5E-FE Engine and Engine Rebuild

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ENGINE AND ENGINE REBUILD PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. Disconnecting the negative battery cable on some vehicles may interfere with the functions of the 2009-04-15 22:48

9307CH03

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on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

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ENGINE REPAIR Engine Assembly REMOVAL & INSTALLATION 5E-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Undercovers Radiator On automatic transaxles, transaxle fluid lines and accelerator cable. Throttle cable. Transaxle fluid and engine oil. Air cleaner assembly and bracket. Charcoal canister. Fuel return and inlet hoses. Speedometer cable. Idle up air hoses from the power steering air control valve. Oxygen sensor wire, the oil pressure switch wire, the coolant fan switch wire, the water temperature gauge wire, the back-up light switch and neutral safety switch wires. All remaining wiring harnesses connected to the engine All necessary vacuum hoses Starter wires. If equipped with cruise control, actuator assembly. Heater hoses. On manual transaxles, clutch release cylinder. Transaxle control cables Power steering pump. Do not disconnect the power steering hoses. Air conditioning compressor. Leave the refrigerant lines connected. Front exhaust pipe Halfshafts Connect a suitable lifting device to the engine lifting hooks. On manual transaxles, rear mounting through-bolt and the rear mounting assembly. On automatic transaxle, front mounting through-bolt and front mounting assembly. Right and left side mounting bolts and brackets. Lift the engine/transaxle assembly out of the vehicle. Starter For automatic transaxles, torque converter clutch mounting bolts. Engine from the transaxle by removing the bolts. To install: 3. Install or connect the following: Transaxle to the engine. On automatic transaxles, install the torque converter clutch and mounting bolts. Install the gray bolt first. Bolts: 20 ft. lbs. (27 Nm).

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Starter. Bolts: 29 ft. lbs. (39 Nm). Lower the engine and transaxle assembly in the vehicle. Right side mounting insulator and temporarily install the through-bolt Left side mounting bracket. Bolts marked (NT): 47 ft. lbs. (64 Nm), Bolts marked (7T): 35 ft. lbs. (48 Nm). Ground strap. Tighten to 35 ft. lbs. (49 Nm). Rear mounting bracket. Bolts: 35 ft. lbs. (48 Nm). Rear insulator through-bolt. Bolt: 47 ft. lbs. (64 Nm). Halfshafts 2 bolts, nut and through-bolt of the right side mounting insulator. Bolts and nut: 47 ft. lbs. (64 Nm). Through-bolt: 54 ft. lbs. (73 Nm). Front exhaust pipe Air conditioning compressor Power steering pump Transaxle control cables On manual transaxles, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm). Idle up air hoses Speedometer cable Heater hoses. If equipped with cruise control, actuator assembly. Starter wires and nut. Vacuum hoses Oxygen sensor wire, oil pressure switch, coolant fan switch wire, water temperature gauge wire, back-up light switch, and the neutral safety switch wires. All wiring Fuel line Charcoal canister. Air cleaner assembly and bracket. Radiator, coolant hoses and on vehicles with automatic transmission, cooling lines. All fluids Undercovers Hood Negative battery cable.

1NZ-FE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Hood Battery and tray Outer front cowl top panel Engine under covers Coolant Engine oil Transaxle oil Accelerator cable Air cleaner cap and related parts Air cleaner case and related parts All tubes, hoses and connectors attached to the engine Accessory drive belts Alternator Radiator With A/C, position the compressor out of the way With MT, the clutch release cylinder

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Transaxle control cables Fusible link Power steering pump Center exhaust pipe Halfshafts Suspension crossmember Rear engine mount 3. Attach a shop crane to the engine hangers. 4. Remove all remaining engine mount bolts/nuts. 5. Remove the engine/transaxle assembly. To install: 6. Install or connect the following: Engine/transaxle assembly into position Right engine mount insulator. Torque the bolts to 35 ft. lbs. (47 Nm). Left engine mount. Torque the bolts to 35 ft. lbs. (47 Nm). Rear engine mount bracket. Torque the bolts to 35 ft. lbs. (47 Nm). Rear engine mount insulator. Torque the bolt to 47 ft. lbs. (64 Nm). Suspension crossmember. Torque the rear mount bolts to 86 ft. lbs. (116 Nm); the front mount bolts to 52 ft. lbs. (70 Nm). Halfshafts Center exhaust pipe Power steering pump Fusible link Transaxle control cables Clutch release cylinder. Torque the 2 bolts to 10 ft. lbs. (13 Nm). Compressor. Torque the 4 bolts to 18 ft. lbs. (25 Nm). Radiator Alternator All remaining tubes, hoses and connectors Air cleaner case Air cleaner cap Accelerator cable Outer front cowl top panel Engine under covers Battery and tray Coolant Engine oil Transaxle oil Hood

7A-FE and 1ZZ-FE Engines

COROLLA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Battery

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4.

5.

6.

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Hood Undercover Drain coolant, oil, and the transaxle assembly. Accelerator cable With automatic transmission, throttle cable from the accelerator cable. Radiator and cooling fan Air cleaner assembly Coolant reservoir tank stay Electrical connector, the hose, the mounting bolt, and remove the washer tank. Cruise control actuator. The Manifold Absolute Pressure (MAP) sensor vacuum hose from the gas filter on the intake manifold The brake booster vacuum hose from the intake manifold With air conditioning: the air conditioning vacuum hose from the actuator With power steering: the air hose from the air pipe With air conditioning: the air conditioning actuator connector Install the following wires and connectors from the right-hand fender apron: A. The ground strap connector B. The MAP sensor connector C. With air conditioning: the air conditioning pressure switch D. The engine wiring harness from the fender apron Remove or disconnect the following: Data Link Connector 1(DLC1) connector and ground strap from the left-hand fender apron. Engine relay box and 4 connectors. Charcoal canister Heater hoses from water inlet housing. Fuel inlet and return hoses. With manual transmission, clutch release cylinder without disconnecting the pipe. Transaxle control cable(s) To disconnect the engine wiring harness, disconnect or remove the following components: Left-hand and right-hand front door scuff plate Lower finish panel Lower panel with the glove compartment Radio and center cluster finish panel Rear console box On manual transmission, shift lever knob On automatic transmission, shifting hole bezel Lower center finish panel Floor carpet bracket The 3 ECM connectors and cowl wire connector Remove or disconnect the remaining components: Air conditioning compressor Front exhaust pipe Halfshafts Power steering pump Engine mounting center member Through-bolt and nut holding the mounting insulator to the mounting bracket. Engine and transaxle assembly. Front and rear engine mounting bracket. Starter Separate the transaxle from the engine. To install:

8. Install or connect the following:

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9.

10.

11.

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Engine to the transaxle. Starter Rear engine mounting bracket Bolts: 57 ft. lbs. (77 Nm). Front engine mounting bracket. Bolts: 57 ft. lbs. (77 Nm). Engine and transaxle assembly into the vehicle. Engine mounting center member. Front engine mounting insulator through-bolt and nut. Bolt: 64 ft. lbs. (87 Nm). Halfshafts Front exhaust pipe Power steering pump. Bolts: 29 ft. lbs. (39 Nm). Install the drive belt. Air conditioner compressor. Bolts: 18 ft. lbs. (25 Nm). Install the drive belt and reconnect the connector. To install and connect the engine wiring harness, perform the following: Push the wire through the cowl Connect the 3 ECM connectors Attach the cowl wire connector Install the floor carpet bracket Install the center lower finish panel With automatic transmission, install the shifting hole bezel, with manual transmission, install the shift lever knob Install the rear console box Install the center cluster finish panel and the radio Install the lower panel with the glove compartment door Install the right-hand and left-hand door scuff plate Install the lower finish panel Install or connect the following: With manual transmission, clutch release cylinder. Transaxle control cable(s) Fuel return and inlet hose. Bolt: 22 ft. lbs. (29 Nm). Heater hoses to the water inlet housing. Charcoal canister Connect the following wires and connectors on the left-hand fender apron: The 4 connectors to the engine relay box Engine relay box The DLC1 connector The connector on the fender apron The ground strap on the fender apron Install or connect on the right-hand fender apron: The ground strap connector The MAP sensor connector With air conditioning, the air conditioning pressure switch The engine wire from the fender apron Install or connect the following: With air conditioning, the air conditioning actuator connector With power steering, the air hoses to the air pipe The vacuum hose from the MAP sensor to the gas filter to the intake chamber The brake booster vacuum hose to the air intake chamber With air conditioning, the air conditioning vacuum hose from the actuator With cruise control, actuator, actuator cable and cover. Electrical connector and vinyl hose Washer tank with the bolt. Coolant reservoir tank stay Air cleaner Radiator and cooling fan With automatic transmission, connect the throttle cable.

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Accelerator cable All fluids Negative battery cable Undercovers and hood

CELICA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Battery Hood Undercover, then drain the engine coolant, engine oil and oil from the transaxle. Accelerator cable, cable bracket, and clamps. Air cleaner Cruise control actuator cable Radiator MAP sensor vacuum hose from the gas filter on the intake manifold Power steering air hose from the intake manifold Power steering hose from the air the air pipe Brake booster vacuum hose from the intake manifold Air conditioning idle-up valve Air conditioning idle-up valve hose from the intake manifold Air conditioning idle-up valve hose from the air pipe DLC1 from the bracket Engine wiring harness from the bracket Ground cable from the body and the ground strap from the body Heater hoses from the water outlet Heater hose from the water bypass pipe Fuel inlet hose from the fuel filter and the fuel return hose from the return pipe EVAP hose from the charcoal canister Engine wiring harness from the engine compartment relay box 4. To remove the engine wiring harness from the passenger's compartment, remove or disconnect the following: The scuff plate The cowl side trim The finish panel from the lower instrument panel Remove the front side of the floor carpet The wiring harness from the clamp of the ECM bracket The 3 ECM connectors The circuit opening relay connector The 3 connectors from the connectors on the bracket The air conditioning amplifier connector The MAP sensor connector The MAP sensor wire from the clamp on the bracket The wire clamp from the bracket The 2 nuts holding the engine wiring harness to the cowl 5. Remove or disconnect the following: Front exhaust pipe. Halfshafts.

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Alternator drive belt. Air conditioning drive belt, compressor connector, and compressor. Do not disconnect the air conditioning lines Remove the drive belt and remove the 4 bolts that secure the power steering pump. Without disconnecting the lines, securely hang the pump out of the way. Air conditioning relay box On manual transmission, clutch release cylinder from the transaxle. Transaxle control cable(s) On automatic transmission, transaxle control cable from the engine mounting center member. Exhaust pipe support bracket. 6. To remove the engine mounting center member, remove the following components: The 2 dust covers from the rear side of the member The air conditioning pipe from the bracket The bolt and nut holding the front engine mounting bracket to the mounting insulator The bolt holding the rear engine mounting bracket to the insulator The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator. 7. Remove or disconnect the remaining components: Attach an engine chain hoist to the engine hangers. Left-hand engine mounting bracket from the mounting insulator. Through-bolt and the left-hand mounting insulator. Ground strap connector. Right-hand engine mounting bracket from the mounting insulator. Lift the engine and transaxle assembly from the vehicle Transaxle from the engine assembly. To install: 8. Install or connect the following: Transaxle to the engine assembly. Engine into the engine compartment. Right-hand engine mounting bracket to the mounting insulator. Temporarily install the 3 nuts. Left-hand engine mounting insulator to the body with the through-bolt. Left-hand engine mounting bracket to the mounting insulator and install the 2 bolts and nut. Bolts and nut: 47 ft. lbs. (64 Nm). Left-hand engine mounting through-bolt to the body. Bolt: 54 ft. lbs. (73 Nm). Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 Nm), 14mm nut: 38 ft. lbs. (52 Nm). Engine ground strap connector and remove the engine hoist. 9. To install the engine mounting center member, perform the following: Attach the center member together with the rear engine mounting insulator to the front suspension member Temporarily install the 2 bolts and nut holding the center member to the body Install the rear engine mounting bracket. Bolts: 58 ft. lbs. (78 Nm) Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member Temporarily install the bolt holding the rear engine mounting bracket to the insulator Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm) Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm) Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm) Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm

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Install the air conditioning pipe to the bracket and install the 2 dust covers to the center member 10. Install or connect the following: Exhaust pipe support bracket. Bolts to 14 ft. lbs. (19 Nm). Transaxle control cable(s) On automatic transmission, transaxle control cable to the engine mounting center member. On manual transmission, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt. Air conditioning relay box to the body. Power steering pump. 12mm bolts: 14 ft. lbs. (19 Nm). 14mm bolts: 29 ft. lbs. (39 Nm). Install the drive belt. Adjusting bolt: 29 ft. lbs. (39 Nm). Air conditioning compressor. Bolts: 18 ft. lbs. (25 Nm). Install the air conditioning drive belt with the adjusting bolt and tighten the idler pulley locknut to 29 ft. lbs. (39 Nm). Connect the connector. Alternator drive belt Halfshafts Front exhaust pipe. 11. To install the engine wiring harness in the passenger compartment, perform the following: Push the harness through the cowl panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket Connect the harness to the clamp on the ECM Connect the 3 ECM connectors and the circuit opening relay connector Connect the 3 connectors to the connectors on the bracket Connect the air conditioning amplifier connector Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff plate 12. Install or connect the following: Engine wiring harness with the 2 connectors to the engine compartment relay box and install the relay box covers. MAP sensor connector MAP sensor wire to the clamp on the bracket MAP sensor vacuum hose to the gas filter on the intake manifold Brake booster vacuum hose to the intake manifold Air conditioning idle-up valve connector Air conditioning idle-up valve hose to the intake manifold Air conditioning idle-up valve hose to the air pipe DLC1 to the bracket Engine harness protector to the bracket Ground cable and the ground strap Heater hose to the water outlet and the heater hose to the water bypass pipe Fuel inlet hose to the fuel filter Fuel inlet hose with 2 new gaskets and the union bolt. Bolt: 22 ft. lbs. (30 Nm). Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister Power steering air hoses to the intake manifold and the air pipe. Radiator On the model equipped with cruise control, install the actuator cable to the clamps. Accelerator cable to the throttle body, cable bracket, and the clamps. Air cleaner Battery tray and battery. Hood Refill the transaxle assembly, engine oil and coolant. Negative battery cable Engine undercover.

2ZZ-GE Engine

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Battery Hood Undercover, then drain the engine coolant, engine oil and oil from the transaxle. Accelerator cable, cable bracket, and clamps. Air cleaner ECM box Cruise control actuator cable Radiator MAP sensor vacuum hose from the gas filter on the intake manifold Power steering air hose from the intake manifold Power steering hose from the air the air pipe Brake booster vacuum hose from the intake manifold Air conditioning idle-up valve Air conditioning idle-up valve hose from the intake manifold Air conditioning idle-up valve hose from the air pipe DLC1 from the bracket Engine wiring harness from the bracket Ground cable from the body and the ground strap from the body Heater hoses from the water outlet Heater hose from the water bypass pipe Fuel inlet hose from the fuel filter and the fuel return hose from the return pipe EVAP hose from the charcoal canister Engine wiring harness from the engine compartment relay box 4. To remove the engine wiring harness from the passenger's compartment, remove or disconnect the following: The scuff plate The cowl side trim The finish panel from the lower instrument panel Remove the front side of the floor carpet The wiring harness from the clamp of the ECM bracket The 3 ECM connectors The circuit opening relay connector The 3 connectors from the connectors on the bracket The air conditioning amplifier connector The MAP sensor connector The MAP sensor wire from the clamp on the bracket The wire clamp from the bracket The 2 nuts holding the engine wiring harness to the cowl 5. Remove or disconnect the following: Front exhaust pipe. Exhaust manifold Halfshafts. Alternator drive belt. Air conditioning drive belt, compressor connector, and compressor. Do not disconnect the air conditioning lines Remove the drive belt and remove the 4 bolts that secure the power steering pump. Without disconnecting the lines, securely hang the pump out of the way. Air conditioning relay box On manual transmission, clutch release cylinder from the transaxle. Transaxle control cable(s)

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On automatic transmission, transaxle control cable from the engine mounting center member. Exhaust pipe support bracket. 6. To remove the engine mounting center member, remove the following components: The 2 dust covers from the rear side of the member The air conditioning pipe from the bracket The bolt and nut holding the front engine mounting bracket to the mounting insulator The bolt holding the rear engine mounting bracket to the insulator The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator. 7. Remove or disconnect the remaining components: Attach an engine chain hoist to the engine hangers. Left-hand engine mounting bracket from the mounting insulator. Through-bolt and the left-hand mounting insulator. Ground strap connector. Right-hand engine mounting bracket from the mounting insulator. Lift the engine and transaxle assembly from the vehicle Transaxle from the engine assembly. To install: 8. Install or connect the following: Transaxle to the engine assembly. Engine into the engine compartment. Right-hand engine mounting bracket to the mounting insulator. Temporarily install the 3 nuts. Left-hand engine mounting insulator to the body with the through-bolt. Left-hand engine mounting bracket to the mounting insulator and install the 2 bolts and nut. Bolts and nut: 47 ft. lbs. (64 Nm). Left-hand engine mounting through-bolt to the body. Bolt: 54 ft. lbs. (73 Nm). Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 Nm), 14mm nut: 38 ft. lbs. (52 Nm). Engine ground strap connector and remove the engine hoist. 9. To install the engine mounting center member, perform the following: Attach the center member together with the rear engine mounting insulator to the front suspension member Temporarily install the 2 bolts and nut holding the center member to the body Install the rear engine mounting bracket. Bolts: 58 ft. lbs. (78 Nm) Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member Temporarily install the bolt holding the rear engine mounting bracket to the insulator Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm) Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm) Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm) Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm Install the air conditioning pipe to the bracket and install the 2 dust covers to the center member Exhaust manifold 10. Install or connect the following: Exhaust pipe support bracket. Bolts to 14 ft. lbs. (19 Nm). Transaxle control cable(s) On automatic transmission, transaxle control cable to the engine mounting center member. On manual transmission, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt.

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Air conditioning relay box to the body. Power steering pump. 12mm bolts: 14 ft. lbs. (19 Nm). 14mm bolts: 29 ft. lbs. (39 Nm). Install the drive belt. Adjusting bolt: 29 ft. lbs. (39 Nm). Air conditioning compressor. Bolts: 18 ft. lbs. (25 Nm). Install the air conditioning drive belt with the adjusting bolt and tighten the idler pulley locknut to 29 ft. lbs. (39 Nm). Connect the connector. Alternator drive belt Halfshafts Front exhaust pipe. 11. To install the engine wiring harness in the passenger compartment, perform the following: Push the harness through the cowl panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket Connect the harness to the clamp on the ECM Connect the 3 ECM connectors and the circuit opening relay connector Connect the 3 connectors to the connectors on the bracket Connect the air conditioning amplifier connector Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff plate 12. Install or connect the following: Engine wiring harness with the 2 connectors to the engine compartment relay box and install the relay box covers. MAP sensor connector MAP sensor wire to the clamp on the bracket MAP sensor vacuum hose to the gas filter on the intake manifold Brake booster vacuum hose to the intake manifold Air conditioning idle-up valve connector Air conditioning idle-up valve hose to the intake manifold Air conditioning idle-up valve hose to the air pipe DLC1 to the bracket Engine harness protector to the bracket Ground cable and the ground strap Heater hose to the water outlet and the heater hose to the water bypass pipe Fuel inlet hose to the fuel filter Fuel inlet hose with 2 new gaskets and the union bolt. Bolt: 22 ft. lbs. (30 Nm). Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister Power steering air hoses to the intake manifold and the air pipe. Radiator On the model equipped with cruise control, install the actuator cable to the clamps. Accelerator cable to the throttle body, cable bracket, and the clamps. Air cleaner Battery tray and battery. Hood Refill the transaxle assembly, engine oil and coolant. Negative battery cable Engine undercover.

5S-FE Engine

CAMRY AND CAMRY SOLARA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before

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proceeding. On the Camry Solara, strut tower brace. Battery and battery tray. Hood. Engine undercover, then drain the engine coolant and oil. Accelerator cable from the throttle body. With automatic transmission, throttle cable. Air cleaner, resonator, and air intake hose. On models with cruise control, actuator cover, actuator with the bracket. Ground strap at the battery carrier Radiator and coolant reservoir hose Washer tank, electrical lead and hose 3. To disconnect the wiring harness, tag and disconnect the following: The 5 connectors to the engine relay box The igniter connector The noise filter connector The connector at the left-hand fender apron The 2 ground straps from the left-hand and right-hand fender aprons The DLC1 Disconnect the MAP sensor connector 4. Remove or disconnect the following: Dash panel undercover, glove compartment door, glove compartment, cowl harness connectors and the 2 ECM connectors. Heater hoses, fuel return hose, and fuel inlet hose. With manual transmission, starter and the clutch release cylinder. Don't disconnect the hydraulic line, simply hang the cylinder out of the way. Transaxle control cables at the transaxle Tag and disconnect all remaining vacuum hoses and connectors. Engine wire from the cowl panel Without disconnecting the refrigerant lines, air conditioning compressor Front exhaust pipe bracket and the front pipe from the exhaust manifold. Halfshafts Without disconnecting the hydraulic lines, power steering pump Left engine mounting insulator Right rear engine mounting insulator Front right engine mounting insulator p>

Use a hoist to remove the engine assembly — Camry 5S-FE engine <

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5. Attach an engine lifting device to the lift hooks. Remove the 3 bolts and disconnect the control rod. Slowly and carefully, lift the engine/transaxle assembly out of the engine compartment. 6. If equipped with automatic transmission, remove the starter. Separate the engine assembly from the transaxle. To install: 7. Install or connect the following: Engine assembly to the transaxle. With automatic transmission, starter Engine control rod. Bolts: 47 ft. lbs. (64 Nm). Front right engine mount. Bolts: 59 ft. lbs. (80 Nm). Rear engine mount. Nuts: 48 ft. lbs. (66 Nm). Left mount. Bolts (3 or 4): 47 ft. lbs. (64 Nm). Power steering pump. Bolts: 31 ft. lbs. (43 Nm). Install the drive belt and connect the 2 air hoses to the air pipe. Halfshafts Front pipe to the manifold. Nuts: 46 ft. lbs. (62 Nm). Air conditioning compressor. Bolts: 20 ft. lbs. (27 Nm). 8. Feed the engine harness through the cowl and reattach the clamp to the cowl. Make the following connections: The 2 ECM connectors The 2 cowl wire connectors Install the glove compartment and door Install the lower instrument panel and the undercover 9. Install or connect the following: Vacuum hoses and the transaxle control cables On manual transmission vehicles, release cylinder and the starter Fuel inlet hose and tighten it to 22 ft. lbs. (29 Nm). Connect the return hose and the 2 heater hoses. Attach the 5 connectors to the relay box The connectors from the left-hand fender apron Install the engine relay box The igniter connector On California models, the ignition coil connector The noise filter connector The 2 ground straps from the left-hand and right-hand fender apron The DLC1 The MAP sensor connector. Washer tank and connect the electrical lead and hose Coolant reservoir hose and the radiator With cruise control, actuator and bracket. Connect the actuator connector and install the cover. Ground strap to the battery carrier. Air cleaner assembly On California models, air hose to the air cleaner assembly and connect the air intake temperature sensor connector. With automatic transmission, throttle cable Accelerator cable Battery tray and battery On Camry Solara models, strut tower brace Hood Oil and coolant. Negative battery cable Undercover

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CELICA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Fuel system pressure Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Battery Hood Undercover Coolant and oil Accelerator cable from the throttle body, the cable bracket and clamps Air cleaner assembly With cruise control, actuator from the bracket. Radiator The MAP sensor The MAP sensor wire from the clamp The MAP sensor vacuum hose from the gas filter on the intake manifold The brake booster vacuum hose from the intake manifold The DLC1 from the bracket The igniter connector On California models, the ignition coil connector On California models, the ignition coil high tension wire, the noise filter, the wire clamp from bracket, the ignition coil and igniter assembly, and disconnect the wire from the bracket The ground cable from the body The ground strap from the body The heater hose from the water outlet and bypass pipe The fuel inlet hose from the fuel filter and the fuel return hose from the return pipe The EVAP hose from the charcoal canister Engine wiring harness from the engine compartment relay box. 3. To remove the engine wiring harness from the passenger's compartment, remove or disconnect the following: The scuff plate The cowl side trim The finish panel from the lower instrument panel Remove the front side of the floor carpet The wiring harness from the clamp of the ECM bracket The 3 ECM connectors The circuit opening relay connector The 3 connectors from the connectors on the bracket The air conditioning amplifier connector The wire clamp from the bracket The 2 nuts holding the engine wiring harness to the cowl 4. Remove or disconnect the following: Front exhaust pipe Halfshafts Alternator drive belt Air conditioning compressor and suspend it securely out of the way. Power steering pump. Securely hang the pump out of the way. On manual transmission, the starter. On manual transmission, the clutch release cylinder and associated components Transaxle control cable(s) from the transaxle On automatic transmission model, transaxle control cable from the engine mounting center member.

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Exhaust pipe support bracket 5. To remove the engine mounting center member, remove the following components: The 2 dust covers from the rear side of the member The air conditioning pipe from the bracket The bolt and nut holding the front engine mounting bracket to the mounting insulator The bolt holding the rear engine mounting bracket to the insulator The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member The 2 bolts (automatic transmission) or 3 bolts (manual transmission) and rear engine mounting bracket. Remove the center member with the rear mounting insulator. 6. Attach an engine chain hoist to the engine hangers. 7. Remove or disconnect the following: Left-hand engine mount bracket from the mounting insulator Left-hand mounting insulator Ground strap connector Right-hand engine mount bracket from the mounting insulator Halfshaft bearing bracket Transaxle To install: 8. Install or connect the following: Transaxle to the engine assembly and reattach the halfshaft bearing bracket. Bolts: 47 ft. lbs. (64 Nm). Transaxle/engine assembly into engine compartment. Right-hand engine mount bracket to the mounting insulator, and temporarily install the bolt and 2 nuts. Left-hand engine mounting insulator to the body with the through-bolt. Left-hand engine mount bracket to the mounting insulator and install the 2 nuts and bolt (manual transmission) or the 2 bolts (automatic transmission). Bolts and nuts: 47 ft. lbs. (64 Nm). 9. Tighten the left-hand engine mounting through-bolt to the body: 54 ft. lbs. (73 Nm). Tighten the bolt and 2 nuts holding the right-hand mounting bracket to the insulator: 27 ft. lbs. (37 Nm) and nut: 38 ft. lbs. (52 Nm). 10. Install the engine ground strap connector. 11. To install the engine mounting center member, perform the following: Attach the center member together with the rear engine mounting insulator to the front suspension member Temporarily install the 2 bolts holding the center member to the body Install the rear engine mounting bracket with the 2 bolts (automatic transmission) or the 3 bolts (manual transmission). Bolt: 58 ft. lbs. (79 Nm). Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member Temporarily install the bolt holding the rear engine mounting bracket to the insulator Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm). Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm). Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm). Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm). Install the air conditioning pipe to the bracket and install the 2 dust covers to the center member 12. Install or connect the following: Exhaust pipe support bracket. Bolts: 14 ft. lbs. (19 Nm). Transaxle control cable(s) to the transaxle. 13. On the automatic transmission vehicles, transaxle control cable to the engine mounting center member. 14. On manual transmission model only, install and/or connect the following:

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The clutch release cylinder. Bolts: 108 inch lbs. (12 Nm). The bracket with the bolt and the tube to the bracket with the clamp The tube with the clamp and bolt The back-up switch connector 15. Install or connect the following: On manual transmission model only, starter, starter wire, and starter connector. Power steering pump. 3 mounting bolts: 32 ft. lbs. (44 Nm); adjusting bolt: 29 ft. lbs. (39 Nm); pivot bolt: 32 ft. lbs. (44 Nm) Hoses to the air tube. Air conditioning compressor. Bolts: 18 ft. lbs. (24 Nm) Alternator drive belt Halfshafts Front exhaust pipe 16. To install the engine wiring harness to the passenger's compartment, perform the following: Push the harness through the cowl panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket. Connect the harness to the clamp on the ECM. Connect the 3 ECM connectors and the circuit opening relay connector. Connect the 3 connectors to the connectors on the bracket. Connect the air conditioning amplifier connector. Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff plate. 17. Install or connect the following: Engine wiring harness with the 2 connectors to the engine compartment relay box and install the relay box covers. The MAP sensor connector The MAP sensor wire to the clamp on the bracket The MAP sensor vacuum hose to the gas filter on the intake manifold The brake booster vacuum hose to the intake manifold The DLC1 to the bracket The engine harness protector to the bracket On California models, the engine harness clamp to the bracket and the ignition coil and igniter assembly with the 3 bolts, and install the harness to the bracket The igniter connector On California model, the ignition coil connector, high tension wire to the coil, and the noise filter The ground cable and the ground strap to the body The heater hose to the water outlet and the heater hose to the water bypass pipe Fuel inlet hose to the fuel filter Fuel inlet hose with 2 new gaskets and the union bolt. Bolt: 22 ft. lbs. (30 Nm). Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister Radiator With cruise control, actuator and connect the connector Accelerator cable to the throttle body, the cable bracket, and the clamps. Air cleaner Battery tray and battery Hood Oil and coolant Negative battery cable Undercover

1MZ-FE Engine

AVALON, CAMRY AND CAMRY SOLARA

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Fuel system pressure Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Battery and battery tray Engine oil and coolant Accelerator and throttle cables Cruise control actuator, if equipped Air cleaner assembly, mass air flow meter and air cleaner hose Radiator Engine relay box 2 igniter connectors Noise filter connector Connector from the left-hand fender apron 2 ground straps and any other electrical connections keeping them from being removed. Vacuum hoses from the engine. Fuel inlet and return hoses Heater hoses Transaxle control cable from the transaxle Instrument panel undercover, the lower instrument panel and glove box assembly. 3 ECM connectors, the 5 cowl wire connectors, and the cooling fan ECM connector. Push the engine wire through the cowl panel. Front exhaust pipe Halfshafts Power steering pressure tube Power steering pump Air conditioning compressor without disconnecting the hoses Left-hand engine mounting insulator Right-hand engine mounting insulator Engine mounting shock absorber Front right engine mounting insulator 3. Attach a hoist chain to the engine hangers. 4. Remove or disconnect the following: Coolant reservoir hose and reservoir tank Right-side engine mounting stay bracket Engine control rod and bracket assembly NOTE: Make certain all wires, connectors and hoses are cleared from the engine. 5. Engine/transaxle assembly from the vehicle. To install: 6. Carefully lower the engine position. Keep the engine level while aligning the engine mounts. 7. Install or connect the following: Engine control rod and bracket. Tighten to 47 ft. lbs. (64 Nm). Right engine mount stay bracket. Tighten to 23 ft. lbs. (31 Nm). Engine ground straps. Coolant reservoir tank Front engine insulator. Tighten to 48 ft. lbs. (66 Nm). Engine mounting shock absorber. Tighten to 35 ft. lbs. (48 Nm). Left and right engine mounts. Tighten to 48 ft. lbs. (66 Nm). Power steering pump and air conditioning compressor

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Power steering pressure tube Halfshafts and front exhaust pipe Engine wires and connectors Transaxle control cable to the transaxle Fuel hoses and heater hoses All vacuum hoses, wiring and connectors Radiator Cruise control actuator Throttle cable and accelerator cable MAF meter, the air cleaner assembly, and air cleaner hose. Coolant and engine oil Battery tray and battery. Hood Negative battery cable

2JZ-GE and 2JZ-GTE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. Do not start any work for at least 90 seconds to prevent accidental deployment of the air bag. Hood Radiator Fuel pressure CAUTION The fuel injection system remains under pressure even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Oil Accelerator cable and cruise control actuator Air cleaner assembly, volume air flow meter, and the air intake hose Drive belt by turning the tensioner clockwise Fan, fan clutch, and the water pump pulley Charcoal canister Heater water hoses Brake booster vacuum hose EVAP hose. Noise filter connector Ignition coil connector Engine wire from the wire clamp Rubber cap, nut and wire from the alternator Engine room main wire Igniter connector Theft deterrent horn connector Engine wire from the 2 wire clamps Wire clamp and power steering solenoid valve connector Ground strap from the cylinder block by removing the bolt Rubber cap, nut, and the wire from the starter Fuel inlet hose from the engine. Suspend the hose union upward. Fuel return hose from the fuel return guide. Fuel return hose from the fuel return hose. Plug the hose end.

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26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48.


Engine wire from the intake manifold stay. Power steering pump Power steering pressure tube Air conditioning compressor without disconnecting the hoses. Engine wire from the cowl panel Remove the scuff plate from the right door. Take out the front side of the floor carpet. Remove the 2 nuts and ECM protector. Remove the nut and disconnect the ECM from the floor panel. Disconnect the 2 connectors from the ECM. Disconnect the connector from the instrument panel wire. Disconnect the connector from the connector cassette. Pull out the engine wire from the cabin. With manual transmission, upper console panel, shift lever boots, and holding bolts. With manual transmission, clutch release cylinder and the ground strap from the transmission. No. 2 front exhaust pipe Exhaust pipe heat insulator Driveshaft With automatic transmissions, control rod from the shift lever by removing the nut. Support the transmission with a jack. Remove the rear support member by removing the 8 bolts. Attach the engine hoist chain to the engine and raise the engine slightly. Remove or disconnect the following: Nuts holding the engine front mounting insulators to the front suspension crossmember. Engine from the vehicle. Oil dipstick guide from the transmission Engine wire from the transmission Starter connector, 2 bolts, engine wire bracket, and the starter. With automatic transmissions, oil cooler tubes from the transmission. With automatic transmissions, torque converter clutch mounting bolts. Transmission To install:

49. Assemble the engine and transmission. Tighten the bolts as follows: 14mm: 29 ft. lbs. (39 Nm) 17mm: 43 ft. lbs. (72 Nm) 50. Install or connect the following: With automatic transmission, torque converter clutch mounting bolts by first installing the gray bolt, then install the other 5 bolts. Bolts: 25 ft. lbs. (33 Nm). With automatic transmission, oil cooler tubes to the transmission. Union nuts: 25 ft. lbs. (33 Nm). Starter Engine wire to the transmission With automatic transmission, oil dipstick guide and dipstick Engine and transmission as an assembly to the vehicle. Keep slight tension on the engine until the mounting bolts and nuts are installed. Engine front mounting insulators to the front suspension crossmember. Nuts: 43 ft. lbs. (59 Nm). Bolts holding the support member to the body. Bolts: 19 ft. lbs. (25 Nm). Nuts holding the support member to the engine rear mounting insulator. Nuts: 10 ft. lbs. (13 Nm). Driveshaft 51. With automatic transmissions, transmission control rod as follows: Shift the shift lever to the N position. Fully turn the control shaft lever back and return 2 notches. The control shaft is now in the neutral position. Connect the control rod to the shift lever with the nut. Tighten the nut to 108 inch lbs. (13 Nm).

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52. Install or connect the following: Exhaust pipe heat insulator No. 2 front exhaust pipe With manual transmission, clutch release cylinder and ground strap. Tighten the clutch release cylinder bolts to 108 inch lbs. (13 Nm) and the ground strap bolt to 27 ft. lbs. (37 Nm). With manual transmission, upper console panel, shift lever boots, and holding bolts. Engine wire through the cowl panel. Connect the connector to the connector cassette. Connect the connector to the instrument panel wire connector. Connect the 2 connectors to the ECM. Insert the ECM bracket into the stay on the floor panel. Install the ECM with the nut. Install the ECM protector with the 2 nuts. Install the floor carpet. Install the scuff plate. Engine wire to the cowl panel Air conditioning compressor to the engine Power steering tube with the 2 clamp bolts. Power steering pump. Lower bolt: 43 ft. lbs. (58 Nm); upper bolt: 29 ft. lbs. (39 Nm); rear stay bolts: 29 ft. lbs. (39 Nm); front bracket bolts: 43 ft. lbs. (58 Nm). Engine wire bracket Fuel return hose to the fuel return pipe Fuel return hose to the clamp of the oil dipstick guide Fuel inlet hose with the 2 new gaskets and the union bolt. Bolt: 22 ft. lbs. (29 Nm). Wires and connectors EVAP hose Brake booster vacuum hose Heater hoses Charcoal canister Water pump pulley, fan, and the fan clutch Drive belt to the engine Air cleaner, VAF meter, and the intake air connector pipe. Control cables to the throttle body Oil Radiator Negative battery cable Hood

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Water Pump

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Water_Pump.htm

Water Pump REMOVAL & INSTALLATION 5E-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant Alternator With distributorless ignition, intake manifold stay bracket by disconnecting the wire clamps and removing the 2 nuts. With distributor ignition, remove the intake manifold stay bracket by removing the 2 nuts and 2 bolts. Water inlet pipe Oil dipstick guide Alternator adjusting bar Water pump attaching bolt and nuts. Water pump To install: 3. Install or connect the following: 0.08–0.12 in. (2–3mm) bead of sealant to the groove in the pump. O-ring, lubricated with a little soap and water, on the water inlet pipe. Water pump. Bolts: 13 ft. lbs. (17 Nm). Oil dipstick guide Alternator adjusting bar Dipstick guide clamp bolt Water inlet pipe. Bolt: 65 inch lbs. (7.5 Nm). Water bypass, heater inlet and water inlet hoses For distributorless ignition engines, install the intake manifold bracket by installing the 2 bolts and the wire clamp. Bolts: 15 ft. lbs. (20 Nm). For distributor ignition, install the intake manifold bracket by installing the 2 bolts. Bolts: 15 ft. lbs. (20 Nm). Alternator and belt. Coolant Negative battery cable

1NZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Engine coolant Accessory drive belt Water pump pulley, using a holding tool Water pump and gasket (3 bolts; 2 nuts)

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To install: 3. Install or connect: Water pump, with a new gasket. Torque the nuts and bolts to 96 inch lbs. (11 Nm). Pulley. Torque the bolts to 11 ft. lbs. (15 Nm). Drive belt Coolant

4A-FE and 7A-FE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant Right-hand engine mounting insulator No. 2 and No. 3 timing belt covers With power steering, front engine mount insulator. With power steering, electric cooling fan. Engine wire On the 7A-FE engine, crankshaft position sensor connector Dipstick guide and dipstick Water temperature sender gauge connector No. 2 water inlet Water pump To install: 3. Install or connect the following: Water pump. Bolts: 10 ft. lbs. (14 Nm). Water inlet No. 2. Nuts: 11 ft. lbs. (15 Nm). Water temperature sender gauge connector Oil dipstick guide mounting bolt. Bolt: 82 inch lbs. (9 Nm). On the 7A-FE engine, crankshaft position sensor connector. Engine wire With power steering, electric cooling fan. With power steering, front mounting insulator. Through-bolt and nut. Nut: 64 ft. lbs. (87 Nm). Mounting bolts: 47 ft. lbs. (64 Nm). No. 2 and No. 3 timing belt covers Right-hand engine mounting insulator Coolant Negative battery cable

1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Right-hand engine under cover Coolant Drive belt. Water pump To install:

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3. Install or connect the following: Water pump. Bolts marked A (short): 80 inch lbs. (9 Nm). Bolts marked B (long): 96 inch lbs. (11 Nm).

Water pump bolt identification — 1.8L (1ZZ-FE) engine

Drive belt Right engine under cover Coolant

2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Right-hand engine under cover Coolant Drive belt Water pump pulley Water pump and O-ring To install: 3. Install or connect the following: Water pump with new O-ring. Bolts: 80 inch lbs. (9 Nm). Water pump pulley. Bolts: 11 ft. lbs. (15 Nm). Drive belt Right engine under cover Coolant

5S-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Right engine undercover Coolant Lower radiator hose from the water outlet.

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Timing belt, timing belt tension spring, and the No. 2 idler pulley. Alternator, drive belt and the adjusting bar if necessary. 2 nuts holding the water pump to the water bypass pipe and remove the 3 bolts in sequence. Water pump cover assembly Gasket and 2 O-rings from the water pump and the bypass pipe. Water pump from the water pump cover by removing the 3 bolts in sequence. To install: 3. Install or connect the following: Water pump to the water pump cover. Bolts: 78 inch lbs. (9 Nm) in proper sequence.

Install the 3 water pump bolts in this sequence — 2.2L (5S-FE) engine

Water pump cover to the water bypass pipe, but do not install the nuts yet. Water pump and tighten the 3 bolts in sequence. Bolts: 78 inch lbs. (9 Nm). Nuts: 82 inch lbs. (9 Nm). Alternator drive belt adjusting bar. Bolt: 13 ft. lbs. (18 Nm). No. 2 idler pulley and the timing belt tension spring Lower radiator hose Timing belt Right engine undercover Coolant Negative battery cable.

1MZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant Timing belt No. 2 idler pulley 3 clamps and engine wire from the rear timing belt cover. Rear timing belt cover Water pump To install:

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3. Install or connect the following: Liquid sealer to the gasket, water pump and engine block. Water pump. Bolts and nuts: 53 inch lbs. (6 Nm). Rear timing belt cover. Bolts: 74 inch lbs. (9 Nm). Engine wire with the 3 clamps to the rear timing belt cover. No. 2 idler pulley. Bolt: 32 ft. lbs. (43 Nm). With the flange side outward, right-hand camshaft pulley. Align the knock pin hole on the camshaft pulley with the knock pin on the camshaft. Bolt: 65 ft. lbs. (88 Nm). With the flange side inward, left-hand camshaft pulley. Align the knock pin hole on the camshaft pulley with the knock pin on the camshaft. Bolt: 94 ft. lbs. (125 Nm). Timing belt Coolant. Negative battery cable

2JZ-GE and 2JZ-GTE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Air cleaner and MAF meter assembly Radiator With manual transmission, drive belt tensioner damper. Loosen the 4 nuts holding the fan clutch to the water pump. Drive belt from the engine Fan, fan clutch, and the water pump pulley. Water inlet, lower radiator hose assembly, and the thermostat. Timing belt. Alternator On turbo models, turbo water hoses from the water outlet. Except for the California vehicles, exhaust manifold heat insulator. Water outlet and No. 1 water bypass pipe No. 2 water bypass from the water pump No. 3 turbo water hose from the water pump. Water pump. O-ring To install: 3. Install or connect the following: O-ring Water pump to the water bypass pipe, with thin layer of liquid sealant applied on engine and water pump. Do not install the nut at this time. Water pump. Be sure to replace the bolts to their original positions. Bolts: 15 ft. lbs. (21 Nm). 2 nuts holding the No. 2 water bypass pipe to the water pump. Nuts: 15 ft. lbs. (21 Nm). No. 3 turbo water hose to the water pump. Water bypass outlet and No. 1 water bypass pipe. Turbo water hoses to the water outlet. Alternator Except for California vehicle, exhaust manifold heat insulator Engine wire bracket Timing belt Thermostat, water inlet, and the lower radiator hose assembly. Water pump pulley, fan, fluid clutch assembly, and the drive belt. Fan nuts: 12 ft. lbs. (16 Nm).

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With manual transmission, drive belt tensioner damper. Radiator Air cleaner and MAF meter assembly. No. 1 air hose Negative battery cable Coolant

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Cylinder Head

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Cylinder_Head.htm

Cylinder Head REMOVAL & INSTALLATION NOTE: The cylinder head bolt torque sequence illustrations are found in Section 1, following the Torque Specifications Chart.

5E-FE Engine Removal of intake manifold, throttle body, exhaust front pipe and manifold — 1.5L (5E-FE) engine

Exploded view of cylinder head disassembly — 1.5L (5E-FE) engine

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Right engine undercover Drain all necessary fluids All necessary components to gain access to the timing belt. Timing belt Intake and Exhaust manifolds Camshafts, following the proper sequences and procedures. NOTE: Loosen the cylinder head bolts in several passes and in the reverse order of the installation sequence. 3. Cylinder head. Make note of cylinder bolt positions and replace them in their original position. To install: NOTE: The head bolts stretch and must be replaced once removed. 4. Install or connect the following: 2 different size head bolts, lightly oiled, in their correct positions and tighten them in several passes in the proper sequence, evenly, to 33 ft. lbs. (44 Nm). Mark each bolt with a reference mark and tighten each bolt in sequence an additional 90 degrees. Camshafts and all other components following the proper sequences and procedures.

1NZ-FE Engine

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Battery ground cable Coolant Water filler Outer front cowl top panel Alternator Air cleaner Accelerator cable Center exhaust pipe Exhaust manifold support Exhaust manifold Ignition coil Spark plugs PCV hoses Throttle body Engine wiring harness at the head Intake manifold Camshaft position sensor ECT sensor Oil control valve PCV valve Oil filer cap Cylinder head cover Fuel injectors Timing chain cover Camshaft sprockets and valve timing control assembly Camshafts Cylinder head. Remove the bolts in a circular pattern, in several stages, starting from the ends and working towards the center. To install: NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart. 3. Install or connect the following: Cylinder head, using a new gasket. The Lod. No. on the gasket faces UP. 4. Tighten the cylinder head bolts, in sequence, in 3 steps: Step 1: 22 ft. lbs. Step 2: Plus a 90 degree turn Step 3: Plus a 90 degree turn 5. Install or connect the following: Water bypass pipe. Torque the bolt to 80 inch lbs. (9 Nm). Camshafts 6. Camshaft bearing caps in 2 stages: Step: 10 ft. lbs. (13 Nm) Step 2: 17 ft. lbs. (23 Nm) 7. Install or connect the following: Sprockets and valve timing controller assembly, aligning the knock pin and hole. Torque the bolts to 47 ft. lbs. (64 Nm). Check and adjust the valves. Cylinder head cover Oil filler cap PCV valve

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ECT sensor Camshaft position sensor Timing chain cover Intake manifold Engine wiring harness Throttle body PCV hoses Spark plugs Ignition coils Exhaust manifold Exhaust manifold support. Torque the bolts to 27 ft. lbs. (37 Nm). Front exhaust pipe. Torque the nuts to 46 ft. lbs. (62 Nm). Accelerator cable Air cleaner Alternator Water filler Coolant Battery ground cable

4A-FE and 7A-FE Engines Exploded view of engine accessories and right-hand engine under cover — 1.6L (4A-FE) and 1.8L (7A-FE) Engines.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.

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View of engine intake, exhaust, ignition, and fuel system location — 1.6L (4A-FE) and 1.8L (7A-FE) engines.

Exhaust and intake manifold All necessary components to gain access to the cylinder head using the diagram above. Right-hand engine mounting insulator Timing belt from the camshaft timing pulley and remove the pulley. Alternator bracket Oil dipstick guide and dipstick No. 2 water inlet Intake and exhaust camshafts following the proper sequences and procedures.

Illustration of disassembled cylinder head assembly — 1.6L (4A-FE) and 1.8L (7A-FE) Engines.

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Uniformly loosen the bolts in the reverse order of the installation sequence. Remove the 10 cylinder head bolts in several passes and in sequence. NOTE: Cylinder head warpage or cracking could result from removing the bolts in the incorrect order. 3. Cylinder head assembly from the cylinder block dowels. To install: 4. Clean the gasket mating surfaces. 5. The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the cylinder head bolts. Uniformly tighten the 10 cylinder head bolts in several passes and in sequence. NOTE: The cylinder head bolts are in lengths of 3.54 in. (90mm) and 4.25 in. (108mm). The 3.54 in. (90mm) bolts (A) are to be installed in the intake side of the cylinder head. The 4.25 in. (108mm) bolts (B) are to be installed in the exhaust manifold side of the cylinder head. 6. 7. 8. 9.

Tighten the cylinder head bolts by 90 degrees in sequence. Tighten an additional 90 degrees. Install the intake and exhaust camshafts following the proper sequences and procedures. Check and adjust valve clearance. Install all components in reverse order of removal referencing the above diagrams for proper torque specs.

1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

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2. Remove or disconnect the following: Battery ECU box Coolant reservoir Air cleaner assembly Accelerator cable Alternator Exhaust pipe Exhaust manifold Coils Spark plugs PCV hoses Throttle body Injectors Wiring harness Intake manifold Camshaft position sensor ECT sensor PCV valve Oil filler cap Camshaft sprockets Camshafts Hoses Cylinder head bolts in sequence. To prevent damage to the cylinder head, loosen each bolt about 1 ⁄4 of a turn during each pass until the bolts are loose. Cylinder head To install:

Fig. 1: Cylinder head component removal — 1ZZ-FE engine

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3. Clean and degrease the surface of the cylinder head and engine block. 4. Install or connect the following: New gasket on the engine block with the Lod No. stamp facing up. Cylinder head Apply a light coat of oil to cylinder head bolt threads and tighten in sequence. Replace any bolt that appears deformed. Bolts: 36 ft. lbs. (49 Nm). Tighten each bolt in sequence an additional 90 degree turn. Camshafts Sprockets Oil filler cap PCV valve ECT sensor Intake manifold Wiring harness Exhaust manifold Exhaust pipe Alternator accelerator cable Air cleaner ECM box Battery Coolant

Exploded view of engine accessories and right-hand engine under cover — 1.8L (1ZZ-FE) Engines.

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Cylinder Head

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View of engine intake, exhaust, ignition, and fuel system location — 1.8L (1ZZ-FE) engines.

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Cylinder Head

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Illustration of disassembled cylinder head assembly — 1.8L (1ZZ-FE) Engines.

Position the head gasket correctly on the cylinder head — 1.8L (1ZZ-FE) engine

2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Battery ECU box Coolant reservoir Air cleaner assembly

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Cylinder Head

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Accelerator cable Alternator Exhaust pipe Exhaust manifold Coils Spark plugs PCV hoses Throttle body Injectors Wiring harness Intake manifold Camshaft position sensor ECT sensor PCV valve Oil filler cap Camshaft sprockets Camshafts Hoses Cylinder head bolts in sequence. To prevent damage to the cylinder head, loosen each bolt about 1 ⁄4 of a turn during each pass until the bolts are loose. Cylinder head To install:

Fig. 2: Cylinder head component exploded view — 2ZZ-GE engine

3. Clean and degrease the surface of the cylinder head and engine block.

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4. Install or connect the following: New gasket on the engine block with the Lod No. stamp facing up. Cylinder head Apply a light coat of oil to cylinder head bolt threads and tighten in sequence. Replace any bolt that appears deformed. Bolts: 26 ft. lbs. (49 Nm). Tighten each bolt in sequence an additional 180 degree turn. Camshafts Sprockets Oil filler cap PCV valve ECT sensor Intake manifold Wiring harness Exhaust manifold Exhaust pipe Alternator accelerator cable Air cleaner ECM box Battery Coolant

5S-FE Engine Exploded view of engine accessories and right-hand engine under cover — 1.8L (1ZZ-FE) Engines.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before

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proceeding.

View of engine, exhaust, ignition and fuel system location — 1.8L (1ZZ-FE) Engines.

View of engine, intake, ignition and fuel system location — 1.8L (1ZZ-FE) Engines.

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Cylinder Head

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All necessary components to gain access to the cylinder head using the diagram above. NOTE: On California vehicles, remove the Vacuum Switching Valve (VSV) for fuel pressure control and EGR. On all vehicles (except California), remove the VSV for EGR. 3. Timing belt NOTE: Support the timing belt, so that the meshing of the crankshaft timing pulley and the timing belt does not shift. Be careful not to drop anything inside the timing belt cover. 4. 5. 6. 7.

Engine hangers and the alternator bracket. Camshafts following the proper sequences and procedures. Cylinder head bolts in several passes and in the reverse order of the installation sequence. Cylinder head from the cylinder block, disengaging the cylinder head from the block dowel pins.

Illustration of disassembled cylinder head assembly — 1.8L (1ZZ-FE) Engines.

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Cylinder Head

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To install: NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart. 8. Install or connect the following: Gasket and cylinder head Cylinder head bolts, lightly oiled. Tighten, in several passes and in sequence, to 36 ft. lbs. (49 Nm). Tighten the cylinder head bolts an additional 90 degrees in sequence. Then, tighten an additional 90 degrees. Camshafts and all other components following the proper sequences and procedures. Check and adjust valve clearance. Sealant to the 2 new semi-circular seals and install the seals to the cylinder head. Cylinder head cover with new gasket. Nuts: 17 ft. lbs. (23 Nm).

2JZ-GTE Engine Removal of air box, engine under cover and front exhaust pipe — 3.0L (2JZ-GTE) engine

2009-04-15 22:50

Cylinder Head

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable from the battery. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Drain all necessary fluids. Turbocharger

Diagram of intake and exhaust manifolds — 3.0L (2JZ-GTE) engine

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Cylinder Head

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Exhaust manifold With manual transmission, drive belt tensioner damper. Drive belt Water outlet and No. 1 water bypass pipe. Power steering pump without disconnecting the hoses as follows:

Exploded view of intake manifold and throttle body — 3.0L (2JZ-GTE) engine

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Cylinder Head

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Intake manifold and delivery pipe assembly by removing the 4 bolts and 2 nuts. Upper 2 timing belt covers (Nos. 2 and 3). Drive belt tensioner Timing belt from the camshaft pulleys. If the belt is to be reused, place matchmarks on the belt and gears before removing the belt. Mark the belt with an arrow to show direction of rotation. Ignition coils, spark plugs, and cylinder head covers. While holding each camshaft with a wrench, camshaft bolts and gears. No. 4 (inner) timing belt cover. Remove the camshafts following the proper sequences and procedures.

Exploded view of cylinder head — 3.0L (2JZ-GTE) engine

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Cylinder Head

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Cylinder head Engine hangers and the ground strap. Camshaft position sensors EGR cooler Valve lifters and shims. Make note of the positions of the lifters and shims. When installing the lifters and shims, install them in the same position as removal. Compress the valve spring and remove the 2 keepers. Spring retainer, valve spring, valve and spring seat. Oil seal To install: 3. Install or connect the following: New valve oil seals and assemble the cylinder head. Engine hangers and ground strap. Bolts: 29 ft. lbs. (39 Nm). Camshaft position sensors and EGR cooler. Bolts: 78 inch lbs. (9 Nm). Cylinder head gasket Cylinder head Head bolts, lightly oiled and plate washers. Uniformly tighten the head bolts in several passes in the correct order, to 25 ft. lbs. (34 Nm). Tighten each bolt an additional 90 degrees. Again, tighten the bolts 90 degrees. NOTE: Correct bolt torque must be achieved in 3 steps; do not attempt to shorten the procedure by combining the 2, 90 degree steps. Cylinder head covers, spark plugs, ignition coils, and timing belt. Intake manifold and delivery pipe assembly by installing a new gasket and engine wire. Bolts and nuts: 20 ft. lbs. (27 Nm). Fuel inlet pipe by installing a new gasket and the union bolt. Bolt: 30 ft. lbs. (42 Nm).

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Cylinder Head

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Fuel inlet pipe clamp bolt to the intake manifold. All other components in the reverse of installation. Power steering pump. Bolts: 43 ft. lbs. (58 Nm). Water outlet and No. 1 water bypass pipe. Bolts: 15 ft. lbs. (21 Nm). ECT sensor and sender gauge connectors. Upper radiator hose to the water outlet. Drive belt With manual transmission, drive belt tensioner damper. Nuts: 14 ft. lbs. (20 Nm). 2 new gaskets to the cylinder head. Exhaust manifold. Bolts: 29 ft. lbs. (39 Nm). Turbocharger Coolant Negative battery cable

2JZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel pressure in the fuel lines. 3. Remove or disconnect the following: Negative battery cable. Wait at least 90 seconds before performing any other work. All necessary engine fluids Undercovers Accelerator, throttle control (automatic transmission only) and cruise control cables from the throttle body.

Removal of the air duct assembly, exhaust manifold, front exhaust pipe and engine under cover — 3.0L (2JZ-GE) engine

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Cylinder Head

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Air cleaner duct Air cleaner, airflow meter, and the intake air pipe. Drive belt, the fan and fluid coupling, and the water pump pulley. Front exhaust pipe Except for California vehicles, the manifold heat insulator. Oxygen sensor connector(s) Exhaust manifolds and gaskets Power steering pump without disconnecting the hoses Brake booster vacuum hose EVAP hose

Removal of the intake manifold and throttle body — 3.0L (2JZ-GE) engine

Throttle body and intake air connector assembly. Air intake chamber stays No. 2 vacuum pipe and VSV assembly. No. 3 timing belt cover by removing the oil filler cap. Cylinder head rear cover Spark plug wires from the cylinder head covers. Distributor and wires. Spark plugs Timing belt Water bypass outlet and No. 1 bypass pipe. Fuel return hose Engine wire bracket from the intake manifold. Oil dipstick and guide. Starter

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Cylinder Head

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Air intake chamber Vacuum control valve set Intake manifold and gaskets

View of cylinder head covers, camshafts, and the cylinder head — 3.0L (2JZ-GE) engine

Cylinder head covers (valve covers). Camshaft timing pulleys. Hold the hexagon portion of the camshaft with a wrench and remove the pulley mounting bolt and camshaft pulley. No. 4 timing belt cover. Camshafts following the proper sequences and procedures. Cylinder head bolts in the reverse order of the installation sequence. Cylinder head To install: 4. Install or connect the following: New gasket on the cylinder block Plate washers and cylinder head bolts, lightly coated with engine oil. Tighten the bolts to 25 ft. lbs. (34 Nm). Tighten each bolt an additional 90 degrees. Again, tighten the bolts another 90 degrees of rotation. Position camshafts in the cylinder head with the cam lobes and the knock pins in the correct position. Position the No. 3 and No. 7 bearing caps in place, then uniformly and alternately tighten them temporarily. New oil seals over the camshafts. 5. Clean the surfaces of the No. 1 bearing cap and cylinder head with cleaner. Apply seal packing to the

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Cylinder Head

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No. 1 bearing cap. 6. Install camshafts following the proper sequences and procedures. 7. Press the 2 oil seals in as far as they will go. 8. Rotate each camshaft until the forward straight (knock) pin is straight up. Loosen exhaust No. 1, 2, and 6 bearing cap bolts until they can be turned by hand; tighten, in several passes, to 14 ft. lbs. (20 Nm). Loosen intake No. 1, 2, and 5 and tighten, in several passes, to 14 ft. lbs. (20 Nm). 9. Turn each camshaft 1⁄3 of a revolution (120 degrees). Loosen exhaust Nos. 4 and 7 bearing cap bolts; tighten, in several passes, to 14 ft. lbs. (20 Nm). Loosen intake No. 4 and 6 bearing cap bolts; tighten, in several passes, to 14 ft. lbs. (20 Nm). 10. Turn each camshaft an additional 1⁄3 of a revolution, loosen exhaust bearing cap bolts Nos. 3 and 5, then tighten them, in several passes, to 14 ft. lbs. (20 Nm). Loosen intake bearing cap bolts No. 3 and 7, then tighten them, in several passes to 14 ft. lbs. (20 Nm). 11. Check and adjust the valve clearance. 12. Install or connect the following: No. 4 timing belt cover. Bolts: 78 inch lbs. (9 Nm). Camshaft timing pulleys. Align the shaft pin with the pulley groove and slide the pulley on. Install the bolt temporarily. Hold the hex portion of the camshaft with a wrench and tighten the pulley bolt to 59 ft. lbs. (79 Nm). Cylinder head covers Intake manifold with a new gasket. Bolts: 20 ft. lbs. (27 Nm). Injectors Delivery pipe. Bolts: 20 ft. lbs. (27 Nm). Fuel inlet pipe. Bolt: 30 ft. lbs. (42 Nm). Clamp bolt to the intake manifold Fuel pressure pulsation damper. Intake manifold stay. Bolts: 29 ft. lbs. (39 Nm). Water outlet and No. 1 bypass hose assembly. Engine wire protector to the intake manifold with the 3 nuts. 6 injector connectors. ECT sensor connector and sender gauge. 2 wire clamps and the 2 ground straps to the intake manifold with the bolts. Engine wire bracket to the water pump with the bolt. Vacuum control valve set. Bolts: 15 ft. lbs. (21 Nm). VSV connector Air intake chamber as follows. Bolts and nut: 20 ft. lbs. (27 Nm). Bolt holding the engine wire protector to the air intake chamber. Vacuum sensing hose to the fuel pressure regulator (except for California vehicles) Starter Oil and transmission dipstick tubes. Engine wire bracket Fuel return hose Water bypass outlet and No. 1 water bypass pipe. 13. Install the timing belt as follows: A. Turn the crankshaft pulley and align its groove with the timing mark, 0, on the No. 1 timing belt cover. B. Align the timing marks on the camshaft timing gears and the No. 4 timing belt cover. C. Install the timing belt. D. Double check that all the timing marks for the crankshaft pulley and the camshaft gears are aligned as they were during disassembly. E. Set the timing belt tensioner: F. Use a press to slowly push in the pushrod on the tensioner. This will require between 220–2200 pounds of pressure. G. Align the holes of the pushrod and housing. Place a 1.5mm hex wrench through the holes to keep the pushrod retracted.

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H. I. J. K.

Release the press and install the dust boot onto the tensioner. Install the tensioner; alternately tighten the bolts: 20 ft. lbs. (26 Nm). Remove the hex wrench from the tensioner with a pair of pliers. Turn the crankshaft pulley 2 full turns clockwise. Check that each pulley's timing marks align correctly after the 2 turns. If any mark does not align, remove the timing belt and reinstall it. 14. Install or connect the following: Drive belt tensioner. Bolts: 15 ft. lbs. (21 Nm). No. 2 timing belt cover Spark plugs Distributor and spark plug wires. No. 3 timing belt cover Cylinder head rear cover No. 2 vacuum pipe and VSV assembly Air intake chamber stays. Bolt and nut: 13 ft. lbs. (18 Nm). Throttle body and intake air connector assembly. EVAP hose Brake booster vacuum hose Power steering pump Exhaust manifolds No. 2 front exhaust pipe Water pump pulley, fan, fluid coupling assembly, and the drive belt. Pulley bolts: 12 ft. lbs. (16 Nm). Air cleaner, VAF meter, and the intake air connector pipe assembly. Air cleaner duct Cruise control cable, throttle control, and accelerator cables. Coolant Negative battery cable Engine undercover

1MZ-FE Engine Removal of the right-hand fender apron, front exhaust pipe, and air cleaner assembly — 3.0L (1MZ-FE) engine

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Cylinder Head

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. All necessary engine fluids Accelerator cable and the throttle cable on vehicles equipped with an automatic transaxle. Air cleaner cover, air flow meter, air duct, cruise control actuator and bracket (if equipped), the 2 engine ground straps, right engine mounting support, radiator hoses, and 2 heater hoses. Fuel feed and return lines and plug the lines. Pressure hose, plug, and remove from V-bank cover. Vacuum hoses from: Fuel pressure VSV; Fuel pressure regulator; Cylinder head rear plate; Intake air control valve VSV; EGR vacuum modulator; EGR valve All necessary connectors and hoses. Ground straps and the hydraulic motor pressure hose 2 nuts and the power steering pressure tube. Engine hanger and the intake chamber support.

Timing belt and pulleys — 3.0L (1MZ-FE) engine

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Ignition coils and the spark plugs, timing belt, camshaft pulleys and the timing belt rear cover, cylinder head rear plate, water inlet pipe, and water outlet.

Intake manifold removal — 3.0L (1MZ-FE) engine

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Intake manifold and fuel rail assembly. EGR pipe

Exhaust manifold removal — 3.0L (1MZ-FE) engine

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Exhaust manifolds Dipstick assembly and the power steering pump bracket. Valve covers and the camshaft position sensor. Camshafts following the proper sequences and procedures. 2 (1 on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the installation sequence. Cylinder head gasket. To install:

Cylinder head gasket position and torque specification — 3.0L (1MZ-FE) engine

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Cylinder Head

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3. Install or connect the following: New cylinder head gasket on cylinder block. Place the cylinder head onto the gasket. Cylinder head bolts into the cylinder head. Bolts: 40 ft. lbs. (54 Nm), then an additional 90 degrees 2 remaining 8mm bolts. Bolts: 13 ft. lbs. (18 Nm). Camshafts following the proper sequences and procedures. Check and adjust the valves. Sealant to the cylinder heads where the camshaft supports meet the cylinder heads. All remaining components in reverse of removal using the diagrams for the proper torque figure.

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Turbocharger

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Turbocharger.htm

Turbocharger REMOVAL & INSTALLATION 3.0L (2JZ-GTE) Engine Exploded view of the turbocharger component assembly — Supra with 3.0L (2JZ-GTE) engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Cruise control actuator cable No. 1 air hose Air cleaner and MAF meter assembly as follows: Theft deterrent horn Front lower arm bracket stay Front upper crossmember extension No. 2 front exhaust pipe as follows: Heat insulator for the No. 2 front exhaust pipe. With automatic transmission, automatic transmission oil cooler tubes. Engine wire protector Heater hose from the No. 3 water bypass pipe. EVAP hose from the No. 1 vacuum pipe. IAC valve pipe from the No. 2 air tube No. 1 vacuum pipe from the air tubes VSV assembly Crankshaft position sensor connector from the clamp. Water bypass hose (from the water pump) from the No.1 turbo water pipe. Water bypass hose (from the water outlet) from the No. 1 turbo water pipe. Water bypass hose (from the water outlet) from the No. 2 turbo water pipe. No. 2 turbo water pipe from the No. 4 air tube.

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No. 1 air tube from the No. 1 turbocharger by removing the 2 bolts. 2 bolts holding the No. 4 air tube to the No. 1 turbocharger. Air hose from the No. 4 air tube. Air hose from the intake air connector. No. 4 air tube and air bypass valve assembly. Intake air control valve and gasket by removing the 2 nuts. Air hose from the No. 2 air tube. PCV hose from the No. 2 cylinder head cover. Intake air connector and No. 1 air tube assembly. Air inlet duct and cable bracket. Heat insulator for the turbocharger. Exhaust bypass pipe and gasket Exhaust gas control valve stay Main heated oxygen sensor Exhaust gas control valve No. 1 turbocharger stay No. 2 turbocharger stay Union bolt holding the No. 1 turbo oil pipe to the cylinder block. Remove the 2 gaskets. 2 nuts and disconnect the turbo oil pipe from the turbocharger. Remove the gaskets. Turbo oil hose from the turbo oil outlet on the No. 1 oil pan. Remove the No. 1 turbo oil pipe. Union bolt holding the No. 2 turbo oil pipe to the cylinder block. Remove the 2 gaskets. Turbo oil pipe from the turbocharger. Remove the 2 gaskets. Turbo oil hose from the turbo oil outlet on the No. 1 oil pan and remove the turbo oil pipe. Turbochargers and turbine outlet elbow assembly No. 1 vacuum pipe from the No. 2 turbocharger No. 2 air tube and No. 3 water bypass pipe assembly from the No. 2 turbocharger Exhaust manifold plate from the turbine outlet elbow. No. 2 turbo water pipe from the No. 2 turbocharger Bearing housing side plate from the No. 1 turbocharger No. 1 turbo water pipe from the No. 1 turbocharger Bearing housing side plate from the No. 2 turbocharger No. 1 turbocharger from the turbine outlet elbow No. 2 turbocharger from the turbine outlet elbow To install: 3. Install or connect the following: No. 2 turbocharger to the turbine outlet elbow by installing a new gasket and 6 new nuts. Nuts: 18 ft. lbs. (25 Nm). No. 1 turbocharger to the turbine outlet elbow by installing a new gasket and 6 new nuts. Nuts: 18 ft. lbs. (25 Nm). Bearing housing side plate to the No. 2 turbocharger by installing a new gasket and 2 nuts. Nuts: 78 inch lbs. (9 Nm). No. 1 turbo water pipe to the No. 1 turbocharger by installing a new gasket and 2 nuts. Nuts: 78 inch lbs. (9 Nm). Bearing housing side plate to the No. 1 turbocharger by installing a new gasket and 2 nuts. Nuts: 78 inch lbs. (9 Nm). No. 2 turbo water pipe to the No. 2 turbocharger by installing a new gasket and 2 nuts. Nuts: 78 inch lbs. (9 Nm). Exhaust manifold plate to the turbine outlet elbow. No. 2 air tube and No. 3 water bypass pipe assembly to the No. 2 turbocharger. Bolts: 15 ft. lbs. (21 Nm). No. 1 vacuum pipe to the No. 2 turbocharger. Turbochargers and turbine outlet elbow assembly. Install 8 new nuts and uniformly tighten the nuts in several passes. Nuts: 40 ft. lbs. (54 Nm).

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Water bypass hose (from the No. 2 turbo water pipe) to the No. 2 water bypass pipe. Heater hose (from the No. 3 water bypass pipe) to the No. 2 water bypass pipe. Install the No. 2 turbo oil pipe. Nuts: 15 ft. lbs. (21 Nm) Union bolt to hold the turbo oil pipe to the cylinder block. Bolt: 29 ft. lbs. (39 Nm) No. 1 turbo oil pipe. Nuts: 15 ft. lbs. (21 Nm) Union bolt to hold the turbo oil pipe to the cylinder block. Bolts: 29 ft. lbs. (39 Nm). No. 2 turbocharger stay. Nut and bolt: 32 ft. lbs. (43 Nm). No. 1 turbocharger stay. Nut and bolt: 32 ft. lbs. (43 Nm). Exhaust gas control valve by installing 2 new gaskets and the 3 nuts. Nuts: 51 ft. lbs. (69 Nm). Main heated oxygen sensor. Nuts: 14 ft. lbs. (20 Nm). Exhaust gas control valve stay. Bolt and nut: 32 ft. lbs. (43 Nm). Exhaust bypass pipe by installing 2 new gaskets and 4 new nuts. Nuts: 18 ft. lbs. (25 Nm). Heat insulator for the turbocharger. Air inlet duct by installing the cable bracket, bolt, and 2 nuts. Intake air connector and No. 1 air tube assembly. PCV hose to the No. 2 cylinder head cover. Air hose to the No. 2 air tube. Intake air control valve and gasket. Nuts: 15 ft. lbs. (21 Nm). No. 4 air tube and air bypass valve assembly. Air hose to the intake air connector. Air hose to the No. 4 air tube. 2 bolts holding the No. 4 air tube to the No. 1 turbocharger. Bolts: 15 ft. lbs. (21 Nm). No. 1 air tube to the No. 1 turbocharger. Bolts: 15 ft. lbs. (21 Nm). No. 2 turbo water pipe to the No. 4 air tube by installing the bolt. Water bypass hose (from the water outlet) to the No. 2 turbo water pipe. Water hose (from the water outlet) to the No. 1 turbo water pipe. Water bypass hose (from the water pump) to the No. 1 turbo water pipe. Crankshaft position sensor connector to the clamp. VSV assembly and connect the 2 VSV connectors. Engine wire to the wire clamp. Air hose to the hose clamp. Air hose to the actuator for the exhaust gas control valve. Air hose to the actuator for the waste gate valve. Install the No. 1 vacuum pipe to the air tubes and install the 3 bolts. 2 air hoses (from the vacuum pressure tank) to the vacuum pipe. Air hose to the VSV for the intake air control valve. Air hose (from the No. 2 air tube) from the vacuum pipe. 2 air hoses (from the VSV for exhaust bypass valve) to the vacuum pipe. Vacuum hose (from the air bypass valve) to the No. 1 air tube. Air hose (from the VSV for exhaust gas control valve) to the vacuum pipe. Air hose (from the VSV for waste gate valve) to the vacuum pipe. Air hose to the No. 1 air tube. Air hose to the No. 4 air tube. Engine wire to the 3 clamps. VSV connector for the exhaust bypass valve. VSV connector for the intake air control valve. IAC valve pipe to the clamp. Air hose to the No. 2 air tube. Air hose (from the No. 1 vacuum pipe) to the IAC valve pipe. Engine wire to the clamp. EVAP hose to the No. 1 vacuum pipe. Heater hose to the No. 3 water bypass pipe. Engine wire protector Automatic transmission oil cooler tubes Heat insulator for the No. 2 front exhaust pipe

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No. 2 front exhaust pipe. Nuts: 46 ft. lbs. (62 Nm). Pipe support bracket. Bolts: 32 ft. lbs. (43 Nm). 2 bolts and nuts to hold the front exhaust pipe to the No. 2 front exhaust pipe. Bolts and nuts: 43 ft. lbs. (58 Nm). Upper front crossmember extension. Bolts: 22 ft. lbs. (29 Nm). Nuts: 25 ft. lbs. (33 Nm). Front lower arm bracket stay. Bolts: 33 ft. lbs. (44 Nm). Nut: 43 ft. lbs. (59 Nm). Theft deterrent horn Air cleaner and MAF meter assembly as follows: Air cleaner duct No. 1 air hose Cruise control actuator cable Undercover Coolant Negative battery cable

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Intake Manifold

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Intake_Manifold.htm

Intake Manifold REMOVAL & INSTALLATION 5E-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant Accelerator cable With automatic transmission, throttle cable. PCV hose Air cleaner All electrical wires and vacuum hoses that interfere with removal of the intake manifold. EGR pipe and EGR valve Throttle body assembly Air intake chamber stay With distributor ignition, air pipe Engine wire clamps Intake manifold stay Intake manifold Intake manifold gasket To install: 3. Install or connect the following: Using a new gasket, intake manifold. Nuts and bolts: 14 ft. lbs. (19 Nm). Intake manifold stay. Bolt(s) and nut(s): 15 ft. lbs. (20 Nm). With distributor ignition, vacuum hoses, then the air pipe. Bolts: 48 inch lbs. (6 Nm). Air intake chamber stay Throttle body, using a new gasket. Nuts and bolts: 108 inch lbs. (13 Nm). All components to the throttle body. EGR pipe and EGR valve. All electrical wires and vacuum hoses removed from the intake manifold. Air cleaner hose Coolant Negative battery cable

1NZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Battery ground cable Coolant Water filler Outer front cowl top panel Alternator

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Air cleaner Accelerator cable Ignition coil PCV hoses Throttle body Intake manifold To install: 3. Install or connect the following: Intake manifold. Uniformly tighten the bolts and nuts, in several passes, from the ends, working towards the center, to 22 ft. lbs. (30 Nm). Engine wiring harness Throttle body PCV hoses Ignition coils Accelerator cable Air cleaner Alternator Water filler Coolant Battery ground cable

4A-FE and 7A-FE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant Throttle body Ground strap connector Hoses from the intake chamber With air conditioning, hose from the idle-up valve. With power steering, air hose from the air pipe. Air intake chamber cover and gasket. With EGR, the EGR VSV. Intake manifold stay Air pipe Fuel injector connectors Fuel inlet hose from the delivery pipe. Place a shop towel under the connection to absorb the fuel. Fuel return hose from the fuel pressure regulator and the air hose from the IAC valve to the air pipe. Delivery pipe with the 4 injectors. Ground strap, intake manifold and the 2 gaskets. To install:

Installing the EGR and intake manifold gaskets — 1.6L (4A-FE) and 1.8L (7A-FE) engines

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3. Install or connect the following: New intake manifold gasket, new EGR gasket to the cylinder head, with the protrusion facing down. Intake manifold and ground strap. A nut: 108 inch lbs. (13 Nm). All other nuts and bolts: 14 ft. lbs. (19 Nm). Injectors and delivery pipe With EGR, the EGR VSV. Air intake chamber cover with a new gasket. Throttle body Air pipe and fuel inlet hose. Fuel return hose to the pressure regulator and the air hose from the IAC valve to the air pipe. Intake manifold stay. 12mm head bolt: 14 ft. lbs. (19 Nm). 14mm head bolt: 29 ft. lbs. (39 Nm). Hoses to the intake chamber If equipped, air hoses the idle-up valve and the air pipe. Ground strap connector and fuel injector connectors. Coolant Negative battery cable.

1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Drive belt and alternator Air intake duct Accelerator cable Exhaust pipe from the manifold. Exhaust manifold support bracket Spark plug wires, then ignition coils. Spark plugs PCV hoses Throttle body assembly 2 bolts securing the wiring harness protector Wiring connectors and ground wires Intake manifold support bracket Intake manifold and gasket.

Intake manifold mounting fastener locations — 1.8L (1ZZ-FE) engine 2009-04-15 22:50

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To install: 3. Install or connect the following: Intake manifold. Bolts and nuts: 14 ft. lbs. (18.5 Nm). Harness wiring to the cylinder head and harness protector. Fuel injectors, throttle body and the PCV hoses. Spark plugs and ignition coils. Bolts and nuts: 80 inch lbs. (9 Nm). Exhaust manifold and support bracket. Bolts: 37 ft. lbs. (49 Nm). Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm). Oxygen sensor. Nuts: 14 ft. lbs. (20 Nm). Accelerator cable and air intake duct. Alternator and drive belt. Coolant Negative battery cable

2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Drive belt and alternator Air intake duct Accelerator cable Spark plug wires, then ignition coils. Spark plugs PCV hoses Throttle body assembly Wiring harness Hoses and tubes connected to the head Intake manifold support bracket Intake manifold and gasket. To install: 3. Install or connect the following:

Fig. 1: Intake manifold bolt installation — 2ZZ-GE engine

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Intake manifold. Bolts A: 20 ft. lbs. (27 Nm); bolt B: 34 ft. lbs. (46 Nm) Harness wiring to the cylinder head and harness protector. Fuel injectors, throttle body and the PCV hoses. Spark plugs and ignition coils. Bolts and nuts: 80 inch lbs. (9 Nm). Oxygen sensor. Nuts: 14 ft. lbs. (20 Nm). Accelerator cable and air intake duct. Alternator and drive belt. Coolant Negative battery cable

5S-FE Engine


1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant Accelerator cable. With automatic transmission, throttle cable from the throttle body. Intake air temperature sensor connector On California models, air cleaner hose. Air cleaner hose clamp bolt, air cleaner cap clips, air hose from the throttle body, and the air cleaner cap together with the resonator and air cleaner hose. Electrical connections and hoses from the throttle body. Throttle body. Type A throttle bodies are secured with 4 bolts and Type B throttle bodies are secured with 2 bolts and 2 nuts. Vacuum hose bracket and the engine wiring harness. EGR valve No. 1 air intake chamber, and manifold stays. Intake manifold and gasket To install:

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3. Install or connect the following: Intake manifold with a new gasket. Bolts and nuts: 14 ft. lbs. (19 Nm). Wire clamps to the wire brackets on the intake manifold. Vacuum hose bracket and engine wiring harness No. 1 air intake chamber and manifold stays. 14mm bolts: 31 ft. lbs. (42 Nm). 12mm bolts: 16 ft. lbs. (22 Nm). EGR valve Throttle body with a new gasket. Hoses and electrical connections to the throttle body. NOTE: The protrusion on the gasket should be facing down and the water hose connections on the throttle body should also face down. 4. On type A throttle body, Bolts: 14 ft. lbs. (19 Nm). Bolt A is 45mm in length and bolt B is 55mm.

Mounting bolt length identification for the throttle body — 2.2L (5S-FE) engine

5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

On type B throttle body, bolts and nuts: 14 ft. lbs. (19 Nm). PCV hose 2 vacuum hoses to the EGR modulator Vacuum hose to the TVV for EVAP IAC valve connector Throttle position sensor connector Air cleaner hose to the throttle body Air cleaner cap with the resonator and air cleaner hose. Intake air temperature sensor connector On California models, air hose to the air cleaner hose. With automatic transmission, throttle cable. Accelerator cable Coolant Negative battery cable

CELICA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure.

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3. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant IAT sensor connector High tension spark plug wire from air cleaner hose. Accelerator cable from the clamp and the cruise control actuator cable from the clamps. For California vehicles, air hose for the idle up from the air cleaner hose Clamps and the air cleaner cap from the air cleaner case. Air cleaner hose from the throttle body. Air cleaner cap and hose assembly. Throttle body Vacuum sensor hose from the gas filter Brake booster vacuum line With air conditioning, air conditioning idle-up valve. EGR temperature sensor connector and sensor connector from the wiring connector. EVAP hose from the charcoal canister and hose clamp from the bracket on the air tube. Vacuum hoses from the VSV for the EGR. Vacuum modulator from the clamp on the intake manifold. EGR valve, vacuum modulator, vacuum hoses assembly and gasket. Intake manifold stay Automatic transmission throttle control cable 2 power steering air hose(s) from the air tube and the intake manifold Air hose from the fuel pressure regulator Hose bracket (for EGR) and the air tube. Vacuum pipe Knock sensor connector and ground cables VSV assembly for fuel pressure control and EGR PCV hose, accelerator, automatic transmission throttle control cables and bracket Engine wiring harness protector from the bracket on the starter, VSS connector, engine wiring harness protector from the left-hand side of the intake manifold. Fuel injector connectors and engine wiring harness protector from the front side of the intake manifold. Engine wiring harness protector from the No. 2 timing belt cover Fuel inlet hose from the delivery pipe. Fuel return hose from the return pipe. Engine wiring harness between the intake manifold and the cylinder head. Intake manifold and gasket To install: 4. Insert the intake manifold between the cylinder head and the firewall. Insert the engine wiring harness between the intake manifold and the cylinder head. 5. Install or connect the following: Intake manifold. Bolts and nuts: 14 ft. lbs. (19 Nm). Fuel inlet pipe to the fuel delivery hose. Bolt: 25 ft. lbs. (34 Nm). Fuel return hose to the return hose. Engine wiring harness protector to the No. 2 timing belt cover in reverse of removal sequence. Install the harness protector to the 2 brackets on the front side of the intake manifold. Fuel injector connectors. The Nos. 1 and 3 injector connectors are brown; the No. 2 and 4 connectors are gray. Engine wiring harness protector to the left-hand side of the intake manifold with the bolt and connect the VSS sensor connector. Engine wiring harness protector to the starter bracket. Cable bracket to the intake manifold, and the accelerator and automatic transmission throttle

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control cables. PCV hose to the intake manifold. VSV for fuel pressure control and EGR. Knock sensor connector and ground cable to the intake manifold. Air tube and hose bracket (for EGR) Power steering air hose(s) to the air tube and the intake manifold Vacuum sensing hose to the fuel pressure regulator Automatic transmission throttle control cable to the clamp on the rear side of the intake manifold. Intake manifold stay bolt. Bolt: 15 ft. lbs. (21 Nm). Nut: 32 ft. lbs. (44 Nm). EGR valve. Bolt: 43 ft. lbs. (59 Nm). Nuts: 108 inch lbs. (13 Nm). Vacuum modulator Vacuum hoses to the VSV for the EGR and hose clamp to the bracket on the air tube. With air conditioning, the air conditioning idle-up valve. EGR gas temperature sensor connector and the sensor connector to the bracket on the intake manifold. EVAP hose to the charcoal canister. Vacuum sensor hose to the gas filter and the brake booster vacuum hose. Throttle body assembly Air filter, air cleaner cap, hose assembly, air cleaner hose to the throttle body, and secure the air cleaner cap with the 4 clamps. Accelerator and cruise control cables to the clamps. High tension spark plug wire to the air cleaner hose. IAT sensor connector. Coolant Negative battery cable.

Intake manifold mounting fastener locations — 2.2L (5S-FE) engine

1MZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel pressure from the fuel lines. 3. Remove or disconnect the following: Negative battery terminal. If equipped with an air bag system, wait at least 90 seconds or longer before performing any other work. Air cleaner hose V-bank cover Air cleaner chamber assembly

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Accelerator cable automatic transmission throttle cable TPS connector IAC valve connector EGR gas temperature sensor connector Air conditioning idle up valve connector VSV connector for the Acoustic Control Induction System (ACIS) VSV connector for the fuel pressure control Disconnect the VSV for the EVAP VSV connector for the EGR DLC1 from the bracket on the intake air control valve Power steering pressure tube from the No. 1 engine hanger by removing the 2 bolts. Brake booster vacuum hose from the intake air control valve for the ACIS PCV hose from the PCV valve on the right-hand cylinder head Ground strap and cable from the air intake air control valve from the ACIS Ground cable from the air intake chamber Vacuum hose clamp from fuel pipe 2 bypass hoses from the throttle body 2 power steering air hoses to the air intake chamber. Air assist hose from the throttle body Remove the EVAP hose from the pipe on emission control valve set 2 vacuum hoses from the pipes on the cylinder head rear plate Vacuum sensing hose from the fuel pressure regulator Engine wire clamp from emission control valve set 2 bolts and the No. 1 engine hanger. 2 bolts and the air intake chamber stay. No. 2 EGR pipe and 2 gaskets by removing the 4 nuts. Hose from the VSV from the EVAP. Air intake chamber assembly and gasket. Fuel injector connectors Air assist hoses and pipe Fuel return hose from the No. 1 fuel pipe. Fuel inlet hose from the fuel filter. Delivery pipes and injectors from the engine Heater hoses Intake manifold To install: 4. Thoroughly clean the intake manifold and cylinder head surfaces. 5. Install or connect the following: Intake manifold. Nuts and bolts: 11 ft. lbs. (15 Nm). Heater hoses to the intake manifold. 2 new grommets to each injector. 2 new O-rings, lightly oiled, on each injector. Install the injectors NOTE: Be sure to position the injector electrical connector outward. 6. 4 spacers in position on the intake manifold. 7. Right-hand delivery pipe and the No. 1 fuel pipe together with the 3 injectors in position on the intake manifold. 8. 2 bolts, temporarily, holding the right-hand delivery pipe to the intake manifold. 9. Bolt, temporarily, holding the No. 1 fuel pipe to the intake manifold. 10. Left-hand delivery pipe and the No. 2 fuel pipe together with the 3 injectors in position.

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11. Fuel return hose to the fuel pressure regulator. 12. 2 bolts, temporarily, holding the left-hand delivery pipe to the intake manifold. 13. No. 2 fuel pipe, temporarily, to the left and right-hand delivery pipes with the union bolts and 2 new gaskets. NOTE: Check that the injectors rotate smoothly. If the injectors do not rotate smoothly, the probable cause is incorrect installation of the O-rings. Replace the O-rings. 14. 15. 16. 17.

Tighten the 4 bolts holding the delivery pipes to the intake manifold. Bolts: 84 inch lbs. (10 Nm). Tighten the bolt holding the No. 1 fuel pipe to the intake manifold. Bolts: 14 ft. lbs. (20 Nm). Tighten the 2 union bolts holding the No. 2 fuel pipe to the delivery pipes. Bolts: 24 ft. lbs. (33 Nm). Install or connect the following: Fuel inlet hose to the fuel filter. Use 2 new gaskets when installing the union bolt. Fuel return hose to the No. 1 fuel pipe. When routing the fuel return hose, pass the hose under the heater hoses. Air assist hoses to the intake manifold, then the air assist pipe to the bracket on the No. 1 fuel pipe. Injector connectors Air intake chamber assembly. Bolts and nuts: 32 ft. lbs. (43 Nm). Hose to the VSV for the EVAP system. 2 new gaskets and No. 2 EGR pipe with the 4 nuts. Nuts: 108 inch lbs. (12 Nm). No. 1 engine hanger with the 2 bolts. Bolts: 19 ft. lbs. (39 Nm). Air intake chamber stay with the 2 bolts. Bolts: 14 ft. lbs. (20 Nm). Brake booster vacuum hose to the intake air control valve for the ACIS. PCV hose to the PCV valve on the right-hand cylinder head. Ground strap and cable to the intake air control valve for the ACIS. Connect the ground cable and strap with the nut. Nut: 10 ft. lbs. (15 Nm) Ground cable to air intake chamber Vacuum hose clamp to fuel pipe. 2 water bypass hoses to the throttle body. Air assist hose to the throttle body. 2 power steering air hoses to the air intake chamber. Connect the EVAP hose to the pipe on the emission control valve set 2 vacuum hoses to the pipes on the cylinder head rear plate. Vacuum sensing hose to the fuel pressure regulator. Engine wire clamp to the emission control valve set. Power steering pressure tube with the 2 nuts. TPS sensor connector IAC valve connector EGR gas temperature sensor connector air conditioning idle up valve connector VSV connector for the ACIS VSV connector for the fuel pressure control For California vehicles, install the VSV connector for the EVAP VSV connector for the EGR DLC1 to the bracket on the intake air control valve Accelerator cable automatic transmission throttle cable V-bank cover Air cleaner hose Coolant Negative battery cable

2JZ-GE Engine

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. Wait at least 90 seconds before proceeding with any other work. Coolant VSV connector Vacuum sensing hose from the fuel pressure control and the air intake chamber. With automatic transmissions, transmission dipstick and guide. EGR pipe EGR gas temperature sensor connector from the No. 2 vacuum pipe and wiring connector. No. 2 vacuum pipe from the air intake chamber and from the intake manifold. 2 nuts holding the throttle body bracket to the cylinder head. Intake air connector from the air intake chamber by removing the 4 bolts and 2 nuts. Engine wire protector from the air intake chamber. 3 vacuum hoses from the No. 1 vacuum pipe. Vacuum hose from the air intake chamber Power steering air hose from the air intake chamber Brake booster vacuum hose from the air intake chamber by removing the union bolt and 2 gaskets Vacuum hose (from the actuator for ACIS) from the No. 1 vacuum pipe Fuel pressure regulator vacuum sensing hose from the air intake chamber, (except California) 2 nuts holding the air intake chamber stays to the cylinder head 2 bolts and disconnect the 2 air intake chamber stays from the air intake chamber. Air intake chamber by removing the nut and 5 bolts. CAUTION Relieve the fuel pressure in the fuel line before disconnecting any fuel lines. Failure to do so may result in fire and/or explosion. Fuel return hose Oil dipstick and guide Engine wire bracket from the water pump. Ground straps from the intake manifold. Wire clamps from the intake manifold. 6 injector connectors ECT sensor and the ECT sender gauge connectors Engine wire protector from the intake manifold. Intake manifold stay Fuel inlet pipe clamp bolt from the intake manifold. Union bolt and disconnect the fuel inlet pipe. Intake manifold and gaskets. To install: 3. Thoroughly clean the contact surfaces of the head and manifold. 4. Install or connect the following: New gasket and intake manifold. Bolts and nuts: 20 ft. lbs. (27 Nm). Inlet pipe with new gaskets. Bolt: 30 ft. lbs. (42 Nm). clamp bolt to the intake manifold. Intake manifold stay. Bolts: 29 ft. lbs. (39 Nm). Engine wire protector to the intake manifold with the 3 nuts. 6 injector connectors ECT sender gauge and connectors 2 wire clamps to the intake manifold with the bolts. 2 ground straps to the intake manifold with the bolts. Engine wire bracket to the water pump with the bolt. New gasket on the air intake chamber

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NOTE: The protrusion on the gasket faces rearward. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Intake air chamber, nut and 5 bolts. 2 air intake chamber stays to the air intake chamber. Bolts: 13 ft. lbs. (18 Nm). 2 nuts holding the air intake chamber to the cylinder head. Nuts: 13 ft. lbs. (18 Nm). Except California vehicles, connect the vacuum sensing hose (from the fuel pressure regulator) to the air intake chamber. Vacuum hose (from the actuator for ACIS) to the No. 1 vacuum pipe. Brake booster vacuum hose to the air intake chamber. Tighten the union bolt to 22 ft. lbs. (29 Nm). Power steering air hose to the air intake chamber Vacuum hose (from the No. 2 vacuum pipe) to the air intake chamber 3 vacuum hoses (from the No. 2 vacuum pipe) to the No. 1 vacuum pipe Engine wire protector to the air intake chamber and install the bolt. 4 bolts and 2 nuts holding the intake air connector to the air intake chamber. Throttle body bracket to the cylinder head. Nuts: 15 ft. lbs. (21 Nm). No. 2 vacuum pipe to the air intake chamber and intake manifold. Nuts: 20 ft. lbs. (27 Nm). EGR gas temperature sensor connector. EGR pipe. Union nut: 47 ft. lbs. (64 Nm). Bolts: 20 ft. lbs. (27 Nm). Oil dipstick guide and dipstick. Fuel return hose With automatic transmission, transmission oil dipstick guide and dipstick. VSV for the fuel pressure control. Negative battery cable Coolant

2JZ-GTE Engine 1. 2. 3. 4.

Before servicing the vehicle, refer to the precautions in the beginning of this section. Relieve fuel system pressure. Drain the engine coolant from the radiator and engine. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Undercover Accelerator and cruise control actuator cables Throttle position sensor connector Sub throttle position sensor connector Sub throttle actuator connector Throttle body from the air intake chamber by removing the 2 bolts and 2 nuts. Gasket from the throttle body. EVAP hose Water bypass hose (from the No. 4 water bypass pipe) Power steering air hose Throttle body With automatic transmissions, transmission dipstick and guide. Oil dipstick and guide Air intake chamber stay Control cable bracket from the air intake chamber. IAC valve connector Turbo pressure sensor connector VSV connector for the fuel pressure control VSV connector for the EGR valve Engine wire protector IAC valve pipe from the clamp on the cylinder head cover and disconnect the air hose form the

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IAC valve Air hose (from the air intake chamber) from the vacuum pipe on the IAC valve pipe Air hose for the EGR from the valve pipe PCV hose from the PCV valve Vacuum sensing hose from the fuel pressure regulator Water bypass hose (from the IAC valve) from the No. 4 water bypass pipe EVAP hose (from the air intake chamber) from the vacuum pipe on the manifold stay EVAP hose (from the vacuum pipe on the No. 4 water bypass pipe) from the No. 2 vacuum pipe EVAP hose (from the charcoal canister) from the No. 2 vacuum pipe Power steering air hose from the air intake chamber Brake booster vacuum hose from the union on the air intake chamber EGR gas temperature sensor connector from the No. 2 vacuum pipe and wiring connector. EGR pipe. No. 4 water bypass pipe Intake manifold stay Ground cable from the intake manifold Engine wire protector from the intake manifold. Engine wire protector from the brackets. Engine wire bracket. Air intake air chamber assembly from the intake manifold. Water bypass hose from the IAC valve. 6 injector connectors Camshaft position sensor connectors Engine wire clamps from the injector holders Fuel inlet pipe from the delivery pipe. Fuel return pipe from the fuel pressure regulator. Intake manifold and delivery pipe assembly. To install: 5. Install or connect the following: New gasket, the intake manifold and delivery pipe assembly. Bolts and nuts: 20 ft. lbs. (27 Nm). Fuel return pipe to the fuel pressure regulator. Union bolts: 20 ft. lbs. (27 Nm). Fuel inlet pipe to the delivery pipe. Union bolt: 30 ft. lbs. (41 Nm). Engine wire clamps to the injector holders. Camshaft position sensor connectors Injector connectors. The No. 1, 3, and 5 injector connectors are dark gray; the No. 2, 4, and 6 injector connectors are gray. Air intake chamber gasket. Water bypass hose to the IAC valve. Air intake chamber assembly to the intake manifold and install the 5 bolts and 2 nuts. Tighten the nuts and bolts in several passes to 20 ft. lbs. (27 Nm). Engine wire protector Ground cable to the intake manifold Intake manifold stay. Bolts: 29 ft. lbs. (39 Nm). No. 4 water bypass pipe EGR pipe and gasket with the 2 bolts. Bolts: 20 ft. lbs. (27 Nm). Union bolt holding the EGR pipe to the EGR valve. Bolt: 47 ft. lbs. (64 Nm). EGR gas temperature sensor connector. Brake booster vacuum hose to the union on the air intake chamber Power steering air hose to the air intake chamber EVAP hose (from the charcoal canister) to the No. 2 vacuum pipe EVAP hose (from the vacuum pipe on the No. 4 water bypass pipe) to the No. 2 vacuum pipe EVAP hose (from the air intake chamber) to the vacuum pipe on the manifold stay Water bypass hose (from the IAC valve) to the No. 4 water bypass pipe

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Vacuum sensing hose to the fuel pressure regulator PCV hose to the PCV valve Air hose for the EGR to the valve pipe Air hose (from the air intake chamber) to the vacuum pipe on the IAC valve pipe Connect the IAC valve pipe to the clamp on the cylinder head cover Connect the air hose to the IAC valve Engine wire protector to the vehicle body with the bolt. VSV connector for the EGR valve and the fuel pressure control Turbo pressure sensor and the IAC valve connectors Control cable bracket to the intake chamber. Bolts: 14 ft. lbs. (19 Nm). Intake chamber stay. Nut and bolt: 14 ft. lbs. (19 Nm). Oil dipstick guide and dipstick. Use a new O-ring for the dipstick guide. Transmission oil dipstick guide and dipstick. Use a new O-ring for the dipstick guide. Throttle body Power steering air hose Water bypass hose (from the cylinder head) Water bypass hose (from the No. 4 water bypass pipe) EVAP hose Gasket and throttle body to the air intake chamber. Nuts and bolts: 15 ft. lbs. (21 Nm). Sub throttle actuator connector Sub throttle position sensor connector Throttle position sensor connector Cruise control actuator and the accelerator cables Air hose Coolant Undercover Negative battery cable

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Exhaust_Manifold.htm

Exhaust Manifold REMOVAL & INSTALLATION 5E-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable from the battery. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. All electrical wires and vacuum hoses that interfere with removal of the exhaust manifold. Exhaust heat insulator Exhaust pipe stay Exhaust pipe from the manifold by removing the 2 bolts and 2 compression springs. Exhaust manifold To install: 3. Clean the gasket surfaces 4. Install or connect the following: Exhaust manifold. Bolts: 35 ft. lbs. (47 Nm). Exhaust stay to the engine and exhaust manifold. Bolt and nuts: 29 ft. lbs. (40 Nm). Exhaust manifold heat insulator. Bolts: 69 inch lbs. (8 Nm). Exhaust pipe to the exhaust manifold with the 2 compression springs and 2 bolts. Bolts: 46 ft. lbs. (62 Nm). All electrical wires and vacuum hoses that were disconnected for removal of the exhaust manifold. Negative battery cable

1NZ-FE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable from the battery. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. All electrical wires and vacuum hoses that interfere with removal of the exhaust manifold. Exhaust heat insulator Exhaust pipe stay Exhaust pipe from the manifold by removing the 2 bolts and 2 compression springs. Exhaust manifold To install: 3. Clean the gasket surfaces 4. Install or connect the following: Exhaust manifold. Bolts: 20 ft. lbs. (27 Nm). Exhaust stay to the engine and exhaust manifold. Bolt and nuts: 29 ft. lbs. (40 Nm). Exhaust manifold heat insulator. Bolts: 71 inch lbs. (8 Nm). Exhaust pipe to the exhaust manifold with the 2 compression springs and 2 bolts. Bolts: 46 ft. lbs. (62 Nm).

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All electrical wires and vacuum hoses that were disconnected for removal of the exhaust manifold. Negative battery cable

4A-FE and 7A-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Bolts holding the front exhaust pipe to the mounting bracket. Front exhaust pipe from the manifold. Main oxygen sensor connector Upper heat insulator Exhaust manifold and gasket. Lower heat insulator from the exhaust manifold. To install: 3. Install or connect the following: Lower heat insulator to the exhaust manifold. New gasket and the exhaust manifold. Nuts, uniformly tightened in several passes: 25 ft. lbs. (34 Nm). Upper heat insulator Front exhaust pipe with a new gasket to the exhaust manifold. Nuts: 46 ft. lbs. (62 Nm). Main oxygen sensor connector Negative battery cable

1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Drive belt and alternator Air intake duct Accelerator cable Exhaust pipe from the manifold Exhaust manifold support bracket Heat insulator from the dash panel. Upper heat insulator Exhaust manifold If necessary, the lower heat insulator from the exhaust manifold.

Exhaust manifold mounting nut locations — 1.8L (1ZZ-FE) engine

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To install: 3. Install or connect the following: Lower heat insulator on the exhaust manifold. Bolts: 108 inch lbs. (12 Nm). Exhaust manifold using a new gasket. Nuts, tightened several passes: 27 ft. lbs. (37 Nm). Upper heat insulator. Bolts: 108 inch lbs. (12 Nm). Heat insulator on the dash panel. Exhaust manifold support bracket. Bolts in an alternating pattern: 37 ft. lbs. (49 Nm). Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm). Oxygen sensor, using new gasket and nuts. Nuts: 14 ft. lbs. (20 Nm). Accelerator cable and air intake duct. Alternator and drive belt. Coolant Negative battery cable

2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Drive belt and alternator Air intake duct Accelerator cable Exhaust pipe from the manifold Exhaust manifold support bracket Heat insulator from the dash panel. Upper heat insulator Exhaust manifold If necessary, the lower heat insulator from the exhaust manifold. To install: 3. Install or connect the following: Lower heat insulator on the exhaust manifold. Bolts: 15 ft. lbs. (20 Nm).

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Exhaust manifold using a new gasket. Nuts, tightened several passes: 37 ft. lbs. (50 Nm). Upper heat insulator. Bolts: 15 ft. lbs. (20 Nm). Heat insulator on the dash panel. Exhaust manifold support bracket. Bolts: 37 ft. lbs. (49 Nm). Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm). Oxygen sensor, using new gasket and nuts. Nuts: 14 ft. lbs. (20 Nm). Accelerator cable and air intake duct. Alternator and drive belt. Coolant Negative battery cable

5S-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Bolts holding the front exhaust pipe to the mounting bracket. Front exhaust pipe from the manifold. Main oxygen sensor connector and the sub oxygen sensor connector. Left-hand exhaust manifold stay Upper manifold heat insulator Right-hand exhaust manifold stay Exhaust manifold, and the 3-way catalytic converter assembly. Oxygen sensor and gasket from the exhaust manifold. Sub oxygen sensor from the 3-way catalytic converter. Lower heat insulator from the exhaust manifold. 3-way catalytic converter heat insulators. 3-way Catalytic Converter (TWC), gasket, retainer and cushion from the exhaust manifold. To install: 3. Place the cushion, retainer, and a new gasket on the TWC and reinstall it to the exhaust manifold with the bolts and the nuts. Bolts and nuts: 22 ft. lbs. (30 Nm). 4. Install or connect the following: Lower manifold heat insulator and TWC heat insulators with the bolts. Main oxygen sensor to the exhaust manifold with a new gasket and new nuts. Nuts: 14 ft. lbs. (19 Nm). Sub oxygen sensor to the front TWC and tighten to 33 ft. lbs. (45 Nm). Exhaust manifold, using new gasket and front TWC assembly to the engine with the nuts. Nuts, tighten uniformly in several passes: 36 ft. lbs. (49 Nm). Right-hand exhaust manifold stay. Bolts and nuts: 31 ft. lbs. (42 Nm). Upper heat insulator Left-hand exhaust manifold stay. Bolt: 29 ft. lbs. (39 Nm). Nut: 31 ft. lbs. (42 Nm). Main and the sub oxygen sensors connectors. Front exhaust pipe with a new gasket to the TWC. Nuts: 46 ft. lbs. (62 Nm). Front exhaust pipe to the exhaust pipe bracket. Bolts: 14 ft. lbs. (19 Nm). Negative battery cable

1MZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

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Negative battery cable from the battery. Undercovers Front exhaust pipe from the exhaust manifold. EGR pipe from the exhaust manifold. Heated oxygen sensor connector from the right exhaust manifold. Exhaust manifold stay Exhaust manifold To install: 3. Install or connect the following: Exhaust manifold using new gasket. Bolts, uniformly tightened: 36 ft. lbs. (49 Nm). Exhaust manifold stay. Bolt and nut: 15 ft. lbs. (20 Nm). Heated oxygen sensor connector to the right exhaust manifold. EGR pipe, using new gaskets, to the exhaust manifold and the engine. Nuts: 108 inch lbs. (12 Nm). Front exhaust pipe, using new gasket, to the exhaust manifold. Nuts: 46 ft. lbs. (62 Nm). Undercovers Negative battery cable

2JZ-GTE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Coolant Cruise control actuator cable from the throttle body No. 1 air hose Air cleaner and MAF meter assembly Theft deterrent horn from the body. Undercover Front lower arm bracket stay Front upper crossmember extension No. 2 front exhaust pipe Heat insulator for the No. 2 front exhaust pipe With automatic transmission, automatic transmission oil cooler tubes from the engine. Engine wire protector from the body Heater hose from the No. 3 water bypass pipe. EVAP hose from the No. 1 vacuum pipe. IAC valve pipe from the No. 2 air tube No. 1 vacuum pipe from the air tubes VSV assembly Crankshaft position sensor connector from the clamp. Water bypass hose (from the water pump) from the No.1 turbo water pipe. Water bypass hose (from the water outlet) from the No. 1 turbo water pipe. Water bypass hose (from the water outlet) from the No. 2 turbo water pipe. No. 2 turbo water pipe from the No. 4 air tube. No. 1 air tube from the No. 1 turbocharger by removing the 2 bolts. 2 bolts holding the No. 4 air tube to the No. 1 turbocharger. Air hose from the No. 4 air tube. Air hose from the intake air connector. No. 4 air tube and air bypass valve assembly. Intake air control valve and gasket by removing the 2 nuts. Air hose from the No. 2 air tube.

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PCV hose from the No. 2 cylinder head cover. Intake air connector and No. 1 air tube assembly. Air inlet duct and cable bracket Heat insulator for the turbocharger Exhaust bypass pipe and gasket Exhaust gas control valve stay Main heated oxygen sensor by disconnecting the electrical connector and 2 nuts. Exhaust gas control valve No. 1 turbocharger stay No. 2 turbocharger stay Union bolt holding the No. 1 turbo oil pipe to the cylinder block. Remove the 2 gaskets. 2 nuts and disconnect the turbo oil pipe from the turbocharger. Remove the gaskets. Turbo oil hose from the turbo oil outlet on the No. 1 oil pan. Remove the turbo oil pipe. Union bolt holding the No. 2 turbo oil pipe to the cylinder block. Remove the 2 gaskets. Turbo oil pipe from the turbocharger. Remove the 2 gaskets. Turbo oil hose from the turbo oil outlet on the No. 1 oil pan and remove the turbo oil pipe. Heater hose (from the No. 3 water bypass pipe) from the No. 2 water bypass pipe. Water bypass hose (from the No. 2 turbo water pipe) from the No. 2 water bypass pipe. 8 nuts holding the turbochargers to the exhaust manifold. 2 turbochargers and turbine outlet elbow assembly. 2 gaskets. Exhaust manifold To install: 3. Install or connect the following: Exhaust manifold with 2 new gaskets. Tighten the nuts, in several passes and in sequence: 29 ft. lbs. (39 Nm).

Exhaust manifold bolt installation sequence — 3.0L (2JZ-GTE) engine

2 new gaskets and the turbochargers and turbine outlet elbow assembly to the exhaust manifold. 8 new nuts and uniformly tighten the nuts in several passes. Nuts: 40 ft. lbs. (54 Nm). Water bypass hose (from the No. 2 turbo water pipe) to the No. 2 water bypass pipe. Heater hose (from the No. 3 water bypass pipe) to the No. 2 water bypass pipe. No. 2 turbo oil pipe. Nuts: 15 ft. lbs. (21 Nm). Union bolt: 29 ft. lbs. (39 Nm). No. 1 turbo oil pipe. Nuts: 15 ft. lbs. (21 Nm). Union bolt: 29 ft. lbs. (39 Nm). No. 2 turbocharger stay. Nut and bolt: 32 ft. lbs. (43 Nm). No. 1 turbocharger stay. Nut and bolt: 32 ft. lbs. (43 Nm). Exhaust gas control valve by installing 2 new gaskets and the 3 nuts. Nuts: 51 ft. lbs. (69 Nm). Main heated oxygen sensor. Nuts: 14 ft. lbs. (20 Nm).

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Exhaust gas control valve stay. Bolt and nut: 32 ft. lbs. (43 Nm). Exhaust bypass pipe, with 2 new gaskets. Nuts: 18 ft. lbs. (25 Nm). Heat insulator for the turbocharger Air inlet duct Intake air connector and No. 1 air tube assembly. PCV hose to the No. 2 cylinder head cover. Air hose to the No. 2 air tube. Intake air control valve and gasket. Nut: 15 ft. lbs. (21 Nm). No. 4 air tube and air bypass valve assembly. Air hose to the intake air connector. Air hose to the No. 4 air tube. 2 bolts holding the No. 4 air tube to the No. 1 turbocharger. Bolt: 15 ft. lbs. (21 Nm). No. 1 air tube to the No. 1 turbocharger and install the 2 bolts. Bolts: 15 ft. lbs. (21 Nm). No. 2 turbo water pipe to the No. 4 air tube Water bypass hose (from the water outlet) to the No. 2 turbo water pipe. Water hose (from the water outlet) to the No. 1 turbo water pipe. Water bypass hose (from the water pump) to the No. 1 turbo water pipe. Crankshaft position sensor connector to the clamp. VSV assembly No. 1 vacuum pipe to the air tubes and install the 3 bolts. 2 air hoses (from the vacuum pressure tank) to the vacuum pipe. Air hose to the VSV for the intake air control valve. Air hose (from the No. 2 air tube) from the vacuum pipe. 2 air hoses (from the VSV for exhaust bypass valve) to the vacuum pipe. Vacuum hose (from the air bypass valve) to the No. 1 air tube. Air hose (from the VSV for exhaust gas control valve) to the vacuum pipe. Air hose (from the VSV for waste gate valve) to the vacuum pipe. Air hose to the No. 1 air tube. Air hose to the No. 4 air tube. Engine wire to the 3 clamps. VSV connector for the exhaust bypass valve. VSV connector for the intake air control valve. IAC valve pipe to the No. 2 air tube EVAP hose to the No. 1 vacuum pipe. Heater hose to the No. 3 water bypass pipe. Engine wire protector to the body Automatic transmission oil cooler tubes to the engine. Heat insulator for the No. 2 front exhaust pipe No. 2 front exhaust pipe, using new gasket. Nuts: 46 ft. lbs. (62 Nm). Front exhaust pipe to the No. 2 exhaust pipe and install the pipe support bracket. Bolts: 32 ft. lbs. (43 Nm). Bolts and nuts to hold the front exhaust pipe to the No. 2 front exhaust pipe. Tighten to 43 ft. lbs. (58 Nm). Upper front crossmember extension. Bolts to 22 ft. lbs. (29 Nm). Nuts: 25 ft. lbs. (33 Nm). Front lower arm bracket stay. Bolts: 33 ft. lbs. (44 Nm). Nut: 43 ft. lbs. (59 Nm). Theft deterrent horn Air cleaner and MAF meter Air cleaner duct No. 1 air hose Cruise control actuator cable to the throttle body Undercover Coolant Negative battery cable

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2JZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. Wait at least 90 seconds before performing any other work. O2sensors at the exhaust manifolds. If equipped, outside heat insulator 3. Remove the 4 nuts to disconnect the manifold from the front exhaust pipe. Loosen the mounting nuts to the exhaust manifolds and remove the 2 manifolds and the gasket. To install: 4. Scrape the mating surfaces of all old gasket material. 5. Install or connect the following: Manifolds with a new gasket. Nuts: 29 ft. lbs. (39 Nm). Front exhaust pipe, using new gasket, to the exhaust manifolds. Nuts: 46 ft. lbs. (62 Nm). Outer heat insulator. Nuts: 13 ft. lbs. (18 Nm). O2sensors Undercovers Negative battery cable

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Front Crankshaft Seal

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Front_Crankshaft_Se...

Front Crankshaft Seal REMOVAL & INSTALLATION NOTE: The following procedures apply to engines using a timing belt. The procedures for front cover seals can be found later in this section.

5E-FE Engine NOTE: The front oil seal can be removed from the engine without removing the oil pump. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable from the battery. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Front covers and the timing belt Crankshaft timing belt sprocket WARNING When removing the front seal, be extremely careful not to damage the crankshaft. 3. Using a knife, cut off the oil seal lip. 4. Tape the end of a flat bladed tool to avoid damaging crankshaft. Pry out the oil seal using the taped end of the tool. 5. Inspect the oil seal riding surface on the crankshaft for signs of wear or damage. To install: 6. Wipe the seal bore with a clean rag. 7. Apply multipurpose grease the lip of a new oil seal. 8. Drive the oil seal into place. Be sure the seal surface is flush with the oil pump case edge. Work from the front of the cover. Be extremely careful not to damage the seal. 9. Install or connect the following: Sprocket without disturbing the Woodruff key. Timing belt and front covers Negative battery cable

4A-FE, 7A-FE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Timing belt and crankshaft sprocket 3. Using a utility knife, cut off the oil seal lip. WARNING When removing the oil seal, be careful not to damage the crankshaft or the oil pump housing.

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4. Carefully pry out the oil seal from the oil pump housing. To install: 5. Apply clean engine oil to the new oil seal. 6. Coat the inside of the new oil seal with multi-purpose grease. 7. Install or connect the following: New oil seal to the oil pump Timing belt and crankshaft sprocket Negative battery cable

5S-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. NOTE: The front oil seal can be removed from the engine without removing the oil pump. 3. 4. 5. 6.

Timing belt covers and the timing belt Front crankshaft gear from the crankshaft. Be sure not to damage any part of the crankshaft. Using a knife, cut off the oil seal lip. Pry out the oil seal. Wrap the edge of the tool with a rag or tape to prevent damaging the crankshaft. Be careful not to damage the crankshaft. To install:

7. 8. 9. 10.

Using a new seal, apply a thin layer of liquid sealer to the outside of the seal. Apply multi purpose grease to the new oil seal lip. Oil seal until its surface is flush with the oil pump body edge. Install or connect the following: Timing belt and the timing belt covers All other components Negative battery cable

1MZ-FE Engine

AVALON, CAMRY AND CAMRY SOLARA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Timing belt Crankshaft timing gear 3. Cut out the lip portion of the oil seal. 4. Tape the end of a suitable prybar to protect the crankshaft and carefully remove the oil seal. WARNING Be careful not to damage the crankshaft sealing surface.

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To install: 5. Apply multi-purpose grease to the lip of a new oil seal. Also apply a light coating of liquid sealant to the outside of the oil seal. 6. Oil seal, until its surface is flush with the oil pump case edge. 7. Install or connect the following: Crankshaft timing gear Timing belt Negative battery cable

2JZ-GE and 2JZ-GTE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Timing belt Crankshaft timing pulley 3. Cut the oil seal lip. 4. Tape the end of a small prying tool and remove the oil seal. WARNING Be careful not to damage the crankshaft. To install: 5. Apply multi-purpose grease to a new oil seal lip. 6. Oil seal, until its surface is flush with the oil pump case edge. 7. Install or connect the following: Crankshaft timing pulley Timing belt

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Camshaft(s)

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Camshaft_s_.htm

Camshaft(s) REMOVAL & INSTALLATION 5E-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Valve cover Timing belt assembly Camshaft timing sprocket WARNING Due to the relatively small amount of camshaft thrust clearance, the camshaft must be kept level during removal. If the camshaft is not level on removal, the portion of the head receiving the thrust may crack or be damaged. 3. Set the intake camshaft so the service bolt holes of the intake camshaft gears are directly up. 4. Remove each front bearing cap of the intake and exhaust camshafts. 5. Secure the intake camshaft sub-gear to the main gear with a 6mm diameter bolt, 16–20mm long and with a pitch of 1.0mm. Be sure that the torsional spring force of the subgear has been eliminated by the above operation. 6. In correct sequence, loosen and remove the 8 bolts of the 4 bearing caps of the exhaust camshaft and remove the exhaust camshaft. If the camshaft is not being lifted out straight, install the middle bearing cap and loosen it evenly to keep the camshaft straight. 7. In the reverse order of the installation sequence, loosen and remove the 8 bolts of the 4 bearing caps of the intake camshaft and remove the intake camshaft. If the camshaft is not being lifted out straight, install the middle bearing cap and loosen it evenly to keep the camshaft straight. 8. Remove the adjusting shim. To install: 9. 10. 11. 12.

Install the valve shim to the engine. Apply engine oil to the surface of the intake camshaft. Place the intake camshaft on the cylinder head so the service bolt points directly up. Install the 4 rearward bearing caps in their original order and temporarily tighten them evenly. Do not tighten the bolts at this time.

Securing the intake camshaft subgear to the main gear — 1.5L (5E-FE) engine

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Camshaft(s)

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Exhaust and intake camshaft gear timing marks — 1.5L (5E-FE) engine

Correct exhaust and intake camshaft gear timing mark alignment — 1.5L (5E-FE) engine

Tighten the intake camshaft bearing cap bolts in sequence — 1.5L (5E-FE) engine

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Camshaft(s)

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Tighten the exhaust bearing cap bolts according to the sequence shown — 1.5L (5E-FE) engine

13. Apply engine oil to the portion of the exhaust camshaft. 14. Engage the exhaust camshaft gear to the intake camshaft gear by matching the proper timing marks on each gear. 15. Roll down the exhaust camshaft onto the bearing journals while engaging the gears with each other. NOTE: There are other marks present for the "S" engine. Do not use these marks. 16. Install the 4 rearward intake bearing caps in their original order and tighten evenly. Do not tighten the bolts at this time. 17. Remove the service bolt. 18. Clean the mating surfaces of the No. 2 bearing cap and apply sealer. Install and temporarily tighten the bolts. Install the camshaft housing plug. 19. Tighten the intake camshaft cap bolts to 108 inch lbs. (13 Nm), in the proper sequence. 20. Apply grease to a new camshaft oil seal lip and install it as far as the deepest part of the cylinder head. 21. Install the No. 1 bearing cap and temporarily tighten the bolts. 22. Tighten the exhaust camshaft bearing cap bolts to 108 inch lbs. (13 Nm) evenly and in the proper sequence. 23. Turn the camshaft 1 revolution and check that the timing marks of the camshaft gears are aligned. 24. Check and adjust the valve clearance. 25. Install or connect the following: Valve cover Camshaft timing sprocket. Bolt: 37 ft. lbs. (50 Nm). Timing belt Negative battery cable to the battery

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Camshaft(s)

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1NZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Battery ground cable Coolant Water filler Outer front cowl top panel Alternator Air cleaner Accelerator cable Center exhaust pipe Exhaust manifold support Exhaust manifold Ignition coil Spark plugs PCV hoses Throttle body Engine wiring harness at the head Intake manifold Camshaft position sensor ECT sensor Oil control valve PCV valve Oil filer cap Cylinder head cover Fuel injectors Timing chain cover Camshaft sprockets and valve timing control assembly Camshafts To install:

Fig. 1: Camshaft bolt torque sequence — 1NZ-FE engine

3. Install or connect the following: Camshafts. Camshaft bearing caps in 2 stages: 1st---10 ft. lbs. (13 Nm); 2nd---17 ft. lbs. (23 Nm). Sprockets and valve timing controller assembly, aligning the knock pin and hole. Torque the bolts to 47 ft. lbs. (64 Nm). Check and adjust the valves. Cylinder head cover

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Camshaft(s)

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Oil filler cap PCV valve ECT sensor Camshaft position sensor Timing chain cover Intake manifold Engine wiring harness Throttle body PCV hoses Spark plugs Ignition coils Exhaust manifold Exhaust manifold support. Torque the bolts to 27 ft. lbs. (37 Nm). Front exhaust pipe. Torque the nuts to 46 ft. lbs. (62 Nm). Accelerator cable Air cleaner Alternator Water filler Coolant Battery ground cable

4A-FE and 7A-FE Engines Positioning the exhaust camshaft for removal — 1.6L (4A-FE) and 1.8L (7A-FE) engines

Setting the knockpin to remove the intake camshaft — 1.6L (4A-FE) engine

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Camshaft(s)

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Spark plug wires Valve cover Timing belt covers Timing belt and idler pulley 3. Set the exhaust camshaft so that the knock pin is slightly above the cylinder head. This angle allows the No. 1 and No. 3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly. 4. Remove the 2 bolts and the front bearing cap of the intake camshaft. 5. Secure the intake camshaft end gear to the sub-gear with a service bolt. The service bolt should match the following specifications: Thread diameter: 6.0mm Thread pitch: 1.0mm Bolt length: 16mm 6. Uniformly loosen each intake camshaft bearing cap bolt in several passes in the reverse order of the installation sequence. WARNING The camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the thrust may crack or become damaged. In turn, this could cause the camshaft to bind or break. Before removing the intake camshaft, be sure the rotational force has been removed from the sub-gear; that is, the gear should be in a neutral or "unloaded" state. 7. Remove the 4 bearing caps and remove the intake camshaft. NOTE: If the camshaft cannot be removed straight and level, install and tighten the No. 3 bearing cap. Alternately loosen the bolts on the bearing cap a little at a time while pulling upwards on the camshaft gear. DO NOT attempt to pry or force the cam loose with tools. 8. With the intake camshaft removed, turn the exhaust camshaft approximately 105 degrees, so that the guide pin in the end is just past the 5 o'clock position. This angle allows the No. 1 and the No. 3 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly. 9. Loosen the camshaft bearing cap bolts a little at a time and in the reverse order of the installation sequence. 10. Remove the bearing caps and remove the exhaust camshaft. After removal, label each cap. NOTE: If the camshaft cannot be removed straight and level, install and tighten the No. 3 bearing cap. Alternately loosen the bolts on the bearing cap a little at a time while pulling upwards on the

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Camshaft(s)

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camshaft gear. DO NOT attempt to pry or force the cam loose with tools. 11. Remove the valve lifter shims and hydraulic lifters. Identify each lifter and shim as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in a sealed container. To install: 12. Install the valve lifters into their original positions and install the shims. Check the valve clearance and replace the shims as necessary. 13. When reinstalling, remember that the camshafts must be handled carefully and kept straight and level to avoid damage. 14. Apply multi-purpose grease to the portion of the camshaft. 15. Place the exhaust camshaft on the cylinder head so that the cam lobes press evenly on the lifters for cylinders Nos. 1 and 3. This will place the guide pin on the camshaft slightly counterclockwise from the vertical axis (about 5 o'clock). 16. Apply a light coat of clean engine oil to the camshaft bearing cap bolts. Install the 5 bearing caps in position according to the number cast into the cap. The arrow should point towards the pulley end (front) of the motor.

Securing the intake camshaft subgear to the drive gear — 1.6L (4A-FE) engine

Exhaust camshaft bearing cap tightening sequence — 1.6L (4A-FE) and 1.8L (7A-FE) engines

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Camshaft(s)

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Intake camshaft bearing cap tightening sequence — 1.6L (4A-FE) and 1.8L (7A-FE) engines

17. Tighten the bearing cap bolts uniformly and in several passes in the proper sequence to 108 inch lbs. (13 Nm). 18. Apply multi-purpose grease to a new exhaust camshaft oil seal. 19. Install the exhaust camshaft oil seal using a seal driver. Be very careful not to install the seal on a slant or allow it to tilt during installation. 20. Set the exhaust camshaft so that the guide pin is slightly above the cylinder head. 21. Apply multi-purpose grease to the portion of the intake camshaft. 22. Hold the intake camshaft next to the exhaust camshaft and engage the gears by matching the installation marks on each gear.

Engaging the intake camshaft gear to the exhaust camshaft gear, matching the installation marks — 1.6L (4A-FE) engine

NOTE: DO NOT use the TDC timing marks for the timing belt. 23. Keeping the gears engaged, roll the intake camshaft down and into its bearing journals. This angle allows the No. 1 and the No. 3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly. 24. Apply a light coat of clean engine oil to the camshaft bearing cap bolts and install the 4 bearing caps. Observe the numbers on each cap and make certain the arrows point to the pulley end (front) of the motor. 25. Uniformly tighten each of the 8 bearing cap bolts in several passes in the proper sequence: 108 inch lbs. (13 Nm). 26. Remove any retaining pins or bolts in the intake camshaft gears.

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Camshaft(s)

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27. Apply a light coat of clean engine oil to the camshaft bearing cap bolts and install the No. 1 bearing cap for the intake camshaft. Bolts: 108 inch lbs. (13 Nm). NOTE: If the No. 1 bearing cap does not fit properly, push the camshaft gear backwards by prying between the cylinder head and camshaft gear. 28. Turn the exhaust camshaft clockwise, and set it with the guide pin facing upward. Check that the timing marks of the camshaft gears are aligned. The camshaft assembly installation marks should now be in the 12 o'clock position. 29. Secure the exhaust camshaft and install the timing belt pulley. Bolt: 43 ft. lbs. (59 Nm). 30. Check and adjust valve clearance. 31. Be sure that both the crankshaft and camshaft positions are set correctly, insuring that they are both set to TDC/compression for No. 1 cylinder. 32. Install or connect the following: Timing belt Timing belt covers and the valve cover Spark plug wires Negative battery cable

1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Cylinder head cover 3. Turn the crankshaft so that the No. 1 piston is at TDC on the compression stroke. Check to see that the point marks on the camshaft sprockets are facing each other, if not, rotate the crankshaft 1 full revolution.

The sprocket marks will align when the No. 1 piston is at TDC on the compression stroke — 1.8L (1ZZ-FE) engine

Hold the camshaft with a wrench while removing the sprocket bolt — 1.8L (1ZZ-FE) engine

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4. Tie the timing chain to each sprocket with string or wire to maintain correct valve timing. 5. Hold the camshafts with a wrench and remove the bolts securing the sprockets to the camshafts. 6. Using several passes, gradually remove the bearing cap bolts in the proper sequence. Then, remove the camshafts,

Camshaft bearing cap bolt removal sequence — 1.8L (1ZZ-FE) engine

To install: 7. Lubricate the camshafts with clean engine oil and place them on the cylinder head. Be sure to position the lobes for the No. 1 cylinder as shown in the illustration. 8. Install the bearing caps in their original positions. Apply clean engine oil to the threads and under the heads of the bearing cap bolts. After tightening the bolts on the No. 1 bearing cap to 17 ft. lbs. (23 Nm), tighten the remaining bolts in sequence using several passes to 10 ft. lbs. (13 Nm).

When installing the camshafts, position the lobes for the No. 1 cylinder as shown — 1.8L (1ZZ-FE) engine

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Camshaft bearing cap bolt tightening sequence — 1.8L (1ZZ-FE) engine <

9. Check the valve clearance and make adjustments as needed. 10. Install or connect the following: Camshaft sprockets and the chain Cylinder head cover Negative battery cable

2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Cylinder head cover 3. Turn the crankshaft so that the No. 1 piston is at TDC on the compression stroke. Check to see that the point marks on the camshaft sprockets are facing each other, if not, rotate the crankshaft 1 full revolution. 4. Tie the timing chain to each sprocket with string or wire to maintain correct valve timing. 5. Hold the camshafts with a wrench and remove the bolts securing the sprockets to the camshafts. 6. Using several passes, gradually remove the bearing cap bolts in the proper sequence. Then, remove the camshafts, To install:

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7. Lubricate the camshafts with clean engine oil and place them on the cylinder head. Be sure to position the lobes for the No. 1 cylinder as shown in the illustration.

Fig. 2: Camshaft bearing cap torque sequence — 2ZZ-GE engines

8. Install the bearing caps in their original positions. Apply clean engine oil to the threads and under the heads of the bearing cap bolts. After tightening the bolts on the No. 1 bearing cap to 14 ft. lbs. (18 Nm), tighten the remaining bolts in sequence using several passes to 14 ft. lbs. (18 Nm). 9. Check the valve clearance and make adjustments as needed. 10. Install or connect the following: Camshaft sprockets and the chain Cylinder head cover Negative battery cable

5S-FE Engine Intake camshaft removal and installation positioning — 2.2L (5S-FE) engine

Exhaust camshaft removal and installation positioning — 2.2L (5S-FE) engine

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Camshaft(s)

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Spark plug wires Timing belt, gears, and the covers Any wire connectors, clamps, cables, or components necessary in order to remove the cylinder head cover. Cylinder head cover and gasket 3. Set the No. 1 cylinder to TDC. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing belt cover. Check that the valve lifters on the No. 1 cylinder are loose and valve lifters on the No. 4 cylinder are tight. If not, rotate the crankshaft 360 degrees. NOTE: Since the thrust clearance on both the intake and exhaust camshafts is small, the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may damage the bearing surface, causing the camshaft to seize during engine operation. 4. Remove exhaust camshaft as follows: A. Set the knock pin of the intake camshaft at 10–45 degrees BTDC of camshaft angle on the cylinder head. This angle will help to lift the exhaust camshaft level and evenly by pushing the No. 2 and No. 4 cylinder camshaft lobes of the exhaust camshaft toward their valve lifters. B. Secure the exhaust camshaft sub-gear to the main gear using a service bolt. The manufacturer recommends a bolt 0.63–0.79 in. (16–20mm) long with a thread diameter of 6mm and a 1mm thread pitch. When removing the exhaust camshaft, be sure that the torsional spring force of the sub-gear has been eliminated. C. Remove the No. 1 and No. 2 rear bearing cap bolts and remove the cap. Uniformly loosen and remove the bearing cap bolts on the No. 1, No. 2, and No. 4 bearing caps in several passes and in the reverse order of the installation sequence. Do not remove bearing cap bolts to No. 3 bearing cap at this time. Remove the No. 1, 2, and 4 bearing caps. D. Alternately loosen and remove the bearing cap bolts on the No. 3 bearing cap. As these bolts are loosened check to see that the camshaft is being lifted out straight and level. NOTE: If the camshaft is not lifted out straight and level, tighten the No. 3 bearing cap bolts. Reverse the order of Steps 7c through 7a and reset the intake camshaft knock pin to 10–45 degrees BTDC, then repeat Steps 7a through 7c. Do not attempt to pry the camshaft from its mounting.

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E. Remove the No. 3 bearing cap and exhaust camshaft from the engine. 5. Remove intake camshaft as follows: A. Set the knock pin of the intake camshaft at 80–115 degrees BTDC of the camshaft angle on the cylinder head. This angle will help to lift the intake camshaft level and evenly by pushing No. 1 and No. 3 cylinder camshaft lobes of the intake camshaft toward their valve lifters. B. Remove the 2 front bearing cap bolts and remove the front bearing cap and oil seal. If the cap will not come apart easily, leave it in place without the bolts. C. Uniformly loosen and remove the bearing cap bolts to No. 1, No. 3, and the No. 4 bearing caps in several phases and in the reverse order of the installation sequence. Do not remove bearing cap bolts to the No. 2 bearing cap at this time. Remove No. 1, 3, and 4 bearing caps. D. Alternately loosen and remove bearing cap bolts to the No. 2 bearing cap. As these bolts are loosened and after breaking the adhesion on the front bearing cap, check to see that the camshaft is being lifted out straight and level. NOTE: If the camshaft is not lifting out straight and level tighten the No. 2 bearing cap bolts. Reverse Steps 8b through 8d, then start over from Step 8b. Do not attempt to pry the camshaft from its mounting. E. Remove the No. 2 bearing cap with the intake camshaft from the engine. 6. Remove the valve lifter shims and hydraulic lifters. Identify each lifter and shim as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in a sealed container. To install: 7. Install the valve lifters into their original positions and shims. NOTE: Before installing the intake camshaft, apply multi-purpose grease to the camshaft. 8. Install the intake camshaft, as follows: A. Position the camshaft at 80–115 degrees BTDC of camshaft angle on the cylinder head. B. Apply sealant to the front bearing cap. C. Coat the bearing cap bolts with clean engine oil. D. Tighten the camshaft bearing caps evenly in sequence and in several passes to 14 ft. lbs. (19 Nm). E. Apply MP grease to a new oil seal lip, and by using a suitable tool, tap a new oil seal into place.

Intake camshaft bearing cap bolt tightening sequence — 2.2L (5S-FE) engine

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Exhaust camshaft bearing cap bolt tightening sequence — 2.2L (5S-FE) engine

Exhaust camshaft as follows: F. Set the knock pin of the camshaft at 10–45 degrees BTDC of camshaft angle on the cylinder head. G. Apply multipurpose grease to the camshaft. H. Position the exhaust camshaft gear with the intake camshaft gear so that the timing marks are in alignment with one another. Be sure to use the proper alignment marks on the gears. Do not use the assembly reference marks. I. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals. J. Coat the bearing cap bolts with clean engine oil. K. Tighten the camshaft bearing caps evenly in sequence and in several passes to 14 ft. lbs. (19 Nm). Remove the service bolt from the assembly. 9. Check and adjust valve clearance. 10. Install or connect the following: Cylinder head cover Timing belt and related components. Electrical connectors, cables, brackets, and components attached to the cylinder head cover. Spark plug wires

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Negative battery cable

1MZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Timing belt and idler pulley Camshaft timing pulleys Cylinder head covers NOTE: The thrust clearance on both the intake and exhaust camshafts is very small; the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may be caught in the cylinder head, causing the head to break or the camshaft to seize. 3. Remove the exhaust and intake camshafts from the right side cylinder head, as follows: A. Turn the camshaft with a wrench until the 2 pointed marks on the drive and driven gears are aligned. (The right camshaft gears have 2 marks apiece; the left side camshaft gears have 1 mark each.) B. Secure the exhaust camshaft sub-gear to the main gear using a service bolt. A bolt 0.63–0.79 in. (16–20mm) long with a 6mm thread diameter and a 1mm pitch is recommended. When removing the exhaust camshaft be sure the sub-gear is not loaded; all the force must be eliminated. C. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps, keeping them in the correct order. D. Remove the exhaust camshaft from the engine. E. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the proper sequence. Remove the bearing caps, keeping them in order, remove the oil seal, then, lift out the intake camshaft. 4. Remove the exhaust and intake camshafts from the left side cylinder head, as follows: A. Turn the camshaft with a wrench until the pointed marks on the drive and driven gears are aligned. (The right camshaft gears have 2 marks apiece; the left side camshaft gears have 1 mark each.) B. Secure the exhaust camshaft sub-gear to the main gear using a service bolt. A bolt 0.63–0.79 in. (16–20mm) long with a 6mm thread diameter and a 1mm pitch is recommended. When removing the exhaust camshaft be sure the sub-gear is not loaded; all the force must be eliminated. C. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps. Keep the caps in the correct order. D. Remove the exhaust camshaft from the engine. E. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the reverse order of the installation sequence. Remove the bearing caps, keeping them in order, remove the oil seal, then lift out the intake camshaft. 5. Remove the valve lifter shims and hydraulic lifters. If the lifters are to be reused, store them upside down in a sealed container. To install:

Aligning the camshaft gear timing marks for the right camshafts — 3.0L (1MZ-FE) engine

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Camshaft installation for the right exhaust camshaft — 3.0L (1MZ-FE) engine

Bearing cap bolt tightening sequence for the right exhaust camshaft — 3.0L (1MZ-FE) engine

Bearing cap bolt tightening sequence for the right intake camshaft — 3.0L (1MZ-FE) engine

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Bearing cap bolt tightening sequence for the left exhaust camshaft — 3.0L (1MZ-FE) engine

Bearing cap bolt tightening sequence for the left intake camshaft — 3.0L (1MZ-FE) engine

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6. Install the valve lifters into their original positions and shims. Check the valve clearance and replace the shims as necessary. NOTE: Before installing the camshafts in either cylinder head, apply multi-purpose grease to each camshaft. 7. Install the right camshafts, as follows: A. Position the intake camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical. The mark should be at the "3 o'clock" position. B. Apply sealant to the No. 1 bearing cap. C. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence. D. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degrees angle from vertical. The mark must align with the marks on the other gear. E. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence. F. Remove the service bolt. 8. Install the left camshaft, as follows: A. Position the intake camshaft on the head so that the alignment mark is at a 90degrees angle from vertical. The mark should be at the "9 o'clock" position. B. Apply sealant to the No. 1 bearing cap. C. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence. D. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degree angle from vertical. The mark should be at the "3 o'clock" position and must align with the marks on the other gear. E. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence. F. Remove the service bolt. 9. Apply multi-purpose grease to new camshaft oil seals. Install the seals. 10. Install or connect the following: No. 3 (rear) timing belt cover Camshaft timing gears Idler pulley, timing belt and covers Cylinder head (valve) covers

2JZ-GTE and 2JZ-GE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Timing belt from the engine Cylinder head covers Camshaft sprocket No. 4 (inner) timing belt cover No. 1 camshaft bearing cap bolts and bearing caps. All remaining bearing cap bolts. Note that there are separate sequences for the exhaust and intake camshafts. Lift off all 12 bearing caps. Exhaust and intake camshafts

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Valve lifter shims and hydraulic lifters. Identify each lifter and shim as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in a sealed container. To install: 3. Install or connect the following: Valve lifters into their original positions Shims. Check the valve clearance and replace the shims as necessary. NOTE: When reinstalling, remember that the camshafts must be handled carefully and kept straight and level to avoid damage. 4. 5. 6. 7. 8. 9. 10.

Camshafts, coated with engine oil No. 3 and No. 7 bearing caps in place Cap bolts, coated with oil. Then tighten them temporarily. New oil seals, coated with multi-purpose grease, over the camshafts 2 No. 1 bearing caps. The mating surfaces should be coated with sealant. Install the bolts. All remaining bearing caps All remaining cap bolts, coated with clean oil. Tighten them, in several passes, in the correct sequence, to 14 ft. lbs. (20 Nm). Note that there are separate sequences for the intake and exhaust sides.

During installation, position the knock pins as shown — 3.0L (2JZ-GE and 2JZ-GTE) engines

Camshaft bearing cap bolt tightening sequence — 3.0L (2JZ-GE and 2JZ-GTE) engines

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Tightening the camshafts (Step 1) — 3.0L (2JZ-GE and 2JZ-GTE) engines



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11. Oil seal, as far as it will go 12. Rotate each camshaft until the forward straight (knock) pin is straight up. Loosen exhaust No. 1, 2 and 6 bearing cap bolts until they can be turned by hand; retighten them to 14 ft. lbs. (20 Nm). Loosen intake No. 1 and 2 bolts and retighten to 14 ft. lbs. (20 Nm). 13. Turn each camshaft 1⁄3 of a revolution (120 degrees). Loosen exhaust Nos. 4 and 7 bearing cap bolts; tighten them to 14 ft. lbs. (20 Nm). Loosen intake Nos. 4 and 6 bearing cap bolts; tighten them to 14 ft. lbs. (20 Nm). 14. Turn each camshaft an additional 1⁄3 of a revolution, loosen exhaust bearing cap bolts No. 3 and 5, then tighten them to 14 ft. lbs. (20 Nm). Loosen intake bearing cap bolts No. 3 and 7, then tighten them to 14 ft. lbs. (20 Nm). 15. Check and adjust the valve clearance. 16. Install or connect the following: No 4. inside timing belt cover and the camshaft pulleys. Align the shaft pin with the pulley groove and slide the pulley on. Install the bolt temporarily. Hold the hex portion of the camshaft with a wrench; tighten the pulley bolt to 59 ft. lbs. (79 Nm). Cylinder head covers Timing belt Negative battery cable

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Valve_Lash.htm

Valve Lash ADJUSTMENT Adjusting shim chart (intake and exhaust) — 5E-FE engine

Adjusting shim chart (intake and exhaust) — 4A-FE, 7A-FE, 5S-FE, 1MZ-FE, 2JZ-GE and 2JZ-GTE engines

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Adjusting shim chart (intake) — 1ZZ-FE engine

Adjusting shim chart (exhaust) — 1ZZ-FE engine

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Adjusting shim chart (intake) — 2ZZ-GE engine

Adjusting shim chart (exhaust) — 2ZZ-GE engine

Adjusting shim chart (exhaust) — 1NZ-FE engine

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Adjusting shim chart (intake) — 1NZ-FE engine

Common method of removing valve shims

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1NZ-FE Engine NOTE: Adjust the valve clearance when the engine is cold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Cylinder head cover 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the timing marks on the camshaft sprockets and valve timing controller are facing up (12 o'clock). If not, turn the crankshaft 1 complete revolution (360 degrees). 5. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 1 and 2. Measure the exhaust valves at No. 1 and 3. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.010–0.014 in. (0.25–0.35mm).

Intake valves (1 and 2) and exhaust valves (1 and 3) — 1NZ-FE engine

6. Turn the crankshaft pulley 1 revolution (360 degrees) and align the timing mark as before. 7. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 3 and 4. Measure the exhaust valves at No. 2 and 4. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.010–0.014 in. (0.25–0.35mm). 8. To adjust the valve clearance: A. Set the No.1 cylinder at TDC compression. Place matchmarks on the timing chain and sprockets. B. Remove the 2 plugs from the timing chain cover. C. Turn the exhaust camshaft clockwise slightly while rotating the stopper plate on the tensioner downward. Push in on the tension plunger. When the stopper plate cannot be easily lowered, rotate the exhaust camshaft clockwise and counterclockwise slightly. Insert a 3mm bar into the holes in the stopper plate and tensioner to lock the tensioner. Remove the timing chain. D. Remove the valve timing controller assembly. E. Remove the lifters. 9. Determine the replacement adjusting shim size by either using the chart or the following formula: Intake: N = T + A - 0.008 in. (0.20mm) Exhaust: N = T + A - 0.012 in. (0.30mm) T = Thickness of removed shim A = Measured valve clearance

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10. 11. 12. 13.

N = Thickness of new shim Install a new shim. Recheck the valve clearance. Install the cylinder head covers. Connect the negative battery cable.

5E-FE NOTE: Adjust the valve clearance when the engine is cold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Cylinder head covers 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover.

Intake valves (3 and 4) and exhaust valves (2 and 4) — 5E-FE engine

4. Check that the timing marks on the camshaft sprockets are in alignment with the marks on the No. 4 timing cover. If not, turn the crankshaft 1 complete revolution (360 degrees). 5. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 1 and 2. Measure the exhaust valves at No. 1 and 3. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.012–0.016 in. (0.31–0.41mm).


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6. Turn the crankshaft pulley 1 revolution (360 degrees) and align the groove with the timing mark 0 of the No.1 timing belt cover. 7. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 3 and 4. Measure the exhaust valves at No. 2 and 4. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.012–0.016 in. (0.31–0.41mm).


8. To adjust the valve clearance: A. Remove the adjusting shim and turn the crankshaft to position the cam lobe of the camshaft on the valve to be adjusted upward. B. Turn the valve lifter so that the notch is perpendicular to the camshaft and facing the spark plug side. C. Using SST 09248-55040 (valve lifter press), or equivalent, hold the camshaft in place. D. Using SST 09248-55040 (valve lifter press), or equivalent, press down the valve lifter and place SST 09248-05420 (valve lifter stopper), or equivalent between the camshaft and valve lifter. E. Remove the SST 09248-44040 tool. F. Using a small screwdriver and a magnetic finger, remove the adjusting shim. 9. Determine the replacement adjusting shim size by either using the chart or the following formula: Intake: N = T + A - 0.008 in. (0.20mm) Exhaust: N = T + A - 0.014 in. (0.36mm)

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10. 11. 12. 13.

T = Thickness of removed shim A = Measured valve clearance N = Thickness of new shim Install a new shim. Recheck the valve clearance. Install the cylinder head covers. Connect the negative battery cable.

4A-FE, 7A-FE and 1ZZ-FE Engine

Intake valves (3 and 4) and exhaust valves (2 and 4) — 1.6L (4A-FE) and 1.8L (7A-FE and 1ZZ-FE) engines

Fig. 1: Timing marks at TDC compression — 1ZZ-FE engine

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NOTE: Adjust the valve clearance when the engine is cold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. Cylinder head covers 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the timing marks on the camshaft sprockets are in alignment with the marks on the No. 4 timing cover. If not, turn the crankshaft 1 complete revolution (360 degrees). 5. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 1 and 2. Measure the exhaust valves at No. 1 and 3. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.010–0.014 in. (0.25–0.35mm). 6. Turn the crankshaft pulley 1 revolution (360 degrees) and align the groove with the timing mark 0 of the No.1 timing belt cover. 7. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 3 and 4. Measure the exhaust valves at No. 2 and 4. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.010–0.014 in. (0.25–0.35mm). 8. To adjust the intake valve clearance: A. Remove the intake camshaft. B. Using a small screwdriver and a magnetic finger, remove the adjusting shim. C. Determine the replacement adjusting shim size by either using the chart or the following formula: Intake: N = T + A - 0.008 in. (0.20mm) T = Thickness of removed shim A = Measured valve clearance N = Thickness of new shim D. Install a new shim. E. Install intake camshaft. F. Recheck the valve clearance. 9. To adjust the exhaust valve clearance: A. Turn the crankshaft to position the cam lobe of the camshaft on the valve to be adjusted, upward. B. Turn the valve lifter so that the notch is perpendicular to the camshaft and facing the spark plug side. C. Using SST 09248–55040 (valve lifter press), or equivalent, hold the camshaft in place. D. Using SST 09248–55040 (valve lifter press), or equivalent, press down the valve lifter and place SST 09248–05420 (valve lifter stopper), or equivalent between the camshaft and valve lifter. E. Remove the SST 09248–44040 tool. F. Using a small screwdriver and a magnetic finger, remove the adjusting shim. 10. Determine the replacement adjusting shim size by either using the chart or the following formula: Exhaust: N = T + A - 0.014 in. (0.36mm)

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T = Thickness of removed shim A = Measured valve clearance N = Thickness of new shim 11. Install a new shim. 12. Recheck the valve clearance. 13. Install or connect the following: Cylinder head covers Negative battery cable

2ZZ-GE Engine NOTE: Adjust the valve clearance when the engine is cold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. Cylinder head covers 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the timing marks on the camshaft sprockets are in alignment with the upper edge of the timing cover. If not, turn the crankshaft 1 complete revolution (360 degrees). 5. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 1 and 2. Measure the exhaust valves at No. 1 and 3. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.014–0.018 in. (0.36–0.45mm). 6. Turn the crankshaft pulley 1 revolution (360 degrees) and align the groove with the timing mark 0 of the No.1 timing belt cover. 7. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 3 and 4. Measure the exhaust valves at No. 2 and 4. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.014–0.018 in. (0.36–0.45mm). 8. To adjust the intake valve clearance: A. Remove the intake camshaft. B. Using a small screwdriver and a magnetic finger, remove the adjusting shim. C. Determine the replacement adjusting shim size by either using the chart or the following formula: Intake: N = T + A - 0.008 in. (0.20mm) T = Thickness of removed shim A = Measured valve clearance N = Thickness of new shim D. Install a new shim. E. Install intake camshaft. F. Recheck the valve clearance. 9. To adjust the exhaust valve clearance: A. Turn the crankshaft to position the cam lobe of the camshaft on the valve to be adjusted, upward. B. Turn the valve lifter so that the notch is perpendicular to the camshaft and facing the spark plug side. C. Using SST 09248–55040 (valve lifter press), or equivalent, hold the camshaft in place. D. Using SST 09248–55040 (valve lifter press), or equivalent, press down the valve lifter and place SST 09248–05420 (valve lifter stopper), or equivalent between the camshaft and valve lifter. E. Remove the SST 09248–44040 tool. F. Using a small screwdriver and a magnetic finger, remove the adjusting shim. 10. Determine the replacement adjusting shim size by either using the chart or the following formula: Exhaust: N = T + A - 0.014 in. (0.36mm) T = Thickness of removed shim A = Measured valve clearance

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N = Thickness of new shim 11. Install a new shim. 12. Recheck the valve clearance. 13. Install or connect the following: Cylinder head covers Negative battery cable

5S-FE Engine NOTE: Adjust the valve clearance when the engine is cold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Cylinder head covers 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the timing marks on the camshaft sprockets are in alignment with the marks on the No. 4 timing cover. If not, turn the crankshaft 1 complete revolution (360 degrees). 5. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 1 and 2. Measure the exhaust valves at No. 1 and 3. A. The intake valve clearance cold is 0.007–0.011 in. (0.19–0.29mm). B. The exhaust valve clearance cold is 0.011–0.015 in. (0.28–0.38mm).

Intake valves (1 and 2) and exhaust valves (1 and 3) — 2.2L (5S-FE) engine

6. Turn the crankshaft pulley 1 revolution (360 degrees) and align the groove with the timing mark 0 of the No.1 timing belt cover. 7. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 3 and 4. Measure the exhaust valves at 2 and 4. A. The intake valve clearance cold is 0.007–0.011 in. (0.19–0.29mm). B. The exhaust valve clearance cold is 0.011–0.015 in. (0.29–0.38mm).

Intake valves (3 and 4) and exhaust valves (2 and 4) — 2.2L (5S-FE) engine

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8. To adjust the valve clearance: A. Turn the crankshaft to position the cam lobe of the camshaft on the valve to be adjusted, upward. B. Turn the valve lifter so that the notch is perpendicular to the camshaft and facing the spark plug side. C. Using SST 09248–55040 (valve lifter press), or equivalent, hold the camshaft in place. D. Using SST 09248–55040 (valve lifter press), or equivalent, press down the valve lifter and place SST 09248–05420 (valve lifter stopper), or equivalent between the camshaft and valve lifter. E. Remove the SST 09248–44040 tool. F. Using a small screwdriver and a magnetic finger, remove the adjusting shim. 9. Determine the replacement adjusting shim size by either using the chart or the following formula: Intake: N = T + A - 0.009 in. (24mm) Exhaust: N = T + A - 0.013 in. (0.33mm) T = Thickness of removed shim A = Measured valve clearance N = Thickness of new shim 10. Install a new shim. 11. Recheck the valve clearance. 12. Install or connect the following: Cylinder head covers Negative battery cable

1MZ-FE engine NOTE: Adjust the valve clearance when the engine is cold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Accelerator/throttle cable from the throttle linkage Air cleaner cover, air flow meter, and air duct assembly V-bank cover Emission control valve set Air intake chamber Engine harness from the injectors and the ignition coils Ignition coils and keep them in order for reassembly Spark plugs Cylinder head covers 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the valve lifters on the No. 1 intake are loose and the No. 1 exhaust are tight. If not, turn the crankshaft 1 complete revolution (360 degrees).

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NOTE: All measurements should be written down. These recorded measurements will need to be used in conjunction with a mathematical formula to determine the thickness of the replacement shims. 5. Measure the clearance between the valve lifters and the camshaft. Record the measurements on valves No. 1 and 6 intake; No. 2 and 3 exhaust.

Adjust these valves during the 1st step — 3.0L (1MZ-FE) engine

A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.010–0.014 in. (0.25–0.35mm). 6. Turn the crankshaft 2⁄3 of a revolution (240 degrees). Record the measurements on valves No. 2 and 3 intake; No. 4 and 5 exhaust.

Adjust these valves during the 2nd step — 3.0L (1MZ-FE) engine

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7. Turn the crankshaft another 2⁄3 of a revolution. Record the measurements on valves No. 4 and 5 intake; No. 1 and 6 exhaust.

Adjust these valves during the 3rd step — 3.0L (1MZ-FE) engine

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8. Remove the adjusting shim by turning the crankshaft to position the cam lobe of the camshaft in the up position on the valve to be adjusted. Using a small thin flat bladed tool, turn the valve lifter so that the notches are perpendicular to the camshaft. Press down the valve lifter with SST 09248–55010 part A, or equivalent. Place SST 09248–55010 part B between the camshaft and the valve lifter; remove part A. 9. Remove the adjusting shim with a magnet and a small screwdriver. 10. Determine the replacement adjusting shim size by either using the charts or the following formulas: Intake: N = T + (A - 0.008 in./0.020mm) Exhaust: N = T + (A - 0.012 in./0.30mm) T = Thickness of removed shim A = Measured valve clearance N = Thickness of new shim 11. Select a new shim with a thickness as close as possible to the calculated value. Install the new replacement shim. NOTE: Shims are available in 17 sizes in increments of 0.0020 in. (0.050mm), from 0.0984 in. (2.500mm) to 0.1299 in. (3.300mm). 12. Recheck the valve clearance. 13. Install or connect the following: Cylinder head covers Spark plugs and the ignition coils Engine wiring harness to the injectors and the coils Intake chamber Emission control valve set V-bank cover Air flow meter, air duct, and air cleaner cover Negative battery cable

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2JZ-GE and 2JZ-GTE Engines NOTE: Adjust the valve clearance when the engine is cold. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Cylinder head covers 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the timing marks on the camshaft sprockets are in alignment with the marks on the No. 4 timing cover. If not, turn the crankshaft 1 complete revolution (360 degrees).

Valve clearance inspection (before turning crankshaft 360 degrees) — 2JZ-GE and 2JZ-GTE engines

5. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 1, 2 and 4. Measure the exhaust valves at No. 1, 3 and 5. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.010–0.014 in. (0.25–0.35mm). 6. Turn the crankshaft pulley 1 revolution (360 degrees) and align the groove with the timing mark 0 of the No.1 timing belt cover.

Valve clearance inspection (after turning crankshaft 360 degrees) — 2JZ-GE and 2JZ-GTE engines

7. Measure the clearance between the valve lifter and the camshaft. Record the measurements on the intake valves No. 3, 5 and 6. Measure the exhaust valves at No. 2, 4, and 6. A. The intake valve clearance cold is 0.006–0.010 in. (0.15–0.25mm). B. The exhaust valve clearance cold is 0.010–0.014 in. (0.25–0.35mm). 8. To adjust the valve clearance: A. Remove the adjusting shim and turn the crankshaft to position the cam lobe of the camshaft on the

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adjusting valve upward. B. Turn the valve lifter so that the notches are perpendicular to the camshaft. C. Using SST 09248–55040 (valve lifter press), or equivalent, hold the camshaft in place. D. Using SST 09248–55040 (valve lifter press), or equivalent, press down the valve lifter and place SST 09248–05420 (valve lifter stopper), or equivalent between the camshaft and valve lifter. E. Remove the SST 09248–44040 tool. F. Using a small screwdriver and a magnetic finger, remove the adjusting shim. 9. Determine the replacement adjusting shim size by either using the chart or the following formula: Intake: N = T + (A - 0.008 in./0.20mm) Exhaust: N = T + (A - 0.012 in./0.30mm) T = Thickness of removed shim A = Measured valve clearance N = Thickness of new shim 10. Recheck the valve clearance. 11. Install or connect the following: Cylinder head covers Negative battery cable

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Oil Pan

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Oil_Pan.htm

Oil Pan REMOVAL & INSTALLATION 5E-FE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Engine oil Hood Oil dipstick Timing belt Suspend the engine with a hoist. NOTE: Do not raise the engine more than necessary, since wiring and other components can be damaged. 3. 4. 5. 6. 7. 8.

Crankshaft timing sprocket and oil pump sprocket Air conditioning compressor and mounting bracket With distributor ignition, exhaust pipe stay Oxygen sensor Front exhaust pipe Oil pan To install:

9. Clean all gasket mating surfaces. 10. Install or connect the following: Oil pan, with new gasket and sealer. Bolts: 10 ft. lbs. (13 Nm). Front exhaust pipe using a new gasket. Bolts: 46 ft. lbs. (62 Nm). Oxygen sensor Exhaust pipe stay. Bolts: 14 ft. lbs. (19 Nm). Air conditioning compressor mounting bracket. Bolts: 20 ft. lbs. (27 Nm). Air conditioning compressor. Bolts: 18 ft. lbs. (25 Nm). Crankshaft timing and oil pump sprockets Timing belt Oil dipstick Oil Negative battery cable Hood

1NZ-FE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Engine oil Oil filter

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Oil Pan

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Front exhaust pipe Engine under covers Oil pan bolts 3. Using a thin blade, cut the sealer holding the oil pan and lower the pan. 4. Installation is the reverse of removal. Use RTV sealer. Torque the bolts, in a criss-cross pattern, to 80 inch lbs. (9 Nm).

4A-FE Engine

COROLLA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Undercovers Oil Front exhaust pipe Stiffener plate Bolts and nuts holding the oil pan. Cut off the applied sealer. Oil pan. To install: 3. Thoroughly clean both sealing surfaces 4. Apply a 3–5mm bead of RTV sealant to the No. 1 oil pan flange. 5. Install or connect the following: Oil pan. Bolts and nuts: 43 inch lbs. (5 Nm). Stiffener plate. Bolts: 17 ft. lbs. (23 Nm). Front exhaust pipe Oil Negative battery cable. Undercovers

Oil pan sealer application pattern — 1.6L (4A-FE) and 1.8L (7A-FE) engines

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7A-FE Engine

COROLLA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Undercovers Oil Front exhaust pipe No. 2 oil pan No. 1 oil pan To install: 3. Remove any old sealant from the oil pan flange and thoroughly clean both sealing surfaces. 4. Apply a 3–5mm bead of sealant to the No. 1 oil pan flange. 5. Install or connect the following: No. 1 oil pan. Bolts A: 12 ft. lbs. (16 Nm); Bolts B: 69 inch lbs. (8 Nm). Oil pan to transaxle bolts. Bolts: 17 ft. lbs. (23 Nm).

Mounting bolts A and B for the oil pans — 1.8L (7A-FE) engine

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6. Apply a 3–5mm bead of sealant to the No. 2 oil pan flange. 7. Install or connect: No. 2 oil pan. Bolts and nuts: 43 inch lbs. (5 Nm). Front exhaust pipe Hood Oil Negative battery cable Undercovers

CELICA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Right-hand front wheel Undercovers Oil Front exhaust pipe With automatic transmission, transaxle control cable from the engine mounting center member. With air conditioning, air conditioning pressure pipe from the engine center mounting member. Front exhaust pipe support bracket 3. Support the engine assembly 4. Remove or disconnect the following: Rear engine mounting insulator and the engine mounting center member and install an engine hanger and suspend the engine with an engine sling device. Oil dipstick guide and the dipstick No. 2 oil pan Baffle plate Oil strainer and strainer gasket No. 1 oil pan To install: 5. Remove any old sealant from the oil pan flange and thoroughly clean both sealing surfaces. 6. Apply a 3–5mm bead of sealant to the No. 1 oil pan flange. 7. Install or connect the following: No. 1 oil pan. Tighten the 14 new A bolts to 12 ft. lbs. (16 Nm). Install the 6 B bolts and tighten the

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bolts to 69 inch lbs. (8 Nm). 3 bolts holding the No. 1 oil pan to the transaxle and tighten the bolts to 17 ft. lbs. (23 Nm). Oil strainer and gasket with 3 new nuts. Nuts: 82 inch lbs. (9 Nm). Oil pan baffle plate. Bolts and nuts: 69 inch lbs. (8 Nm). 8. Apply a 3–5mm bead of sealant to the No. 2 oil pan flange. 9. Install or connect the following: No. 2 oil pan. Bolts and nuts: 43 inch lbs. (5 Nm). Rear engine mounting insulator and engine mounting center member The remaining components in the reverse order they were removed. Oil Negative battery cable. Undercovers

1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Undercovers Oil Front exhaust pipe Oil pan mounting bolts and nuts Oil pan, cutting off the applied sealer. To install: 3. Remove any old sealant from the oil pan flange and thoroughly clean the sealing surface. 4. Install or connect the following: Oil pan. Tighten the bolts and nuts in several passes. Bolts and nuts: 80 inch lbs. (9 Nm). Front exhaust pipe Oil Negative battery cable Undercovers

Apply sealant to the oil pan as shown — 1.8L (1ZZ-FE) engine

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Oil Pan

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2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Undercovers Oil Front exhaust pipe Oil pan mounting bolts and nuts Oil pan, cutting off the applied sealer. To install: 3. Remove any old sealant from the oil pan flange and thoroughly clean the sealing surface. 4. Install or connect the following: Oil pan. Tighten the bolts and nuts in several passes. Bolts and nuts: 80 inch lbs. (9 Nm). Front exhaust pipe Oil Negative battery cable Undercovers

5S-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.

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Oil Pan

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Oil Undercovers Front exhaust pipe Engine mounting center member On Celica, the 3-way Catalytic Converter (TWC) Rear end stiffener plate Oil dipstick Oil pan bolts and nuts. Cut off the applied sealer. NOTE: Do not use the cutting tool for the oil pump body side and rear oil seal retainer. To install: 3. Remove any old sealant from the oil pan flange and thoroughly clean both sealing surfaces. 4. Install or connect the following: Oil pan. Uniformly tighten the bolts and nuts in several passes. Bolts and nuts: 48 inch lbs. (5.4 Nm) Oil dipstick Rear end stiffener plate On Celica, the TWC. Engine mounting center member Front exhaust pipe Oil Negative battery cable Undercovers

Oil pan sealing diagram — 2.2L (5S-FE) engine

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Oil Pan

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1MZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Fender apron seal Undercover Oil Front exhaust pipe Front exhaust pipe bracket from the No. 1 oil pan.

No. 1 oil pan mounting bolt locations — 3.0L (1MZ-FE) engine

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No. 2 oil pan mounting bolt locations — 3.0L (1MZ-FE) engine

Flywheel housing undercover Bolts and nuts from the No. 2 oil pan. Oil strainer and gasket Remove the No.1 oil pan Baffle plate from the No. 1 oil pan To install: 3. Clean all mating surfaces of the oil pans. 4. Install or connect the following: Baffle plate to the No. 1 oil pan and tighten: 69 inch lbs. (8 Nm). Install the No. 1 oil pan. with liquid sealant. Uniformly tighten the bolts and nuts in several passes. 10mm head bolt: 69 inch lbs. (8 Nm). 12mm head bolt: 14 ft. lbs. (19.5 Nm). 14mm head bolt-27 ft. lbs. (37.2 Nm) Flywheel housing undercover. Bolts: 69 inch lbs. (7.8 Nm). Oil strainer. Nuts: 69 inch lbs. (7.8 Nm). No. 2 oil pan. Apply liquid sealant to the oil pan and engine block. Uniformly tighten the bolts and nuts in several passes. Bolts: 69 inch lbs. (7.8 Nm). Flywheel housing undercover Front exhaust pipe bracket to the No. 1 oil pan. Bolts: 15 ft. lbs. (21 Nm). Front exhaust pipe. Exhaust manifolds to the front exhaust pipe nuts: 46 ft. lbs. (62 Nm). Front

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exhaust pipe to the center exhaust pipe. Bolts and nuts: 41 ft. lbs. (56 Nm). Bracket with the 2 bolts. Bolts: 14 ft. lbs. (19 Nm). Support stay with the 2 bolts. Bolts: 22 ft. lbs. (29 Nm). Undercover Right fender apron seal Oil

2JZ-GE and 2JZ-GTE Engines NOTE: The No. 1 oil pan can not be removed with the engine in the vehicle. The engine/transmission assembly must be removed. If only the No. 2 oil pan is being serviced, the engine/transmission assembly can remain in the vehicle.

Upper oil pan sealant application — 3.0L (2JZ-GE and 2JZ-GTE) engines

Lower oil pan sealant application — 3.0L (2JZ-GE and 2JZ-GTE) engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Engine/transmission assembly, then separate the transmission from the engine. Timing belt Idler pulley

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Crankshaft timing pulley Oil dipstick and guide Oil sensor lead, 4 attaching bolts and oil level sensor. Lower (No. 2) oil pan. Oil strainer and gasket Baffle plate On turbocharged engines, turbo oil outlet pipe Upper (No. 1) oil pan. O-ring To install: 3. Install or connect the following: New O-ring in the block. Apply a 1⁄8 inch (3–4mm) sealant bead to the pan mating surface. Upper pan. 12mm bolts to 15 ft. lbs. (21 Nm). 14mm bolts to 29 ft. lbs. (39 Nm). On turbocharged engines, the turbo oil outlet pipe and gasket. Nuts: 20 ft. lbs. (27 Nm). 2 turbo oil outlet hoses. Baffle plate and oil strainer. Tighten both to 78 inch lbs. (9 Nm). Lower oil pan in the same manner as the upper pan. Bolts to 78 inch lbs. (9 Nm). Oil level sensor, using a new gasket. Tighten to 48 inch lbs. (5.4 Nm). Oil dipstick and guide, the timing pulleys and belt, and transmission to the engine. Engine and transmission All fluids

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Oil Pump

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http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Oil_Pump.htm

Oil Pump REMOVAL & INSTALLATION 5E-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery terminal. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Oil Oil dipstick Timing belt Oil pan Oil strainer with the O-ring Pressure regulator valve Oil pump and tension spring bracket. Nut and oil pump pulley. To install: 3. Clean all gasket mating surfaces. 4. Install or connect the following: Oil pump pulley by first placing the driven rotors into the pump body with the marks facing the front. Oil pump pulley. Nut: 27 ft. lbs. (37 Nm). Pressure regulator valve. Tighten to 22 ft. lbs. (30 Nm). Oil strainer, using a new O-ring. Bolts: 84 inch lbs. (10 Nm). Oil pan, using a new gasket and sealer. All remaining components in the reverse order they were removed. Oil Negative battery cable Hood

1NZ-FE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Timing chain cover 2 bolts, 3 screws and the oil pump cover from the timing chain cover Drive and driven rotors Plug, spring and relief valve 3. Inspect the relief valve motion 4. Check rotor side clearance: 0.0012–0.0035 in. (0.03–0.09mm). 5. Check rotor tip clearance: 0.0024–0.0071 in. (0.06–0.18mm). 6. Check rotor-to-body clearance: 0.0098–0.0128 in. (0.250–0.325mm).

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To install: 7. Install or connect the following: Relief valve and spring. Torque the plug to 18 ft. lbs. (24 Nm). Drive and driven rotors with the marks on the cover side Cover. Torque the bolts to 80 inch lbs. (9 Nm); the screws to 96 inch lbs. (11 Nm). Timing chain cover Engine oil Battery cable

4A-FE Engine

COROLLA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Undercovers Oil Front exhaust pipe Timing belt Idler pulley and tension spring Crankshaft timing pulley Oil dipstick guide, dipstick and oil pan. Oil strainer and gasket Oil pump, and the gasket. To install: 3. Install or connect the following: New gasket on the cylinder block Oil pump, engaging the splined teeth of the oil pump drive rotor with the large teeth of the crankshaft. 7 mounting bolts. The long bolts are 1.38 in. (35mm) and the short bolts are 0.98 in. (25mm). Bolts: 16 ft. lbs. (21 Nm) Oil strainer, with new gasket. Tighten to 82 inch lbs. (9 Nm). Oil pan Idler pulley and tension spring Timing belt Front exhaust pipe Oil dipstick guide and the dipstick Crankshaft timing pulley. Align the timing pulley set key with the groove of the pulley. Be sure the flange side of the pulley faces inward. Hood Oil Negative battery cable Undercovers

7A-FE Engine

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Oil Pump

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CELICA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Undercovers Oil Front exhaust pipe With automatic transmission, transaxle control cable from the engine mounting center member. With air conditioning, air conditioning pressure pipe from the engine mounting center member. Front exhaust pipe support bracket Rear engine mounting insulator and the engine mounting center member. Timing belt Idler pulley and tension spring Crankshaft timing pulley Oil dipstick guide and dipstick No. 2 oil pan, baffle plate, oil strainer, and the No. 1 oil pan. Oil pump, by carefully tapping the oil pump body with a plastic tipped hammer. Gasket To install: 3. Install or connect the following: New gasket on the cylinder block Oil pump, engaging the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft. 7 oil pump mounting bolts. The long bolts are 1.38 in. (35mm) long and the short bolts are 0.98 in. (25mm) long. Bolts: 16 ft. lbs. (21 Nm) No. 1 oil pan, oil strainer, baffle plate and the No. 2 oil pan. Timing belt Rear engine mounting insulator and engine mounting center member. Front exhaust pipe support bracket With air conditioning, air conditioning pressure pipe to engine mounting center member clamp. With automatic transmission, transaxle control cable to the engine mounting center member. Front exhaust pipe Hood Oil Negative battery cable Undercovers

COROLLA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Undercovers Oil

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Timing belt Idler pulley and tension spring Crankshaft timing pulley Oil dipstick guide, the crankshaft position sensor, and the dipstick. Front exhaust pipe No. 2 oil pan, baffle plate, oil strainer and No. 1 oil pan. NOTE: Be careful not to damage the contact surfaces of the cylinder block and the No. 1 oil pan. 3. Crankshaft position sensor 4. Oil pump To install: 5. Install or connect the following: New gasket to the cylinder block Oil pump 7 oil pump mounting bolts. The long bolts are 1.38 in. (35mm) and the short bolts are 0.98 in. (25mm). Bolts: 16 ft. lbs. (21 Nm) Crankshaft position sensor No. 1 oil pan, strainer, baffle plate and No. 2 oil pan. Dipstick and dipstick guide, with new O-ring. Crankshaft position sensor to dipstick guide mounting bolt. Bolt: 82 inch lbs. (9 Nm). Idler pulley and the tensioner spring with the mounting bolt. Do not tighten the bolt, but push the pulley as far left as possible. Align the timing pulley set key with the groove of the pulley and slide the pulley on with the flange facing in. Idler pulley and the tensioner spring with the mounting bolt. Do not tighten the bolt, but push the pulley as far left as possible. Timing belt. Front exhaust pipe Hood Oil Negative battery cable Undercovers

1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Oil Timing chain and crankshaft sprocket Oil pump and gasket To install: 3. Clean the mounting surface. 4. Install or connect the following: Oil pump, with new gasket. Bolts: 80 inch lbs. (9 Nm). Crankshaft sprocket and timing chain Oil Negative battery cable

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Oil Pump

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Exploded view of the oil pump mounting — 1.8L (1ZZ-FE) engine

2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Oil Timing chain and crankshaft sprocket Oil pump and gasket To install: 3. Clean the mounting surface. 4. Install or connect the following: Oil pump, with new gasket. Bolts: 80 inch lbs. (9 Nm). Crankshaft sprocket and timing chain Oil Negative battery cable

5S-FE Engine


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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Hood Oil Front exhaust pipe Rear end stiffener plate Oil dipstick and oil pan Oil strainer and gasket Timing belt and pulleys Crankshaft position sensor Oil pump and gasket To install: 3. Install or connect the following: Oil pump with new gasket. Bolts: 82 inch lbs. (9 Nm). NOTE: The long bolts are 1.38 in. (35mm) and all the others are 0.98 in. (25mm). 4. 5. 6. 7.

Crankshaft position sensor Timing belt and pulleys Oil strainer with new gasket. Tighten to 48 inch lbs. (5 Nm). Oil pan and dipstick NOTE: The pan must be installed within 5 minutes of sealant application or the procedure will have to be repeated.

8. 9. 10. 11. 12.

Rear end stiffener plate. Bolts: 27 ft. lbs. (37 Nm). Front exhaust pipe Oil Negative battery cable Hood

CELICA

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Oil Undercovers Front exhaust pipe Engine mounting center member Sub oxygen sensor wiring. Right-hand side exhaust manifold stay, TWC with gasket, retainer, and cushion. Rear end stiffener plate Oil dipstick Oil pan, cutting off the applied sealer. NOTE: Do not use the tool for the oil pump body side and rear oil seal retainer.

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3. 4. 5. 6. 7.

Oil strainer, baffle plate, and the gasket Timing belt No. 2 idler pulley and crankshaft timing pulley. Oil pump pulley Oil pump and gasket To install:

8. Install or connect the following: Oil pump, with new gasket. Bolts, uniformly tightened in several passes: 78 inch lbs. (9 Nm). Bolt A is 0.98 in. (25mm) long and bolt B is 1.38 in. (35mm) long.

Oil pump mounting bolt identification — 2.2L (5S-FE) engine

Oil pump pulley. Nut: 18 ft. lbs. (24 Nm). Crankshaft timing pulley and the No. 2 idler pulley. Timing belt New gasket, oil strainer and baffle plate. Bolts and nuts: 48 inch lbs. (5 Nm). Oil pan and dipstick. Rear end stiffener plate Cushion, retainer, and a new gasket to the front TWC. Bolts and nuts: 21 ft. lbs. (29 Nm). Right-hand side exhaust manifold stay. Bolts and nuts: 31 ft. lbs. (42 Nm) Sub oxygen sensor connector Engine mounting center member Front exhaust pipe Oil Negative battery cable Undercovers

1MZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Fender apron seal Undercover Oil

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Front exhaust pipe Front exhaust pipe bracket from the No. 1 oil pan. Alternator drive belt Air conditioning compressor Power steering pump drive belt and adjusting strut. Timing belt and belt pulleys Rear timing belt cover Air conditioning compressor housing bracket No. 2 oil pan, oil strainer, No.1 oil pan and baffle plate. Crankshaft position sensor 9 oil pump bolts. Make a note of the position of the each bolt. Oil pump body by prying between the oil pump and main bearing cap O-ring from the cylinder block Plug, gasket, spring, and relief valve from the oil pump body 9 screws, pump body cover, drive, and driven rotors To install: 3. Install or connect the following: Driven rotors, drive, pump body cover 9 screws Oil pump relief valve, spring, gasket, and the plug to the oil pump body New O-ring on the cylinder block Liquid sealant to the oil pump and engine block Oil pump to the engine block Bolts, uniformly tightened in several passes: 10mm head: 69 inch lbs. (8 Nm). 12mm head: 14 ft. lbs. (20 Nm) Crankshaft position sensor. Bolt: 69 inch lbs. (8 Nm). Baffle plate to the No. oil pan. Tighten to 69 inch lbs. (8 Nm). No. 1 oil pan, oil strainer and No. 2 oil pan. Air conditioning compressor housing bracket. Bolts: 18 ft. lbs. (25 Nm). Rear timing belt cover. Bolts: 74 inch lbs. (9 Nm). Timing belt pulleys Timing belt Adjusting strut and power steering drive belt. Bolt and nut: 32 ft. lbs. (43 Nm). Air conditioning compressor Alternator drive belt Front exhaust pipe bracket to the No. 1 oil pan. Bolts: 15 ft. lbs. (21 Nm). Front exhaust pipe Undercover Right fender apron seal Oil Negative battery cable

2JZ-GE and 2JZ-GTE Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. Engine and transmission. Separate the transmission from the engine. Timing belt Idler pulley Crankshaft timing pulley

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Oil Pump

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Oil dipstick and tube, oil level sensor, No. 2 (lower) oil pan, oil strainer and oil baffle plate. With turbocharger, turbo oil outlet pipe. No.1 (upper) oil pan Oil pump, by driving the pump off the cylinder block using a brass drift. O-rings To install:

Oil pump sealant application — 3.0L (2JZ-GE and 2JZ-GTE) engines

3. Install or connect the following: 2 new O-rings in the cylinder block A 1⁄8 inch (3–4mm) bead of sealant around the pump mating surface Oil pump. Bolts: 15 ft. lbs. (21 Nm) O-ring on the block A bead of sealant around the No. 1 oil pan No.1 oil pan. Bolts: 12mm heads to 15 ft. lbs. (21 Nm). 14mm heads to 29 ft. lbs. (39 Nm). With turbocharger, turbo oil outlet pipe. Bolts: 20 ft. lbs. (27 Nm). Oil baffle plate, oil strainer, No. 2 oil pan, oil lever sensor and oil dipstick with a new O-ring. Crankshaft and idler pulley Timing belt Engine and transmission All fluids Negative battery cable

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2009-04-15 22:52

Rear Main Seal

1 sur 7

http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Rear_Main_Seal.htm

Rear Main Seal REMOVAL & INSTALLATION 5S-FE, 7A-FE, 1ZZ-FE, 2ZZ-GE and 1NZ-FE Engines 1. Remove or disconnect the following: Transaxle Clutch assembly Flywheel or flexplate 2. Use a small sharp knife to cut off the lip of the oil seal. Take great care not to score any metal with the knife. 3. Use a small prytool to pry the old seal from the retaining plate. Be careful not to damage the plate. Protect the tip of the tool with tape and pad the fulcrum point with cloth. 4. Inspect the crankshaft and seal lip contact surfaces for any sign of damage. To install: 5. Apply a light coat of multi-purpose grease to the lip of a new oil seal. Loosely fit the seal into place by hand, making sure it is not crooked. 6. Use a seal driver of the correct size to install the seal. Tap it into place until the surface of the seal is flush with the edge of the housing.

1MZ-FE Engine 1. Remove or disconnect the following: Transaxle Clutch cover assembly and flywheel or driveplate Remove the rear end plate.

Fig. 1: Always place the seal on blocks of wood, then tap the seal from the retainer — 1MZ-FE engine

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Rear Main Seal

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Oil seal retainer and gasket. Discard the gasket or sealant. 2. Use a small prybar to pry the oil seal from the retaining plate. Be careful not to damage the plate. To install: 3. Clean the retainer contact surfaces thoroughly and lubricate the new oil seal with multi-purpose grease. 4. Drive the oil seal into the retainer until its surface is flush with the edge of the retainer. Make sure that the seal is installed evenly in the retainer to ensure proper sealing. 5. Apply a 1⁄8 inch bead of sealant to the oil seal retainer. Install the retainer and install the dust seal. Tighten the bolts to 69 inch lbs. (8 Nm).

Fig. 2: Apply sealant to the rear oil seal retainer — 1MZ-FE engine

6. 7. 8. 9.

Install the rear end plate. On automatic transaxle equipped vehicles, install the driveplate. On manual transaxle equipped vehicles, install the clutch disc and clutch cover. Install the transaxle.

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Rear Main Seal

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4A-FE Engine 1. Remove or disconnect the following: Transaxle With a manual transaxle, the pressure plate and flywheel With an automatic transaxle, the flexplate Rear endplate Rear oil seal retainer

Fig. 3: Unbolting the rear main oil seal retainer — 4A-FE engine

2. Using a small prybar, pry the rear oil seal retainer from the mating surfaces. 3. Using a drive punch or a hammer and small screwdriver, drive the oil seal from the rear bearing retainer.

Fig. 4: Removing the rear main oil seal from the retainer — 4A-FE engine, note the supports under the housing

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Rear Main Seal

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4. Using a putty knife, clean the gasket mounting surfaces. Make certain that the contact surfaces are completely free of oil and foreign matter. To install: 5. Clean the oil seal mounting surface. 6. Using multi-purpose grease, lubricate the new seal lips. 7. Using a suitable seal installation tool, tap the seal straight into the bore of the retainer.

Fig. 5: Tap a new oil seal in until the surface is flush with the seal edge — 4A-FE engine

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Rear Main Seal

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8. Position a new gasket on the retainer and coat it lightly with gasket sealer. Fit the seal retainer into place on the engine; be careful when installing the oil seal over the crankshaft. 9. Install the 6 retaining bolts and tighten them to 84 inch lbs. (9.5 Nm) 10. Install the rear end plate. Tighten its bolts to 90 inch lbs. (10 Nm). 11. Reinstall either the flexplate (automatic) or the flywheel (manual), carefully observing the matchmarks made earlier. Tighten the flexplate bolts or the flywheel bolts to specifications. 12. Install the clutch disc and pressure plate (manual transaxle). 13. Reinstall the transaxle.

5E-FE Engine CAUTION On models equipped with a Supplemental Restraint System (SRS), work must NOT be started until at least 90 seconds have passed from the time the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery. 1. Remove or disconnect the following: Transaxle With a manual transaxle, the clutch assembly and flywheel

Removing the rear endplate

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Rear Main Seal

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Loosening the rear main seal attaching bolts

Removing the rear main seal

With an automatic transaxle, the flexplate The rear endplate 2009-04-15 22:52

Rear Main Seal

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Rear oil seal retainer 2. Using a small prpbar, pry the rear oil seal retainer from the mating surfaces. 3. Using a drive punch or a hammer and a small prytool, drive the oil seal from the rear bearing retainer. NOTE: When removing the rear oil seal, be careful not to damage the seal mounting surface. 4. Using a putty knife, clean the gasket mounting surfaces. Make certain that the contact surfaces are completely free of oil and foreign matter. To install: 5. 6. 7. 8. 9. 10. 11. 12. 13.

Clean the oil seal mounting surface. Using multi-purpose grease, lubricate the new seal lips. Using a seal installation tool or a smooth, round driver, tap the seal straight into the bore of the retainer. Position a new gasket on the retainer and coat it lightly with gasket sealer. Fit the seal retainer into place on the motor; be careful when installing the oil seal over the crankshaft. Install the oil seal retainer bolts. Tighten them 82 inch lbs. (9.3 Nm). Install the rear endplate. Tighten the bolts until snug. Reinstall either the flexplate or the flywheel. Install the torque converter (automatic) or the clutch disc and pressure plate (manual). Reinstall the transaxle.

2JZ-GE and 2JZ-GTE Engines 1. Remove the transmission. 2. Remove the clutch cover assembly and flywheel (manual trans.) or the flexplate (auto. trans.). 3. Use a small, sharp knife to cut off the lip of the oil seal. Take great care not to score any metal with the knife. 4. Use a small prybar to pry the old seal from the retaining plate. Be careful not to damage the plate. Protect the tip of the tool with tape and pad the fulcrum point with cloth. 5. Inspect the crankshaft and seal lip contact surfaces for any sign of damage. To install: 6. Apply a light coat of multi-purpose grease to the lip of a new oil seal. Loosely fit the seal into place by hand, making sure it is not crooked. 7. Use a seal driver. Tap it into place until the surface of the seal is flush with the edge of the housing.

2009-04-15 22:52

Timing Chain, Sprockets, Front Cover and Seal

1 sur 10

http://arrc.epnet.com/autoapp/9307TOY/9307CH03_Timing_Chain__Spr...

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 1ZZ-FE Engine

1997–99

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Right engine cover Accessory drive belt and generator Power steering pump, without disconnecting the hoses. Right engine mount Cylinder head cover Turn the crankshaft so the No. 1 piston is at TDC on the compression stroke. Crankshaft pulley Crankshaft position sensor from the timing chain cover. Accessory drive belt tensioner. Right engine mounting bracket Chain tensioner Water pump Timing chain cover Crankshaft angle sensor plate Timing chain tensioner slipper Timing chain and crankshaft timing sprocket. To install: 3. Install or connect the following: Crankshaft sprocket with timing chain. Be sure to align the No. 1 mark link with the mark on the sprocket. Timing chain on the camshaft sprockets. Align the Nos. 53 and 67 mark links with the marks on the camshaft sprockets.

Align the No. 1 mark link with the mark on the crankshaft sprocket — 1.8L (1ZZ-FE) engine

2009-04-15 22:52


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Align mark links Nos. 53 and 67 with the marks on the camshaft sprockets as shown — 1.8L (1ZZ-FE) engine

Chain tensioner slipper. Bolt: 14 ft. lbs. (18.5 Nm). Crankshaft angle sensor plate New seal in the front cover Silicone sealant to the timing chain cover as illustrated Timing chain cover 4. Water pump. Tighten the bolts marked "C" to 80 inch lbs. (9 Nm) and tighten the remaining bolts to 14 ft. lbs. (18.5 Nm). Be sure to install the bolts in their original locations. Bolt lengths: A. A: 1.77 in. (45mm) B. B: 1.38 in. (35mm) C. C: 1.18 in. (30mm) D. D: 0.98 in. (25mm)

Timing chain cover bolt identification — 1.8L (1ZZ-FE) engine

2009-04-15 22:52


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5. Install or connect the following: Right engine mounting bracket. Bolts, with sealant applied: 35 ft. lbs. (47 Nm). Drive belt tensioner. Bolt: 51 ft. lbs. (69 Nm). Nut: 21 ft. lbs. (29 Nm). Crankshaft position sensor. Tighten to 80 inch lbs. (9 Nm). Crankshaft pulley. Bolt: 102 ft. lbs. (138 Nm). 6. Release the ratchet pawl and compress the chain tensioner. Place the hook on the pin to keep the tensioner compressed.

Compress the timing chain tensioner and place the hook on the pin — 1.8L (1ZZ-FE) engine

7. Install the tensioner, using a new O-ring. Torque the bolts to 80 inch lbs. (9 Nm). 8. Turn the crankshaft counterclockwise and remove the hook from the pin. Turn the crankshaft clockwise and be sure the slipper is pushed by the plunger. 9. Check the valve timing by turning the crankshaft clockwise until the mark of the pulley is aligned with the mark on the timing chain cover. The marks on the camshaft sprockets should be facing each other as shown. 10. Install or connect the following: Silicone sealant to the 2 areas where the timing chain cover meets the cylinder head. Cylinder head cover. Bolts with washers in the sequence shown: 80 inch lbs. (9 Nm). Bolts without washers: 96 inch lbs. (11 Nm). Right engine mount. Bolts: Marked A: 47 ft. lbs. (64 Nm). Marked B: 19 ft. lbs. (26 Nm). Nut: 38 ft.

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lbs. (52 Nm). Power steering pump Alternator and drive belt Right engine undercover Negative battery cable Washer tank Coolant

2000–01

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Right engine cover Accessory drive belt and generator Power steering pump, without disconnecting the hoses. Right engine mount Cylinder head cover Turn the crankshaft so the No. 1 piston is at TDC on the compression stroke. Crankshaft pulley Crankshaft position sensor from the timing chain cover. Accessory drive belt tensioner. Right engine mounting bracket Chain tensioner Water pump Timing chain cover Crankshaft angle sensor plate Timing chain tensioner slipper Timing chain and crankshaft timing sprocket. Timing chain vibration damper Valve timing control assembly and camshaft timing sprocket 3. Drive the seal from the cover. 4. Pull the chain to its full length and measure the length of any 16 consecutive links. The length should not exceed 4.827 inches (122.6mm). 5. Check the slipper and damper wear. Maximum wear should not exceed 0.039 in. (1mm). 6. The tensioner plunger should move smoothly and lock into place with finger pressure. To install: 7. Apply engine oil from the tip of the intake camshaft, back to 16mm. 8. Align the timing mark on the valve timing controller with the knock pin and gently push the valve timing controller onto the camshaft. 9. Set the No.1 piston to TDC compression. The key on the crankshaft should be at 12 o'clock. 10. Install or connect the following: Sprockets. Torque the bolt to 33 ft. lbs. (45 Nm). Turn the camshafts to align the point marks on the sprockets. Chain damper. Bolts: 96 inch lbs. (11 Nm). Timing chain and crankshaft sprocket. Be sure to align the yellow chain link with the mark on the crankshaft sprocket. Timing chain on the camshaft sprockets. Align the yellow links with the marks on the camshaft sprockets. Chain tensioner slipper. Bolt: 14 ft. lbs. (18.5 Nm).

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11.

12. 13.

14. 15. 16. 17.

18.


Crankshaft angle sensor plate with the F mark forward New seal in the front cover Silicone sealant to the timing chain cover as illustrated Timing chain cover Water pump. Tighten the 10mm bolts marked "C" to 80 inch lbs. (9 Nm), those marked "A" to 10 ft. lbs. (13 Nm), and the remaining 10mm bolts to 96 inch lbs. (11 Nm). Tighten the 12mm bolts to 14 ft. lbs. (18.5 Nm). Be sure to install the bolts in their original locations. Bolt lengths: A. A: 1.77 in. (45mm) B. B: 1.38 in. (35mm) C. C: 1.18 in. (30mm) D. D: 0.98 in. (25mm) With a Torx wrench, tighten the stud bolt to 82 inch lbs. (9.3 Nm). Install or connect the following: Right engine mounting bracket. Bolts, with sealant applied: 35 ft. lbs. (47 Nm). Drive belt tensioner. Bolt: 51 ft. lbs. (69 Nm). Nut: 21 ft. lbs. (29 Nm). Crankshaft position sensor. Tighten to 80 inch lbs. (9 Nm). Crankshaft pulley. Bolt: 102 ft. lbs. (138 Nm). Release the ratchet pawl and compress the chain tensioner. Place the hook on the pin to keep the tensioner compressed. Install the tensioner, using a new O-ring. Torque the bolts to 80 inch lbs. (9 Nm). Turn the crankshaft counterclockwise and remove the hook from the pin. Turn the crankshaft clockwise and be sure the slipper is pushed by the plunger. Check the valve timing by turning the crankshaft clockwise until the mark of the pulley is aligned with the mark on the timing chain cover. The marks on the camshaft sprockets should be facing each other as shown. Install or connect the following: Silicone sealant to the 2 areas where the timing chain cover meets the cylinder head. Cylinder head cover. Bolts with washers in the sequence shown: 80 inch lbs. (9 Nm). Bolts without washers: 96 inch lbs. (11 Nm). Right engine mount. Bolts and nuts: 38 ft. lbs. (52 Nm). Power steering pump Alternator and drive belt Right engine undercover Negative battery cable Washer tank Coolant

Fig. 1: Timing chain link marks — 1ZZ-FE and 2ZZ-GE engines

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Right front wheel Alternator Power steering pump Right engine mount insulator. Use a jack and wood block for support. With A/C, the bolt holding the liquid tube to the insulator Ignition coils Cylinder head cover 3. Place No.1 cylinder on TDC compression. Make sure that the timing marks on the camshaft sprockets and valve timing controller assembly are facing UP (12 o'clock). If not, turn the crankshaft 360 degrees to align the marks. 4. Remove or disconnect the following: Crankshaft pulley bolt Pulley and pin Crankshaft position sensor Right engine mount bracket Water pump Oil control valve 13 bolts, 1 nut and 1 stud bolt. Pry the cover off. 2 O-rings from the block and pan Chain tensioner Tensioner slipper Chain vibration damper Chain 5. Drive the seal from the cover. 6. Pull the chain to its full length and measure the length of any 16 consecutive links. The length should not exceed 4.85 inches (123.2mm). 7. Check the slipper and damper wear. Maximum wear should not exceed 0.039 in. (1mm). 8. The tensioner plunger should move smoothly and lock into place with finger pressure. To install: 9. Set the crankshaft at 140 degrees ATDC. Set the camshaft sprockets at 20 degrees ATDC; then, reset the crankshaft to 20 degrees ATDC.

Fig. 2: Timing chain installation — 1NZ-FE engine

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Fig. 3: Measuring the timing chain — 1NZ-FE engine

10. Install or connect the following: New seal, driven into place until flush with the cover edge Vibration damper. Torque the bolts to 80 inch lbs. (9 Nm). Timing chain NOTE: A new chain will have 3 marked links to align with the 3 sprockets, as shown in the accompanying illustration.

Fig. 4: Timing cover bolt installation — 1NZ-FE engine

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11. 12. 13. 14.

Slipper Tensioner. Torque the bolts to 80 inch lbs. (9 Nm). Cover, using a 4–5mm bead of RTV sealer and new O-rings to the block and pan Uniformly tighten the bolts in several passes, using the accompanying illustration, to: A, C, E and G: 96 inch lbs. (11 Nm) B, D and F: 18 ft. lbs. (24 Nm) 15. Bolt lengths are as follows: A: 20mm B: 30mm C: 35mm D: 20mm E: 35mm 16. Install or connect the following: Right engine mount bracket. Coat all but the end 2 threads of the bolt with RTV sealer. Torque the bolt to 41 ft. lbs. (55 Nm). Crankshaft position sensor. Torque bolt A to 66 inch lbs. (7.5 Nm); bolts B to 96 inch lbs. (11 Nm). Oil control valve. Torque: 71 inch lbs. (8 Nm). Crankshaft pulley and pin. Torque the bolt to 94 ft. lbs. (128 Nm). Cylinder head cover with RTV gasket material at the 2 locations shown. Uniformly tighten the bolts and nuts, in several passes, to 84 inch lbs. (10 Nm). PCV hoses Ignition coils Right engine mount insulator. Torque the bolts and nuts to 35 ft. lbs. (47 Nm). Power steering pump Alternator Right under cover Wheel

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Coolant Battery cable

2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Coolant Right engine cover Accessory drive belt and generator Power steering pump, without disconnecting the hoses. Right engine mount Cylinder head cover Turn the crankshaft so the No. 1 piston is at TDC on the compression stroke. Crankshaft pulley Crankshaft position sensor from the timing chain cover. Accessory drive belt tensioner. Right engine mounting bracket Chain tensioner Water pump Timing chain cover Crankshaft angle sensor plate Timing chain tensioner slipper Timing chain and crankshaft timing sprocket. Timing chain vibration damper Valve timing control assembly and camshaft timing sprocket 3. Drive the seal from the cover. 4. Pull the chain to its full length and measure the length of any 16 consecutive links. The length should not exceed 4.827 inches (122.6mm). 5. Check the slipper and damper wear. Maximum wear should not exceed 0.039 in. (1mm). 6. The tensioner plunger should move smoothly and lock into place with finger pressure.

Fig. 5: Timing mark identification at TDC compression — 1ZZ-FE and 2ZZ-GE engines

To install: 7. Apply engine oil from the tip of the intake camshaft, back to 16mm. 8. Align the timing mark on the valve timing controller with the knock pin and gently push the valve timing

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controller onto the camshaft. 9. Set the No.1 piston to TDC compression. The key on the crankshaft should be at 12 o'clock. 10. Install or connect the following: Sprockets. Torque the bolt to 33 ft. lbs. (45 Nm). Turn the camshafts to align the point marks on the sprockets. Chain damper. Bolts: 96 inch lbs. (11 Nm). Timing chain and crankshaft sprocket. Be sure to align the yellow chain link with the mark on the crankshaft sprocket. Timing chain on the camshaft sprockets. Align the yellow links with the marks on the camshaft sprockets. Chain tensioner slipper. Bolt: 14 ft. lbs. (18.5 Nm). Crankshaft angle sensor plate with the F mark forward New seal in the front cover Silicone sealant to the timing chain cover as illustrated Timing chain cover 11. Install the water pump. Tighten the 10mm bolts marked "C" to 80 inch lbs. (9 Nm), those marked "A" to 10 ft. lbs. (13 Nm), and the remaining 10mm bolts to 96 inch lbs. (11 Nm). Tighten the 12mm bolts to 14 ft. lbs. (18.5 Nm). Be sure to install the bolts in their original locations. Bolt lengths: A. A: 1.77 in. (45mm) B. B: 1.38 in. (35mm) C. C: 1.18 in. (30mm) D. D: 0.98 in. (25mm) 12. With a Torx wrench, tighten the stud bolt to 82 inch lbs. (9.3 Nm). 13. Install or connect the following: Right engine mounting bracket. Bolts, with sealant applied: 35 ft. lbs. (47 Nm). Drive belt tensioner. Bolt: 51 ft. lbs. (69 Nm). Nut: 21 ft. lbs. (29 Nm). Crankshaft position sensor. Tighten to 80 inch lbs. (9 Nm). Crankshaft pulley. Bolt: 102 ft. lbs. (138 Nm). 14. Release the ratchet pawl and compress the chain tensioner. Place the hook on the pin to keep the tensioner compressed. 15. Install the tensioner, using a new O-ring. Torque the bolts to 80 inch lbs. (9 Nm). 16. Turn the crankshaft counterclockwise and remove the hook from the pin. Turn the crankshaft clockwise and be sure the slipper is pushed by the plunger. 17. Check the valve timing by turning the crankshaft clockwise until the mark of the pulley is aligned with the mark on the timing chain cover. The marks on the camshaft sprockets should be facing each other as shown. 18. Install or connect the following: Silicone sealant to the 2 areas where the timing chain cover meets the cylinder head. Cylinder head cover. Bolts with washers in the sequence shown: 80 inch lbs. (9 Nm). Bolts without washers: 96 inch lbs. (11 Nm). Right engine mount. Bolts and nuts: 38 ft. lbs. (52 Nm). Power steering pump Alternator and drive belt Right engine undercover Negative battery cable Washer tank Coolant

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Piston and Ring Positioning

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Piston and Ring Positioning Fig. 6: Piston ring positioning — 1NZ-FE engine

Fig. 7: Piston and connecting rod positioning — 1NZ-FE engine

Before removing the caps from the connecting rods, be sure to matchmark them as shown

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5E-FE, 1ZZ-FE, 2ZZ-GE engine — piston ring identification mark locations

5E-FE, 1ZZ-FE, 2ZZ-GE engine — piston ring end-gap spacing

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5E-FE, 1ZZ-FE, 2ZZ-GE engine — pistonto-connecting rod assembly

4A-FE and 7A-FE engine — compression ring positioning

4A-FE and 7A-FE engine — piston ring end-gap spacing

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3S-GTE engine — compression ring positioning

3S-GTE engine — piston ring end-gap spacing

3S-GTE and 5S-FE engines — piston-to-connecting rod assembly

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5S-FE engine — compression ring positioning

5S-FE engine — piston ring end-gap spacing

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1MZ-FE, 2JZ-GE and 2JZ-GTE engines — compression ring positioning

1MZ-FE engine — piston ring end-gap spacing

Avalon 1MZ-FE engine — piston-to-connecting rod assembly

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Camry 1MZ-FE engine — piston-to-connecting rod assembly

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2JZ-GE and 2JZ-GTE engines — piston ring end-gap spacing

2JZ-GE and 2JZ-GTE engines — piston-to-connecting rod assembly

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ACCESSORY DRIVE BELTS

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ACCESSORY DRIVE BELTS Accessory drive belts are usually divided into two basic types: V-belts (conventional, cogged, and flat multiribbed) and serpentine (multi-ribbed) belts. The flat multi-ribbed V-belt actually resembles a serpentine belt, however, unlike a serpentine belt, only the inner surface of the belt makes contact with the components' pulleys. (Rarely, the back of multi-ribbed V-belts may ride against an idler or tensioner pulley, however.) V-belts ride in pulleys with V-shaped groove(s) to rotate various accessories, such as the power steering pump, air conditioner compressor, alternator/generator, water pump and air pump. Only the inside of a V-belt is used, unlike a serpentine belt which utilizes both sides. V-belts typically operate one or two accessories per belt, whereas a single serpentine belt can drive all of the accessories. V-belts and a few serpentine belts require periodic adjustment because the belts are under tension and stretch over time. Most serpentine belts utilize an automatic belt tensioner that constantly provides the proper tension to the belt.

Typical accessory drive belts found on vehicles today

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V-Belts

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V-Belts INSPECTION Although different maintenance intervals are given by each manufacturer, it is a good rule of thumb to inspect the drive belts every 15,000 miles (24,000 km) or 12 months (whichever occurs first). Determine the belt tension at a point half-way between the pulleys by pressing on the belt with moderate thumb pressure. The belt should deflect about 1⁄4 – 1⁄2 in. (6–13mm) at this point. Note that "deflection" is not play, but the ability of the belt, under actual tension, to stretch slightly and give. Inspect the belts for the following signs of damage or wear: glazing, cracking, fraying, crumbling or missing chunks. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. A belt that is fraying will have the fabric backing de-laminating itself from the belt. A belt that is crumbling or missing chunks will have voids in the cross-section of the belt, some times the section missing chunks will be in the pulley groove and not easily seen. All worn or damaged drive belts should be replaced immediately. It is best to replace all drive belts at one time, as a preventive maintenance measure. Although, it is generally easier on the component to have the belt too loose than too tight, a very loose belt may place a high impact load on a bearing due to the whipping or snapping action of the belt. A belt that is slightly loose may slip, especially when component loads are high. This slippage may be hard to identify. For example, the generator belt may run okay during the day, then slip at night when the headlights are turned ON. Slipping belts wear quickly not only due to the direct effect of slippage but also because of the heat the slippage generates. Extreme slippage may even cause a belt to burn. A very smooth, glazed appearance on the belt's sides, as opposed to the obvious pattern of a fabric cover, indicates that the belt has been slipping.

An example of a healthy drive belt

Deep cracks in this belt will cause flex, building up heat that will eventually lead to belt failure

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V-Belts

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The cover of this belt is worn, exposing the critical reinforcing cords to excessive wear

Installing too wide a belt can result in serious belt wear and/or breakage

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ADJUSTMENT

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ADJUSTMENT CAUTION On vehicles with an electric cooling fan, disable the power to the fan by disengaging the fan motor wiring connector or removing the negative battery cable before replacing or adjusting the drive belts. Otherwise, the fan may engage even though the ignition is OFF. Belt tension can be checked by pressing on the belt at the center point of its longest straight span. The belt should give approximately 1⁄4 – 1⁄2 in. (6–13mm). If the belt is loose it will slip, whereas if the belt is too tight it will damage the bearings in the driven unit. For the purposes of V-belt tensioning, there are generally three types of mounting for the various components driven by the drive belt. The first method, referred to as pivoting type without adjuster, is designed so that the component is secured by at least 2 bolts. One of the bolts is a pivoting bolt and the other is the lockbolt. When both bolts are loosened so that the component may move, the component pivots on the pivoting bolt. The lockbolt passes through the component and a slotted bracket, so that when the lockbolt's nut is tightened the component is held in that position. There are no automatic adjusting mechanisms used with this type of mounting. The second method of component mounting, referred to as pivoting type with adjuster, is almost identical except for the addition of an adjuster of some sort. Usually, the adjuster is composed of a bracket attached to the component and a threaded adjusting bolt. After loosening the pivoting and lockbolts, the adjusting bolt can be tightened or loosened to increase or decrease the drive belt's tension. With this type of mounting, you do not have to hold the component in a tensioned position and tighten the pivoting and lockbolts; the adjusting bolt does the job for you. Some versions of this method of mounting use an adjuster which is built into one of the components mounting braces. The brace attaches the component to the engine and incorporates a threaded adjuster in its mid-span, so that when the threaded adjuster is turned the brace shortens or lengthens. This in turn increases or decreases the amount of tension on the component. The third type of mounting, referred to as stationary type, is designed so that the component is mounted on its brackets. There are no pivoting or lockbolts, and the component is not designed to be moved. Rather, this type of mounting uses an extra tensioner idler pulley assembly. The drive belt is tensioned by adjusting the position of the idler pulley, usually accomplished by turning the adjuster bolt on the idler mechanism.

A typical pivoting accessory with an adjusting bolt

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ADJUSTMENT

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An accessory that is fixed will have an adjustable pulley — notice the square slot to aid the adjustment

Pivoting Type

WITHOUT ADJUSTER

1. Disconnect the negative battery cable. 2. Loosen the component's lockbolt and pivoting bolt only enough for the component to move. 3. Using a prytool, move the component either closer to, or farther away from the engine, to provide the

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ADJUSTMENT

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correct tension on the belt. WARNING If using a metal prytool, always wrap the end with a rag or towel to prevent accidentally damaging the component from undue stress. 4. Once the proper amount of tension is applied to the drive belt, hold the prytool with one hand while tightening the lockbolt securely with the other hand. 5. Release the pressure from the prytool and tighten the pivoting bolt securely. 6. Double check the drive belt's tension, in case the component moved slightly while tightening the bolts. 7. Connect the negative battery cable.

WITH ADJUSTER

This type of drive belt is tensioned by a tensioner, which makes precise tension adjustment easy. 1. Disconnect the negative battery cable. 2. Loosen the component's pivot and lockbolts. 3. Inspect the tensioner assembly on the component; the tensioner adjusting bolt may use a locknut or screw to prevent it from loosening over time. On the type of adjuster with a threaded mounting brace, there may be two jam nuts used on either side of the threaded coupling. If such locking fasteners are found, loosen them. 4. Turn the tensioner adjusting bolt or threaded coupling to increase or decrease the amount of tension on the drive belt, as necessary. 5. When the belt tension is correct, tighten the lockbolt and the pivot bolt. 6. If equipped, tighten the tension adjusting bolt locknut or screw to prevent the adjuster from slowly loosening over time. If equipped, tighten the two jam nuts. 7. Connect the negative battery cable.

Stationary Type

IDLER PULLEY WITH ADJUSTING BOLT

1. Loosen the idler bracket pivot bolt and locking bolts. 2. Adjust the belt tension by inserting the proper size ratchet in the square slot of the idler bracket and rotating the bracket until tension is applied. 3. While holding the tension on the belt with the ratchet, tighten the locking bolts, then the pivot bolt.

IDLER PULLEY WITHOUT ADJUSTING BOLT

1. Loosen the mounting/pivot bolt behind the idler pulley. 2. Swivel the idler pulley with a pair of pliers or a wrench on the bearing mounting until the proper tension is achieved. 3. While holding the idler pulley, at the proper tension, tighten the mounting/pivot bolt.

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REMOVAL & INSTALLATION

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REMOVAL & INSTALLATION If a belt must be replaced, the driven unit or idler pulley must be loosened and moved to its extreme loosest position, generally by moving it toward the center of the motor. After removing the old belt, check the pulleys for dirt or built-up material which could affect belt contact. Carefully install the new belt, remembering that it is new and unused; it may appear to be just a little too small to fit over the pulley flanges. Fit the belt over the largest pulley (usually the crankshaft pulley at the bottom center of the motor) first, then work on the smaller one(s). Gentle pressure in the direction of rotation is helpful. Some belts run around a third, or idler pulley, which acts as an additional pivot in the belt's path. It may be possible to loosen the idler pulley as well as the main component, making your job much easier. Depending on which belt(s) you are changing, it may be necessary to loosen or remove other interfering belts to get at the one(s) you want. When buying replacement belts, remember that the fit is critical according to the length of the belt ("diameter"), the width of the belt, the depth of the belt and the angle or profile of the V shape or the ribs. The belt shape should match the shape of the pulley exactly; belts that are not an exact match can cause noise, slippage and premature failure. After the new belt is installed, draw tension on it by moving the driven unit or idler pulley away from the motor and tighten its mounting bolts. This is sometimes a three or four-handed job; you may find an assistant helpful. Be sure that all the bolts you loosened get retightened and that any other loosened belts also have the correct tension. A new belt can be expected to stretch a bit after installation so be prepared to readjust your new belt, if needed, within the first two hundred miles of use.

Pivoting Type CAUTION On vehicles with an electric cooling fan, disable the power to the fan by disengaging the fan motor wiring connector or removing the negative battery cable before replacing or adjusting the drive belts. Otherwise, the fan may engage even though the ignition is OFF.

WITHOUT ADJUSTER

1. Disconnect the negative battery cable. 2. Loosen the accessory's slotted adjusting bracket bolt. If the hinge bolt is excessively tight, it too will have to be loosened. 3. Push the component toward the engine to provide enough slack in the belt so that it will slide over one of the accessory drive pulleys. Remove the drive belt from the accessory drive pulleys and from the vehicle. To install: 4. Position the new drive belt over the component pulleys. Be sure that it is routed correctly. 5. Adjust the tension of the belt, as described earlier in this section. 6. Connect the negative battery cable.

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WITH ADJUSTER

1. Disconnect the negative battery cable. 2. Loosen the component's pivot and lockbolts. 3. Inspect the tensioner assembly on the component; the tensioner adjusting bolt may use a locknut or screw to prevent it from loosening over time. On the type of adjuster with a threaded mounting brace, there may be two jam nuts used on either side of the threaded coupling. If such locking fasteners are found, loosen them. 4. Turn the tensioner adjusting bolt or threaded coupling to relieve all tension from the drive belt. 5. Slip the belt off of the accessory pulley, then remove it from the other pulleys. Remove the belt from the vehicle. To install: 6. Route the new belt on the component pulleys. Make certain that it is routed correctly; incorrect routing could cause components to spin backward, possibly damaging it. 7. Once the belt is correctly positioned on all of the pulleys, adjust the tension as described earlier in this section. 8. Connect the negative battery cable.

Stationary Type

IDLER PULLEY WITH ADJUSTING BOLT

1. 2. 3. 4.

Disconnect the negative battery cable. Loosen the idler bracket pivot bolt and locking bolts. Move the idler pulley until the most amount of slack is gained. Remove the drive belt from the accessory pulley, then from the other applicable pulleys. To install:

5. Position the new belt over the crankshaft pulley, the idler pulley and the accessory pulley. Make certain that it is correctly routed, otherwise it could cause the accessory to be rotated backwards. This could cause damage to the accessory. 6. Adjust the belt tension, as described earlier in this section. 7. While holding the tension on the belt with the ratchet, tighten the locking bolts, then the pivot bolt. 8. Connect the negative battery cable.

IDLER PULLEY WITHOUT ADJUSTING BOLT

1. Disconnect the negative battery cable. 2. Loosen the mounting/pivot bolt behind the idler pulley. 3. Remove the drive belt from the accessory pulley, then from the other applicable pulleys. To install: 4. Position the new belt over the crankshaft pulley, the idler pulley and the accessory pulley. Make certain that it is correctly routed, otherwise it could cause the accessory to be rotated backwards. This could cause damage to the accessory.

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5. Swivel the idler pulley with a pair of pliers or a wrench on the bearing mounting until the proper tension is achieved. 6. While holding the idler pulley, at the proper tension, tighten the mounting/pivot bolt. 7. Connect the negative battery cable.

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Serpentine Belts

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Serpentine Belts INSPECTION Although many manufacturers recommend that the drive belt(s) be inspected every 30,000 miles (48,000 km) or more, it is really a good idea to check them at least once a year, or at every major fluid change. Whichever interval you choose, the belts should be checked for wear or damage. Obviously, a damaged drive belt can cause problems should it give way while the vehicle is in operation. But, improper length belts (too short or long), as well as excessively worn belts, can also cause problems. Loose accessory drive belts can lead to poor engine cooling and diminished output from the alternator, air conditioning compressor or power steering pump. A belt that is too tight places a severe strain on the driven unit and can wear out bearings quickly. Serpentine drive belts should be inspected for rib chunking (pieces of the ribs breaking off), severe glazing, frayed cords or other visible damage. Any belt which is missing sections of 2 or more adjacent ribs which are 1 ⁄2 in. (13mm) or longer must be replaced. You might want to note that serpentine belts do tend to form small cracks across the backing. If the only wear you find is in the form of one or more cracks are across the backing and NOT parallel to the ribs, the belt is still good and does not need to be replaced.

Typical wear patterns for a serpentine drive belt

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Serpentine Belts

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ADJUSTMENT

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ADJUSTMENT Periodic drive belt tensioning is not necessary, because an automatic spring-loaded tensioner is used with these belts to maintain proper adjustment at all times. The tensioner is also useful as a wear indicator. When the belt is properly installed, the arrow on the tensioner housing must point within the acceptable range lines on the tensioner's face. If the arrow falls outside the range, either an improper belt has been installed or the belt is worn beyond its useful life span. In either case, a new belt must be installed immediately to assure proper engine operation and to prevent possible accessory damage.

Typical drive belt automatic tensioner wear indicator

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REMOVAL & INSTALLATION Because serpentine belts use a spring loaded tensioner for adjustment, belt replacement tends to be somewhat easier than it used to be on engines where accessories were pivoted and bolted in place for tension adjustment. Basically, all belt replacement involves is to pivot the tensioner to loosen the belt, then slide the belt off of the pulleys. The two most important points are to pay CLOSE attention to the proper belt routing (since serpentine belts tend to be "snaked" all different ways through the pulleys) and to be sure the V-ribs are properly seated in all the pulleys. Although belt routing diagrams have been included in this section, the first places you should check for proper belt routing are the labels in your engine compartment. These should include a belt routing diagram which may reflect changes made during a production run. 1. Disconnect the negative battery cable for safety. This will help assure that no one mistakenly cranks the engine over with your hands between the pulleys, and that the cooling fan cannot activate while servicing the belt(s). NOTE: Take a good look at the installed belt and make a note of the routing. Before removing the belt, be sure the routing matches that of the belt routing label or one of the diagrams in this book. If for some reason a diagram does not match (you may not have the original engine or it may have been modified), carefully note the changes on a piece of paper. 2. For tensioners equipped with a 1⁄2 in. (13mm) square hole, insert the drive end of a large breaker bar into the hole. Use the breaker bar to pivot the tensioner away from the drive belt. For tensioners not equipped with this hole, use the proper-sized socket and breaker bar (or a large handled wrench) on the tensioner idler pulley center bolt to pivot the tensioner away from the belt. This will loosen the belt sufficiently that it can be pulled off of one or more of the pulleys. It is usually easiest to carefully pull the belt out from underneath the tensioner pulley itself. 3. Once the belt is off one of the pulleys, gently pivot the tensioner back into position. DO NOT allow the tensioner to snap back, as this could damage the tensioner's internal parts. 4. Now finish removing the belt from the other pulleys and remove it from the engine. To install: 5. While referring to the proper routing diagram (which you identified earlier), begin to route the belt over the pulleys, leaving whichever pulley you first released it from for last. 6. Once the belt is mostly in place, carefully pivot the tensioner and position the belt over the final pulley. As you begin to allow the tensioner back into contact with the belt, run your hand around the pulleys and be sure the belt is properly seated in the ribs. If not, release the tension and seat the belt. 7. Once the belt is installed, take another look at all the pulleys to double check your installation. 8. Connect the negative battery cable, then start and run the engine to check belt operation. 9. Once the engine has reached normal operating temperature, turn the ignition OFF and check that the belt tensioner arrow is within the proper adjustment range.

Often the underhood label will display the serpentine drive belt routing

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Relieve the belt tension by pivoting the automatic tensioner away from the belt, then remove the belt

Verifying serpentine belt alignment in the pulley

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Fig. 1 Accessory drive belt routing — Toyota 1.5L (5EFE) engines

Fig. 2 Serpentine drive belt routing — Toyota 1.8L (1ZZFE) engines

Fig. 3 Accessory drive belt routing — Toyota 1.8L (7AFE) and 1.6L (4AFE) engines

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Fig. 4 Accessory drive belt routing — Toyota 2.2L (5SFE) engines

Fig. 5 Serpentine drive belt routing — Toyota 3.0L (2JZGTE and 2JZGE) engines

Fig. 6 Accessory drive belt routing — Toyota 3.0L (1MZFE) engines

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TIMING BELTS - GENERAL INFORMATION

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TIMING BELTS - GENERAL INFORMATION Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valvetrain of an overhead camshaft engine. Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage: Does the owner know if, or when the belt was replaced? If the vehicle purchased is used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace or at least inform the owner that the vehicle is equipped with a timing belt. Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).

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Interference Engines

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Interference Engines Engines, chain-or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing were disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time. An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

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TIMING BELT SERVICE

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TIMING BELT SERVICE Inspection NOTE: For manufacturers recommended service interval, refer to the maintenance interval chart located in this manual. The average replacement interval for a timing belt is approximately 60,000 miles (96,000km). If, however, the timing belt is inspected earlier or more frequently than suggested, and shows signs of wear or defects, the belt should be replaced at that time. WARNING Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.

Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist: Hardening of the rubber — back side is glossy without resilience and leaves no indentation when pressed with a fingernail Cracks on the rubber backing Cracks or peeling of the canvas backing Cracks on rib root Cracks on belt sides Missing teeth or chunks of teeth Abnormal wear of belt sides — the sides are normal if they are sharp, as if cut by a knife If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval. WARNING On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.

Broken tooth may be due to a damaged pulley

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TIMING BELT SERVICE

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Back surface worn or cracked from a possible overheated engine or interference with the belt cover

Side wear from improper installation

Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt

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TIMING BELT SERVICE

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Removal & Installation

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Removal & Installation TOYOTA MODELS 1.5L (5E-FE) Engine 1. Remove all necessary components for access to the timing belt covers. CAUTION If equipped with an air bag, be sure to disconnect the negative battery cable and wait at least 90 seconds before proceeding. 2. Remove the No. 2 timing belt cover. 3. Rotate the engine clockwise until the crankshaft pulley is aligned with the 0 mark on the No. 1 timing belt cover. Verify the hole in the camshaft timing pulley is aligned with the timing mark on the No. 1 bearing cap. If not as specified, rotate the crankshaft an additional 360 degrees. 4. For vehicles with A/C and/or power steering, remove the four bolts to the No. 2 crankshaft pulley. Then, remove the No. 2 crankshaft pulley. 5. Using Toyota tools SST 09213-14010 and SST 09330-00021, remove the No. 1 crankshaft pulley bolt. 6. Using a crankshaft pulley/damper puller (such as Toyota tool SST 09950-50010), remove the No. 1 crankshaft pulley from the crankshaft. 7. Remove the No. 3 timing belt cover (plug). 8. Remove the No. 1 timing belt cover and timing belt guide. 9. Place matchmarks on the timing belt on both sides of the cam and crankshaft gear timing marks. Also, place an arrow on the top surface of the belt to indicate the direction of travel. 10. Using pliers, remove the tension spring. 11. Loosen the No. 1 idler pulley bolt and push the pulley to the left as far as it will go, then temporarily tighten the bolt. 12. Remove the belt.

Turn the engine two revolutions, then ensure the timing marks are still aligned — Toyota 1.5L (5E-FE) engine

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To install: 13. For vehicles with a distributor (distributor ignition), use the crankshaft bolt to turn the crankshaft until the timing marks on the sprocket and oil pump body align. This is method is used to set the piston at Top Dead Center (TDC) before the marks on the belt cover can be seen. 14. For vehicles with a crankshaft position sensor (distributorless ignition), use the crankshaft bolt to turn the crankshaft until the rotor side of the crankshaft position sensor faces inward. 15. Turn the camshaft and align the hole of the camshaft timing pulley with the timing mark of the bearing cap. The matchmarks, if using the old belt should align. Place the belt over the crankshaft pulley and the idler pulleys. 16. Install the belt on the crankshaft gear (using the matchmarks if reinstalling the old belt) and install the timing belt guide with flange out. 17. Loosen the No. 1 idler pulley bolt until the pulley is moved slightly by the spring tension. 18. Turn the crankshaft pulley two revolutions from TDC-to-TDC. NOTE: Always rotate the crankshaft clockwise. 19. 20. 21. 22. 23. 24. 25.

Check that the pulleys align with the reference marks. If not, reinstall the belt. When the timing is verified, tighten the adjuster pulley (No. 1 idler pulley) to 13 ft. lbs. (18 Nm). Install No. 1 and No. 3 lower timing belt covers. Install the No. 1 crankshaft pulley and tighten the pulley bolt to 112 ft. lbs. (152 Nm). Tighten the four No. 2 crankshaft pulley bolts to 14 ft. lbs. (19 Nm). Install the No. 2 timing belt cover with the four bolts. Install the remaining components in the reverse order of the removal procedure. When installing the right-hand engine mounting insulator, tighten the bracket bolt to 47 ft. lbs. (64 Nm) and the through-bolt to 54 ft. lbs. (73 Nm).

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1.6L (4A-FE) and 1.8L (7A-FE) Corolla engines 1. Remove all necessary components for access to the timing belt covers. CAUTION If equipped with an air bag, be sure to disconnect the negative battery cable and wait at least 90 seconds before proceeding. 2. Turn the crankshaft to align the timing mark on crankshaft pulley at 0, setting the piston in No. 1 cylinder at Top Dead Center (TDC) on the compression stroke. Check that the valve lifters on the No. 1 cylinder are loose. If not, turn crankshaft pulley 1 complete revolution (360 degrees). 3. Remove the nine bolts and timing belt covers from the engine. 4. Slide the timing belt guide from crankshaft. 5. Set the camshaft and crankshaft timing sprockets to align the marks. WARNING Do not turn crankshaft or camshaft independently after removal of timing belt. Binding or damage to engine components could result. If the timing belt is to be reused, mark timing belt with arrow showing direction of engine revolution. Place matchmarks where timing belt meets with crankshaft timing sprocket and camshaft timing sprocket to ensure installation in the same position. 6. Remove the timing belt tensioner bolt, tensioner and the tension spring. 7. Remove the timing belt from camshaft and crankshaft timing sprockets. 8. Remove the timing belt. WARNING Do not bend, twist or turn the timing belt inside out. Do not allow the belt to come in contact with oil, coolant or steam. To install:

Sprocket alignment for timing belt replacement — Toyota 1.6L (4A-FE) and 1.8L (7A-FE) engines

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NOTE: Inspect the camshaft timing sprocket to ensure mark is still aligned as indicated. 9. Reinstall the timing belt tensioner and the tension spring. Pry the tensioner to the left as far as it will go and temporarily tighten the retaining bolt. 10. Install the timing belt. If reinstalling the old belt, observe the matchmarks made during removal. Be sure the belt is fully and squarely seated on the sprockets. 11. Loosen the retaining bolt for the timing belt tensioner and allow it to tension the belt. 12. Temporarily install the crankshaft pulley bolt and turn the crank clockwise 2 full revolutions from TDC to TDC. Insure that each timing mark realigns exactly. 13. Tighten the timing belt tensioner bolt to 27 ft. lbs. (37 Nm). 14. Measure the timing belt deflection at the SIDE point, looking for 1⁄4 in. (5–6mm) of deflection at 4.4 lbs. (2 kg) of pressure. If the deflection is not correct, adjust with the timing belt tensioner. 15. Install the timing belt guide, with the cup side facing outward, onto the crankshaft and install the timing belt covers from the lowest to the highest. Tighten the nine cover bolts to 62 inch lbs. (7 Nm). 16. Install all applicable remaining components. During assembly, be sure to tighten the crankshaft pulley bolt to 87 ft. lbs. (118 Nm), the mounting bracket-to-engine mount bolt to 47 ft. lbs. (64 Nm), the mounting bracket-to-engine mount nuts to 38 ft. lbs. (52 Nm), the engine mount-to-body bolt A to 19 ft. lbs. (25 Nm), the engine mount-to-body bolts B to 19 ft. lbs. (25 Nm), the engine mount-to-body bolt C to 19 ft. lbs. (25 Nm), if equipped with cruise control.

2.2L (5S-FE) Engines 1. Remove all necessary components for access to the timing belt covers. CAUTION

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If equipped with an air bag, be sure to disconnect the negative battery cable and wait at least 90 seconds before proceeding. 2. Remove the No. 2 timing cover. 3. Position the No. 1 cylinder to Top Dead Center (TDC) on the compression stroke by turning the crankshaft pulley and aligning its groove with the timing mark 0 of the No. 1 timing belt cover. Check that the hole of the camshaft timing pulley is aligned with the alignment mark of the bearing cap. If not, turn the crankshaft one revolution (360 degrees). 4. Remove the timing belt from the camshaft timing pulley, as follows: A. If reusing the belt, place matchmarks on the timing belt and the camshaft pulley. Loosen the mount bolt of the No. 1 idler pulley and position the pulley toward the left as far as it will go. Tighten the bolt. Remove the belt from the camshaft pulley. 5. Remove the camshaft timing pulley as follows: A. Using Toyota tools Nos. 09249-63010 and 09960-10010, remove the bolt and the camshaft pulley. 6. Remove the crankshaft pulley as follows: A. Use Toyota tools Nos. 09213-54015 and 09330-00021 to hold the crankshaft pulley. Remove the pulley set bolt and remove the pulley using a puller. 7. Remove the No. 1 timing belt cover. 8. Remove the timing belt and the belt guide. If reusing the belt mark the belt and the crankshaft pulley in the direction of engine rotation and matchmark for correct installation.

Crankshaft positioning for timing belt removal and installation — Toyota 2.2L (5S-FE) engine

Using a spanner wrench, turn the camshaft into position so that the alignment mark is visible through the hole in the sprocket — Toyota 2.2L (5S-FE) engine

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To install: 9. Install the crankshaft timing pulley, as follows: A. Align the timing pulley set key with the key groove of the pulley. B. Slide on the timing pulley with the flange side facing inward. 10. Install the No. 2 idler pulley and tighten the bolt to 31 ft. lbs. (42 Nm). Be sure that the pulley moves freely. 11. Temporarily install the No. 1 idler pulley and tension spring. Pry the pulley toward the left as far as it will go. Tighten the bolt. Be sure that the pulley rotates freely. 12. Temporarily install the timing belt, as follows:

Sprocket alignment for timing belt replacement — Toyota 2.2L (5S-FE) engine

13. 14. 15. 16.

17.

A. Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and the oil pump body. B. If reusing the old belt, align the marks made during removal, and install the belt with the arrow pointing in the direction of the engine revolution. Install the timing belt guide with the cup side facing outward. Install the No. 1 timing belt cover. Install the crankshaft pulley. Align the pulley set key with the key groove of the pulley and slide on the pulley. Tighten the bolt to 80 ft. lbs. (108 Nm). Install the camshaft timing pulley as follows: A. Align the camshaft knock pin with the knock pin groove of the pulley and slide on the timing pulley. Tighten the bolt to 40 ft. lbs. (54 Nm). With the No. 1 cylinder set at TDC on the compression stroke, install the timing belt (all timing marks aligned). If reusing the belt, align with the marks made during the removal procedure: A. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing belt cover. Be sure the camshaft sprocket hole is aligned with the mark on the bearing cap. 2009-04-15 23:04


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18. Connect the timing belt to the camshaft timing pulley. 19. Check that the matchmark on the timing belt matches the end of the No. 1 timing belt cover. 20. Once the belt is installed, be sure that there is tension between the crankshaft timing pulley and the camshaft pulley. 21. Check the valve timing as follows: A. Loosen the No. 1 idler pulley mount bolt 1⁄2 turn. Turn the crankshaft pulley two revolutions from TDC in the clockwise direction. Always turn the crankshaft pulley clockwise. B. Be sure that the all the timing marks are aligned. C. Slowly turn the crankshaft pulley 1 7⁄8 revolutions. Align its groove with the mark at 45°Before Top Dead Center (BTDC) on the No. 1 timing belt cover for the No. 1 cylinder. D. Tighten the No. 1 idler pulley mount bolt to 31 ft. lbs. (42 Nm). 22. Install the No. 2 timing belt cover as follows: A. Install the upper gasket to the No. 1 timing belt cover. B. Disconnect the engine wire protector between the cylinder head cover and the No. 3 timing belt cover. C. Install the gasket to the timing belt cover. D. Install the belt covers and all remaining components. During assembly, tighten the right engine mount bracket bolts to 38 ft. lbs. (52 Nm), the engine mount insulator bolt to 47 ft. lbs. (64 Nm), the through-bolt to 54 ft. lbs. (78 Nm), the power steering reservoir bracket bolt to 21 ft. lbs. (28 Nm), the power steering reservoir-to-bracket bolt to 27 ft. lbs. (37 Nm) and the nut to 38 ft. lbs. (52 Nm).

3.0L (1MZ-FE) Engine 1. Remove all necessary components for access to the timing belt covers. CAUTION If equipped with an air bag, be sure to disconnect the negative battery cable and wait at least 90 seconds before proceeding. 2. Remove the lower timing belt cover by removing the four bolts. 3. Remove the No. 2 timing belt cover as follows: A. Remove the bolt and disconnect the engine wire protector from the No. 3 (rear) timing belt cover. B. Disconnect the engine wire protector clamp from the No. 3 timing belt cover. C. Remove the five bolts from the No. 2 timing belt cover. D. Remove the No. 2 cover from the engine. 4. Remove the right engine mounting bracket by removing the nut and two bolts. 5. Remove the crankshaft timing belt guide. 6. Temporarily install the crankshaft pulley bolt. 7. Turn the crankshaft and align the crankshaft timing pulley groove with the oil pump alignment mark. Always turn the engine clockwise. 8. Ensure the timing mark of the camshaft timing pulleys and rear timing belt covers are aligned. If not, turn the engine over an additional 360 degrees (one revolution). 9. Remove the crankshaft pulley bolt. NOTE: If the belt is to be reused, align the installation marks on the belt to the marks on the pulleys. If the marks have worn off, make new ones. 10. Alternately loosen the two timing belt tensioner bolts. Remove the tensioner and dust boot. 11. Remove the timing belt.

Camshaft and crankshaft timing belt sprocket alignment mark positioning for belt service — Toyota 3.0L (1MZ-FE) engine

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To install: 12. 13. 14. 15.

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Remove any oil or water from the pulleys. Align the front mark of the timing belt with the dot mark of the crankshaft timing pulley. Align the installation marks on the timing belt with the timing marks of the camshaft pulleys. Install the timing belt in the following order: A. Crankshaft pulley. B. Water pump pulley. C. Left camshaft pulley. D. No. 2 idler pulley. E. Right camshaft pulley. F. No. 1 idler pulley. Using a press, slowly press the timing belt tensioner until the holes of the pushrod and housing align. Insert a 0.05 in. (1.27mm) hexagonal Allen wrench through the holes to preserve the setting position. Install the dust boot to the tensioner. Install the tensioner with the two bolts. Alternately tighten the bolts to 20 ft. lbs. (27 Nm). Remove the Allen wrench. Turn the crankshaft clockwise and align the crankshaft timing pulley groove with the oil pump alignment mark. Ensure the camshaft timing marks align with the timing marks on the rear timing belt cover. Install the timing belt guide. Install the right engine mounting bracket and tighten the bolts to 21 ft. lbs. (28 Nm). Install the upper timing belt cover with the five bolts. Tighten the bolts to 74 inch lbs. (8 Nm). Install the engine wire protector clamp to the No. 3 timing belt cover. Install the engine wire protector to the No. 3 timing belt cover with the bolt. Install the lower timing belt cover by installing the four bolts. Tighten the bolts to 74 inch lbs. (8 Nm). Install the remaining components. During installation be sure to tighten the crankshaft pulley bolt to 159 ft.

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lbs. (215 Nm) and the No. 2 alternator bracket nut to 21 ft. lbs. (28 Nm).

3.0L (2JZ-GTE and 2JZ-GE) Engines 1. Remove all necessary components for access to the timing belt covers. CAUTION If equipped with an air bag, be sure to disconnect the negative battery cable and wait at least 90 seconds before proceeding. 2. Remove the upper two timing belt covers (Nos. 2 and 3). 3. Remove the drive belt tensioner. 4. Set the No. 1 cylinder to Top Dead Center (TDC) on the compression stroke. Turn the crankshaft pulley clockwise to align the groove with the 0 mark on the lower (No. 1) timing belt cover. Check that the timing marks on the camshaft pulleys are aligned with the marks on the rear belt cover. If the camshaft marks do not align, turn the crankshaft another 360 degrees. 5. Alternately loosen the two bolts holding the timing belt tensioner. Remove the bolts and remove the tensioner. 6. Remove the timing belt from the camshaft pulleys. If the belt is to be reused, place matchmarks on the belt and gears before removing the belt. Mark the belt with an arrow to show direction of rotation. 7. Using Toyota tool SST 09960-10010, remove the bolts for the camshaft timing gears. 8. Remove the camshaft gears from the engine. 9. If necessary, disconnect the oil cooler tubes from the front of the engine by removing the two bolts and hose clamps. 10. Remove the crankshaft pulley by using Toyota tool 09330-0021 to hold the pulley and using tool 09213-70010 to remove the pulley bolt. 11. Remove the lower (No. 1) timing belt cover and the timing belt guide. 12. Remove the timing belt. If the belt is to be reused, protect it from contact with oil, grease or fluids.

Camshaft timing mark alignment — Toyota 3.0L (2JZ-GTE and 2JZ-GE) engines

Crankshaft timing marks; notice the timing mark difference between the engines — Toyota 3.0L (2JZ-GTE and 2JZ-GE) engines

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To install: 13. Use the crankshaft pulley bolt to turn the crankshaft (clockwise) until the mark on the gear aligns with the oil pump body. Check all the pulleys and gears for cleanliness; remove any grease, oil or coolant. Install the timing belt onto the crankshaft gear and idler pulleys. 14. Install the timing belt guide with the cupped side facing outward. 15. Install the No. 1 timing belt cover. 16. Install the crankshaft pulley. Align the set key with the groove. Hold the pulley with the proper tool and tighten the pulley bolt to 239 ft. lbs. (324 Nm). 17. If equipped with automatic transmission, connect the oil cooler tubes with the clamps and two bolts. 18. Install the camshaft gears as follows: A. Align the camshaft knock pin with the groove on the gear and slide on the timing gear. B. Temporarily install the timing gear bolt. C. Using the same tools as removal, tighten the camshaft gear bolts to 59 ft. lbs. (79 Nm). D. Turn the crankshaft pulley and align its groove with the timing mark, 0 on the No. 1 timing belt cover. E. Align the timing marks on the camshaft timing gears and the No. 4 timing belt cover. 19. Finish installing the timing belt. 20. Double check that all the timing marks for the crankshaft pulley and the camshaft gears are aligned as they were during disassembly. 21. Set the timing belt tensioner: A. Use a press to slowly push in the pushrod on the tensioner. This will require between 220–2200 lbs. (100–1000 kg) of pressure. B. Align the holes of the pushrod and housing. Place a 0.06 in. (1.5mm) hex wrench through the holes to keep the pushrod retracted. C. Release the press and install the dust boot onto the tensioner. 22. Install the tensioner; alternately tighten the bolts to 20 ft. lbs. (26 Nm). 23. Remove the hex wrench from the tensioner with a pair of pliers. 24. Turn the crankshaft pulley two full turns clockwise. Check that each pulley's timing marks align correctly after the two turns. If any mark does not align, remove the timing belt and reinstall it. 25. Install the drive belt tensioner and tighten the bolts to 15 ft. lbs. (21 Nm). 26. Install the Nos. 2 and 3 timing belt covers. 27. Install all remaining components. During assembly be sure to tighten the drive belt tensioner damper nuts to 14 ft. lbs. (20 Nm).

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5E-FE Engine and Engine Rebuild

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