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EM–1142AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
58. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood (see page ED-7).
(b) Adjust the hood (see page ED-5).
59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
60. PERFORM REGISTRATION
(a) When replacing the engine assembly, perform
vehicle stability control system recognition in ECM
(see page CC-12).
61. RESET MEMORY (for Automatic Transaxle)
(a) When replacing the engine assembly, perform the
RESET MEMORY procedure (A/T initialization) for
U241E (2WD) (see page AX-18) and for U140F
(4WD) (see page AX-18).
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–123
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DISASSEMBLY
1. REMOVE IDLER PULLEY (See page EM-23)
2. REMOVE OIL DIPSTICK
3. REMOVE OIL DIPSTICK GUIDE (See page EM-57)
4. REMOVE MANIFOLD STAY (See page EM-57)
5. REMOVE NO. 2 MANIFOLD STAY (See page EM-58)
6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT
INSULATOR (See page EM-58)
7. REMOVE EXHAUST MANIFOLD CONVERTER SUB-
ASSEMBLY (See page EM-58)
8. REMOVE WATER INLET (See page CO-15)
9. REMOVE THERMOSTAT
10. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, pipe and gasket.
11. REMOVE NO. 3 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, pipe and gasket.
12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(See page EM-26)
13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSEMBLY (See page ES-395)
14. REMOVE KNOCK SENSOR (See page ES-420)
15. REMOVE RADIO SETTING CONDENSER (See page
EM-63)
16. REMOVE OIL PRESSURE SWITCH ASSEMBLY (See
page EM-63)
17. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR (See page EM-63)
18. REMOVE CAMSHAFT POSITION SENSOR (See page
EM-64)
19. REMOVE IGNITION COIL ASSEMBLY (See page IG-9)
A112226
A126940
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EM–1242AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
20. REMOVE SPARK PLUG
21. REMOVE OIL FILLER CAP SUB-ASSEMBLY
22. REMOVE OIL FILLER CAP GASKET
23. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(See page EC-18)
24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-24)
25. REMOVE CYLINDER HEAD COVER GASKET
26. REMOVE OIL FILTER SUB-ASSEMBLY (See page LU-
4)
27. REMOVE OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, remove the oil
filter union.
28. REMOVE CRANKSHAFT POSITION SENSOR (See
page ES-402)
29. REMOVE WATER PUMP PULLEY (See page CO-11)
30. REMOVE WATER PUMP ASSEMBLY (See page CO-
11)
A132575
A128158
A128159
A128166
A126912E01
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–125
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31. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket.
32. REMOVE OIL PAN SUB-ASSEMBLY (See page EM-
24)
33. REMOVE CRANKSHAFT PULLEY (See page EM-25)
34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See
page EM-26)
35. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(See page EM-26)
36. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR
PLATE
37. REMOVE TIMING CHAIN GUIDE (See page EM-28)
38. REMOVE CHAIN TENSIONER SLIPPER (See page
EM-28)
39. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See
page EM-28)
40. REMOVE CHAIN SUB-ASSEMBLY
41. REMOVE CRANKSHAFT TIMING SPROCKET
42. REMOVE NO. 2 CHAIN SUB-ASSEMBLY (See page
EM-29)
43. REMOVE OIL PUMP DRIVE GEAR
44. REMOVE OIL PUMP ASSEMBLY (See page LU-12)
45. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove
the 20 bearing cap bolts in the sequence shown in
the illustration.
(b) Remove the 10 bearing caps, then remove the
camshaft and No. 2 camshaft.
46. REMOVE CYLINDER HEAD SUB-ASSEMBLY (See
page EM-62)
A128176
A132571
A128185
A128186
F050596E02
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EM–1262AZ-FE ENGINE MECHANICAL – ENGINE UNIT
EM
47. REMOVE CYLINDER HEAD GASKET
48. REMOVE CYLINDER BLOCK WATER JACKET
SPACER
(a) Using needle-nose pliers, remove the cylinder block
water jacket spacer from the water jacket.
NOTICE:
Before turning the cylinder block upside down,
make sure that the water jacket spacer is
removed, as it will fall out.
49. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
50. REMOVE OIL CONTROL VALVE FILTER
(a) Using a 6 mm socket hexagon wrench, remove the
plug and gasket.
(b) Remove the oil control valve filter.
51. INSPECT BALANCE SHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while moving the balance shaft back and forth.
Standard thrust clearance:
0.05 to 0.09 mm (0.0020 to 0.0035 in.)
Maximum thrust clearance:
0.09 mm (0.0035 in.)
If the thrust clearance is greater than the maximum,
replace the balance shaft housing and bearings. If
necessary, replace the balance shaft.
A126929
A128208
A128209
A128210
A128196
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2AZ-FE ENGINE MECHANICAL – ENGINE UNITEM–127
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52. INSPECT BALANCE SHAFT OIL CLEARANCE
(a) Using several steps, uniformly loosen and remove
the 8 bolts in the sequence shown in the illustration.
(b) Remove the balance shaft housing from the
crankcase.
HINT:
Keep the lower bearing and balance shaft housing
together.
(c) Lift out the No. 1 and No. 2 balance shafts.
HINT:
Keep the upper bearing with the crankcase.
(d) Clean each bearing and journal.
(e) Check each bearing and journal for pitting and
scratches.
If a bearing or journal is damaged, replace the
bearings. If necessary, replace the balance shaft.
(f) Inspect the balance shaft housing bolt.
(1) Using a vernier caliper, measure the length of
the bolts from the seat to the end.
Standard bolt length:
58.3 to 59.7 mm (2.295 to 2.350 in.)
Maximum bolt length:
60.3 mm (2.374 in.)
If the bolt length is greater than the maximum,
replace the balance shaft bolt.
(g) Place the No. 1 and No. 2 balance shafts onto the
crankcase.
(h) Lay a strip of Plastigage across each journal.
(i) Install the balance shaft housing.
(j) Apply a light coat of engine oil on the threads and
under the heads of the bolts.
(k) Using several steps, uniformly install and tighten the
8 bolts in the sequence shown in the illustration.
Torque: 21.6 N*m (220 kgf*cm, 16 ft.*lbf)
A128197E01
A132569E01
A131575E01
A090849E04
A128197E03
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EM–1282AZ-FE ENGINE MECHANICAL – ENGINE UNIT
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(l) Mark the front of the bolts with paint.
(m) Retighten the bolts 90
as shown in the illustration.
(n) Check that the paint mark is now at a 90
angle to
the front.
(o) Remove the balance shaft housing from the
crankcase.
(p) Measure the Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.049 mm (0.0002 to 0.0019 in.)
Maximum oil clearance:
0.049 mm (0.0019 in.)
NOTICE:
Remove the Plastigage completely after the
measurement.
If the oil clearance is greater than the maximum,
replace the bearing. If necessary, replace the
balance shaft.
HINT:
If replacing a bearing, select a new one with the
same number.
Standard balance shaft housing journal bore
diameter
Standard balance shaft journal diameter:
22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Standard bearing center wall thickness
53. REMOVE BALANCE SHAFT
A037134E02
Item Specified Condition
Mark 1 26.000 to 26.006 mm (1.0236 to
1.0239 in.)
Mark 2 26.007 to 26.012 mm (1.0239 to
1.0214 in.)
Mark 3 26.013 to 26.018 mm (1.0241 to
1.0243 in.)
Item Specified Condition
Mark 1 1.486 to 1.489 mm (0.05850 to
0.05862 in.)
Mark 2 1.490 to 1.492 mm (0.05866 to
0.05874 in.)
Mark 3 1.493 to 1.495 mm (0.0585 to 0.0586
in.)
A132569E01
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54. REMOVE NO. 1 BALANCE SHAFT BEARING
55. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the lip of the oil seal.
(b) Using a screwdriver with its tip wrapped with tape,
pry out the oil seal.
NOTICE:
After removing, check the crankshaft for
damage. If damaged, smooth the surface with
400-grit sandpaper.
56. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Using several steps, uniformly loosen and remove
the 11 bolts in the sequence shown in the
illustration.
A128204E01
A098356E01
A112229E01