN TENSIONER (a) Lift up the stopper plate, then unlock the plunger. (b) Push in the plunger to the end with the plunger unlocked. Plunger Unlock Stopper Plate A092824E01 (c) Lower the stopper plate with the plunger pushed to the end, then lock the plunger. Plunger Stopper Plate Lock A092825E01 (d) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked. HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily. A087621E01 EM–34 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN (e) Remove the 2 bolts and chain tensioner. A089044E01 38. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the bolt and tensioner slipper. EM A088883E02 39. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and chain vibration damper. A088884E01 40. REMOVE CHAIN (a) Remove the chain from the engine. A088885E01 INSPECTION 1. Measuring Area 01234 5 16 A050062E01 INSPECT CHAIN (a) Using a spring scale, pull the timing chain with a force of 140 N (14.3 kgf, 31.5 lbf) and measure the length of it. Maximum chain elongation: 124.2 mm (4.890 in.) If the elongation is greater than the maximum, replace the chain. 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–35 HINT: Perform the measurements at 3 or more random places to obtain the average length. 2. INSPECT NO. 1 CHAIN TENSIONER (a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. (b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. 3. INSPECT CHAIN TENSIONER SLIPPER (a) Measure the chain tensioner slipper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the slipper. 4. INSPECT NO. 1 CHAIN VIBRATION DAMPER (a) Measure the vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the damper. A011223E02 A037065E01 A037066E01 EM EM–36 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN INSTALLATION 1. 40q Timing Mark INSTALL CHAIN (a) Set the position of the No. 1 cylinder to 20° ATDC. NOTICE: To prevent the pistons from hitting against valves, the following procedures must be performed in the order below. (1) Set the crankshaft between 40 to 140° ATDC. (2) Set the cams of the intake and exhaust timing sprockets to 20° ATDC. (3) Reset the crankshaft to 20° ATDC. (b) Install the chain vibration damper with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) EM A092826E01 20° ATDC (c) Align the timing marks of the camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain. HINT: To prevent the exhaust camshaft from springing back, turn it using a wrench and set it at the mark on the chain. Mark Plate Timing Mark Mark Plate Timing Mark 30° A081877E03 (d) Install the chain tensioner slipper with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088883E02 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–37 (e) Install the chain tensioner with the 2 bolts. (1) Lift up the stopper plate, then unlock the plunger. (2) Push in the plunger to the end with the plunger unlocked. Plunger Unlock Stopper Plate A092824E01 (3) Lower the stopper plate with the plunger pushed to the end, then lock the plunger. Plunger EM Stopper Plate Lock A092825E01 (4) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked. Plunger Stopper Plate A080976E02 HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily. A087621E01 (f) A089044E01 (5) Install the chain tensioner with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (6) Remove the bar from the chain tensioner. Check the tension between the intake and exhaust camshaft timing sprockets. 2. INSTALL OIL PUMP SEAL (See page LU-17) 3. INSTALL TIMING CHAIN COVER (See page LU-19) 4. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-443) EM–38 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-438) 6. INSTALL ENGINE MOUNTING BRACKET (a) Install the engine mounting bracket with the 4 bolts. Torque: 55 N*m (561 kgf*cm, 41 in.*lbf) 7. INSTALL ENGINE MOUNTING SPACER (a) Install the engine mounting spacer with the 2 bolts. Torque: 55 N*m (561 kgf*cm, 41 in.*lbf) 8. INSTALL ENGINE MOUNTING INSULATOR RH (a) Install the engine mounting insulator RH with the 3 bolts and 4 nuts. Torque: 52 N*m (530 kgf*cm, 38 in.*lbf) 9. INSTALL CRANKSHAFT PULLEY (a) Align the hole of the crankshaft damper with the straight pin, then install the crankshaft damper. (b) Using SST, hold the crankshaft damper and tighten the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 Torque: 128 N*m (1,305 kgf*cm, 95 in.*lbf) NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. A087351E01 EM A087350E01 A089869E01 SST A092652E01 10. INSTALL WATER PUMP (See page CO-11) 11. INSTALL DRIVE BELT (See page EM-6) 12. CHECK DRIVE BELT TENSION (See page EM-6) 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–39 13. INSTALL PURGE VSV (a) Install the purge VSV with the bolt. (b) Connect the hose and connector. A087345E01 Seal Packing 11 A092514E01 9 7 5 10 1 8 3 2 6 14. INSTALL CYLINDER HEAD COVER (a) Apply seal packing to the 2 locations shown in the illustration, then install the cylinder head cover. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the cylinder head cover within 3 minutes after applying seal packing. • Do not start the engine within 2 hours of installing. (b) Install the cylinder head cover with the 9 bolts and 2 nuts. (c) Using several steps, tighten the bolts and nuts to the specified torque in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 74 in.*lbf) 4 A035756E02 (d) Install the ignition coil with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A087344E01 EM EM–40 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN (e) Install the brake master cylinder reservoir cover to the cylinder head cover. A087341E01 (f) Install the wire harness and brake master cylinder reservoir cover with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (g) Connect the fuel injector connector and ignition coil connector. EM A087340E01 15. INSTALL WINDSHIELD WASHER JAR (a) Install the windshield washer with the 2 bolts and nut. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) for bolt A 14 N*m (143 kgf*cm, 10 in.*lbf) for bolt B 5.5 N*m (56 kgf*cm, 49 in.*lbf) for nut (b) Connect the 2 connectors and wire harness. A B A092653E01 16. INSTALL RESERVOIR BRACKET (a) Install the reservoir bracket with the 3 bolts and connect the wire harness clamp. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) A087337E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–41 17. INSTALL BRAKE MASTER CYLINDER RESERVOIR (a) Attach the claw and install the master cylinder reservoir with the 2 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (b) Connect the connector. A087336E02 18. INSTALL NO. 2 AIR CLEANER INLET (a) Install the air cleaner inlet with the clip. EM A087335E01 19. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts and tighten the clamp. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) for bolt 3.0 N*m (31 kgf*cm, 27 in.*lbf) for clamp (b) Connect the MAF meter connector and clamp. A087334E01 (c) Connect the No. 1 air inlet, and then tighten the clamp. 20. INSTALL FRONT COWL TOP PANEL OUTER 21. INSTALL WINDSHIELD WIPER MOTOR AND WIPER LINK ASSEMBLY (See page WW-16) 22. INSTALL COWL TOP VENTILATOR LOUVER RH 23. INSTALL COWL TOP VENTILATOR LOUVER LH A086911E01 24. INSTALL HOOD TO COWL TOP SEAL 25. INSTALL FRONT WIPER ARM LH (See page WW-16) 26. INSTALL FRONT WIPER ARM RH (See page WW-16) 27. INSTALL WIPER ARM HEAD CAP 28. ADD ENGINE OIL (See page LU-4) 29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 30. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) EM–42 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 31. INSTALL REAR DECK FLOOR BOARD (See page CH8) 32. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 33. ADD ENGINE COOLANT (See page CO-7) 34. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 35. INSTALL RADIATOR SUPPORT OPENING COVER 36. INSTALL NO. 4 CENTER ENGINE UNDER COVER 37. INSTALL NO. 3 ENGINE UNDER COVER 38. INSTALL FRONT WHEELS EM 39. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EM–43 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD CYLINDER HEAD 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS x6 AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) WIRE HARNESS 9.0 (92, 80 in.*lbf) RADIATOR SUPPORT OPENING COVER 5.5 (56, 49 in.*lbf) EM x2 3.0 (31, 27 in.*lbf) WINDSHIELD WASHER JAR ASSEMBLY CLAMP x2 5.5 (56, 49 in.*lbf) 7.5 (76, 66 in.*lbf) x3 NO. 2 AIR CLEANER INLET BRAKE MASTER CYLINDER RESERVOIR COVER BRAKE MASTER CYLINDER RESERVOIR 8.5 (87, 75 in.*lbf) RESERVOIR BRACKET 4.9 (50, 43 in.*lbf) PURGE VSV 14 (143, 10) x3 x2 ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE UNDER COVER LH x3 x2 x4 A124494E02 EM–44 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD WINDSHIELD WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL EM COWL TOP VENTILATION LOUVER LH COWL TOP VENTILATION LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) WINDSHIELD MOTOR WITH WIPER LINK ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E06 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD x 12 EM–45 11 (112, 8.1) INVERTER COVER 11 (112, 8.1) EM NO. 2 INVERTER COOLING HOSE NO. 1 INVERTER COOLING HOSE ENGINE ROOM MAIN WIRE HARNESS NO. 1 CIRCUIT BREAKER SENSOR CONNECTOR NO. 6 INVERTER COOLING HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A124445E02 EM–46 EM 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD HEATER WATER HOSE FUEL MAIN TUBE FUEL PIPE CLAMP 9.0 (92, 80 in.*lbf) OIL DIPSTICK GUIDE 9.0 (92, 80 in.*lbf) RADIATOR INLET HOSE NO. 1 WATER BY-PASS PIPE NO. 2 WATER BY-PASS HOSE HEATER WATER HOSE COMPRESSION SPRING 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part FRONT EXHAUST PIPE ASSEMBLY GASKET A129335E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–47 EM 21 (214, 16) 21 (214, 16) 8.0 (82, 71 in.*lbf) 21 (214, 16) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) MG2 POWER CABLE 8.0 (82, 71 in.*lbf) INVERTER WITH CONVERTER ASSEMBLY MG1 POWER CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124446E03 EM–48 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 10 (102, 7.4) 10 (102, 7.4) x4 10 (102, 7.4) IGNITION COIL 10 (102, 7.4) x4 x2 x7 x2 VENTILATION HOSE EM CYLINDER HEAD COVER NO. 2 VENTILATION HOSE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A124495E02 EM–49 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 52 (530, 38) 52 (530, 38) ENGINE MOUNTING INSULATOR RH 7.5 (76, 66 in.*lbf) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ENGINE MOUNTING BRACKET EM 55 (560, 41) 52 (530, 38) CRANKSHAFT POSITION SENSOR 24 (245, 18) STUD BOLT 32 (326, 24) 7.5 (76, 66 in.*lbf) 24 (245, 18) x2 11 (112, 8.1) STRAIGHT PIN x 11 128 (1,305, 95) OIL PUMP SEAL CRANKSHAFT PULLEY O-RING 11 (112, 8.1) TIMING CHAIN COVER 11 (112, 8.1) x3 GASKET x2 DRIVE BELT 15 (153, 11) N*m (kgf*cm, ft.*lbf) : Specified torque WATER PUMP 11 (112, 8.1) WATER PUMP PULLEY Non-reusable part Grease application A124496E02 EM–50 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD NO. 1 CHAIN TENSIONER EM CHAIN TENSIONER SLIPPER 9.0 (92, 80 in.*lbf) CHAIN 9.0 (92, 80 in.*lbf) NO. 1 CHAIN VIBRATION DAMPER N*m (kgf*cm, ft.*lbf) : Specified torque A124497E03 EM–51 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 23 (235, 17) x3 NO. 1 CAMSHAFT BEARING CAP x 16 x8 13 (133, 10) NO. 2 CAMSHAFT BEARING CAP NO. 2 CAMSHAFT CAMSHAFT TIMING SPROCKET CAMSHAFT 64 (653, 47) CAMSHAFT TIMING GEAR 64 (653, 47) 1st: 29 (296, 21) 2nd: 90° 3rd: 90° EM x 10 CYLINDER HEAD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124504E01 EM–52 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 9.0 (92, 80 in.*lbf) FUEL DELIVERY PIPE 19 (194, 14) 19 (194, 14) O-RING DELIVERY PIPE SPACER FUEL INJECTOR EM x4 INSULATOR 9.0 (92, 80 in.*lbf) NO. 1 WATER BY-PASS PIPE 8.0 (82, 71 in.*lbf) 9.0 (92, 80 in.*lbf) x3 x2 x2 27 (275, 20) EXHAUST MANIFOLD GASKET GASKET NO. 1 EXHAUST MANIFOLD INSULATOR CYLINDER HEAD 20 (204, 15) x2 x3 GASKET INTAKE MANIFOLD N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A129819E01 EM–53 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD VALVE LIFTER VALVE SPRING RETAINER LOCK VALVE SPRING RETAINER VALVE SPRING VALVE STEM OIL SEAL VALVE SPRING SEAT EM INTAKE VALVE GUIDE BUSH EXHAUST VALVE GUIDE BUSH CAMSHAFT BEARING CAP SETTING RING PIN 44 (449, 33) NO. 1 TAPER SCREW PLUG GASKET 4.0 (41, 35 in.*lbf) STUD BOLT 9.0 (92, 80 in.*lbf) STUD BOLT CYLINDER HEAD GASKET 10 (102, 7) STUD BOLT 30 (306, 22) OIL CONTROL VALVE FILTER INTAKE VALVE EXHAUST VALVE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116722E02 EM–54 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD REMOVAL EM A087632E01 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 2. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures (see page HV-519). 3. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 4. REMOVE REAR DECK FLOOR BOX (See page CH-4) 5. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE SERVICE PLUG GRIP (See page HB-154) 8. DISCONNECT FRONT EXHAUST PIPE ASSEMBLY (a) Remove the 2 bolts and 2 compression rings, then disconnect the exhaust pipe assembly front from the exhaust manifold. 9. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter from the vehicle (see page HV-530). 10. REMOVE CHAIN (a) Remove the chain from the engine (see page EM28). 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–55 11. DISCONNECT WIRE HARNESS (a) Disconnect the connectors and wire harnesses shown in the illustration. EM A087634E01 12. REMOVE FUEL MAIN TUBE (a) Remove the fuel pipe clamp. A087635E01 EM–56 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (b) Disconnect the fuel tube from the fuel delivery pipe. NOTICE: Even if the fuel tube is stuck and cannot be disconnected, do not use any tools. Push and pull the parts with the quick connector pinched to disconnect the tube. (c) Cover the disconnected fuel tube and fuel delivery pipe with a plastic bag in order to prevent foreign objects from entering them. A087636E01 13. DISCONNECT RADIATOR INLET HOSE (a) Disconnect the radiator inlet hose from the cylinder head. EM A087637E01 14. DISCONNECT HOSES (a) Disconnect the hoses from the cylinder head as shown in the illustration. A087638E01 15. DISCONNECT NO. 1 WATER BY-PASS PIPE (a) Remove the bolt and disconnect the water by-pass pipe. 16. REMOVE OIL DIPSTICK GUIDE (a) Disconnect the hoses shown in the illustration. (b) Remove the bolt and disconnect the dipstick guide. A087639E01 1 3 5 4 17. REMOVE CYLINDER HEAD (a) Remove the No. 1 and No. 2 camshaft bearing caps in the sequence shown in the illustration, then remove the camshaft and No. 2 camshaft. NOTICE: Uniformly loosen the bolts, keeping the camshaft level. 2 A087641E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 3 7 9 6 1 5 10 8 EM–57 (b) Using an 8 mm bi-hexagon wrench, loosen the cylinder head bolts in several steps in the sequence shown in the illustration. Then remove the cylinder head bolts and washer. NOTICE: • When removing the bolt, do not drop the washer into the engine. • Removing the cylinder head bolts in the wrong order may cause damage to the cylinder head. (c) Remove the cylinder head. 2 4 A035286E02 18. REMOVE CYLINDER HEAD GASKET 19. REMOVE INTAKE MANIFOLD (See page EM-99) 20. REMOVE EXHAUST MANIFOLD (See page EM-100) 21. REMOVE NOISE FILTER (See page EM-101) 22. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-445) 23. REMOVE FUEL DELIVERY PIPE (See page EM-122) 24. REMOVE FUEL INJECTOR (See page EM-123) DISASSEMBLY 1. REMOVE NO. 1 TAPER SCREW PLUG (a) Using a 10 mm hexagon wrench, remove the taper screw plug and gasket. 2. REMOVE OIL CONTROL VALVE FILTER (a) Using an 8 mm hexagon wrench, remove the screw plug. (b) Remove the filter and gasket. 3. REMOVE VALVE LIFTER HINT: Keep the valve lifters in the correct order so that they can be returned to their original locations when reassembling. A088717E02 A038128E02 A088718E01 EM EM–58 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 4. REMOVE INTAKE VALVE (a) Using SST, compress the valve spring and remove the 2 retainer locks, valve, retainer and valve spring. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) HINT: Keep the valves, valve springs and spring retainers in the correct order so that they can be returned to their original locations when reassembling. 5. REMOVE EXHAUST VALVE (a) Using SST, compress the valve spring and remove the 2 retainer locks, valve, retainer and valve spring. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) HINT: Keep the valves, valve springs and spring retainers in the correct order so that they can be returned to their original locations when reassembling. 6. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seal. 7. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seat. HINT: Keep the valve seats in the correct order so that they can be returned to their original locations when reassembling. SST A037109E02 EM A080961E01 A080962E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 8. EM–59 REMOVE STUD BOLT (a) Using E5 and E7 "torx" sockets, remove the 7 stud bolts. Upper Side Front Side Exhaust Manifold Side EM Intake Manifold Side A092363E02 9. A088720E01 REMOVE CAMSHAFT BEARING CAP SETTING RING PIN (a) Remove the 2 ring pins indicated in the illustration. EM–60 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD INSPECTION 1. Cylinder Block Side INSPECT CYLINDER HEAD FOR FLATNESS (a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces of the cylinder head and cylinder block, and cylinder head and manifolds. Maximum warpage Surface Cylinder block side Specified Condition 0.05 mm (0.0020 in.) Intake manifold side 0.10 mm (0.0039 in.) Exhaust manifold side 0.10 mm (0.0039 in.) Intake Manifold Side If the warpage is greater than the maximum, replace the cylinder head. EM Exhaust Manifold Side A050931E01 2. INSPECT CYLINDER HEAD FOR CRACKS (a) Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. 3. INSPECT CYLINDER HEAD SET BOLT (a) Using a vernier caliper, measure the length of the head bolts from the seat to the end. Standard length: 142.8 to 144.2 mm (5.622 to 5.677 in.) Maximum length: 147.1 mm (5.791 in.) If the length is greater than the maximum, replace the bolt. A001071E01 Underhead Length A098332E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 4. EM–61 INSPECT CYLINDER BLOCK FOR FLATNESS (a) Using a precision straightedge and feeler gauge, measure the surface that is in contact with the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. EM A037353E01 5. INSPECT INTAKE VALVE (a) Check the overall valve length. Standard overall length: 89.25 mm (3.5138 in.) Minimum overall length: 88.95 mm (3.5020 in.) If the overall length is less than the minimum, replace the valve. EM02534E06 (b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.970 to 4.985 mm (0.1957 to 0.1963 in.) Z000052E01 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.7 mm (0.028 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM00181E03 EM–62 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 6. INSPECT EXHAUST VALVE (a) Check the overall valve length. Standard overall length: 87.90 mm (3.4606 in.) Minimum overall length: 87.60 mm (3.4488 in.) If the overall length is less than the minimum, replace the valve. (b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.965 to 4.980 mm (0.1955 to 0.1961 in.) (c) Check the valve head margin thickness. Standard margin thickness: 1.15 mm (0.0453 in.) Minimum margin thickness: 0.85 mm (0.0335 in.) If the margin thickness is less than the minimum, replace the valve. 7. INSPECT VALVE SPRING (a) Using a vernier caliper, measure the free length of the valve spring. Standard free length: 59.77 mm (2.3531 in.) If the free length is not as specified, replace the spring. EM EM00801E01 (b) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring. EM00988E01 EM00281E01 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Standard installed tension: 140 to 154 N (14.2 to 15.7 kgf, 31.5 to 34.6 lbf) at 32.5 mm (1.280 in.) Maximum working tension: 180 to 198 N (18.4 to 20.2 kgf, 40.5 to 44.5 lbf) at 25.1 mm (0.988 in.) If the installed tension is not as specified, replace the valve spring. EM–63 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 8. INSPECT VALVE GUIDE BUSH OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.010 to 5.030 mm (0.1972 to 0.1980 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance Guide Bush A001478E01 Specified Condition Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance Guide Bush Specified Condition Intake 0.08 mm (0.0032 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see page EM69). 9. Width A050036E01 45° 20° 1.0 to 1.4 mm (0.039 to 0.055 in.) A092365E01 INSPECT INTAKE AND EXHAUST VALVE SEAT (a) Apply a light coat of Prussian blue 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 INTAKE VALVE SEAT (a) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. EM EM–64 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 75° 45° (b) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (c) Hand-lap the valve and valve seat with an abrasive compound. (d) Recheck the valve seating position. 1.0 to 1.4 mm (0.039 to 0.055 in.) A092366E01 45° 11. REPAIR EXHAUST VALVE SEAT (a) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. 20° EM 1.0 to 1.4 mm (0.039 to 0.055 in.) A092365E01 75° 45° (b) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (c) Hand-lap the valve and valve seat with an abrasive compound. (d) Recheck the valve seating position. 1.0 to 1.4 mm (0.039 to 0.055 in.) A092366E01 12. INSPECT VALVE LIFTER (a) Using a micrometer, measure the lifter diameter. Standard lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) P016860E01 A088724E01 13. INSPECT VALVE LIFTER OIL CLEARANCE (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Standard lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (b) 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: 0.1 mm (0.0039 in.) 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–65 If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 14. INSPECT CAMSHAFT TIMING GEAR OPERATION (a) Check the lock of the camshaft timing gear. (1) Clamp the camshaft in a vise, and check that the camshaft timing gear is locked. NOTICE: Be careful not to damage the camshaft. Retard Side Paths Advance Side Paths Close Open Vinyl Tape Open (b) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with tape as shown in the illustration. HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with the tape. (2) Puncture the tape for the advance oil path and for the retard oil path on the opposite side from the advance oil path. Close Rubber Piece A051761E02 Retard Side Path Advance Side Path (3) Apply about 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure into the 2 broken tape paths (the advance side path and retard side path). NOTICE: Cover the paths with cloth or equivalent to prevent oil from splashing. A051762E01 Retard Side Path Decompress Advanced Side Path Hold Pressure A051763E01 (4) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when reducing the air pressure of the timing retard path. HINT: The lock pin is released, and the camshaft timing gear revolves in the advance direction. EM EM–66 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (5) When the camshaft timing gear reaches the most advanced position, release the air pressure from the timing retard side path, and then release the air pressure from the timing advance side path. NOTICE: The camshaft timing gear assembly occasionally shifts to the retard side abruptly if the air compression of the advanced side path is released first. This often results in the breakage of the lock pin. (c) Check the smooth movable range. (1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly. Standard condition: Smooth movable range is about 22.5° NOTICE: Be sure to perform this check by hand. Do not use air pressure. (d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked at the most retarded position. EM A037071E01 A037072E01 15. INSPECT CAMSHAFT TIMING GEAR (a) Wrap the chain around the timing sprocket. (b) Using a vernier caliper, measure the diameter of the timing gear with the chain. Minimum gear diameter (w/ chain): 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the sprocket. NOTICE: The vernier caliper must come into contact with the chain link when measuring. 16. INSPECT CAMSHAFT TIMING SPROCKET (a) Wrap the chain around the timing sprocket. (b) Using a vernier caliper, measure the diameter of the timing gear with the chain. Minimum gear diameter (w/ chain): 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the sprocket. NOTICE: The vernier caliper must come into contact with the chain link when measuring. EM–67 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 17. INSPECT CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. A088725E01 (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 42.310 to 42.410 mm (1.6657 to 1.6697 in.) Minimum cam lobe height: 42.16 mm (1.6598 in.) If the cam lobe height is less than the minimum, replace the camshaft. A037113E01 (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal A037114E01 Specified Condition No. 1 journal 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm (0.9035 to 0.9041 in.) If the journal diameter is not as specified, check the oil clearance. 18. INSPECT NO. 2 CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 44.046 to 44.146 (1.7341 to 1.7380 in.) Minimum cam lobe height: 43.90 mm (1.7283 in.) If the cam lobe height is less than the minimum, replace the camshaft. EM EM–68 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition No. 1 journal 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm (0.9035 to 0.9041 in.) If the journal diameter is not as specified, check the oil clearance. 19. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshafts. EM (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head. A001455E01 20. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps and the camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) for No. 1 13 N*m (129 kgf*cm, 9 ft.*lbf) for No. 2 NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. Plastigage A001452E01 (f) A001453E01 Measure the Plastigage at its widest point. Standard oil clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum oil clearance: 0.115 mm (0.0045 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head. NOTICE: Completely remove the Plastigage. EM–69 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD REPLACEMENT 1. REPLACE INTAKE VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). A001067E01 (b) Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) SST EM A037110E01 (c) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard bore diameter Bush size A001445E01 Specified Condition STD 9.685 to 9.706 mm (0.3813 to 0.3821 in.) O/S 0.05 9.735 to 9.756 mm (0.3833 to 0.3841 in.) If the bush bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bush bore to a dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). If the bush bore diameter of the cylinder head is greater than 9.756 mm (0.3841 in.), replace the cylinder head. (d) Heat the cylinder head to 80 to 100°C (176 to 212°F). (e) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Standard protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) SST 9.0 to 9.4 mm A080977E02 EM–70 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (f) 2. A001447E01 Using a sharp 5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and the valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) REPLACE EXHAUST VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) (c) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard bore diameter EM Bush size Specified Condition STD 9.685 to 9.706 mm (0.3813 to 0.3821 in.) O/S 0.05 9.735 to 9.756 mm (0.3833 to 0.3841 in.) If the bush bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bush bore to a dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). If the bush bore diameter of the cylinder head is greater than 9.756 mm (0.3841 in.), replace the cylinder head. (d) Heat the cylinder head to 80 to 100°C (176 to 212°F). (e) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Standard protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) (f) Using a sharp 5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–71 REASSEMBLY 8.5 to 9.5 mm A080980E03 1. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN (a) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height. Standard protrusion height: 8.5 to 9.5 mm (0.335 to 0.374 in.) 2. INSTALL STUD BOLT (a) Using E5 and E7 "torx" sockets, install the 7 stud bolts. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) for bolt A 4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt B 10 N*m (102 kgf*cm, 7.4 ft.*lbf) for bolt C 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt D EM EM–72 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD A C EM D B Stud Bolt A 26.5 mm (1.043 in.) 43.5 mm (1.713 in.) 19.5 mm (0.768 in.) Stud Bolt B 38.5 mm (1.516 in.) 12.0 mm (0.472 in.) 12.0 mm (0.472 in.) 28.5 mm (1.220 in.) 49.5 mm (1.949 in.) Stud Bolt C 13.0 mm (0.512 in.) Stud Bolt D 22.5 mm (0.886 in.) 37.5 mm (1.476 in.) 13.0 mm (0.512 in.) A117402E01 3. Intake Side Exhaust Side Gray Black A092940E02 INSTALL VALVE STEM OIL SEAL (a) Apply a light coat of engine oil to the valve stem. NOTICE: Installing the oil seals for the intake and exhaust onto the opposite valve guide bush may cause failures. HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black. 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–73 (b) Using SST, push in a new oil seal. SST 09201-41020 SST A001063E01 4. INSTALL INTAKE VALVE (a) Install the valve, spring seat, valve spring and spring retainer. NOTICE: Install the same parts in the same combination to their original locations. A001065E01 (b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) SST A037109E01 (c) Using a plastic-faced hammer and valve stem (not in use) with the tip wrapped in tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 5. A007307E01 INSTALL EXHAUST VALVE (a) Install the valve, spring seat, valve spring, and spring retainer. (b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) (c) Using a plastic-faced hammer and valve stem (not in use) with the tip wrapped in tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. EM EM–74 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD Mesh 6. INSTALL OIL CONTROL VALVE FILTER (a) Using an 8 mm hexagon wrench, install the filter with a new gasket and the screw plug. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 7. INSTALL VALVE LIFTER (a) Apply a light coat of engine oil to the valve lifter. (b) Install the valve lifter. (c) Check that the valve lifter rotates smoothly by hand. 8. INSTALL NO. 1 TAPER SCREW PLUG (a) Using a 10 mm hexagon wrench, install the taper screw plug with a new gasket. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A050664E01 EM A088717E02 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–75 INSTALLATION 1. INSTALL FUEL INJECTOR (See page EM-155) 2. INSTALL FUEL DELIVERY PIPE (See page EM-156) 3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (See page ES-446) 4. INSTALL NOISE FILTER (See page EM-102) 5. INSTALL EXHAUST MANIFOLD (See page EM-102) 6. INSTALL INTAKE MANIFOLD (See page EM-103) 7. INSTALL CYLINDER HEAD GASKET (a) Place a new head gasket on the cylinder block with the Lot No. facing upward. NOTICE: • Remove any oil from the contact surface. • Be careful of the installation direction. • Do not damage the cylinder head gasket when installing it. Lot No. 8. A092832E02 Cylinder Head Diameter: 4.5 to 5.5 mm Cylinder Head Gasket Cylinder Block INSTALL CYLINDER HEAD HINT: The cylinder head bolts are tightened in 2 successive steps. (a) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Standard seal diameter: 4.5 to 5.5 mm (0.177 to 0.217 in.) NOTICE: • Remove any oil from the contact surface. • Install the cylinder head within 3 minutes of applying seal packing. (b) Apply a light coat of engine oil to the threads of the cylinder head bolts. Seal Packing A073748E02 8 4 2 5 10 6 1 3 (c) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 9 7 A035286E03 EM EM–76 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 90° (d) Mark the front of the cylinder head bolt with paint. (e) Retighten the cylinder head bolts by an additional 90° and then another 90°, as shown in the illustration. (f) Check that the paint mark is now 180° opposite to the front. 90° Front Paint Mark EM A092833E01 9. 40q Timing Mark INSTALL CAMSHAFT NOTICE: If turning the camshaft with the chain removed, turn the crankshaft counterclockwise by 40° from TDC/ compression. (a) Apply engine oil to the cam and cylinder head journals. A092826E01 (b) Place the camshaft and No. 2 camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. Timing Mark A093712E01 (c) Check the front marks and numbers on the No. 1 and No. 2 camshaft bearing caps, then temporarily install them. A087642E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 5 3 1 2 4 No. 1 Camshaft Bearing Cap EM–77 (d) Uniformly tighten the No. 2 camshaft bearing caps in several steps in the sequence shown in the illustration. Torque: 13 N*m (130 kgf*cm, 9.6 ft.*lbf) NOTICE: Uniformly loosen the bolts, keeping the camshaft level. (e) Install the No. 1 camshaft bearing cap. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) A093713E01 10. INSTALL OIL DIPSTICK GUIDE (a) Install the dipstick guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Connect the hose. 11. INSTALL NO. 1 WATER BY-PASS PIPE (a) Connect the water by-pass pipe with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A087640E01 12. CONNECT HOSES (a) Connect the hoses shown in the illustration. A087638E01 13. REMOVE RADIATOR INLET HOSE (a) Connect the radiator inlet hose. A087637E01 14. CONNECT FUEL MAIN TUBE (a) Push the fuel tube into the fuel delivery pipe until it makes a "click" sound. HINT: • If the fuel tube is connected too tightly, apply a light coat of engine oil to the tip of the fuel delivery pipe. • After connecting, check that the fuel tube is securely connected by pulling it. A087643E01 EM EM–78 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (b) Install the fuel pipe clamp. 15. CONNECT WIRE HARNESS (a) Connect the connectors and wire harnesses shown in the illustration. A087635E01 EM A087634E01 16. INSTALL CHAIN (a) Install the chain to the engine (see page EM-35). 17. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the inverter with converter to the vehicle (see page HV-535). 18. INSTALL FRONT EXHAUST ASSEMBLY (See page EX-3) 19. INSTALL SERVICE PLUG GRIP (See page HB-154) 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–79 20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 21. CHECK FOR FUEL LEAKS (See page FU-8) 22. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 23. INSTALL REAR DECK FLOOR BOX (See page CH-8) 24. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 25. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EM EM–80 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY ENGINE ASSEMBLY 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS WINDSHIELD WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 EM HOOD TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY FRONT OUTER COWL TOP PANEL 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E04 EM–81 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY x 12 11 (112, 8.1) EM INVERTER COVER 11 (112, 8.1) NO. 2 INVERTER COOLING HOSE INVERTER WITH CONVERTER ASSEMBLY NO. 1 INVERTER COOLING HOSE ENGINE ROOM MAIN WIRE HARNESS NO. 1 CIRCUIT BREAKER SENSOR CONNECTOR NO. 6 INVERTER COOLING HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A124481E01 EM–82 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY INVERTER WITH CONVERTER ASSEMBLY 8.0 (82, 71 in.*lbf) EM 21 (214, 16) 21 (214, 16) 21 (214, 16) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) MG2 POWER CABLE 8.0 (82, 71 in.*lbf) MG1 POWER CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124446E02 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–83 x6 RADIATOR SUPPORT OPENING COVER 8.5 (87, 75 in.*lbf) INVERTER BRACKET 21 (214, 16) 20 (204, 15) COOLER BRACKET x5 5.0 (51, 44 in.*lbf) EM 25 (255, 18) x2 RADIATOR SUPPORT HOOD LOCK CONTROL CABLE HOOD LOCK HORN CONNECTOR FRONT BUMPER COVER ENGINE UNDER COVER RH x3 x2 x2 N*m (kgf*cm, ft.*lbf) : Specified torque x3 x4 ENGINE UNDER COVER LH A124482E01 EM–84 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY NO. 1 INVERTER COOLING HOSE RADIATOR OUTLET HOSE RADIATOR INLET HOSE NO. 2 INVERTER COOLING HOSE WIRE HARNESS FAN MOTOR CONNECTOR EM HOSE CLAMP RADIATOR DRAIN COCK PLUG HOSE CLAMP NO. 1 HEAT STORAGE WATER BY-PASS HOSE TEMPERATURE SWITCH CONNECTOR NO. 5 INVERTER COOLING HOSE A124483E01 EM–85 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY x4 7.5 (76, 66 in.*lbf) FAN WITH MOTOR ASSEMBLY 5.0 (51, 44 in.*lbf) RADIATOR SUPPORT UPPER RH 5.0 (51, 44 in.*lbf) RADIATOR SUPPORT UPPER LH 3.9 (40, 35 in.*lbf) RADIATOR FAN TEMPERATURE SWITCH 3.9 (40, 35 in.*lbf) NO. 2 RADIATOR ASSEMBLY RADIATOR SUPPORT LOWER LH RADIATOR SUPPORT LOWER LH 3.9 (40, 35 in.*lbf) 5.0 (51, 44 in.*lbf) 3.9 (40, 35 in.*lbf) 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124484E01 EM EM–86 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY LOWER CENTER INSTRUMENT PANEL FINISH PANEL x2 POWER OUTLET CONNECTOR EM FRONT FLOOR CARPET GASKET COMPRESSION SPRING 43 (440, 32) x2 GASKET COMPRESSION SPRING x2 FRONT EXHAUST PIPE x4 43 (440, 32) N*m (kgf*cm, ft.*lbf) : Specified torque FRONT FLOOR PANEL BRACE 30 (302, 22) Non-reusable part A124485E01 EM–87 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY COLUMN HOLE COVER SILENCER SHEET NO. 1 AIR CLEANER INLET PURGE VSV FUEL PIPE CLAMP 7.5 (51, 44 in.*lbf) FUEL TUBE STEERING SLIDING YOKE HEATER WATER HOSE NO. 3 HEAT STORAGE WATER BY-PASS HOSE FRONT STABILIZER LINK LH CLIP 49 (500, 36) x3 25 (255, 18) 35 (357, 26) COOLER COMPRESSOR WITH MOTOR ASSEMBLY 89 (908, 66) NO. 3 INVERTER COOLING HOSE FRONT DRIVE SHAFT LH TIE ROD END LH 216 (2,203, 160) FRONT AXLE HUB NUT LH NO. 1 HEAT STORAGE WATER BY-PASS HOSE N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 FRONT SUSPENSION ARM LOWER LH Non-reusable part A124486E01 EM EM–88 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 52 (530, 38) x2 80 (816, 59) EM x2 52 (530, 38) 100 (1,020, 74) x2 x2 x2 x2 x2 56 (571, 41) ENGINE MOVING CONTROL ROD WITH BRACKET 113 (1,152, 83) 157 (1,602, 116) FRONT SUSPENSION CROSSMEMBER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A124487E01 EM–89 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) EM ENGINE HANGER CLAMP 40 (408, 30) ENGINE HANGER FLYWHEEL 40 (408, 30) 49 (500, 36) STARTER HOLE INSULATOR 32 (326, 24) x6 TRANSMISSION INPUT DAMPER x6 20 (204, 15) FLYWHEEL HOUSING SIDE COVER HYBRID VEHICLE TRANSAXLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A124488E01 EM–90 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 9.0 (92, 80 in.*lbf) NO. 1 WATER BY-PASS PIPE 9.0 (92, 80 in.*lbf) x2 EM GASKET OIL DIPSTICK OIL DIPSTICK GUIDE 9.0 (92, 80 in.*lbf) O-RING KNOCK SENSOR 20 (204, 15) ENGINE OIL PRESSURE SWITCH DRIVE BELT 40 (408, 30) IDLER PULLEY RADIATOR OUTLET HOSE 20 (204, 15) 20 (204, 15) x2 x3 GASKET INTAKE MANIFOLD N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124489E01 EM–91 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 9.0 (92, 80 in.*lbf) NO. 1 EXHAUST MANIFOLD INSULATOR x4 EM IGNITION COIL x4 8.0 (82, 71 in.*lbf) x4 9.0 (92, 80 in.*lbf) NOISE FILTER 27 (275, 20) GASKET GASKET 20 (204, 15) ENGINE COOLANT TEMPERATURE SENSOR EXHAUST MANIFOLD 27 (275, 20) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124490E01 EM–92 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY REMOVAL EM 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures (see page HV-519). 2. REMOVE NO. 2 REAR FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE NO. 3 REAR FLOOR BOARD (See page CH4) 5. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE SERVICE PLUG GRIP (See page HB-154) 8. REMOVE FRONT WHEELS 9. REMOVE NO. 3 ENGINE UNDER COVER 10. REMOVE NO. 4 CENTER ENGINE UNDER COVER (See page ET-3) 11. DRAIN ENGINE COOLANT (See page CO-6) 12. DRAIN TRANSAXLE OIL (See page HX-67) 13. REMOVE WIPER ARM HEAD CAP 14. REMOVE FRONT WIPER ARM LH (See page WW-13) 15. REMOVE FRONT WIPER ARM RH (See page WW-13) 16. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 17. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 18. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 19. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-13) 20. REMOVE FRONT OUTER COWL TOP PANEL (See page FU-12) 21. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter from the vehicle (see page HV-530). 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–93 22. REMOVE NO. 2 RADIATOR ASSEMBLY (a) Remove the No. 2 radiator from the vehicle (see page CO-33). 23. DISCONNECT NO. 3 INVERTER COOLING HOSE A087644 24. DISCONNECT NO. 1 HEAT STORAGE WATER BYPASS HOSE (a) Disconnect the hose shown in the illustration. A087645E01 25. DISCONNECT ENGINE WIRE (a) Remove the bolt, then disconnect the ground cable. A087646E01 26. SEPARATE NO. 1 AIR CLEANER INLET (a) Loosen the clamp, then disconnect the air cleaner inlet No. 1 from the air cleaner case. A088023E01 EM EM–94 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 27. REMOVE PURGE VSV (a) Disconnect the connector and hose. (b) Remove the bolt, then remove the vacuum switching valve assembly. A088024E01 28. DISCONNECT FUEL TUBE (a) Remove the fuel pipe clamp. EM A088025E01 (b) Disconnect the fuel tube from the fuel delivery pipe. NOTICE: Even if the fuel tube is stuck and cannot be disconnected, do not use any tools. Push and pull the part with the quick connector pinched to disconnect the tube. (c) Cover the disconnected fuel tube and fuel delivery pipe with plastic bags in order to prevent foreign objects from entering them. A088026E01 29. DISCONNECT HEATER WATER HOSE A088027E01 30. DISCONNECT NO. 3 HEAT STORAGE WATER BYPASS HOSE A088028E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–95 31. DISCONNECT ENGINE WIRE (a) Disconnect the connector from the ECM, then pull the engine wire harness to the engine compartment side. NOTICE: Do not forcibly pull the engine wire harness to the engine compartment side. (b) Disconnect the harness and harness clamp from the engine room main relay block. (c) Disconnect the ground cable. EM A088029E02 A088030E02 32. DISCONNECT HEATER COMPRESSOR WITH MOTOR ASSEMBLY (a) Disconnect the wire harness of the compressor assembly from the harness clamp. (b) Remove the 3 bolts, then disconnect the compressor assembly. HINT: Disconnect the compressor assembly together with the low-pressure and high-pressure hoses, then secure it to the vehicle side with rope. 33. DISCONNECT STEERING SLIDING YOKE (a) Install the seat belt as illustrated so that the steering wheel does not turn. HINT: This prevents an open circuit of the spiral cable. A088159E01 (b) Remove the 2 clips, then remove the column hole cover silencer sheet. A088031E01 EM–96 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Loosen the bolt on the column side (A) of the sliding yoke. (d) Remove the bolt on the gear side (B) of the sliding yoke. (e) Put paint marks on the sliding yoke and intermediate shaft, and then disconnect the sliding yoke. A B 34. REMOVE FRONT EXHAUST PIPE (See page EX-2) Paint Mark A093709E01 35. REMOVE FRONT AXLE HUB NUT LH (See page DS5) 36. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. EM 37. DISCONNECT FRONT STABILIZER LINK LH (See page SP-28) 38. DISCONNECT TIE ROD END LH (See page DS-6) 39. DISCONNECT TIE ROD END RH HINT: Use the same procedures described for the LH side. 40. DISCONNECT NO. 1 FRONT SUSPENSION ARM LOWER LH (See page DS-6) 41. DISCONNECT NO. 1 FRONT SUSPENSION ARM LOWER RH HINT: Use the same procedures described for the LH side. 42. DISCONNECT FRONT AXLE HUB LH (See page DS-6) 43. DISCONNECT FRONT AXLE HUB RH HINT: Use the same procedures described for the LH side. 44. REMOVE FRONT DRIVE SHAFT LH (See page DS-7) 45. REMOVE FRONT DRIVE SHAFT RH (See page DS-7) 46. REMOVE FRONT SUSPENSION CROSSMEMBER (a) Remove the 4 bolts and 2 nuts, then remove the engine moving control rod with bracket. A088033E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–97 (b) Remove the 4 bolts, then remove the front suspension crossmember with power steering gear assembly. A088034E01 47. REMOVE ENGINE AND TRANSAXLE (a) Set the engine lifter as illustrated. EM A088035E01 (b) Remove the 2 bolts and 2 nuts, then disconnect the engine mounting bracket RH and engine mounting insulator RH. (c) Remove the nut, then disconnect the engine mounting insulator bracket LH and engine mounting insulator LH. (d) Operate the engine lifter, then remove the engine assembly with transaxle from the vehicle. A088036E01 48. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the intake air flow meter connector and wire harness clamp. (b) Loosen the clamp, then remove the 2 bolts and air cleaner assembly. A088037E01 EM–98 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 49. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the bolt and ground cable. A088038E01 EM A088039E01 (b) Install the engine hangers to the engine assembly with 2 new bolts as shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 in.*lbf) NOTICE: Be sure to use new bolts to install the engine hangers. HINT: • Engine hanger 12281-21010 • Bolt 91642-81052 (c) Using a chain block and engine sling device, hold the engine assembly with transaxle. (d) Remove the engine wire harness from the engine assembly with transaxle. (e) Remove the 2 bolts, then remove the starter hole insulator and flywheel housing side cover. (f) Remove the hybrid vehicle transaxle assembly from the engine assembly (see page HX-66). A088040E01 50. REMOVE TRANSMISSION INPUT DAMPER (a) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (b) Remove the 6 bolts, then remove the input damper and input damper cover. SST A089849E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–99 51. REMOVE FLYWHEEL (a) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (b) Remove the 6 bolts and flywheel. SST A092534E01 52. REMOVE OIL DIPSTICK GUIDE (a) Remove the dipstick. (b) Remove the bolt and dipstick guide. EM A088041E01 53. REMOVE INTAKE MANIFOLD (a) Remove the bolt and knock control sensor with bracket. (b) Disconnect the wiring harness from the bracket. (c) Disconnect the ventilation hose. (d) Disconnect the water by-pass hose. A088042E01 (e) Remove the 3 bolts and 2 nuts, then remove the intake manifold and gasket. A088043E01 EM–100 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 54. REMOVE NO. 1 WATER BY-PASS PIPE (a) Remove the bolt, then disconnect the wire harness. (b) Remove the 2 nuts and bolt, then remove the water by-pass pipe No. 1 and gasket. 55. REMOVE KNOCK SENSOR (See page ES-459) 56. REMOVE ENGINE OIL PRESSURE SWITCH (See page LU-1) 57. REMOVE DRIVE BELT (See page EM-6) A088045E01 58. REMOVE IDLER PULLEY (a) Remove the nut, then remove the idle pulley assembly from the engine mounting bracket RH. EM A092817E01 59. REMOVE IGNITION COIL (a) Remove the 4 bolts and 4 ignition coils. A088163E01 60. REMOVE EXHAUST MANIFOLD (a) Remove the 4 bolts and exhaust manifold insulator. A088048E01 (b) Remove the 3 bolts and 2 nuts, then remove the exhaust manifold. A088051E02 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–101 61. REMOVE NOISE FILTER (a) Remove the bolt and noise filter. A088050E01 62. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor. A089055E02 INSPECTION 1. INSPECT INTAKE MANIFOLD (a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.004 in.) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. 2. INSPECT EXHAUST MANIFOLD (a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.028 in.) If the warpage is greater than the maximum, replace the manifold. A130329 A130330 INSTALLATION 1. A089055E02 INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket, then install the engine coolant temperature sensor. Torque: 20 N*m (204 kgf*cm, 15 in.*lbf) EM EM–102 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 2. INSTALL NOISE FILTER (a) Install the noise filter with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 3. INSTALL EXHAUST MANIFOLD (a) Install a new gasket, then install the exhaust manifold. (b) Tighten the 3 bolts and 2 nuts in the sequence shown in the illustration. Torque: 27 N*m (275 kgf*cm, 20 in.*lbf) A088050E01 EM 1 4 5 2 3 A088052E02 (c) Install the exhaust manifold insulator with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A088048E01 4. INSTALL IGNITION COIL (a) Install the ignition coil with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 5. INSTALL IDLER PULLEY (a) Temporarily install the idler pulley assembly to the engine mounting bracket RH with the nut. HINT: Tighten the nut to the specified torque when installing the drive belt. 6. INSTALL DRIVE BELT (See page EM-6) 7. INSTALL ENGINE OIL PRESSURE SWITCH (See page LU-1) A088163E01 A092817E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–103 8. INSTALL KNOCK SENSOR (See page ES-460) 9. INSTALL NO. 1 WATER BY-PASS PIPE (a) Install a new gasket, then install the water by-pass pipe with the bolt and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088045E01 10. INSTALL INTAKE MANIFOLD (a) Install a new gasket, then install the intake manifold with the 3 bolts and 2 nuts. A088043E01 (b) Connect the water by-pass hose. (c) Connect the ventilation hose. (d) Install the knock control sensor with bracket with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088042E01 11. INSTALL OIL DIPSTICK GUIDE (a) Apply engine oil to a new O-ring, then install it to the dipstick guide. (b) Install the dipstick guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install the dipstick. A088041E01 EM EM–104 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 12. INSTALL FLYWHEEL (a) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent NOTICE: Remove any oil from the bolts and bolt holes. Adhesive A004869E02 (b) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (c) Install the flywheel with 6 new bolts. Torque: 49 N*m (500 kgf*cm, 36 in.*lbf) (d) After tightening the new bolts to the specified torque, tighten each bolt by an additional 90°. NOTICE: Do not start the engine within 1 hour of installation. EM SST A092534E01 13. INSTALL TRANSMISSION INPUT DAMPER (a) Using SST, align the hole of the input damper. Then temporarily tighten the input damper cover with the 6 bolts. SST 09301-00210 SST A089851E01 (b) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (c) Tighten the 6 bolts. Torque: 20 N*m (204 kgf*cm, 15 in.*lbf) 14. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Install the hybrid vehicle transaxle assembly to the engine assembly with the 6 bolts (see page HX-70). SST A089849E01 (b) Install the flywheel housing side cover and starter hole insulator with the 2 bolts. Torque: 32 N*m (326 kgf*cm, 24 in.*lbf) (c) Install the engine wire harness to the engine assembly with transaxle. A088040E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–105 (d) Remove the bolts and engine hangers. A088039E01 (e) Install the ground cable with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) EM A088038E01 15. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts and tighten the clamp. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) for bolt 3.0 N*m (31 kgf*cm, 27 in.*lbf) for clamp A088037E01 16. INSTALL ENGINE AND TRANSAXLE (a) Set the engine lifter as illustrated. (b) Operate the engine lifter, then install the engine assembly with transaxle to the vehicle. A088035E01 EM–106 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Connect the engine mounting bracket RH and engine mounting insulator RH with the 2 bolts and 2 nuts. Torque: 52 N*m (530 kgf*cm, 38 in.*lbf) (d) Connect the engine mounting insulator bracket LH and engine mounting insulator LH with the nut. Torque: 80 N*m (816 kgf*cm, 59 in.*lbf) EM A088036E01 A A B B 17. INSTALL FRONT SUSPENSION CROSSMEMBER (a) Install the front suspension crossmember with power steering gear assembly with the 4 bolts. Torque: 113 N*m (1,152 kgf*cm, 83 in.*lbf) for bolt A 157 N*m (1,602 kgf*cm, 116 in.*lbf) for bolt B A089852E01 A (b) Install the engine moving control rod with bracket with the 4 bolts and 2 nuts. Torque: 100 N*m (1020 kgf*cm, 74 in.*lbf) for bolt A 56 N*m (571 kgf*cm, 41 in.*lbf) for bolt B A 18. INSTALL FRONT DRIVE SHAFT LH (See page DS-15) 19. INSTALL FRONT DRIVE SHAFT RH (See page DS-15) B B 20. INSTALL FRONT AXLE HUB LH (See page DS-15) A089853E01 21. INSTALL FRONT AXLE HUB RH HINT: Use the same procedures described for the LH side. 22. INSTALL NO. 1 FRONT SUSPENSION ARM LOWER LH (See page SP-20) 23. INSTALL NO. 1 FRONT SUSPENSION ARM LOWER RH HINT: Use the same procedures described for the LH side. 24. CONNECT TIE ROD END LH (See page DS-16) 25. CONNECT TIE ROD END RH HINT: Use the same procedures described for the LH side. 26. CONNECT FRONT STABILIZER LINK LH (See page SP-29) 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–107 27. INSTALL FRONT AXLE HUB NUT LH (See page DS16) 28. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 29. CONNECT STEERING SLIDING YOKE (a) Align the paint marks, then connect the steering sliding yoke with the bolt. Torque: 35 N*m (357 kgf*cm, 26 in.*lbf) (b) Install the column hole cover silencer sheet with the 2 clips. (c) Remove the seat belt from the steering wheel. A B Paint Mark EM A093709E01 30. CONNECT COOLER COMPRESSOR WITH MOTOR ASSEMBLY (a) Install the cooler compressor with the 3 bolts. Torque: 25 N*m (255 kgf*cm, 18 in.*lbf) A088030E02 31. CONNECT ENGINE WIRE (a) Connect the ground cable. (b) Connect the harness and clamp to the engine room main relay block. (c) Push in the engine wire harness, and then connect the wire harness to the ECM. A088029E02 32. CONNECT NO. 3 HEAT STORAGE WATER BY-PASS HOSE (a) Connect the No. 3 heat storage water by-pass hose. A088028E01 EM–108 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 33. CONNECT HEATER WATER HOSE A088027E01 34. CONNECT FUEL TUBE (a) Push the fuel tube into the fuel delivery pipe until it makes a "click" sound. HINT: • If the fuel tube is connected too tightly, apply a light coat of engine oil to the tip of the fuel delivery pipe. • After connecting, check that the fuel tube is securely connected by pulling it. EM A087643E01 (b) Install the fuel pipe clamp. A087635E01 35. INSTALL PURGE VSV (a) Install the purge VSV with the bolt. Torque: 7.5 N*m (76 kgf*cm, 5.5 in.*lbf) (b) Connect the hose and connector. A088024E01 36. CONNECT NO. 1 AIR CLEANER INLET (a) Connect the No. 1 air cleaner inlet to the air cleaner case, and then tighten the clamp. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) A088023E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–109 37. CONNECT ENGINE WIRE (a) Connect the ground cable with the bolt. A087646E01 38. CONNECT NO. 1 HEAT STORAGE WATER BY-PASS HOSE (a) Connect the hose as shown in the illustration. EM A087645E01 39. CONNECT NO. 3 INVERTER COOLING HOSE 40. INSTALL NO. 2 RADIATOR ASSEMBLY (a) Install the radiator to the vehicle (see page CO-34). 41. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the inverter with converter to the vehicle (see page HV-535). A087644E01 42. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 43. INSTALL WINDSHIELD WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-16) 44. INSTALL COWL TOP VENTILATOR LOUVER RH 45. INSTALL COWL TOP VENTILATOR LOUVER LH 46. INSTALL HOOD TO COWL TOP SEAL 47. INSTALL FRONT WIPER ARM LH (See page WW-16) 48. INSTALL FRONT WIPER ARM RH (See page WW-16) 49. INSTALL WIPER ARM HEAD CAP 50. ADD TRANSAXLE OIL (See page HX-74) 51. INSTALL SERVICE PLUG GRIP (See page HB-154) 52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 53. INSTALL NO. 3 REAR FLOOR BOARD (See page CH8) 54. INSTALL REAR DECK FLOOR BOX (See page CH-8) EM–110 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 55. INSTALL NO. 2 REAR FLOOR BOARD (See page CH8) 56. ADD ENGINE COOLANT (See page CO-7) 57. CHECK FOR TRANSAXLE FLUID LEVEL (See page HX-74) 58. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 59. CHECK FOR FUEL LEAKAGE (See page CO-2) 60. CHECK FOR ENGINE OIL LEAKS 61. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 in.*lbf) EM 62. ADJUST FRONT WHEEL ALIGNMENT (a) Adjust the front wheel alignment (see page SP-2). 63. INSTALL NO. 3 ENGINE UNDER COVER 64. INSTALL NO. 4 CENTER ENGINE UNDER COVER 65. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–111 ENGINE UNIT 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS 10 (102, 7) x2 OIL FILLER CAP OIL FILLER CAP GASKET VENTILATION VALVE x7 x2 EM 10 (102, 7) CYLINDER HEAD COVER CYLINDER HEAD COVER GASKET 18 (184, 13) SPARK PLUG N*m (kgf*cm, ft.*lbf) : Specified torque A116718E02 EM–112 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 55 (561, 41) 32 (326, 24) ENGINE MOUNTING BRACKET RH 24 (245, 18) x4 24 (245, 18) CRANKSHAFT POSITION SENSOR TIMING CHAIN COVER x2 EM 11 (112, 8) x 11 7.5 (76, 66 in.*lbf) x2 128 (1,305, 95) CRANKSHAFT PULLEY 11 (112, 8) STRAIGHT PIN OIL PUMP SEAL x3 GASKET x2 WATER PUMP 15 (153, 11) 11 (112, 8) WATER PUMP PULLEY CHAIN TENSIONER SLIPPER 9.0 (92, 80 in.*lbf) CHAIN x2 NO. 1 CHAIN TENSIONER N*m (kgf*cm, ft.*lbf) : Specified torque O-RING Non-reusable part Apply MP grease 9.0 (92, 80 in.*lbf) NO. 1 CHAIN VIBRATION DAMPER A124491E03 EM–113 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 23 (235, 17) NO. 1 CAMSHAFT BEARING CAP x3 x 16 x8 13 (129, 9) NO. 2 CAMSHAFT BEARING CAP CAMSHAFT TIMING SPROCKET EM CAMSHAFT 64 (653, 47) NO. 2 CAMSHAFT CAMSHAFT TIMING GEAR 64 (653, 47) N*m (kgf*cm, ft.*lbf) : Specified torque A116719E01 EM–114 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT CAMSHAFT POSITION SENSOR 1st: 29 (300, 22) 2nd: Turn 90° 3rd: Turn 90° FUEL DELIVERY PIPE 9.0 (92, 80 in.*lbf) CYLINDER HEAD 8.0 (82, 71 in.*lbf) 19 (194, 14) O-RING FUEL INJECTOR x4 SPACER O-RING EM CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY O-RING 7.5 (76, 66 in.*lbf) CYLINDER HEAD GASKET THERMOSTAT ENGINE REAR OIL SEAL 9.0 (92, 80 in.*lbf) GASKET O-RING WATER INLET 5.0 (51, 44 in.*lbf) x2 OIL PAN OIL STRAINER 30 (306, 22) OIL FILTER UNION GASKET 17.5 (178, 13) 11 (112, 8) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease 11 (112, 8) OIL FILTER x 13 x2 24 (245, 18) 5.0 (51, 44 in.*lbf) NO. 2 OIL PAN 37.5 (382, 28) GASKET x9 x2 9.0 (92, 80 in.*lbf) A116720E01 EM–115 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT NO. 1 COMPRESSION RING NO. 2 COMPRESSION RING OIL RING (EXPANDER) CONNECTING ROD OIL RING (SIDE RAIL) PISTON CONNECTING ROD BEARING PISTON PIN EM CONNECTING ROD CAP 5.0 (51, 44 in.*lbf) 1st: 15 (153, 11) 2nd: 90° STRAIGHT PIN 35 (357, 26) STRAIGHT PIN CYLINDER BLOCK WATER DRAIN COCK TIGHT PLUG STRAIGHT PIN STRAIGHT PIN STRAIGHT PIN 11 (112, 8) 5.0 (51, 44 in.*lbf) OIL JET (MASS PRODUCTION PART) OIL JET (SERVICE PART) UPPER MAIN BEARING STRAIGHT PIN STRAIGHT PIN 5.0 (51, 44 in.*lbf) CRANKSHAFT THRUST WASHER CRANKSHAFT N*m (kgf*cm, ft.*lbf) : Specified torque CRANKSHAFT BEARING CAP Non-reusable part Precoated part LOWER MAIN BEARING 1st: 22 (224, 16) 2nd: 90° A124506E01 EM–116 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT DISASSEMBLY 1. REMOVE SPARK PLUG (a) Using a 16 mm plug wrench, remove the 4 spark plugs. 2. REMOVE OIL FILLER CAP (a) Remove the oil filler cap from the cylinder head cover. 3. REMOVE OIL FILLER CAP GASKET (a) Using a screwdriver, remove the gasket from the oil filler cap. HINT: Tape the screwdriver tip before use. 4. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and sensor. 5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Remove the bolt and oil control valve. 6. REMOVE OIL FILTER (a) Using SST, remove the oil filter. SST 09228-06501 EM A065656E01 A088868E02 A088869E02 SST A088870E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 7. EM–117 REMOVE THERMOSTAT (a) Remove the 2 nuts and water inlet. A088871E01 (b) Remove the thermostat. (c) Remove the gasket from the thermostat. EM A088872E01 8. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and sensor. 9. REMOVE WATER PUMP PULLEY (a) Using SST, hold the pump pulley and remove the 3 bolts and pump pulley. SST 09960-10010 (09962-01000, 09963-00600) A088874E02 SST A088875E02 10. REMOVE WATER PUMP (a) Remove the 3 bolts and 2 nuts. (b) Remove the water pump and gasket. A088890E01 EM–118 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 11. REMOVE ENGINE MOUNTING BRACKET RH (a) Remove the 4 bolts and engine mounting bracket RH. A088876E01 12. REMOVE VENTILATION VALVE (a) Remove the ventilation valve from the cylinder head cover. EM A080963E03 13. REMOVE CYLINDER HEAD COVER (a) Remove the 9 bolts, 2 nuts and cylinder head cover. (b) Remove the gasket from the cylinder head cover. A066472E01 14. REMOVE CRANKSHAFT PULLEY (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (2) Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Mark A092837E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–119 (b) Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt. SST 09213-58012 (91111-50845), 09330-00021 NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. SST SST A088877E01 (c) Loosen the crankshaft pulley set bolts until 2 to 3 threads of the bolt is tightened to the crankshaft. (d) Using SST, remove the crankshaft pulley and crankshaft pulley set bolt. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) SST A088878E01 (e) Remove the crankshaft straight pin. A088879E01 15. REMOVE TIMING CHAIN COVER (a) Remove the 15 bolts and nut. A066477E01 EM EM–120 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (b) Using a screwdriver with the tip wrapped in tape, remove the chain cover by prying between the cylinder head and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the chain cover, the cylinder head and the cylinder block. EM A088880E01 (c) Remove the 2 O-rings from the cylinder block and No. 1 oil pan. A088881E01 (d) Using an 8 mm hexagon wrench, remove the screw plug from the oil pump. 16. REMOVE OIL PUMP SEAL (See page EM-138) A088882E01 17. REMOVE NO. 1 CHAIN TENSIONER NOTICE: • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from TDC and align the oil jet hole with the paint mark to prevent the pistons from coming into contact with the valves. • Do not rotate the crankshaft with the chain tensioner removed. Oil Jet Timing Mark A050142E05 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–121 (a) Lift up the stopper plate, then unlock the plunger. (b) Push in the plunger to the end with the plunger unlocked. Plunger Unlock Stopper Plate A092824E01 (c) Lower the stopper plate with the plunger pushed to the end, then lock the plunger. Plunger EM Stopper Plate Lock A092825E01 (d) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked. Plunger Stopper Plate A080976E02 HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily. A087621E01 (e) Remove the 2 bolts and chain tensioner. A089044E01 EM–122 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 18. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the bolt and chain tensioner slipper. A088883E02 19. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and chain vibration damper. EM A088884E01 20. REMOVE CHAIN (a) Remove the chain from the engine. A088885E01 21. REMOVE FUEL DELIVERY PIPE (a) Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors. A088886E01 (b) Remove the delivery pipe spacer from the cylinder head. A088887E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–123 22. REMOVE FUEL INJECTOR (a) Pull out the 4 injectors from the delivery pipe. A088888E02 1 3 5 4 23. REMOVE NO. 2 CAMSHAFT (a) Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration, and then remove the 5 bearing caps and No. 2 camshaft. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. 2 A037074E02 24. REMOVE CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vise. (b) Remove the flange bolt and camshaft timing sprocket. NOTICE: Be careful not to damage the camshaft. A064874E01 2 25. REMOVE CAMSHAFT (a) Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, and then remove the 4 bearing caps and camshaft. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. 4 3 1 A037075E02 Flange Bolt Do Not Remove Straight Pin A050060E02 26. REMOVE CAMSHAFT TIMING GEAR (a) Turn the valve timing controller assembly at the most advanced angle (see page EM-65). (b) Remove the flange bolt and camshaft timing gear. NOTICE: • Be careful not to remove the other 4 bolts. • If reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first. EM EM–124 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 3 7 9 6 1 5 10 8 2 4 A035286E02 27. REMOVE CYLINDER HEAD (a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTICE: • Be careful not to drop washers into the cylinder head. • Head warpage or cracking could result from removing bolts in the incorrect order. 28. REMOVE CYLINDER HEAD GASKET 29. REMOVE OIL FILTER UNION (a) Using a 12 mm hexagon wrench, remove the oil filter union. EM A088892E02 30. REMOVE NO. 2 OIL PAN (a) Remove the oil pan drain plug and gasket. (b) Remove the 9 bolts and 2 nuts. A088893E01 SST SST A088894E02 (c) Insert the blade of SST between the oil pan and No. 2 oil pan, cut off the applied sealer and remove the No. 2 oil pan. SST 09032-00100 NOTICE: Be careful not to damage the oil pan and No. 2 oil pan. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–125 31. REMOVE OIL STRAINER (a) Remove the bolt, 2 nuts, oil strainer and gasket. A084113E01 32. REMOVE OIL PAN (a) Loosen and remove the 13 bolts uniformly in several steps. EM A088895E01 (b) Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan. NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block. HINT: Tape the screwdriver tip before use. A088896E01 (c) Remove the 2 O-rings from the cylinder block. A088897E01 EM–126 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (d) Using an E5 "torx" socket, remove the 4 stud bolts. A089042E01 33. REMOVE ENGINE REAR OIL SEAL EM A089043E01 34. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.16 to 0.36 mm (0.0063 to 0.0142 in.) Maximum thrust clearance: 0.36 mm (0.0142 in.) If the thrust clearance is greater than the maximum, replace the connecting rod. A084165 35. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly. (b) Using SST, remove the 2 connecting rod cap bolts. SST 09205-16010 (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. SST A084166E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (f) Plastigage EM–127 Lay a strip of Plastigage across the crank pin. A050668E01 (g) Match together the connecting rod and cap in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented. (h) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. Front Mark A091905E01 (i) SST Using SST, tighten the bolts in several steps by the specified torque. SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTICE: Do not turn the crankshaft. A084167E01 90° Paint Mark Engine Front (j) Mark the front of the connecting cap bolts with paint. (k) Retighten the cap bolts by 90° as shown in the illustration. NOTICE: Do not turn the crankshaft. (l) Remove the 2 bolts, connecting rod cap and lower bearing. A050671E02 (m) Measure the Plastigage at its widest point. Standard oil clearance: 0.016 to 0.040 mm (0.0006 to 0.0016 in.) Maximum oil clearance: 0.06 mm (0.0024 in.) NOTICE: Completely remove the Plastigage. A037349E01 EM EM–128 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (n) If the oil clearance is greater than the maximum, select and replace the bearing. If necessary, use an undersized bearing. Mark 1 , 2 or 3 Front Mark A051826E01 Reference Connecting Rod External Diameter Center Bearing Thickness 1 43.000 to 43.008 mm (1.6929 to 1.6932 in.) 1.491 to 1.492 mm (0.0587 to 0.0588 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) 2 43.008 to 43.016 mm (1.6932 to 1.6935 in.) 1.492 to 1.496 mm (0.0588 to 0.0589 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) 3 43.016 to 43.024 mm (1.6935 to 1.6939 in.) 1.496 to 1.500 mm (0.0589 to 0.0591 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) U/S 0.25 43.000 to 43.024 mm (1.6929 to 1.6939 in.) 1.608 to 1.614 mm (0.0633 to 0.0635 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) Number Mark EM A001166E01 Oil Clearance 36. REMOVE PISTON WITH CONNECTING ROD (a) Using a ridge reamer, remove all carbon from the top of the cylinder. (b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: • Keep the bearing, connecting rod and cap together. • Keep the piston and the connecting rod assemblies in the correct order so that they can be returned to their original locations when reassembling. 37. REMOVE CONNECTING ROD BEARING A084170E01 38. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.09 to 0.19 mm (0.0035 to 0.0075 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft and block for wear. Repair or replace if necessary. HINT: Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 in.) 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 3 7 9 5 1 4 8 10 6 2 EM–129 39. REMOVE CRANKSHAFT AND INSPECT OIL CLEARANCE (a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts with SST in the sequence shown in the illustration. SST 09011-38121 (b) Remove the 5 bearing caps and crankshaft. (c) Clean each main journal and bearing. A084171E02 Upper Bearing Oil Groove Lower Bearing Block Side Cap Side A A B B (d) Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap. NOTICE: Do not apply engine oil to the contact surfaces of the cylinder block or the backside of the bearing. HINT: The mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap. Standard clearance: A - B = within 0.8 mm (0.032 in.) (e) Install the crankshaft onto the cylinder block. Mass Production Part Claw Service Part A091909E02 (f) Plastigage A050669E03 Lay a strip of Plastigage across each journal. EM EM–130 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT Front Mark and Number Front Mark Number No. 3 (g) Check the front marks and numbers and install the bearing caps onto the cylinder block. (h) Apply a light coat of engine oil to the threads of the bearing cap bolts. No. 1, 2, 4, 5 A091910E01 (i) 7 3 1 5 9 8 4 2 6 10 EM Using SST, tighten the bolts in several steps by the specified torque in the sequence shown in the illustration. SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) NOTICE: Do not turn the crankshaft. A084171E05 90° Painted Mark Engine Front (j) Mark the front of the bearing cap bolts with paint. (k) Retighten the bearing cap bolts by 90° in the same sequence. (l) Check that the painted mark is now at a 90° angle to the front. NOTICE: Do not turn the crankshaft. (m) Remove the bearing cap. A050671E04 (n) Measure the Plastigage at its widest point. Standard oil clearance: 0.010 to 0.023 mm (0.0004 to 0.0009 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) NOTICE: Completely remove the Plastigage. A037352E03 EM–131 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT No. 1 No. 2 No. 3No. 4 No. 5 HINT: • If the oil clearance is greater than the maximum, select and replace the bearing. If necessary, use an undersized bearing. • To select the correct bearing size, calculate the bearing number by adding together the numbers imprinted on the cylinder block and crank journal. Example: Imprinted number on the cylinder block is 3. Imprinted number on the crank journal is 5. 3 + 5 = 8 Select the bearing with the bearing number 3. Standard cylinder block diameter Cylinder Block Number Bearing Number No. 1 No. 3 No. 5 No. 2 No. 4 Crank Journal Number A091934E01 Number Specified Condition 0 50.000 to 50.003 mm (1.9685 to 1.9686 in.) 1 50.003 to 50.005 mm (1.9686 to 1.9687 in.) 2 50.005 to 50.007 mm (1.9687 to 1.9688 in.) 3 50.007 to 50.010 mm (1.9688 to 1.9689 in.) 4 50.010 to 50.012 mm (1.9689 to 1.9690 in.) 5 50.012 to 50.014 mm (1.9690 to 1.9691 in.) 6 50.014 to 50.016 mm (1.96905 to 1.96913 in.) Standard crankshaft journal diameter Number Specified Condition 0 45.998 to 46.000 mm (1.8109 to 1.8110 in.) 1 45.996 to 45.998 mm (1.81086 to 1.81094 in.) 2 45.994 to 45.996 mm (1.8108 to 1.8109 in.) 3 45.992 to 45.994 mm (1.81071 to 1.81079 in.) 4 45.990 to 45.992 mm (1.8106 to 1.8107 in.) 5 45.988 to 45.990 mm (1.81055 to 1.81063 in.) Reference Cylinder Block Number + Crank Journal Number Bearing Number Center Bearing Thickness Oil Clearance 0 to 2 1 1.992 to 1.995 mm (0.0784 to 0.0785 in.) 0.010 to 0.023 mm (0.0004 to 0.0009 in.) 3 to 5 2 1.995 to 1.998 mm (0.0785 to 0.0787 in.) Same as above 6 to 8 3 1.998 to 2.001 mm (0.0787 to 0.0788 in.) Same as above 9 to 11 4 2.001 to 2.004 mm (0.0788 to 0.0789 in.) Same as above - U/S 0.25 2.111 to 2.117 mm (0.0831 to 0.0834 in.) Same as above 40. REMOVE CRANKSHAFT BEARING 41. REMOVE CRANKSHAFT THRUST WASHER 42. REMOVE PISTON RING SET HINT: Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when reassembling. EM EM–132 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the oil ring (side rail and expander) by hand. A084172E01 SST EM SST SST 43. REMOVE PISTON PIN (a) Using SST, press out the piston pin from the piston. SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150) NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembling. A084173E01 44. REMOVE CYLINDER BLOCK WATER DRAIN COCK (a) Remove the cylinder block water drain cock from the cylinder block. A084175E01 45. REMOVE OIL JET (a) Remove the oil jet from the cylinder block. A084179E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–133 46. REMOVE STUD BOLT (a) Remove the stud bolt for the knock control sensor from the cylinder block. (b) Using an E5 "torx" socket, remove the 6 stud bolts from the cylinder block. A088908E01 Front Side Intake Side EM A092959E02 47. REMOVE RING PIN (a) Remove the 2 oil pump ring pins from the cylinder block. A084194E01 48. REMOVE STRAIGHT PIN (a) Remove the chain tensioner straight pin from the cylinder block. A084195E01 EM–134 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (b) Remove the 2 cylinder head straight pins from the cylinder block. A037182E01 (c) Remove the 2 oil pan straight pins from the cylinder block. EM A084196E01 (d) Remove the 2 end plate straight pins from the cylinder block. 49. REMOVE TIGHT PLUG A084197E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–135 INSPECTION 1. INSPECT CYLINDER BLOCK FOR FLATNESS (See page EM-61) 2. INSPECT CYLINDER BORE (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. (b) Calculate the average of the thrust diameter and axial diameter at position A in the illustration. (c) Calculate the average of thrust diameter and axial diameter at position B in the illustration. Standard diameter: 75.000 to 75.013 mm (2.9528 to 2.9533 in.) Maximum diameter: 75.133 mm (2.9580 in.) If either of the 2 average values is greater than the maximum, replace the cylinder block. Thrust Direction Axial Direction Front A B 10 mm (0.39 in.) Center A091907E02 3. INSPECT PISTON WITH PIN (a) Using a micrometer, measure the diameter of the piston. Align the micrometer so it is 37 mm (1.46 in.) from the top of the piston and at a right angle (90°) to the piston pin holes. Standard piston diameter: 74.941 to 74.979 mm (2.9504 to 2.9519 in.) 37 mm A084180E02 (b) Using a caliper gauge, measure the piston pin hole diameter of the piston. Standard piston pin hole diameter: 18.013 to 18.016 mm (0.7092 to 0.7093 in.) at 20°C (68°F) A084198E01 EM EM–136 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (c) Using a micrometer, measure the piston pin diameter. Standard piston pin diameter: 18.001 to 18.004 mm (0.7087 to 0.7088 in.) NOTICE: Do not change the combination of the piston and piston pin so that they can be returned to their original locations when reassembling. (d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance: 0.009 to 0.015 mm (0.0004 to 0.0006 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the clearance is greater than the maximum, replace the bush. If necessary, replace both the piston and piston pin together. EM00227E01 EM 4. INSPECT PISTON CLEARANCE (a) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.045 to 0.068 mm (0.0018 to 0.0027 in.) Maximum oil clearance: 0.08 mm (0.0032 in.) If the oil clearance is greater than the maximum, replace all 4 pistons. If necessary, replace the cylinder block. 5. INSPECT CONNECTING ROD (a) Using a caliper gauge, measure the internal diameter of the connecting rod. Standard connecting rod inside diameter: 17.965 to 17.985 mm (0.7073 to 0.7081 in.) If the diameter is not within the range of the standard inside diameter, replace the connecting rod. A001185E01 (b) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the misalignment is greater than the maximum, replace the connecting rod assembly. Z000064E01 EM–137 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (2) Check for twist. Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z000065E01 6. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove. Standard ring groove clearance Item Specified Condition No. 1 ring 0.02 to 0.04 mm (0.0008 to 0.0016 in.) No. 2 ring 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil ring 0.02 to 0.06 mm (0.0008 to 0.0024 in.) A084181E01 If the clearance is not as specified, replace the piston. 7. INSPECT PISTON RING END GAP (a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. 110 mm A037354E03 (b) Using a feeler gauge, measure the end gap. Standard end gap Item Standard Maximum No. 1 ring 0.20 to 0.30 mm (0.0079 to 0.0118 in.) 0.61 mm (0.0240 in.) No. 2 ring 0.30 to 0.45 mm (0.0118 to 0.0177 in.) 1.20 mm (0.0472 in.) Oil ring 0.10 to 0.40 mm (0.0039 to 0.0158 in.) 1.15 mm (0.0453 in.) If the end gap is greater than the maximum, replace the piston ring and oil ring. EM07639E01 EM EM–138 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 8. INSPECT CONNECTING ROD BOLT (a) Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 6.6 to 6.7 mm (0.260 to 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than the minimum, replace the bolt. 9. INSPECT CRANKSHAFT (a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the crankshaft. A001470E01 EM A011241E01 A037157E01 ZF06928E01 (b) Inspect the diameter. (1) Using a micrometer, measure the diameter of each main journal as illustrated. Standard diameter: 45.988 to 46.000 mm (1.8106 to 1.8110 in.) If the diameter is not as specified, replace the crankshaft. (2) Calculate the taper and distortion of the main journal. Maximum taper and distortion: 0.02 mm (0.0008 in.) If the taper and distortion are greater than the maximum, replace the crankshaft. (3) Using a micrometer, measure the diameter of each crank pin as illustrated. Standard diameter: 39.992 to 40.000 mm (1.5745 to 1.5748 in.) If the diameter is not as specified, replace the crankshaft. (4) Calculate the taper and distortion of the crank pin. Maximum taper and distortion: 0.02 mm (0.0008 in.) If the taper and distortion are greater than the maximum, replace the crankshaft. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT A038171E01 EM–139 (c) Wrap the chain around the timing sprocket as shown in the illustration. (d) Using a vernier caliper, measure the timing sprocket diameter with the chain wrapped. Standard sprocket diameter (w/ chain): 51.72 mm (2.0362 in.) Minimum sprocket diameter (w/ chain): 50.5 mm (1.988 in.) NOTICE: When measuring the diameter, the vernier caliper must be in contact with the chain roller. If the diameter is less than the minimum, replace the chain and crankshaft. 10. INSPECT CRANKSHAFT BEARING CAP SET BOLT (a) Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter: 7.2 mm (0.283 in.) If the diameter is less than the minimum, replace the bolt. A001194E01 EM EM–140 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT REPLACEMENT 1. REPLACE OIL PUMP SEAL HINT: There are 2 ways to replace the oil seal: remove it with the timing chain cover removed, or remove it with the timing chain cover installed. (a) If the timing chain cover is removed: (1) Using a screwdriver, remove the oil seal. HINT: Tape the screwdriver tip before use. Wooden Block EM A035281E06 SST Wooden Block A037153E02 Cut Position A050694E02 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09950-60010 (09951-00250, 0995100380, 09952-06010), 09950-70010 (09951-07100) NOTICE: • Be careful not to tap the oil seal at an angle. • Keep the lip free of foreign objects. (3) Apply multi-purpose grease to the lip of the oil seal. (b) If the timing chain cover is installed: (1) Using a knife, cut off the lip of the oil seal. (2) Using a screwdriver with the tip wrapped in tape, pry out the oil seal. NOTICE: After removal, check if the crankshaft is not damaged. If it is damaged, smooth the surface with 400-grit sandpaper. (3) Apply multi-purpose grease to the lip of a new oil seal. NOTICE: Keep the lip free of foreign objects. (4) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 NOTICE: • Be careful not to tap the oil seal at an angle. • Wipe any extra grease off the crankshaft. SST A066485E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 2. Cut Position EM–141 REPLACE ENGINE REAR OIL SEAL (a) Using a knife, cut off the lip of the oil seal. (b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal. NOTICE: After removal, check if the crankshaft is damaged. If it is damaged, smooth the surface with 400-grit sandpaper. A088160E02 (c) Apply multi-purpose grease to the lip of a new oil seal. NOTICE: Keep the lip free of foreign materials. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 NOTICE: • Be careful not to tap the oil seal at an angle. • Wipe any extra grease off the crankshaft. SST A088161E01 REASSEMBLY Adhesive 1. INSTALL CYLINDER BLOCK WATER DRAIN COCK (a) Apply adhesive to 2 or 3 threads of the drain cock, and install it within 3 minutes. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent A054747E04 40q 40q A098338E01 (b) Tighten the drain cock to the specified torque. Then rotate the drain cock clockwise until its drain port faces downward. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) NOTICE: • Install the water drain cock within 3 minutes of applying adhesive. • Do not add coolant for at least 1 hour after installation. • Do not rotate the drain cock more than 360° in this step, and never loosen it after setting the drain cock correctly. • The pipe of the drain cock should be within 40° of the vertical position. EM EM–142 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 2. Adhesive INSTALL TIGHT PLUG (a) Apply adhesive to new tight plugs. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent A058129E03 EM (b) Using SST, tap in the tight plugs as shown in the illustration. SST 09950-60010 (09951-00180), 09950-70010 (09951-07100) Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 in.) SST A037185E01 0.2 to 1.2 mm A080981E02 3. 8 mm 20 mm 11.5 to 12.5 mm A091911E02 INSTALL STRAIGHT PIN (a) Using a plastic-faced hammer, tap in a new end plate straight pin. Standard protrusion: 11.5 to 12.5 mm (0.453 to 0.492 in.) HINT: • Pin height: 20 mm (0.787 in.) • Pin diameter: 8 mm (0.315 in.) 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–143 (b) Using a plastic-faced hammer, tap in a new oil pan straight pin. Standard protrusion: 8.5 to 9.5 mm (0.335 to 0.374 in.) HINT: • Pin height: 18 mm (0.709 in.) • Pin diameter: 8 mm (0.315 in.) 8 mm 8.5 to 9.5 mm 18 mm EM A091912E02 (c) Using a plastic-faced hemmer, tap in a new cylinder head straight pin. Standard protrusion: 8.5 to 9.5 mm (0.335 to 0.374 in.) HINT: • Pin height: 18 mm (0.709 in.) • Pin diameter: 8 mm (0.315 in.) 8 mm 8.5 to 9.5 mm 18 mm A091913E02 (d) Using a plastic-faced hammer, tap in a new chain tensioner straight pin. Standard protrusion: 18.5 to 19.5 mm (0.728 to 0.768 in.) HINT: • Pin height: 36 mm (1.417 in.) • Pin diameter: 10 mm (0.394 in.) 10 mm 36 mm 18.5 to 19.5 mm A091914E02 EM–144 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 8 mm 3.5 to 4.5 mm 8 mm EM 4. INSTALL RING PIN (a) Using a plastic-faced hammer, tap in a new oil pump ring pin. Standard protrusion: 3.5 to 4.5 mm (0.134 to 0.177 in.) HINT: • Pin height: 8 mm (0.315 in.) • Pin diameter: 8 mm (0.315 in.) 5. INSTALL STUD BOLT (a) Using an E5 "torx" socket, install the 6 stud bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A091915E02 B C 15.5 mm (0.61 in.) 32.5 mm (1.28 in) A A (M6) 15 mm (0.61 in.) 8.5 mm (0.33 in) B (M6) 9 mm (0.35 in.) 18 mm (0.70 in.) 8 mm (0.31 in.) C (M6) 47 mm (1.85 in.) 12 mm (0.47 in.) A037223E03 NOTICE: Make sure that the bottom of the stud bolt contacts the cylinder block, as shown in the illustration. (b) Install the stud bolt for the knock sensor to the cylinder block. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) A088908E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–145 6. INSTALL OIL JET (a) Align the concave of the cylinder block with the bracket of the oil jet, then tap in the oil jet (the service part). NOTICE: Do not tap the tip of the oil jet. 7. INSTALL CRANKSHAFT (a) Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap. NOTICE: Do not apply engine oil to the contact surface of the cylinder block or the backside of the bearing. HINT: Mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap. Standard clearance: A - B = within 0.8 mm (0.032 in.) Align A091917E01 Upper Bearing Oil Groove Lower Bearing Block Side Cap Side A A B B Mass Production Part Claw Service Part A091909E02 (b) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward. (c) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block. Oil Groove A001191E04 EM EM–146 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (d) Check the front marks and numbers and install the bearing caps onto the cylinder block. (e) Apply a light coat of engine oil to the threads of the bearing cap bolts. Front Mark and Number Front Mark Number No. 3 No. 1, 2, 4, 5 A050917E02 (f) 7 3 1 5 9 8 4 2 6 10 EM Using SST, tighten the bolts in several steps by the specified torque in the sequence shown in the illustration. SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) NOTICE: Check that the crankshaft turns smoothly. A084171E05 (g) Mark the front of the bearing cap bolts with paint. (h) Retighten the bearing cap bolts by 90° in the same sequence. (i) Check that the painted mark is now at a 90° angle to the front. Painted Mark 90° Engine Front A050671E04 8. Front Mark INSTALL PISTON PIN (a) Apply engine oil to the piston pin and the inside surface of the connecting rod. (b) Align the front marks of the piston and connecting rod. A091919E01 (c) Using SST, push in the piston pin. SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150) NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembling. SST SST SST A037366E01 EM–147 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (d) Check the piston pin position. Specified clearance: A - B = -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) B A A089103E02 9. Claw INSTALL CONNECTING ROD BEARING (a) Align the bearing claw with the grooves of the connecting rod and connecting rod cap. NOTICE: Do not apply engine oil to the contact surface of the connecting rod and connecting rod cap and the backside of the bearing. A050672E01 10. INSTALL PISTON RING SET HINT: If reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly. A084172E01 Cord Mark Upward Gap (a) Install the 2 compression rings and oil ring. Code mark Part Paint Color Code Mark No. 1 compression ring Red 1R No. 2 compression ring Blue 2R Oil ring - - Paint Mark A091920E01 (b) Position the piston rings so that the ring ends are as shown in the illustration. No. 1 Compression Ring Oil Ring Front Front Mark No. 2 Compression Ring A091921E02 11. INSTALL PISTON WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, pistons, and the surfaces of the connecting rod bearings. (b) Check the position of the piston ring ends. EM EM–148 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT Front Mark Piston Ring Compressor A091922E02 (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston facing forward. NOTICE: • Do not apply engine oil to the contact surface of the connecting rod cap and the backside of the bearing. • Match the numbered connecting rod cap with the correct connecting rod. (d) Match the connecting rod and cap together in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented. (e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. Front Mark EM A091905E01 (f) SST Using SST, tighten the bolts in several steps by the specified torque. SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A084167E01 90° Painted Mark Engine Front A050671E04 (g) Mark the front of the connecting cap bolts with paint. (h) Retighten the cap bolts by 90° as shown. (i) Check that the crankshaft turns smoothly. EM–149 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 12. INSTALL OIL PAN (a) Using an E5 "torx" socket, install the 4 stud bolts. B 13 mm (0.51 in.) A 22.5 mm (0.89 in.) 16.5 mm (0.65 in.) 27.5 mm (1.08 in.) Stud Bolt A (M6) Stud Bolt B 8 mm (M6) (0.31 in.) 9 mm (0.31 in.) A050686E02 Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 9 mm (0.35 in.) 11 mm (0.43 in.) Seal Packing Seal Packing 4 mm (0.16 in.) 4 mm (0.16 in.) (b) Apply a continuous line of seal packing to the oil pan mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying seal packing. • Do not expose the seal to engine oil for at least 2 hours after installation. A120012E01 (c) Install 2 new O-rings onto the cylinder block. A088897E01 EM EM–150 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 3 15 4 5 6 7 14 2 8 1 9 10 13 12 11 A037067E02 (d) Using several steps, install and uniformly tighten the 13 bolts in the sequence shown in the illustration. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) HINT: Each bolt length is as follows: 49 mm (1.93 in.) for bolt A 88 mm (3.47 in.) for bolt B 144 mm (5.67 in.) for bolt C 13. INSTALL ENGINE REAR OIL SEAL (See page EM140) 14. INSTALL OIL STRAINER (a) Install a new gasket and the oil strainer with the 2 nuts and bolt. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) EM A084113E01 Seal Diameter: 2.5 to 3.5 mm A081876E03 15. INSTALL NO. 2 OIL PAN (a) Apply a continuous line of seal packing to the oil pan mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 2.5 to 3.5 mm (0.098 to 0.14 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying seal packing. • Do not expose the seal to engine oil for at least 2 hours after installation. • Do not start the engine within 2 hours of installation. (b) Install the No. 2 oil pan with the 9 bolts and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install the drain plug with a new gasket. Torque: 37.5 N*m (382 kgf*cm, 28 ft.*lbf) A088893E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–151 16. INSTALL OIL FILTER UNION (a) Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) A088892E02 17. INSTALL OIL FILTER (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. (c) Lightly screw the oil filter into place, and tighten it until the gasket comes into contact with the seat. (d) Using SST, tighten it an additional 3/4 turn. SST 09228-06501 If using a torque wrench, tighten to the specified torque. Torque: 17.5 N*m (178 kgf*cm, 13 ft.*lbf) SST A088870E01 Lot No. A092832E02 18. INSTALL CYLINDER HEAD GASKET (a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward. NOTICE: • Remove any oil from the contact surface. • Pay attention to the mounting orientation of the cylinder head gasket. • Place the cylinder head on the cylinder block gently in order not to damage the gasket at the bottom part of the head. 19. INSTALL CYLINDER HEAD HINT: The cylinder head bolts are tightened in 2 successive steps. Cylinder Head Diameter: 4.5 to 5.5 mm Cylinder Head Gasket Cylinder Block Seal Packing A073748E02 (a) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 3.5 to 4.5 mm (0.177 to 0.217 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying seal packing. (b) Apply a light coat of engine oil to the threads of the cylinder head bolts. EM EM–152 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 8 4 2 5 10 6 1 3 (c) Using several steps, install and uniformly tighten the 10 cylinder head bolts and plate washers with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 9 7 A035286E03 90° EM (d) Mark the front of the cylinder head bolt with paint. (e) Retighten the cylinder head bolts by an additional 90° and then another 90°, as shown in the illustration. (f) Check that the painted mark is now at a 180° angle to the front. 90° Front Paint Mark A092833E01 Straight Pin Groove A080974E04 20. INSTALL CAMSHAFT TIMING GEAR (a) Put the camshaft timing gear and camshaft together so that the straight pin and key groove are offset, as shown in the illustration. (b) Turn the camshaft timing gear assembly clockwise while pushing it lightly towards the camshaft. Push further at the position where the pin fits into the groove. NOTICE: Be careful not to turn the camshaft timing gear to the retard angle (to the right). (c) Check that there is no clearance between the gear fringe and the camshaft. (d) Tighten the flange bolt with the camshaft timing gear fixed in place. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) (e) Check that the camshaft timing gear can move to the retard angle (to the right) and is locked in the most retarded position. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 40q Timing Mark EM–153 21. INSTALL CAMSHAFT (a) Turn the crankshaft by 40° counterclockwise from TDC/compression. A092826E01 3 1 2 4 A037103E03 (b) Apply a light coat of engine oil to the camshaft journals. (c) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (d) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. 22. INSTALL CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vise. (b) Align the knock pin hole of the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: Be careful not to damage the camshaft. A032167E01 5 3 1 2 4 No. 1 Bearing Cap A092834E02 23. INSTALL NO. 2 CAMSHAFT (a) Apply a light coat of engine oil to the camshaft journals. (b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (c) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. (d) Install the No. 1 bearing cap. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 24. INSTALL CHAIN (See page EM-35) 25. INSTALL OIL PUMP SEAL (See page EM-138) EM EM–154 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 26. INSTALL TIMING CHAIN COVER (a) Remove any old packing material from the contact surface. (b) Install 2 new O-rings onto the 2 locations as shown in the illustration. (c) Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration below. A088881E01 Seal Packing Seal Packing EM B B A A C Seal Packing C Seal Packing (Water Pump Part) Diameter: A-A 1.5 to 2.0 mm (0.059 to 0.078 in.) 2.5 mm (0.098 in.) B - B, C - C (After Assembling) 2.5 mm (0.098 in.) or more 5.0 mm (0.197 in.) B - B, C - C 1.5 mm (0.059 in.) 2.5 mm (0.098 in.) Other Part Seal Diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) Diameter: 1.5 to 2.0 mm (0.059 to 0.078 in.) 3.5 to 4.5 mm Water Pump Part Seal Diameter: (0.138 to 0.177 in.) 3.5 to 4.5 mm (0.138 to 0.177 in.) 1.0 mm (0.039 in.) 1.0 mm (0.039 in.) 1.5 to 2.0 mm (0.059 to 0.078 in.) A117400E03 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–155 Seal packing: Water pump part: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the oil pump within 3 minutes of applying seal packing. • Do not expose the seal to engine oil for at least 2 hours after installation. • Do not start the engine for at least 2 hours after installation. (d) Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft, and slide the oil pump into place. A035284E01 D E A A C C C B C A037150E01 (e) Install the oil pump assembly with the 15 bolts and nut. Uniformly tighten the bolts and nut in several steps. Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for bolt A 11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt B 11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt C 24 N*m (245 kgf*cm, 18 ft.*lbf) for nut D 24 N*m (245 kgf*cm, 18 ft.*lbf) for bolt E NOTICE: • Be careful not to disturb the seal packing. • After installing the timing chain case, install the mounting bracket and water pump within 15 minutes. HINT: Each bolt length is as follows: 30 mm (1.18 in.) for bolt A 35 mm (1.38 in.) for bolt B 20 mm (0.79 in.) for bolt C 20 to 14 mm (0.79 to 0.55 in.) for bolt E EM E M – 1 5 6 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT A088879E01 27. INSTALL CRANKSHAFT PULLEY (a) Install the crankshaft straight pin to the crankshaft. (b) Align the hole of the crankshaft pulley with the straight pin, then install the crankshaft pulley. (c) Using SST, hold the crankshaft pulley and tighten the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 Torque: 128 N*m (1,305 kgf*cm, 95 ft.*lbf) NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. 28. INSTALL WATER PUMP (a) Install a new gasket and the water pump with the 3 bolts and 2 nuts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) EM A088890E01 29. INSTALL ENGINE MOUNTING BRACKET RH (a) Install the engine mounting bracket RH with the 4 bolts. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 30. INSPECT VALVE CLEARANCE (See page EM-7) 31. ADJUST VALVE CLEARANCE (See page EM-9) A088876 32. INSTALL FUEL INJECTOR (a) Install new insulators onto each fuel injector. (b) Apply a light coat of spindle oil or gasoline to new Orings and install them onto each fuel injector. (c) Apply a light coat of spindle oil or gasoline to the place where a delivery pipe comes into contact with the O-ring. Insulator O-Ring A050145E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT Connector Turn EM–157 (d) While turning the injector clockwise and counterclockwise, install it to the delivery pipe. NOTICE: • Be careful not to twist the O-ring. • After installing the fuel injectors, check that they turn smoothly. If not, reinstall it with a new O-ring. Push 33. INSTALL FUEL DELIVERY PIPE (a) Install the 2 spacers onto the cylinder head. A050146E01 (b) Install the fuel delivery pipe and 4 fuel injectors together. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt B NOTICE: • Be careful not to drop the fuel injectors when installing the fuel delivery pipe. • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe. A B A089809E02 Seal Packing 11 9 A050172E01 7 5 10 1 8 3 2 6 4 A035756E02 34. INSTALL CYLINDER HEAD COVER (a) Install the gasket onto the cylinder head cover. (b) Apply seal packing to the 2 locations shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the cylinder head cover within 3 minutes of applying seal packing. • Do not start the engine for at least 2 hours after installation. (c) Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts. (d) Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) EM EM–158 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 35. INSTALL VENTILATION VALVE (a) Install the ventilation valve onto the cylinder head cover. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 36. INSTALL OIL FILLER CAP (a) Install a new gasket and the oil filler cap. A080963E02 EM SST 37. INSTALL WATER PUMP PULLEY (a) Temporarily install the water pump pulley with the 3 bolts. (b) Using SST, tighten the 3 bolts. SST 09960-10010 (09962-01000, 09963-00600) Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A086914E01 38. INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring on the sensor. NOTICE: If the O-ring is damaged, replace the sensor. (b) Install the sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) A088874E02 39. INSTALL THERMOSTAT (a) Install a new gasket onto the thermostat. (b) Install the thermostat with the jiggle valve facing upward. HINT: The jiggle valve may be set within 10° on either side as shown in the illustration. 10° 10° Jiggle Valve A092977E01 (c) Install the water inlet with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088871E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–159 40. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Apply a light coat of engine oil to a new O-ring, and install it onto the oil control valve. (b) Install the oil control valve with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Be careful not to twist the O-ring. A088869E02 41. INSTALL CAMSHAFT POSITION SENSOR (a) Apply engine oil to the O-ring. NOTICE: If the O-ring is damaged, replace the sensor. (b) Install the sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A088868E02 42. INSTALL SPARK PLUG (a) Using a 16 mm plug wrench, install the 4 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) EM