14−1

ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

1400Z−01

OVERHAUL
1. REMOVE SPARK PLUG

2. REMOVE ENGINE HANGER NO.1

3. REMOVE THERMOSTAT

(a) Remove the 2 nuts and water inlet.

(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.
4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY(W/ VVT−i)

5. REMOVE OIL FILLER CAP SUB−ASSY

6. REMOVE OIL FILLER CAP GASKET

7. REMOVE CRANK POSITION SENSOR

8. REMOVE CYLINDER HEAD COVER SUB−ASSY

9. REMOVE CYLINDER HEAD COVER GASKET

10. REMOVE WATER PUMP PULLEY

(a) Using SST, fix the pump pulley.

SST 09960−10010 (09962−01000, 09963−01000)
SST (b) Remove the 3 bolts and pump pulley.

B09370

11. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

1NZ−FE,2NZ−FE ENGINE REPAIR MANUAL

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

12. REMOVE CRANKSHAFT DAMPER SUB−ASSY

(a) Set No. 1 cylinder to TDC/compression.

(1) Turn the crankshaft damper, and align its groove
with timing mark ”0” of the chain cover.
Timing Marks
(2) Check that both timing marks on the camshaft tim-
ing sprocket and valve timing controller assembly
are facing right up as shown in the illustration.
A38016 HINT:
If not, turn the crankshaft 1 revolution (360_) and align the
marks as above.

(b) Using SST, remove the pulley bolt.

SST 09213−58012 (91111−50845), 09330−00021
SST
HINT:
If necessary, remove the damper with SST.
SST 09950−50012 (09951−05010, 09952−05010,
09953−05020, 09954−05020)

A50677

13. REMOVE WATER PUMP ASSY

(a) Remove the 3 bolts, 2 nuts and water pump.

14. REMOVE OIL PUMP ASSY

(a) Remove the 15 bolts and nut.

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(b) Using a screwdriver with taping its tip, remove the oil
pump by prying the portions between the cylinder head
and cylinder block.
NOTICE:
Be careful not to damage the contact surfaces of the oil
Tape pump, cylinder head and cylinder block.

A50903

Wooden (c) Remove the 2 O−rings from the cylinder block and oil pan
Blocks No. 1.
(d) Using a hexagon wrench 8, remove the screw plug from
the oil pump.

A35281

15. REMOVE OIL PUMP SEAL

(a) Using a screwdriver with taping its tip, remove the oil seal.

16. REMOVE CHAIN TENSIONER ASSY NO.1

NOTICE:
S Never rotate the crankshaft with the chain tensioner
removed.
Plunger
S When rotating the camshaft with the timing chain re-
moved, rotate the crankshaft counterclockwise 40_
from the TDC before rotating it.
Stopper Plate A11225 (a) Using drivers or equipment, while rotating the stopper
plate of the tensioner upward, push in the plunger of the
chain tensioner as shown in the illustration.
(b) While rotating the stopper plate of the tensioner down-
ward, insert a bar of f 2.5 mm (0.098 in.) into the holes in
the stopper plate and tensioner to fix the stopper plate.
SST 10514
(c) Remove the 2 bolts and chain tensioner.
17. REMOVE CHAIN TENSIONER SLIPPER

18. REMOVE CHAIN VIBRATION DAMPER NO.1

(a) Remove the 2 bolts and damper.

19. REMOVE CHAIN SUB−ASSY

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

20. INSPECT CHAIN SUB−ASSY

(a) Using a spring scale, pull the timing chain with 140 N (14.3
kgf, 31.5 lb) and measure the length of it.
Maximum chain elongation: 123.2 mm (4.850 in.)
Measuring Area If the elongation is greater than maximum, replace the chain.
HINT:
0 1 2 3 4 5
Make the same measurements pulling at 3 or more places se-
16
A30412 A50062 lected at random.

21. REMOVE FUEL DELIVERY PIPE SUB−ASSY

(a) Remove the 3 bolts and delivery pipe with injector.

22. REMOVE FUEL INJECTOR ASSY

(a) Pull out the 4 injectors form the delivery pipe.

23. REMOVE CAM POSITION SENSOR

24. REMOVE NO.2 CAMSHAFT

Oil jet

TimingMark NOTICE:
When rotating the camshaft with the timing chain removed,
rotate the crankshaft counterclockwise 40_ from the TDC
and align the oil jet hole with the paint mark before rotating
it for the valves not to touch the pistons.

A50142

1 3 (a) Uniformly loosen and remove the 11 bearing cap blots, in

5 4 2
several passes, in the sequence shown, and remove the
5 bearing caps and No. 2 camshaft.
NOTICE:
Loosen the each bolt equally with keeping the camshaft
horizontal.

A37074

25. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

(a) Grip the camshaft with a vice.

(b) Remove the fringe bolt and camshaft timing sprocket.
NOTICE:
Be careful not to damage the camshaft.

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

26. REMOVE CAMSHAFT

(a) Uniformly loosen and remove the 8 bearing cap blots, in

several passes, in the sequence shown, and remove the
4 bearing caps and camshaft.
NOTICE:
Loose the each bolt equally with keeping the camshaft hor-
izontal.
2 4 3 1
A37075

27. INSPECT CAMSHAFT TIMING GEAR ASSY(W/ VVT−i)

(a) Check the lock of camshaft timing gear.

(1) Grip the camshaft with a vice, and confirm the cam-
shaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.

(b) Release lock pin.

Retard Side (1) Cover 4 oil paths of cam journal with vinyl tape as
Paths shown in the illustration.
HINT:
The 4 oil paths are provided in the groove of the camshaft. Plug
Advance two of the paths with rubber pieces.
Side Paths (2) Break through the tapes of the advance side path
and the retard side path on the opposite side of the
groove.

Close Open
Close
Open

Vinyl Tape Rubber Piece

A51761

Retard (3) Put air pressure into two broken paths (the advance
Advanced
Side Path Side Path side path and the retard side path) with about 150
kPa (1.5 kgf/cm2).
NOTICE:
Cover the paths with shop rag to avoid oil splashing.

A51762

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

Retard
(4) Confirm if the camshaft timing gear assembly re-
Advanced
Side Path Side Path volves in the timing advance direction when weak-
ening the air pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear, revolves in
the advance direction.
(5) When the camshaft timing gear comes to the most
Decompress advanced position, take out the air pressure of the
Hold Pressure
A51763 timing retard side path, and then, take out that of
timing advance side path.
NOTICE:
Camshaft timing assembly gear occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before retard side path. It often results
the breakage of the lock pin.
(c) Check smooth revolution
(1) Except the position where the lock pin meets at the
most retard angle, let the valve timing controller as-
sembly turn back and forth and check the movable
range and that there is no disturbance.
Standard: Movable smoothly in the range about 22.5_
NOTICE:
Be sure to perform this check by hand, instead of air pres-
sure.
(d) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear assembly is
locked at the most retarded position.

28. REMOVE CAMSHAFT TIMING GEAR ASSY(W/ VVT−i)

Fringe
Bolt
(a)
Turn the valve timing controller assembly at the maximum
advance angle side.
(b) Remove the fringe bolt and camshaft timing gear assem-
bly.
NOTICE:
Straight S Be sure not to remove the other 4 bolts.
Pin A50060 S In case of reusing the camshaft timing gear, then re-
lease the lock pin.
29. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET(W/O VVT−i)

(a) Grip the camshaft with a vice.

(b) Remove the fringe bolt and camshaft timing sprocket.
NOTICE:
Be careful not to damage the camshaft.

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

30. REMOVE CYLINDER HEAD SUB−ASSY

(a)
Using a 8 mm bi−hexagon wrench, uniformly loosen and
remove the 10 cylinder head bolts, in several passes, in
the sequence shown. Remove the 10 cylinder head bolts
and plate washers.
NOTICE:
S Be careful not to drop washers into the cylinder head.
A35286 S Head warpage or cracking could result from remov-
ing bolts in an incorrect order.
31. REMOVE CYLINDER HEAD GASKET

32. REMOVE OIL FILTER SUB−ASSY

(a) Using SST, remove the oil filter.

SST 09228−06501

SST
A38018

33. REMOVE OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, remove the oil filter union.

34. REMOVE ENGINE REAR OIL SEAL

(a) Using a knife, cut off the oil seal lip.

(b) Using a screwdriver with taping its tip, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, mend it with a sandpaper (#400).

A51764

35. REMOVE OIL PAN SUB−ASSY NO.2

(a) Remove the oil pan drain plug and gasket.

(b) Remove the 9 bolts and 2 nuts.

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(c) Insert the blade of SST between oil pan No. 1 and oil pan
No. 2, and cut off applied sealer and remove the oil pan
No. 2.
SST 09032−00100
NOTICE:
Be careful not to damage the oil pan No. 2 contact surface
of the oil pan No. 1 and the oil pan No. 2 flange.

A01456

36. REMOVE OIL STRAINER SUB−ASSY

(a) Remove the bolt, 2 nuts, oil strainer and gasket.

37. REMOVE OIL PAN SUB−ASSY

(a) Uniformly loosen and remove the 13 bolts, in several

passes, in the sequence shown.

A50902

(b) Using screwdriver remove the oil pan No. 1 by prying the
portions between the cylinder block and oil pan No. 1.
NOTICE:
Be careful not to damage the contact surfaces of the oil pan
No. 1 and cylinder block.
(c) Remove the 2 O−rings from the cylinder block.
(d) Remove the 4 stud bolts.

A11272

38. INSPECT CHAIN TENSIONER ASSY NO.1

(a) Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) Release the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.

A11223

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

39. INSPECT CAMSHAFT TIMING GEAR ASSY(W/ VVT−i)

(a) Wrap the chain around the timing sprocket.

(b) Using a vernier calipers, measure the timing gear diame-
ter with chain.
Minimum gear diameter (w / chain):
96.2 mm (3.787 in.)
If the diameter is less than minimum, replace the sprocket.
A37071 NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.

40. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET

(a) Wrap the chain around the timing sprocket.

(b) Using a vernier calipers, measure the timing gear diame-
ter with chain.
Minimum gear diameter (w / chain):
96.2 mm (3.787 in.)
If the diameter is less than minimum, replace the sprocket.
A37072 NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.

41. INSPECT CHAIN TENSIONER SLIPPER

(a) Measure the chain tensioner slipper wears.

Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper.

A37065

42. INSPECT CHAIN VIBRATION DAMPER NO.1

(a) Measure the vibration damper wears.

Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the damper.

A37066

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

43. INSPECT CYLINDER HEAD SET BOLT

Overall Length (a) Using vernier calipers, measure the length of head bolts
from the seat to the end.
Standard bolt length:
142.8 − 144.2 mm (5.622 − 5.677 in.)
Maximum bolt length: 147.1 mm (5.791 in.)
If the length surpasses the maximum, replace the bolt.
A30215

44. INSTALL OIL PAN SUB−ASSY

(a) Install the 4 stud bolts.

Torque: 5.0 N×m (50 kgf×cm, 44 in.×lbf)

Stud Bolt A Stud Bolt B

(6M) (6M)

A50686

(b) Remove any old packing material from the contact sur-
face.

Seal Packing (c) Apply seal packing in the shape of bead (Diameter 2 mm
9mm 4mm − 3 mm (0.0787 − 0.1181 in.)) consequently as shown in
the illustration.
Seal packing:
Part No. 08826−00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
4mm S Install the oil pan within 3 minutes after applying seal
11mm
Seal Packing A50687 packing.
S Do not put into engine oil within 2 hours after instal-
ling.
(d) Install 2 new O−rings to the cylinder block.

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(e) Install and uniformly tighten the 13 bolts, in several

15 14
5 4 3 2 13 passes, in the sequence shown.
12
Torque: 24 N×m (245 kgf×cm, 18 ft×lbf)
HINT:
A B C Each bolt length in indicated in the illustration.
B Bolt A 49 mm (1.929 in.)
Bolt B 88 mm (3.465 in.)
11 Bolt C 144 mm (5.669 in.)
6 7 8 1 10
9 A37067

45. INSTALL OIL STRAINER SUB−ASSY

(a) Install a new gasket and the oil strainer with the 2 nuts and bolt.
Torque: 11 N×m (112 kgf×cm, 8 ft×lbf)
46. INSTALL OIL PAN SUB−ASSY NO.2

(a) Remove any old packing material from the contact sur-
face.

(b) Apply seal packing in the shape of bead (Diameter 2.5 −

3.5 mm (0.0984 − 0.1378 in.)) consequently as shown in
the illustration.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
S Install the oil pan within 3 minutes after applying seal
packing.
Seal Width 2.5 − 3.5 mm A10465 S Do not put into engine oil within 2 hours after instal-
ling.
S Do not start the engine within 2 hours after installing.
(c) Install the oil pan No. 2 with the 9 bolts and 2 nuts.
Torque: 9.0 N×m (92 kgf×cm, 80 in.×lbf)
(d) Install the drain plug with a new gasket.
Torque: 38 N×m (382 kgf×cm, 28 ft×lbf)
47. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, install the oil filter union.

Torque: 30 N×m (306 kgf×cm, 22 ft×lbf)

48. INSTALL OIL FILTER SUB−ASSY

(a) Check and clean the oil filter installation surface.

(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(d) Using SST, tighten it an additional 3/4 turn.

SST 09228−06501

SST
A38018

49. INSTALL CYLINDER HEAD GASKET

Lot. No.

(a) Place a new cylinder head gasket on the cylinder block

surface with the Lot No. stamp upward.
NOTICE:
S Remove any oil from the contact surface.
S Be careful of the installation direction.
S Place the cylinder head quietly in order not to damage
A11249 the gasket with the bottom part of the head.

50. INSTALL CYLINDER HEAD SUB−ASSY

HINT:
Cylinder Head The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply seal packing in the shape of bead (Diameter 3.5 −
f3.5−4.5 4.5 mm (0.1378 − 0.1772 in.)) consequently as shown in
the illustration.
NOTICE:
Cylinder Head
S Remove any oil from the contact surface.
Gasket
S Install the oil pan within 3 minutes after applying seal
Cylinder Block packing.
Seal Packing (b) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
A50688

(c) Using a 8 mm bi−hexagon wrench, install and uniformly

tighten the 10 cylinder head bolts and plate washers, in
several passes, in the sequence shown.
Torque: 29 N×m (300 kgf×cm, 22 ft×lbf)

A35288

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(d) Mark the front of the cylinder head bolt with paint.
90_ 90_
(e) Retighten the cylinder head bolts by 90_ and 90_ in the
numerical order shown.
Front (f) Check that the paint mark is now at a 180_ angle to the
front.

A12126

51. INSTALL ENGINE REAR OIL SEAL

(a) Apply MP grease to a new oil seal lip.

NOTICE:
Keep the lip off foreign materials.
(b) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223−56010
NOTICE:
S Be careful not to tap the oil seal slantingly.
S Wipe off extra grease on the crank shaft.

SST
A50928

Straight 52. INSTALL CAMSHAFT TIMING GEAR ASSY(W/ VVT−i)

Pin
(a) Put the camshaft timing gear assembly and the camshaft
together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
Key
the pin gets into the groove.
Groove
A31033 NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear’s
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 64 N×m (650 kgf×cm, 47 ft×lbf)
(e) Check that the camshaft timing gear assembly can move
to the retard angle side (the right angle), and is locked at
the most retarded position.

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

53. INSTALL CAMSHAFT TIMING GEAR OR

SPROCKET(W/O VVT−i)

(a) Grip the camshaft with a vice.

(b) Align the knock pin hole in the camshaft timing sprocket
with the knock pin of the camshaft, and install the cam-
shaft timing sprocket.
Torque: 64 N×m (650 kgf×cm, 47 ft×lbf)
A32167 NOTICE:
Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT

(a) Apply light coat of engine oil on the camshaft journals.

(b) Place the camshaft on the cylinder head with timing mark
on the camshaft timing gear assembly upward.
(c) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque: 13 N×m (130 kgf×cm, 9 ft×lbf)
NOTICE:
Tighten the each bolt equally with keeping the camshaft
horizontal.

3 1 2 4 A37103

55. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET

(a) Grip the camshaft with a vice.

(b) Align the knock pin hole in the camshaft timing sprocket
with the knock pin of the camshaft, and install the cam-
shaft timing sprocket.
Torque: 64 N×m (650 kgf×cm, 47 ft×lbf)
NOTICE:
A32167 Be careful not to damage the camshaft.

56. INSTALL NO.2 CAMSHAFT

(a) Apply light coat of engine oil on the camshaft journals.

(b) Place the camshaft on the cylinder head with timing mark
on the camshaft timing gear upward.
5 3 1 2 4 (c) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque: 13 N×m (130 kgf×cm, 9 ft×lbf)
NOTICE:
Tighten the each bolt equally with keeping the camshaft
horizontal.
(d) Install the bearing cap No. 1.
Torque: 23 N×m (235 kgf×cm, 17 ft×lbf)
A37104

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

57. INSTALL CAM POSITION SENSOR

(a) Apply engine oil to the O−ring.

NOTICE:
If the O−ring is damaged, replace the cam position sensor.
(b) Install the cam position sensor with the bolt.
Torque: 8.0 N×m (82 kgf×cm, 71 in.×lbf)

ATDC 20_ Mark Plates 58. INSTALL CHAIN SUB−ASSY

(a) After setting the crankshaft at ATDC 40 − 140_, set cams

of intake and exhaust timing sprockets at ATDC 20_ and
then the reset the crankshaft at ATDC 20_.
(b) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N×m (92 kgf×cm, 80 in.×lbf)
Timing Marks (c) Align the match marks of timing chain mark plate (Yellow),
camshaft timing sprocket, camshaft timing gear and
crankshaft timing sprocket to install the timing chain as
shown in the illustration.
HINT:
To prevent the exhaust camshaft from spring back, turn it using
a wrench and set it at the mark on a chain.
(d) Install the chain tensioner slipper.
Mark Plate

30_
Timing Mark A11224

(e) While rotating the stopper plate of the tensioner up−ward,

push in the plunger of the tensioner as shown in the il-
lustration.
(f) While rotating the stopper plate of the tensioner down−
ward, insert a bar of 2.5 mm (0.098 in.) into the holes in
Plunger
the stopper plate and tensioner to fix the stopper plate.
SST 10514
(g) Install the chain tensioner with the 2 bolts.
Stopper Plate A11225 Torque: 9.0 N×m (92 kgf×cm, 80 in.×lbf)
(h) Remove the bar from the chain tensioner.
(i) Check that the tension between the intake and exhaust
camshaft timing sprocket.

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59. INSTALL OIL PUMP SEAL

(a) Using SST and a hammer, tap in a new oil seal until its sur-
SST face is flush with the timing chain cover edge.
Wooden SST 09950−60010 (09951−00250, 09951−00380,
Block 09952−06010), 09950−70010 (09951−07100)
NOTICE:
S Be careful not to tap the oil seal slantingly.
A37153 S Keep the lip off foreign materials.
(b) Apply MP grease to the oil seal lip.
60. INSTALL OIL PUMP ASSY

(a) Install 2 new O−rings to 2 locations as shown in the il-

lustration.
(b) Remove any old packing material from the contact sur-
face.

A35266

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(c) Apply seal packing to the oil pump assembly, cylinder

head and cylinder block as shown in the illustration.
Seal packing:
Water pump part part No. 08826 − 00100 or equivalent
Other part part No. 08826 − 00080 or equivalent.
NOTICE:
S Remove any oil from the contact surface.
S Install the oil pan within 3 minutes after applying seal
packing.
S Do not put into engine oil within 2 hours after instal-
ling.
S Do not start the engine within 2 hours after installing.

FIPG
FIPG
FIPG

Seal Width (08826−00080)

FIPG
(Water Pump Part)
(After Assembling)
Seal Width (08826−00100)

2.5
A51765

(d) Engage the spline teeth of the oil pump drive rotor with the
large teeth of the crankshaft, and slide the oil pump.

A35284

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(e) Install the oil pump assembly with the 15 bolts and a nut.
D E Uniformly tighten the bolts and nut in several passes.
Torque:
A A
Bolt A 24 N×m (245 kgf×cm, 18 ft×lbf)
C
C
Bolt B 11 N×m (113 kgf×cm, 8 ft×lbf)
Bolt C 11 N×m (113 kgf×cm, 8 ft×lbf)
C
Nut D 24 N×m (245 kgf×cm, 18 ft×lbf)
B
Bolt E 24 N×m (245 kgf×cm, 18 ft×lbf)
C A37150 NOTICE:
S Pay attention not to wrap the chain and slipper over
the chain cover seal line.
S After installing the oil pump assembly, must install
the mounting bracket and water pump within 15 min-
utes.
HINT:
Each bolt length in indicated in the illustration.
A 30 mm (1.181 in.)
B 35 mm (1.378 in.)
C 20 mm (0.787 in.)
E 20 − 14 mm (0.787 − 0.551 in.)
61. INSTALL WATER PUMP ASSY

(a) Install the water pump and a new gasket with the 3 bolts
and 2 nuts.
Torque: 11 N×m (113 kgf×cm, 8 ft×lbf)

B09338

62. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

Torque: 55 N×m (561 kgf×cm, 41 ft×lbf)

63. INSTALL WATER PUMP PULLEY

(a) Using SST, install the pump pulley with the 3 bolts.
SST 09960−10010 (09962−01000, 09963−01000)
SST Torque: 15 N×m (150 kgf×cm, 11 ft×lbf)

B09370

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

64. INSTALL CRANKSHAFT DAMPER SUB−ASSY

SST

(a) Align the hole in the crankshaft damper with the pin posi-
tion and install the crankshaft damper.
(b) Using SST, install the pulley bolt.
SST 09330−00021, 09213−58012 (91111−50845)
Torque: 128 N×m (1,300 kgf×cm, 94 ft×lbf)

A11262

65. INSPECT VALVE CLEARANCE

HINT:
Inspect and adjust the valve clearance when the engine is cold.

(a) Set the No. 1 cylinder to the TDC/compression.

(1) Turn the crankshaft damper, and align its groove
with timing mark ”0” of the chain cover.
(2) Check that both timing marks on the camshaft tim-
ing sprocket and valve timing controller assembly
Timing Marks
are facing right up as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360_) and align the
A38016 marks as above.

(b) Check only the valves indicated.

No. 1 Cylinder TDC/Compression
(1) Using a feeler gauge, measure the clearance be-
EX
tween the valve lifter and camshaft.
Valve clearance (Cold) :
Intake 0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust 0.25 − 0.35 mm (0.010 − 0.014 in.)
(2) Record the out−of−specification valve clearance
measurements. They will be used later to determine
IN A50689 the required replacement adjusting shim.
(c) Turn the crankshaft 1 revolution (360_) and align its
groove with the timing mark ”0” of the chain cover.

No. 4 Cylinder TDC/Compression (d) Check only the valves indicated.

EX (1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Valve clearance (Cold) :
Intake 0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust 0.25 − 0.35 mm (0.010 − 0.014 in.)
(2) Record the out−of−specification valve clearance
measurements. They will be used later to determine
IN A50690 the required replacement adjusting shim.

1NZ−FE,2NZ−FE ENGINE REPAIR MANUAL

(RM822E)
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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

66. ADJUST VALVE CLEARANCE

Matchmark
40_ NOTICE:
When rotating the camshaft with the timing chain removed,
rotate the crankshaft damper counterclockwise 40_ from
the TDC and align its groove with matchmark of the chain
cover for the valves not to touch the pistons.

A50156

(a) Set the No. 1 cylinder to the TDC/compression.

(1) Turn the crankshaft damper, and align its groove
with timing mark ”0” of the chain cover.
(2) Check that both timing marks on the camshaft tim-
ing sprocket and valve timing controller assembly
Timing Marks
are facing right up as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360_) and align the
A38016 marks as above.

(b) Place matchmarks on the timing chain and camshaft tim-

Paint Marks
ing sprockets.

Timing Marks
A50135

(c) Using a hexagon wrench 8, remove the screw plug.

A37101

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

Hexagonal Portion (d) Using drivers or equipment, while rotating the stopper
Plunger
Stopper plate of the tensioner upward, turn the exhaust camshaft
Plate right a little and push in the plunger of the chain tensioner
as shown in the illustration.
(e) Insert a bar of f 2 − 3 mm (0.08 − 0.12 in.) into the holes
in the stopper plate and tensioner to fix the stopper plate.
SST 10514
HINT:
A50158 S At this time, it is easier to fix by installing the bar while ro-
tate the camshaft right and left a little.
S Fix the bar with tape so that the bar does not come off.

(f) Hold the hexagonal portion of the camshaft with a

wrench, and remove the bolt.
SST 09023−38400

SST
A50157

(g) Uniformly loosen and remove the 11 bearing cap blots, in

1 3 5 4 2 several passes, in the sequence shown, and remove the
5 bearing caps.
NOTICE:
Loosen the each bolt equally with keeping the camshaft
horizontal.

A35760

(h) Remove the fringe bolt with lifting up the No. 2 camshaft,
then detach the No. 2 camshaft and the camshaft timing
sprocket.

A37148

1NZ−FE,2NZ−FE ENGINE REPAIR MANUAL

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(i) Uniformly loosen and remove the 8 bearing cap blots, in

several passes, in the sequence shown, and remove the
4 bearing caps.
NOTICE:
Loosen the each bolt equally with keeping the camshaft
horizontal.

2 4 3 1
A35766

(j) Hold the timing chain with your hand, and remove the
camshaft and camshaft timing gear assembly.

A35767

(k) Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.

A35227

(l) Remove the valve lifters.

(m) Using a micrometer, measure the thickness of the re-

moved lifter.
(n) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified value.
A Thickness of new lifter
B Thickness of used lifter
C Measured valve clearance
Specified value (Cold):
A01082 Intake A = B + (C − 0.20 mm (0.008 in.))
Exhaust A = B + (C − 0.30 mm (0.012 in.))

1NZ−FE,2NZ−FE ENGINE REPAIR MANUAL

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(o) Select a new lifter with a thickness as close as possible

to the calculated values.
HINT:
Lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), form 5.060 mm (0.1992 in.) to 5.740 mm (0.2260
in.).
(p) Reinstall the valve lifters.
(q) Apply light coat of engine oil on the camshaft journals.

Painted Link (r) As shown in the illustration, install the timing chain on the
camshaft timing gear, with the painted links aligned with
the timing marks on the camshaft timing gear.

Timing Mark A50141

(s) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque: 13 N×m (130 kgf×cm, 9 ft×lbf)
NOTICE:
Tighten the each bolt equally with keeping the camshaft
horizontal.

3 1 2 4 A37107

Painted Link (t) Hold the timing chain, and align the match marks on the
timing chain and camshaft timing sprocket.

Timing Mark A50065

(u) Align the knock pin hole in the camshaft timing sprocket
with the knock pin of the camshaft, and install the sprock-
et to the camshaft.
(v) Temporarily install the timing sprocket bolt.

A37148

1NZ−FE,2NZ−FE ENGINE REPAIR MANUAL

(RM822E)
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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

5 3 1 2 4 (w) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque: 13 N×m (130 kgf×cm, 9 ft×lbf)
NOTICE:
Tighten the each bolt equally with keeping the camshaft
horizontal.
(x) Install the bearing cap No. 1.
Torque: 23 N×m (235 kgf×cm, 17 ft×lbf)
A35763

(y) Hold the hexagon head portion of the camshaft with a

wrench, and install the bolt.
SST 09023−38400
Torque: 64 N×m (650 kgf×cm, 47 ft×lbf)

SST
A50157

(z) Remove the bar from the timing chain tensioner.

(aa) Turn the crankshaft damper, and align its groove with the
timing mark ”0” of the chain cover.
(ab) Check that the match marks on the timing chain and cam-
shaft timing sprockets.
Timing Marks

A38016

(ac) Apply seal packing to 2 or 3 threads of the screw plug end.

Seal packing:
Part No. 08833 − 00070 or equivalent
(ad) Using a hexagon wrench 8, install the screw plug.
Torque: 15 N×m (153 kgf×cm, 11 ft×lbf)

A37101

67. INSTALL FUEL INJECTOR ASSY

Insulator
(a) Install a new insulator and O−ring to each injector.
(b) Apply a light coat of spindle oil or gasoline on the place
where a delivery pipe touches on O−ring.

O−Ring
A50145

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

(c) While turning the injector clockwise and counterclock-

Turn wise, push it to the delivery pipe.
Push
Connector NOTICE:
S Be careful not twist the O−ring.
S After installing injectors, check that they turns
smoothly. If an injector does not, reinstall it with a new
O−ring.

A50146

68. INSTALL FUEL DELIVERY PIPE SUB−ASSY

(a) Install the spacer to the cylinder head.

(b) Install the delivery pipe with the 4 injectors.

A Torque:
Bolt A 19 N×m (194 kgf×cm, 14 ft×lbf)
Bolt B 9.0N×m (92 kgf×cm, 80 in.×lbf)
NOTICE:
S Be careful not to drop the injectors when installing
the delivery pipe.
S Check that the injectors rotate smoothly after instal-
B A35640 ling the delivery pipe.

69. INSTALL CYLINDER HEAD COVER SUB−ASSY

(a) Install the gasket to the cylinder head cover.

(b) Apply seal packing to 2 locations as shown in the illustra-

tion.
Seal packing:
Part No. 08826 − 00080 or equivalent
NOTICE:
S Remove any oil from the contact surface.
S Install the oil pan within 3 minutes after applying seal
packing.
Seal Packing
A50172 S Do not start the engine within 2 hours after installing.

9
(c) Install the cylinder head cover with the 9 bolt, 2 seal wash-
11 5 7
ers and 2 nuts.
(d) Uniformly tighten the bolts and nuts, in the several
passes, in the sequence shown.
10 Torque: 10 N×m (102 kgf×cm, 7 ft×lbf)
1 2

3 6 4
8
A35756

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ENGINE MECHANICAL − PARTIAL ENGINE ASSY (1NZ−FE/2NZ−FE)

70. INSTALL CRANK POSITION SENSOR

(a) Apply engine oil to the O−ring.

NOTICE:
If the O−ring is damaged, replace the crankshaft position sensor.
(b) Install the crankshaft position sensor with the bolt.
Torque: 7.5 N×m (76 kgf×cm, 66 in.×lbf)
71. INSTALL THERMOSTAT

(a) Install a new gasket to the thermostat.

(b) Install the thermostat with the jiggle valve upward.
10_ 10_ HINT:
The jiggle valve may be set within 10_ at either side of the pre-
scribed position.

A50133

(c)
Install the water inlet with the 2 nuts.
Torque: 9.0 N×m (92 kgf×cm, 80 in.×lbf)
72. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY(W/ VVT−i)

Torque: 7.5 N×m (76 kgf×cm, 66 in.×lbf)

73. INSTALL SPARK PLUG

Torque: 18 N×m (184 kgf×cm, 13 ft×lbf)

1NZ−FE,2NZ−FE ENGINE REPAIR MANUAL

(RM822E)