2AZ-FE LUBRICATION LUBRICATION SYSTEM

LU1

LUBRICATION SYSTEM
ON-VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL (a) Warm up the engine, stop the engine and wait for 5 minutes. (b) Check that the engine oil level is between the L and F marks of the oil dipstick. If low, check for leakage and add oil up to the F mark. NOTICE: Do not add engine oil above the F mark. CHECK ENGINE OIL QUALITY (a) Check the oil for deterioration, water intrusion, discoloration or thinning. If the quality is visibly poor, replace the oil. Oil grade: Use ILSAC multigrade engine oil. SAE 5W-20 and SAE 0W-20 engine oil may be used. However, SAE 0W-20 is the best choice for good fuel economy and good starting in cold weather. CHECK OIL PRESSURE (a) Disconnect the oil pressure switch connector. (b) Using a 24 mm deep socket wrench, remove the oil pressure switch.

2.
Recommended Viscosity (SAE)

5W-20, 0W-20 C -29 -18 F -20 0 -7 20 4 40 16 60 27 38 80 100

3.

A112272

Oil Pressure Gauge

(c) Install the oil pressure gauge. (d) Warm up the engine. (e) Measure the oil pressure. Standard oil pressure
Condition Idle 3,000 rpm
A112273E01

LU

Specified Condition 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 170 to 300 kPa (1.7 to 3.1 kgf/cm2, 24 to 44 psi)

LU2

2AZ-FE LUBRICATION LUBRICATION SYSTEM

(f)
Adhesive

A085603E02

Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent (g) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTICE: Do not start the engine within 1 hour of installation. (h) Connect the oil pressure switch connector. (i) Check for engine oil leaks.

LU

2AZ-FE LUBRICATION OIL FILTER

LU3

OIL FILTER
2AZ-FE ENGINELUBRICATION

COMPONENTS

13 (133, 10)

OIL FILTER SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
A134971E01

LU

LU4

2AZ-FE LUBRICATION OIL FILTER

REPLACEMENT
CAUTION: Prolonged and repeated contact with engine oil will cause the loss of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use a waterless hand cleaner to remove any used engine oil. Do not use gasoline, thinners or solvents. For environmental protection, used oil and used oil filters must be disposed of at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. REMOVE OIL FILTER SUB-ASSEMBLY (a) Using SST, remove the oil filter. SST 09228-06501 INSTALL OIL FILTER SUB-ASSEMBLY (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter.

2.

3.
SST

A136225E01

LU
SST

A136227E01

(c) Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat. (d) Using SST, tighten the oil filter. SST 09228-06501 (1) Depending on the work space available, choose from the following. 1. If enough space is available, use a torque wrench to tighten the oil filter. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 2. If enough space is not available to use a torque wrench, tighten the oil filter a 3/4 turn by hand or use a common wrench. 4. ADD ENGINE OIL (a) Clean and install the oil drain plug with a new gasket. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) (b) Add new oil. Standard capacity
Item Drain and refill with oil filter change Standard Condition 4.3 liters (4.5 US qts, 3.8 Imp. qts)

2AZ-FE LUBRICATION OIL FILTER

LU5

4.1 liters (4.3 US qts, 3.6 Imp. qts) 5.0 liters (5.3 US qts, 4.4 Imp. qts)

(c) Install the oil filler cap. 5. CHECK FOR ENGINE OIL LEAKS

LU

2AZ-FE LUBRICATION OIL PUMP

LU5

OIL PUMP
2AZ-FE ENGINELUBRICATION

COMPONENTS
ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
64 (653, 47)

NO. 2 ENGINE MOUNTING BRACKET RH

52 (531, 38)

64 (653, 47)

NO. 1 ENGINE COVER SUB-ASSEMBLY NO. 2 ENGINE MOUNTING STAY RH V-RIBBED BELT
9.8 (100, 87 in.*lbf) 52 (531, 38) 21 (214, 15)

GENERATOR ASSEMBLY

LU

FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque

LU6

2AZ-FE LUBRICATION OIL PUMP

43 (439, 32)

VANE PUMP ASSEMBLY

FRONT EXHAUST PIPE ASSEMBLY

EXHAUST PIPE GASKET

EXHAUST PIPE GASKET

REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET

LU

FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET

ENGINE UNDER COVER RH

ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part
A134947E01

2AZ-FE LUBRICATION OIL PUMP

LU7

9.0 (92, 80 in.*lbf)

IGNITION COIL ASSEMBLY

14 (143, 10) 14 (143, 10) 11 (110, 8)

11 (110, 8)

x6

x2

CYLINDER HEAD COVER SUB-ASSEMBLY

CYLINDER HEAD COVER GASKET

CRANK POSITION SENSOR

LU

CRANKSHAFT PULLEY
25 (255, 18)

OIL PAN SUB-ASSEMBLY

OIL PAN DRAIN PLUG

GASKET

9.0 (92, 80 in.*lbf)

x2

x12
9.0 (92, 80 in.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
A134922E01

LU8

2AZ-FE LUBRICATION OIL PUMP

CRANKSHAFT TIMING SPROCKET NO. 1 CHAIN VIBRATION DAMPER CHAIN SUB-ASSEMBLY

NO. 2 CHAIN SUB-ASSEMBLY CHAIN TENSIONER SLIPPER OIL PUMP DRIVE SPROCKET

19 (194, 14)

SPRING CHAIN TENSIONER PLATE

NO. 1 CRANKSHAFT POSITION SENSOR PLATE

GASKET OIL PUMP DRIVEN SPROCKET x3 OIL PUMP ASSEMBLY

TIMING CHAIN GUIDE

19 (194, 14)

11 (112, 8) 9.0 (92, 80 in.*lbf) 11 (112, 8)

NO. 1 CHAIN TENSIONER ASSEMBLY

LU
60 (607, 44)

GASKET

55 (561, 44)

x4
22 (220, 16)

STUD BOLT
9.0 (92, 80 in.*lbf)

V-RIBBED BELT TENSIONER ASSEMBLY

x8 TIMING CHAIN CASE OIL SEAL

TIMING CHAIN COVER SUB-ASSEMBLY

Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque Apply MP grease

2AZ-FE LUBRICATION OIL PUMP

LU9

8.8 (90, 78 in.*lbf)

GASKET

8.8 (90, 78 in.*lbf)

OIL PUMP STRAINER

OIL PUMP COVER DRIVE ROTOR

DRIVEN ROTOR

49 (500, 36)

OIL PUMP RELIEF VALVE PLUG

LU
OIL PUMP ASSEMBLY

OIL PUMP RELIEF VALVE OIL PUMP RELIEF VALVE SPRING Non-reusable part N*m (kgf*cm, ft.*lbf) : Specified torque
A114157E07

LU10

2AZ-FE LUBRICATION OIL PUMP

REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. 9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-94) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL (See page LU-4) REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) REMOVE NO. 2 ENGINE MOUNTING STAY RH (See page EM-95)

10. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-95) 11. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-96) 12. REMOVE V-RIBBED BELT (See page EM-6) 13. REMOVE GENERATOR ASSEMBLY (See page CH-11) 14. REMOVE VANE PUMP ASSEMBLY (See page EM101) 15. REMOVE IGNITION COIL ASSEMBLY (See page EM106) 16. DISCONNECT VENTILATION HOSE 17. DISCONNECT NO. 2 VENTILATION HOSE 18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-21)

LU

19. SET SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page EM-8) 20. REMOVE CRANKSHAFT PULLEY (See page EM-75) 21. REMOVE CRANK POSITION SENSOR (See page ES411) 22. REMOVE OIL PAN SUB-ASSEMBLY (See page EM22) 23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-22) 24. INSTALL ENGINE HANGERS (See page EM-22) 25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-23) 26. REMOVE ENGINE MOUNTING INSULATOR (See page EM-23)

2AZ-FE LUBRICATION OIL PUMP

LU11

27. REMOVE ENGINE MOUNTING BRACKET RH (See page EM-24) 28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Using a E10 "torx" socket, remove the stud bolt for the drive belt tensioner from the cylinder block. (b) Remove the 12 bolts and 2 nuts.

A128178

(c) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. HINT: Tape the screwdriver tip before use.

LU

A128179

LU12

2AZ-FE LUBRICATION OIL PUMP

29. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver and a hammer, tap out the oil seal. HINT: Tape the screwdriver tip before use. 30. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See page EM-24)
A128180

31. REMOVE CHAIN TENSIONER SLIPPER (See page EM-24) 32. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See page EM-24) 33. REMOVE TIMING CHAIN GUIDE (See page EM-25) 34. REMOVE CHAIN SUB-ASSEMBLY (See page EM-25) 35. REMOVE CRANKSHAFT TIMING SPROCKET (See page EM-25) 36. REMOVE NO. 2 CHAIN SUB-ASSEMBLY (See page EM-25) 37. REMOVE OIL PUMP ASSEMBLY (a) Remove the 3 bolts, oil pump and gasket.

B011673E01

DISASSEMBLY
1. REMOVE OIL PUMP STRAINER (a) Remove the 2 nuts, oil pump strainer and gasket.

LU
B011430E01

2.

REMOVE OIL PUMP RELIEF VALVE (a) Using a 27 mm socket wrench, remove the plug. (b) Remove the valve spring and relief valve.

Relief Valve

Plug

Valve Spring
A052074E02

2AZ-FE LUBRICATION OIL PUMP

LU13

3.

REMOVE OIL PUMP COVER (a) Remove the 5 bolts and oil pump cover. (b) Remove the oil pump rotor.

B011431E01

INSPECTION
1. INSPECT OIL JET (a) Check the oil jet for damage or clogging. If necessary, repair the cylinder block.

A126890

2.

INSPECT OIL PUMP RELIEF VALVE (a) Check the relief valve. (1) Coat the valve with engine oil, and then check that the valve falls smoothly into the valve hole under its own weight. If the valve does not fall smoothly, replace the relief valve. If necessary, replace the oil pump assembly.

A114340

Mark

3.

INSPECT OIL PUMP ROTOR (a) Install the oil pump rotor. (1) Coat the drive rotor and driven rotor with engine oil. (2) Place the drive and driven rotors into the oil pump with the marks facing the pump cover side.

LU

B011423E04

B011420E02

(b) Check the side clearance. (1) Using a feeler gauge and precision straightedge, measure the clearance between the rotors and precision straightedge. Standard clearance: 0.030 to 0.085 mm (0.0012 to 0.0033 in.) Maximum clearance: 0.16 mm (0.0063 in.) If the side clearance is greater than the maximum, replace the oil pump assembly.

LU14

2AZ-FE LUBRICATION OIL PUMP

Feeler Gauge

(c) Check the tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard clearance: 0.080 to 0.160 mm (0.0031 to 0.0063 in.) Maximum clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than the maximum, replace the oil pump assembly.
A114223E01

(d) Check the body clearance. (1) Using a feeler gauge, measure the clearance between the driven rotor and pump body. Standard clearance: 0.100 to 0.170 mm (0.0039 to 0.0067 in.) Maximum clearance: 0.325 mm (0.0128 in.) If the body clearance is greater than the maximum, replace the oil pump assembly.
B011422E01

4. 5. 6. 7.

INSPECT NO. 2 CHAIN SUB-ASSEMBLY (See page EM-138) INSPECT OIL PUMP DRIVE SPROCKET (See page EM-138) INSPECT OIL PUMP DRIVEN SPROCKET (See page EM-139) INSPECT CHAIN TENSIONER PLATE (See page EM140) INSTALL OIL PUMP COVER (a) Install the oil pump cover with the 5 bolts. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) INSTALL OIL PUMP RELIEF VALVE (a) Coat the relief valve with engine oil.

REASSEMBLY
1.

2.

LU
B011431E01

(b) Insert the relief valve and spring into the pump body hole. (c) Using a 27 mm socket wrench, install the plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
Relief Valve

Plug

Valve Spring
A052074E02

2AZ-FE LUBRICATION OIL PUMP

LU15

3.

INSTALL OIL PUMP STRAINER (a) Install a new gasket and the oil strainer with the 2 nuts. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf)

B011430E01

INSTALLATION
1. INSTALL OIL PUMP ASSEMBLY (a) Install a new gasket and the oil pump with the 3 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) INSTALL NO. 2 CHAIN SUB-ASSEMBLY (See page EM-27) INSTALL CRANKSHAFT TIMING SPROCKET (See page EM-28) INSTALL NO. 1 CHAIN VIBRATION DAMPER (See page EM-28) INSTALL CHAIN SUB-ASSEMBLY (See page EM-28) INSTALL CHAIN TENSIONER SLIPPER (See page EM-29) INSTALL TIMING CHAIN GUIDE (See page EM-30) INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See page EM-30) INSTALL TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 (b) Apply a light coat of MP grease to the lip of the oil seal. NOTICE: Keep the gap between the timing chain cover edge and the oil seal free of foreign matter.

2. 3. 4. 5. 6. 7. 8. 9.

B011673E01

SST

LU

A128223E03

10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

LU16

2AZ-FE LUBRICATION OIL PUMP

(b) Apply seal packing (diameter: 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent (c) Apply seal packing in a continuous bead as shown in the illustration.

Seal Packing

4.0 to 4.5 mm (0.157 to 0.177 in.)

A140776E01

Seal Diameter: 4.0 (0.157)

Seal Diameter: 4.0 (0.157)

Seal Diameter: 2.5 to 3.0 (0.098 to 0.118) A Seal Diameter: 4.0 to 4.5 (0.157 to 0.177) D B

4.0 (0.157)

LU

Seal Diameter: 3.0 (0.118)

C 17.5 (0.689) Seal Diameter: 2.5 to 3.0 (0.098 to 0.118) 13.0 (0.512)

Seal Diameter: 5.5 to 6.0 (0.217 to 0.236)

Seal Diameter: 4.5 to 5.0 (0.177 to 0.197)

Seal Diameter: 2.5 to 3.0 (0.098 to 0.118)

: Seal Packing

mm (in.)
A132566E03

2AZ-FE LUBRICATION OIL PUMP

LU17

Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Remove any oil from the contact surface. Install the chain cover within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. (d) Install the timing chain cover with the 12 bolts and 2 nuts. Torque: Bolt A 9.0 N*m (92 kgf*cm, 80 in.*lbf) Bolt B 25 N*m (255 kgf*cm, 18 ft.*lbf) Bolt C 55 N*m (561 kgf*cm, 41 ft.*lbf) Nut 11 N*m (112 kgf*cm, 8 ft.*lbf) Bolt length
Item Length 30 mm (1.18 in.) length for 10 mm head 30 mm (1.18 in.) length for 12 mm head 40 mm (1.57 in.) length for 14 mm head Bolt A Bolt B Bolt C

NUT C C NUT

B A B

B B

B STUD BOLT

(e) Using a E10 "torx" socket, install the stud bolt to the drive belt tensioner. Torque: 22 N*m (220 kgf*cm, 16 ft.*lbf)
A128178E01

11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-30) 12. INSTALL ENGINE MOUNTING BRACKET RH (See page EM-30) 13. INSTALL ENGINE MOUNTING INSULATOR (See page EM-30) 14. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-31) 15. INSTALL CRANK POSITION SENSOR (See page ES411) 16. INSTALL CRANKSHAFT PULLEY (See page EM-76) 17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See page EM-32) 18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-33) 19. INSTALL NO. 2 VENTILATION HOSE 20. INSTALL VENTILATION HOSE 21. INSTALL IGNITION COIL ASSEMBLY (See page EM33) 22. INSTALL VANE PUMP ASSEMBLY (See page EM-113) 23. INSTALL GENERATOR ASSEMBLY (See page CH-19)

LU

LU18

2AZ-FE LUBRICATION OIL PUMP

24. INSTALL V-RIBBED BELT (See page EM-6) 25. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH (See page EM-118) 26. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY (See page EM-119) 27. INSTALL NO. 2 ENGINE MOUNTING STAY RH (See page EM-119) 28. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) 29. ADD ENGINE OIL 30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page EM-120) 31. CHECK ENGINE OIL LEAKS 32. CHECK CHECK EXHAUST GAS LEAKS 33. CHECK IGNITION TIMING (See page EM-1) 34. INSTALL FRONT FENDER APRON SEAL RH 35. INSTALL ENGINE UNDER COVER LH 36. INSTALL ENGINE UNDER COVER RH 37. INSTALL FRONT WHEEL RH 38. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See page EM-121)

LU

2AZ-FE LUBRICATION ENGINE OIL COOLER (w/ Oil Cooler)

LU19

ENGINE OIL COOLER (w/ Oil Cooler)

COMPONENTS

O-RING

WATER BY-PASS HOSE ENGINE OIL COOLER

PLATE WASHER

9.0 (92, 80 in.*lbf) 79 (800, 58)

LU

OIL COOLER UNION BOLT

13 (133, 10)

OIL FILTER SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
A124386E06

LU20

2AZ-FE LUBRICATION ENGINE OIL COOLER (w/ Oil Cooler)

REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH REMOVE FRONT WHEEL OPENING EXTENSION PAD LH REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN ENGINE COOLANT (See page CO-5) DRAIN ENGINE OIL (See page LU-4) REMOVE OIL FILTER SUB-ASSEMBLY (See page LU4) REMOVE ENGINE OIL COOLER (a) Disconnect the 2 oil cooler hoses from the oil cooler. (b) Remove the oil cooler union bolt, plate washer, nut, oil cooler and O-ring.

A114329

INSPECTION
1. INSPECT ENGINE OIL COOLER (a) Check the engine oil cooler for damage or clogging. If necessary, replace the oil cooler.

A124388

LU

2AZ-FE LUBRICATION ENGINE OIL COOLER (w/ Oil Cooler)

LU21

INSTALLATION
1. INSTALL ENGINE OIL COOLER (a) Clean the oil cooler contact surface. (b) Install a new O-ring to the oil cooler.
New O-Ring

A124389E01

(c) Apply a light coat of engine oil to the threads and under the head of the oil cooler union bolt. (d) Install the oil cooler with the plate washer, oil cooler union bolt and nut. Torque: for union bolt 79 N*m (800 kgf*cm, 58 ft.*lbf) for nut 9.0 N*m (92 kgf*cm, 80 in.*lbf) (e) Connect the 2 oil cooler hoses.
A114329

2. 3. 4. 5. 6. 7. 8. 9.

INSTALL OIL FILTER SUB-ASSEMBLY (See page LU4) ADD ENGINE OIL (See page LU-4) ADD ENGINE COOLANT (See page CO-5) CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page CO-1) CHECK ENGINE OIL LEVEL (See page LU-1) INSTALL ENGINE UNDER COVER RH INSTALL ENGINE UNDER COVER LH

10. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 11. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

LU