ENGINE MECHANICAL AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO/HC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . EM–1 EM–2 EM–4 EM–5 IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . EM–12 EM–13 EM–14 EM–28 CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . EM–51 EM–1 ENGINE MECHANICAL – AIR FILTER AIR FILTER Out Side EM0HP–04 INSPECTION Inside A14321 1AZ–FSE ENGINE (RM783E) 1. REMOVE AIR FILTER 2. INSPECT AIR FILTER Visually check that the filter is not excessively dirty, oily or damaged. 3. CLEAN AIR FILTER Clean the filter element with compressed air. First blow from the inside thoroughly. Then blow off the out side of the filter element. 4. REINSTALL AIR FILTER EM–2 ENGINE MECHANICAL – CO/HC CO/HC EM19V–04 INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with specifications. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected (f) EFI system wiring connectors fully plugged (g) Ignition timing check correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS CO/HC Meter A02622 1AZ–FSE ENGINE (RM783E) 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. CHECK CO/HC CONCENTRATION AT IDLE Idle CO concentration: 0 – 0.5 % Idle HC concentration: Applicable local regulation If the CO/HC concentration does not conform to specifications, perform troubleshooting in the order given below. (1) Check the oxygen sensor operation (See page FI–51). (2) See the table next page for possible causes, and then inspect and correct the applicable causes if necessary. EM–3 ENGINE MECHANICAL CO HC – CO/HC Problems Causes Normal High Rough idle 2. Faulty ignitions: S Incorrect timing S Fouled, shorted or improperly gapped plugs 3. Incorrect valve clearance 4. Leaky intake and exhaust valves 5. Leaky cylinders Low High Rough idle (Fluctuating HC reading) 1. Vacuum leaks: S PCV hoses S Intake manifold S Intake air control valve S Throttle body S Brake booster line 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty EFI system: S Faulty fuel pressure release valve S Faulty fuel pressure sensor S Faulty water temperature sensor S Faulty engine ECU S Faulty injectors S Faulty accelerator pedal position sensor S Faulty vacuum sensor 1AZ–FSE ENGINE (RM783E) EM–4 ENGINE MECHANICAL – COMPRESSION COMPRESSION EM19W–03 INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE IGNITION COILS (See page IG–5) 3. REMOVE SPARK PLUGS Compression Gauge A14226 1AZ–FSE ENGINE (RM783E) 4. (a) (b) (c) INSPECT CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,470 kPa (15.0 kgf/cm2, 213 psi) Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less (e) If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. S If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. S If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage through the gasket. 5. REINSTALL SPARK PLUGS 6. REINSTALL IGNITION COILS (See page IG–5) EM–5 ENGINE MECHANICAL – VALVE CLEARANCE VALVE CLEARANCE EM1JT–01 ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE FUEL PUMP (HIGH PRESSURE) (See page FI–13) 2. REMOVE IGNITION COILS 3. DISCONNECT NO. 1 PCV HOSE FROM PCV VALVE 4. REMOVE VSV FOR INTAKE AIR CONTROL VALVE Remove the bolt and VSV. 5. REMOVE CYLINDER HEAD COVER (See page EM–15) 6. (a) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover. A13901 (b) Timing Marks Timing Marks Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. A13902 1 1 1 1 7. (a) 2 2 3 3 1AZ–FSE ENGINE (RM783E) A14188 INSPECT VALVE CLEARANCE Check only the valves indicated. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. EM–6 ENGINE MECHANICAL – VALVE CLEARANCE (2) Record the out–of–specification valve clearance measurements. They will be used later to determine the required replacement adjusting valve lifter. Valve clearance (Cold): 3 3 Turn the crankshaft 1 revolution (360°) and align the mark as above (See step 2). (c) Check only the valves indicated as shown. Measure the valve clearance (See step (a)). 8. (a) ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the TDC/compression (See step 2). Place matchmarks on the timing chain, VVT timing sprocket and camshaft timing sprocket. Remove the 2 nuts, gasket and chain tensioner. A14187 (b) (c) Matchmarks 0.19 – 0.29 mm (0.007 – 0.011 in.) 0.30 – 0.40 mm (0.012 – 0.016 in.) (b) 4 4 4 4 2 2 Intake Exhaust A13690 (d) Hold the hexagonal head portion of the camshaft with a wrench, and loosen the camshaft timing sprocket set bolt. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. A14263 (e) (f) 1 2 5 9 7 3 6 10 8 4 1AZ–FSE ENGINE (RM783E) A14189 Uniformly loosen and remove the 10 camshaft bearing cap bolts in several passes and in the sequence shown. Remove the 5 camshaft bearing caps. EM–7 ENGINE MECHANICAL (g) (h) (i) – VALVE CLEARANCE Raising the camshaft, remove the camshaft timing sprocket set bolt. Disconnect the camshaft timing sprocket with the timing chain from the exhust camshaft. Remove the camshaft timing sprocket from the timing chain. A14227 1 (j) 5 9 7 3 (k) (l) 2 6 10 8 Uniformly loosen and remove the 10 camshaft bearing cap bolts in several passes and in the sequence shown. Remove the 5 camshaft bearing caps. Remove the intake camshaft with the VVT timing sprocket. 4 A14190 (m) Tie the timing chain as shown in the illustration. NOTICE: S Be careful not to drop anything inside the timing chain cover. S Do not allow the chain to come into contact with water or dust. (n) Remove the valve lifter. Valve Lifter A13693 (o) A01082 Determine the replacement valve lifter size according to these Formula or Charts: S Using a micrometer, measure the thickness of the removed valve lifter. S Calculate the thickness of a new valve lifter so the valve clearance comes within the specified value. T .......... Thickness of used valve lifter A ......... Measured valve clearance N ......... Thickness of new valve lifter Intake N = T + (A – 0.24 mm (0.009 in.)) Exhaust N = T + (A – 0.35 mm (0.014 in.)) S Select a new valve lifter with a thickness as close as possible to the calculated values. HINT: S 1AZ–FSE ENGINE (RM783E) Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). EM–8 ENGINE MECHANICAL S – VALVE CLEARANCE (p) Identification number inside the valve lifter shows the value of the two decimal places. (The illustration shows 5.380 mm (0.2118 in.).) Apply a light coat engine oil to new valve lifters. (q) Reinstall the valve lifters. A08425 Valve Lifter A13693 (r) A13696 7 3 1 5 9 4 2 6 10 A 8 A14190 1AZ–FSE ENGINE (RM783E) Align the crankshaft pulley groove with the timing mark 0 of the timing chain cover. (s) Hold the timing chain. (t) Align the matchmarks on the timing chain and VVT timing sprocket, and place the intake camshaft on the cylinder head. (u) Apply a light coat engine oil on the threads and under the camshaft bearing cap bolts. (v) Install the 5 intake camshaft bearing caps in their proper locations (See page EM–47). (w) Uniformly tighten the 10 bearing cap bolts in several passes and in the sequence shown. Torque: 29.5 N·m (300 kgf·cm, 22 ft·lbf) for bolt A 9 N·m (90 kgf·cm, 80 in.·lbf) for others (x) Align the matchmarks on the timing chain and camshaft timing sprocket, and install them. (y) Temporarily install the camshaft timing sprocket with timing chain to the exhaust camshaft with the bolt. (z) Place the exhaust camshaft on the cylinder head. (aa) Apply a light coat engine oil on the threads and under the camshaft bearing cap bolts. (ab) Install the 5 exhaust camshaft bearing caps in their proper locations (See page EM–47). EM–9 ENGINE MECHANICAL 7 3 1 5 9 4 2 6 10 – VALVE CLEARANCE (ac) Uniformly tighten the 10 bearing cap bolts in several passes and in the sequence shown. Torque: 29.5 N·m (300 kgf·cm, 22 ft·lbf) for bolt A 9 N·m (90 kgf·cm, 80 in.·lbf) for others A 8 A14189 (ad) Hold the hexagon head portion of the exhaust camshaft with a wrench, and tighten the bolt. Torque: 54 N·m (550 kgf·cm, 40 ft·lbf) A14263 Matchmarks A13690 1AZ–FSE ENGINE (RM783E) (ae) Check each sprocket aligns with the matchmarks as shown in the illustration. (af) Install the chain tensioner (See page EM–20). (ag) Recheck the valve clearance (See step 7). (ah) Check the valve timing (See page EM–20). 9. REINSTALL CYLINDER HEAD COVER (See page EM–20) 10. REINSTALL VSV FOR INTAKE AIR CONTROL VALVE Install the VSV with the bolt. 11. RECONNECT NO. 1 PCV HOSE 12. REINSTALL IGNITION COILS 13. REINSTALL FUEL PUMP (HIGH PRESSURE) (See page FI–14) 1AZ–FSE ENGINE (RM783E) 5.300 (0.2087) 5.320 (0.2094) 5.380 (0.2118) 5.400 (0.2126) 5.420 (0.2134) 5.440 (0.2142) 30 32 34 36 38 40 42 44 Thickness 5.060 (0.1992) 5.080 (0.2000) 5.100 (0.2008) 5.120 (0.2016) 5.140 (0.2024) 5.160 (0.2031) 5.180 (0.2039) 5.200 (0.2047) 06 08 10 12 14 16 18 20 28 5.280 (0.2079) 52 5.520 (0.2173) 5.500 (0.2165) 50 5.260 (0.2071) 26 5.480 (0.2157) 48 5.240 (0.2063) 24 5.460 (0.2150) 5.220 (0.2055) 22 46 5.360 (0.2110) 5.340 (0.2102) Thickness Lifter No. 74 72 70 68 66 64 62 60 58 56 54 Lifter No. 5.740 (0.2260) 5.720 (0.2252) 5.700 (0.2244) 5.680 (0.2236) 5.660 (0.2228) 5.640 (0.2220) 5.620 (0.2213) 5.600 (0.2205) 5.580 (0.2197) 5.560 (0.2189) 5.540 (0.2181) Thickness mm (in.) – Lifter No. New Valve Lifter Thickness ENGINE MECHANICAL Intake valve clearance (Cold): 0.19 – 0.29 mm (0.007 – 0.011 in.) EXAMPLE: The 5.250 mm (0.2067 in.) valve lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) valve lifter with a new No. 42 valve lifter. Valve Lifter Selection Chart (Intake) EM–10 VALVE CLEARANCE A13314 1AZ–FSE ENGINE (RM783E) 70 5.700 (0.2244) 72 5.720 (0.2252) 36 5.360 (0.2110) 38 5.380 (0.2118) 40 5.400 (0.2126) 42 5.420 (0.2134) 44 5.440 (0.2142) 46 5.460 (0.2150) 48 5.480 (0.2157) 50 5.500 (0.2165) 52 5.520 (0.2173) 5.120 (0.2016) 5.140 (0.2024) 5.160 (0.2031) 5.180 (0.2039) 5.200 (0.2047) 5.220 (0.2055) 5.240 (0.2063) 5.260 (0.2071) 5.280 (0.2079) 12 14 16 18 20 22 24 26 28 68 5.680 (0.2236) 34 5.340 (0.2102) 5.100 (0.2008) 10 5.660 (0.2228) 74 5.740 (0.2260) 66 64 5.640 (0.2220) 62 5.620 (0.2213) 60 5.600 (0.2205) 58 5.580 (0.2197) 56 5.560 (0.2189) Thickness 32 5.320 (0.2094) No. Lifter 5.080 (0.2000) 08 Thickness 54 5.540 (0.2181) 5.060 (0.1992) 06 No. Lifter 30 5.300 (0.2087) Thickness No. Lifter New Valve Lifter Thickness mm (in.) – Exhaust valve clearance (Cold): 0.30 – 0.40 mm (0.012 – 0.016 in.) EXAMPLE: The 5.340 mm (0.2102 in.) valve lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) valve lifter with a new No. 42 lifter. Valve Lifter Selection Chart (Exhaust) ENGINE MECHANICAL VALVE CLEARANCE EM–11 A13315 EM–12 ENGINE MECHANICAL – IGNITION TIMING IGNITION TIMING EM1K2–01 INSPECTION 1. REMOVE NO. 1 ENGINE COVER 2. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 3. CHECK IDLE SPEED (See page EM–13) 4. CONNECT TIMING LIGHT Connect the tester clip of a timing light to the black service wire of the wire harness as shown in the illustration. NOTICE: After using the service wire, be sure to fix it with a vinyl tape. Black A14315 5. (a) TC INSPECT IGNITION TIMING Using SST, connect terminals to TC and CG of the DLC3. SST 09843–18040 HINT: After engine rpm is kept at 900 – 1,500 rpm for 5 seconds, check that it returns to idle speed. SST DLC3 CG A14196 (b) (c) 6. A14197 1AZ–FSE ENGINE (RM783E) Using a timing light, check the ignition timing. Ignition timing: 8 – 12° BTDC @ idle Remove the SST from the DLC3. FURTHER CHECK IGNITION TIMING Ignition timing: 5 – 23° BTDC @ idle HINT: The timing mark moves in a range between 5° and 23°. 7. DISCONNECT TIMING LIGHT 8. REINSTALL NO. 1 ENGINE COVER EM–13 ENGINE MECHANICAL – IDLE SPEED IDLE SPEED EM1JS–01 INSPECTION Hand–held Tester 1. (a) (b) (c) (d) (e) (f) (g) (h) (i) INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All vacuum lines properly connected EFI system wiring connectors fully plugged All operating accessories switched OFF Ignition timing check correctly Transmission in neutral position Air conditioner switched OFF 2. (a) (b) CONNECT HAND–HELD TESTER Connect the hand–held tester to the DLC3. Please refer to the hand–held tester operator’s for further details. DLC3 A14194 Tachometer TAC DLC3 SST 1AZ–FSE ENGINE (RM783E) Battery A14195 If you do not have hand–held tester, connect a tachometer tester probe to terminal TAC of the DLC3 with SST. SST 09843–18030 3. INSPECT IDLE SPEED (a) Race the engine at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed (w/ Cooling fan OFF): 675 ± 50 rpm If the idle speed is not as specified, check the throttle body and air intake system. 4. DISCONNECT HAND–HELD TESTER EM–14 ENGINE MECHANICAL – TIMING CHAIN TIMING CHAIN EM1A0–04 COMPONENTS 25 (255, 18) Fuel Pump z Insulator No. 1 PCV Hose VSV for Intake Air Control Valve Ignition Coil Timing Tensioner 11 (110, 8) z Gasket 21 (215, 15) 9 (90, 80 in.·lbf) 14 (145, 10) Crankshaft Position Sensor 9 (90, 80 in.·lbf) Drive Belt Tensioner 11 (110, 8) x5 43 (440, 32) 59.5 (610, 44) *1 *2 Cylinder Head Cover *3 59.5 (610, 44) x8 21 (220,15) z O–Ring 9 (90, 80 in.·lbf) Crankshaft Timing Chain Cover Front Oil Seal VVT Timing Sprocket Crankshaft Pulley 54 (550, 40) Gasket 170 (1,735, 125) Chain Tensioner Timing Chain Slipper Camshaft Timing Sprocket 54 (550, 40) Timing Chain Guide 19 (195, 14) Alternator 9 (90, 80 in.·lbf) *1: 43 (440, 32) *2: 9 (90, 80 in.·lbf) *3: 9.5 (100, 7) Crankshaft Timing Sprocket Chain Vibration Damper x4 9 (90, 80 in.·lbf) Oil Pan Crank Angle Sensor Plate Oil Pan N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1AZ–FSE ENGINE (RM783E) 52 (530, 38) 9 (90, 80 in.·lbf) x 12 21 (215, 15) 9 (90, 80 in.·lbf) A14318 EM–15 ENGINE MECHANICAL – TIMING CHAIN EM1JU–01 REMOVAL 45° A14319 NOTICE: Under the condition with the timing chain cover removed, in case of rotating the camshafts, make the position of the crankshaft rotated clockwise by about 45° from TDC/comĆ pression of No. 1 cylinder. 1. DRAIN ENGINE OIL 2. REMOVE ALTERNATOR Remove the 2 bolts and alternator. 3. REMOVE FUEL PUMP (HIGH PRESSURE) (See page FI–13) 4. REMOVE IGNITION COILS 5. DISCONNECT NO. 1 PCV HOSE FROM PCV VALVE 6. REMOVE VSV FOR INTAKE AIR CONTROL VALVE Remove the bolt and VSV. 7. REMOVE CYLINDER HEAD COVER Remove the 9 bolts, 2 nuts, cylinder head cover and gasket. A14260 8. (a) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. A13696 (b) Timing Marks Timing Marks A13902 1AZ–FSE ENGINE (RM783E) Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. EM–16 ENGINE MECHANICAL 9. (a) (b) – TIMING CHAIN REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213–54015, 09330–00021 Remove the crankshaft pulley. SST SST A13697 SST SST HINT: If necessary, remove the pulley with SST. SST 09950–40011 (09957–04010), 09950–50012 (09951–05010, 09952–05010, 09953–05020, 09954–05020) 10. REMOVE CRANKSHAFT POSITION SENSOR (See page IG–7) 11. REMOVE OIL PAN (See page LU–7) A14223 12. REMOVE CHAIN TENSIONER Remove the 2 nuts, chain tensioner and gasket. Push A14261 13. REMOVE DRIVE BELT TENSIONER Remove the bolt, nut and drive belt tensioner. A13759 A14221 14. (a) Trox Socket Wrench A14253 1AZ–FSE ENGINE (RM783E) REMOVE TIMING CHAIN COVER Using a trox socket wrench (E10), remove the stud bolt for the drive belt tensioner. EM–17 ENGINE MECHANICAL – TIMING CHAIN (b) (c) Remove the 14 bolts and 2nuts. Using a screwdriver, pry between the timing chain cover and cylinder head or cylinder block. (d) Remove the timing chain cover. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block. 15. REMOVE CRANK ANGLE SENSOR PLATE 16. REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and slipper. 17. REMOVE CHAIN VIBRATION DAMPER Remove the 2 bolts and damper. Pry A14271 18. REMOVE TIMING CHAIN GUIDE Remove the bolt and chain guide. 19. REMOVE TIMING CHAIN 20. REMOVE CRANKSHAFT TIMING SPROCKET A13769 21. A14264 1AZ–FSE ENGINE (RM783E) REMOVE CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET (a) Hold the hexagonal head wrench portion of the camshaft with a wrench, and loosen the sprocket set bolts. NOTICE: Be careful not to damage the cylinder head and valve lifter by a wrench. (b) Remove the bolt and camshaft timing sprocket. (c) Remove the bolt and VVT timing sprocket. NOTICE: Do not disassemble the VVT timing sprocket. EM–18 ENGINE MECHANICAL – TIMING CHAIN EM1A2–03 INSPECTION 1. (a) 122.6 mm 16 Links P04776 INSPECT TIMING CHAIN AND TIMING SPROCKETS Using vernier calipers, measure the length of the 16 links with the chain fully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) If the elongation is greater than maximum, replace the chain. HINT: Make the same pulling measurements at 3 or more places selected at random. (b) (c) Wrap the chain around the timing sprocket. Using vernier calipers, measure the timing sprocket diameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum sprocket diameter (w/ Chain): EM2378 Camshaft 97.3 mm (3.831 in.) Crankshaft 51.6 mm (2.031 in.) If the diameter is less than minimum, replace the chain and sprockets. 2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the slipper and/or damper. Wear A13770 3. (a) Raise Move Lock A13765 1AZ–FSE ENGINE (RM783E) INSPECT CHAIN TENSIONER 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. 4. INSPECT OIL JET (See page LU–9) 5. INSPECT DRIVE BELT TENSIONER Check the oil leakage and crack. If necessary, replace the drive belt tensioner. EM–19 ENGINE MECHANICAL – TIMING CHAIN EM1JV–01 REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the timing chain cover is removed from the cylinder head and block. (1) Using a screwdriver and a hammer, tap out the oil seal. A13766 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309–37010 (3) Apply MP grease to the oil seal lip. SST A13767 (b) SST If the timing chain cover is installed to the cylinder head and block. (1) Using SST, remove the oil seal. SST 09308–10010, 09950–40011 (09957–04010) SST A14273 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309–37010 SST A13737 1AZ–FSE ENGINE (RM783E) EM–20 ENGINE MECHANICAL – TIMING CHAIN EM1A4–02 INSTALLATION 1. (a) Timing Mark A14279 INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET Install the camshaft timing sprocket. (1) Face the timing mark of the sprocket outward. (2) Align the exhaust camshaft knock pin with the knock pin groove on the camshaft timing sprocket with the timing mark, and slide on the camshaft timing sprocket. (3) Temporary install the camshaft timing sprocket set bolt. (4) Hold the hexagon wrench head portion of the exhaust camshaft with a wrench, and tighten the bolt. Torque: 54 N·m (550 kgf·cm, 40 ft·lbf) A14265 (b) Timing Mark A14268 1AZ–FSE ENGINE (RM783E) Install the VVT timing sprocket. (1) Holding the VVT timing sprocket in the position where the VVT timing sprocket knock pin groove is slightly to right of the camshaft pin looking from the front side, install the VVT timing sprocket to the intake camshaft, lightly pressing and turning it counterclockwise. Check that there is virtually no clearance between the VVT timing sprocket and camshaft flange. NOTICE: Be careful not to turn the VVT timing sprocket clockwise when installing it. (2) Temporary install the VVT timing sprocket set bolt. EM–21 ENGINE MECHANICAL – TIMING CHAIN (3) Hold the hexagon wrench head portion of the intake camshaft with a wrench. (4) Taking care of the VVT timing sprocket, tighten the bolt. Torque: 54 N·m (550 kgf·cm, 40 ft·lbf) (5) After tighten the bolt, check that the VVT timing sprocket turns clockwise and that it is locked when the lock pin in hole at the locking point. A14266 2. (a) Timing Marks (b) Timing Marks SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the hexagonal wrench head portion of the intake camshaft, and align the timing marks of the VVT timing sprocket with the No. 1 bearing cap. Turn the hexagonal wrench head portion of the exhaust camshaft, and align the timing marks of the camshaft timing sprocket with the No. 2 bearing cap. A13726 Set Key (c) Upward Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. A14198 3. INSTALL CHAIN VIBRATION DAMPER Install the damper with the 2 bolts. Torque: 9 N·m (90 kgf·cm, 80 in.·lbf) 4. INSTALL CRANKSHAFT TIMING SPROCKET Align the sprocket set key with the key groove of the sprocket, and slide on the sprocket. A13728 Orange or Blue Mark Link Timing Mark A13730 1AZ–FSE ENGINE (RM783E) 5. (a) INSTALL TIMING CHAIN Install the timing chain on the crankshaft timing sprocket with the orange or blue mark link aligned with the timing mark on the crankshaft timing sprocket. EM–22 ENGINE MECHANICAL (b) Yellow or Golden Mark Link Timing Mark – TIMING CHAIN Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the yellow or golden mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket. A13732 6. INSTALL TIMING CHAIN GUIDE Install the timing chain guide with the bolt. Torque: 9 N·m (90 kgf·cm, 80 in.·lbf) A13729 7. (a) Hold (b) INSTALL CHAIN TENSIONER SLIPPER Install the slipper with the bolt. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Check that the slipper is held on the cylinder block stopper. A13733 A14199 1AZ–FSE ENGINE (RM783E) 8. INSTALL CRANK ANGLE SENSOR PLATE Install the plate with the F mark facing forward. 9. INSTALL TIMING CHAIN COVER (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, cylinder block and crank case. S Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. S Thoroughly clean all components to remove all the loose material. S Using a non–residue solvent, clean both sealing surfaces. EM–23 ENGINE MECHANICAL (b) FIPG FIPG – TIMING CHAIN Apply seal packing to the timing chain cover as shown in the illustration. Seal packing: Part No. 08826–00100 or equivalent S Install a nozzle that has been cut to a 3 – 4 mm (0.12 – 0.16 in.) opening. HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap. Seal Width 3 – 4 mm A13735 (c) Seal Width 2 mm Seal Packing 1AZ–FSE ENGINE (RM783E) A13736 Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent S Install a nozzle that has been cut to a 2 mm (0.08 in.) opening. HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap. EM–24 ENGINE MECHANICAL (d) Nut Nut D C C C C A B B B B B TIMING CHAIN Install the timing chain cover with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 9 N·m (90 kgf·cm, 80 in.·lbf) for bolt A 21 N·m (210 kgf·cm, 15 ft.·lbf) for bolt B 43 N·m (440 kgf·cm, 32 ft·lbf) for bolt C 43 N·m (440 kgf·cm, 32 ft·lbf) for bolt D 9 N·m (90 kgf·cm, 80 in.·lbf) for nut HINT: Bolt length: B B – Bolt A 30 mm (1.18 in.) length for 10 mm head Bolt B 30 mm (1.18 in.) length for 12 mm head Bolt C 40 mm (1.57 in.) length for 14 mm head Bolt D 65 mm (2.56 in.) length for 14 mm head B A14278 (e) Trox Socket Wrench Using a torx socket wrench (E10), install the stud bolt for the drive belt tensioner. Torque: 9.5 N·m (100 kgf·cm, 7 ft·lbf) A14253 A13759 A14221 10. INSTALL DRIVE BELT TENSIONER Install the drive belt tensioner with the bolt and nut. Torque: 59.5 N·m (610 kgf·cm, 44 ft·lbf) NOTICE: As the drive belt tensioner should be torqued together with the timing chain cover, so be sure install it within 15 minutes after the timing chain cover is installed. 11. INSTALL OIL PAN (See page LU–12) 12. INSTALL CRANKSHAFT POSITION SENSOR 13. (a) (b) SST SST (c) A13895 1AZ–FSE ENGINE (RM783E) INSTALL CRANKSHAFT PULLEY Clean the crankshaft pulley inside. Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST 09213–54015, 09330–00021 Torque: 170 N·m (1,735 kgf·cm, 125 ft·lbf) EM–25 ENGINE MECHANICAL Raise – TIMING CHAIN 14. (a) INSTALL CHAIN TENSIONER Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. (b) Place a new gasket on the timing chain cover with portion A facing as shown in the illustration. (c) Push the chain tensioner into the timing chain cover, and install the 2 nuts. Torque: 9 N·m (90 kgf·cm, 80 in.·lbf) 15. (a) SET CHAIN TENSION Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. (b) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. Push Hook Pin A13738 Portion A A14262 Push A14261 Hook Disconnect Turn Pin A14269 Plunger Push 1AZ–FSE ENGINE (RM783E) Turn A14270 EM–26 ENGINE MECHANICAL – TIMING CHAIN 16. (a) CHECK VALVE TIMING Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. NOTICE: Always turn the crankshaft clockwise. A13696 (b) Timing Marks Timing Marks Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. A13902 17. (a) (b) Seal Packing A14213 A A B B C A Nut 1AZ–FSE ENGINE (RM783E) A C A Nut A14260 INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent (c) Install the gasket to the cylinder head cover. If the gasket has damage, replace a new one. HINT: Part must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. (d) Install the cylinder head cover with the 9 bolts and 2 nuts. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) for 10 mm head bolt A 21 N·m (215 kgf·cm, 15 ft·lbf) for 12 mm head bolt B 14 N·m (145 kgf·cm, 10 ft·lbf) for 10 mm head bolt C 11 N·m (110 kgf·cm, 8 ft·lbf) for nut 18. INSTALL VSV FOR INTAKE AIR CONTROL VALVE Install the VSV with the bolt. 19. CONNECT NO. 1 PCV HOSE 20. INSTALL IGNITION COILS 21. INSTALL FUEL PUMP (HIGH PRESSURE) (See page FI–14) EM–27 ENGINE MECHANICAL – TIMING CHAIN 22. INSTALL ALTERNATOR Install the alternator with the 2 bolts. Torque: 52 N·m (530 kgf·cm, 38 ft·lbf) for bolt A 21 N·m (215 kgf·cm, 15 ft·lbf) for bolt B 23. FILL WITH ENGINE OIL (See page CO–1) A B A13988 1AZ–FSE ENGINE (RM783E) EM–28 ENGINE MECHANICAL – CYLINDER HEAD CYLINDER HEAD EM1K3–01 COMPONENTS No. 1 PCV Hose Washer 30 (305, 22) Washer 21 (215, 15) Fuel Hose Intake Manifold and Throttle Body Assembly 25 (255, 18) Fuel Pulsation Damper Throttle Bracket 32.5 (330, 24) Fuel Pump (High Pressure) 30 (305, 22) No. 1 Intake Manifold Insulator z Gasket z Insulator Intake Air Control Valve 9 (90, 80 in.·lbf) z Gasket 19 (195, 14) Delivery Pipe w/ Injector Ignition Coil z Gasket Spark Plug z Gasket 12.5 (125, 9) Nozzle Holder Clamp z Fuel Injector Seal 21 (215, 15) 12 (120, 9) Upper Heat Insulator 12 (120, 9) Air Intake Chamber Stay No. 2 Intake Manifold Insulator Camshaft Timing Oil Control Valve (OCV) x5 z Gasket Exhaust Manifold 37 (375, 27) 40 (410, 33) 9 (90, 80 in.·lbf) z O–Ring 40 (410, 33) Exhaust Manifold Stay Exhaust Manifold Stay 52 (530, 38) 12 (120, 9) 21 (215, 15) Alternator N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1AZ–FSE ENGINE (RM783E) No. 2 Lower Heat Insulator No. 1 Lower Heat Insulator A14320 EM–29 ENGINE MECHANICAL – CYLINDER HEAD Cylinder Head Cover 9 (90, 80 in.·lbf) 21 (215, 15) Chain Tensioner z Gasket 14 (145, 10) 9 (90, 80 in.·lbf) 11 (110, 8) Crankshaft Position Sensor 11 (110, 8) x5 Drive Belt Tensioner 43 (440, 32) 59.5 (610, 44) *1 *2 *3 Gasket 59.5 (610, 44) x8 9 (90, 80 in.·lbf) 21 (220, 15) z O–Ring Timing Chain Cover Crankshaft Pulley 170 (1,735, 125) VVT Timing Sprocket Camshaft Timing Sprocket 54 (550, 40) Chain Tensioner Slipper 54 (550, 40) Timing Chain 19 (195, 14) Chain Vibration Damper 9 (90, 80 in.·lbf) Crank Angle Sensor Plate x 12 9 (90, 80 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part 1AZ–FSE ENGINE (RM783E) *1: 43 (440, 32) *2: 9 (90, 80 in.·lbf) *3: 9.5 (100, 7) x4 Oil Pan 9 (90, 80 in.·lbf) A14219 EM–30 ENGINE MECHANICAL – CYLINDER HEAD Valve Lifter 9 (90, 80 in.·lbf) Keeper 29.5 (300, 22) No. 3 Camshaft Bearing Cap Spring Retainer No. 1 Camshaft Bearing Cap Valve Spring z Oil Seal No. 2 Camshaft Bearing Cap Spring Seat Upper Camshaft Bearing Valve Guide Bushing L Oil Pressure Switch 13 (130, 10) Intake Camshaft Lower Camshaft Bearing Camshaft Housing Plug See page EM–47 1st 79 (800, 58) 2nd Turn 90° Camshaft Position Sensor 9 (90, 80 in.·lbf) z O–Ring x 10 Exhaust Camshaft Water Temperature Sensor 13 (130, 10) z Gasket Cylinder Head Valve 9 (90, 80 in.·lbf) z Gasket N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part L Precoated part 1AZ–FSE ENGINE (RM783E) A14211 EM–31 ENGINE MECHANICAL – CYLINDER HEAD EM1JY–01 REMOVAL 1. 2. 3. 4. 5. DRAIN ENGINE OIL REMOVE ALTERNATOR (See page EM–15) REMOVE FUEL PUMP (HIGH PRESSURE) (See page FI–13) REMOVE IGNITION COILS REMOVE SPARK PLUGS 6. (a) (b) (c) REMOVE EXHAUST MANIFOLD Remove the 2 bolts, 2 nuts and 2 exhaust manifold stays. Remove the 3 bolts, nut and upper heat insulator. Remove the 3 bolts and No. 1 lower heat insulator. (d) (e) Remove the 5 nuts, exhaust manifold and gasket. Remove the 4 bolts and No. 2 lower heat insulator. 7. REMOVE INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY AND INTAKE AIR CONTROL VALVE Remove the No. 1 PCV hose. Remove the 2 bolts, 2 nuts, 2 washers and throttle body bracket. Disconnect the 2 vacuum hoses from the intake manifold. Disconnect the 2 water hoses from the throttle body. Remove the 5 bolts, 2 nuts, the intake manifold and throttle body assembly, No. 1 intake manifold insulator, intake air control valve and gasket. Remove the gasket from the intake manifold and throttle body assembly. REMOVE INJECTORS (See page FI–21) REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (OCV) REMOVE CAMSHAFT TIMING CHAIN (See page EM–15) REMOVE CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET (See page EM–15) A14216 A14215 (a) (b) (c) (d) (e) A14272 (f) 8. 9. 10. 11. 1AZ–FSE ENGINE (RM783E) EM–32 ENGINE MECHANICAL 9 10 13 14 17 18 5 15 20 19 8 2 3 4 11 16 CYLINDER HEAD 12. (a) 6 1 12 – 7 A14186 REMOVE CAMSHAFTS Uniformly loosen and remove the 20 bearing cap bolts in several passes and in the sequence shown. (b) Remove the 10 bearing caps, intake camshaft and exhaust camshaft. (c) Remove the camshaft bearings from the No. 1 camshaft bearing cap and intake camshaft No. 1 journal part of the cylinder head. 13. DISCONNECT WATER BYPASS PIPE FROM CYLINDER HEAD Remove the bolt holding the water bypass pipe and cylinder head. 14. (a) (b) 1 5 9 7 3 2 8 10 6 4 A13102 REMOVE CYLINDER HEAD Remove the camshaft housing plug. Using a 10 mm bi–hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts in several passes and in the sequence shown. NOTICE: Head warpage or cracking could result from removing bolts in an incorrect order. (c) Remove the 10 plate washers. (d) Using a screwdriver, pry between the cylinder head and cylinder block, and remove the cylinder head. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. A13104 1AZ–FSE ENGINE (RM783E) EM–33 ENGINE MECHANICAL – CYLINDER HEAD EM1JW–01 DISASSEMBLY 1. REMOVE OIL PRESSURE SWITCH 2. REMOVE WATER TEMPERATURE SENSOR 3. REMOVE CAMSHAFT POSITION SENSOR 4. REMOVE VALVE LIFTERS HINT: Arrange the valve lifters in the correct order. A14185 SST 5. (a) (b) REMOVE VALVES Using SST, compress the valve spring and remove the 2 keepers. SST 09202–70020 (09202–00010) Remove the spring retainer, valve spring and valve. (c) Using needle–nose pliers, remove the oil seal. (d) Using compressed air and a magnetic finger, remove the spring seat by blowing air. SST A14193 A14202 HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. A14192 1AZ–FSE ENGINE (RM783E) EM–34 ENGINE MECHANICAL – CYLINDER HEAD EM1JZ–01 INSPECTION 1. (a) CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston surface. A14175 (b) A14176 Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. 2. INSPECT CYLINDER BLOCK FOR FLATNESS (See page EM–60) 3. (a) CLEAN CYLINDER HEAD Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. A14178 (b) Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. A14179 (c) A14184 1AZ–FSE ENGINE (RM783E) Using a soft brush and solvent, thoroughly clean the cylinder head. EM–35 ENGINE MECHANICAL – CYLINDER HEAD (d) Using a valve guide bushing brush and solvent, clean all the guide bushings. 4. (a) INSPECT CYLINDER HEAD Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: A13880 Cylinder Block Side Cylinder block side 0.05 mm (0.0020 in.) Manifold side 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the cylinder head. Intake Manifold Side Exhaust Manifold Side A14201 (b) Inspect for cracks. Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. A14180 5. (a) (b) EM0580 1AZ–FSE ENGINE (RM783E) CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM–36 ENGINE MECHANICAL – CYLINDER HEAD 6. (a) INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 – 5.530 mm (0.2169 – 0.2177 in.) (b) Using a micrometer, measure the diameter of valve stem. Valve stem diameter: A13879 (c) Z00052 Intake 5.470 – 5.485 mm (0.2154 – 0.2159 in.) Exhaust 5.465 – 5.480 mm (0.2152 – 0.2157 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing (See page EM–43). 7. (a) INSPECT VALVES Check the valve is ground to the correct valve face angle. Valve face angle: 44.5° (b) Check that the surface of the valve for wear. If the valve face is worn, replace the valve. 44.5° EM0180 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.028 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 1AZ–FSE ENGINE (RM783E)