11 11 Engine Block
| Type | Thread | Description | Tightening Specification | |
|---|---|---|---|---|
| 1AZ Main bearing bolts (steel bolts 10.9) | N54 | M10x100 | Replace screws | |
| Jointing torque | 20 Nm | |||
| Torque angle | 70 ° | |||
| 2AZ Bedplate Aluminum screws/bolts are marked with blue paint. | N54 | M10x27 | Replace screws Thread repairs exclusively with Al Heli-coil. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 15 Nm | |||
| Torque angle | 90 ° | |||
| 3AZ Bedplate Aluminum screws/bolts are marked with blue paint. | N54 | M8x37 | Replace screws Thread repairs exclusively with Al Heli-coil. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 10 Nm | |||
| Torque angle | 90 ° | |||
| 4AZ Bedplate Aluminum screws/bolts are marked with blue paint. | N54 | M10x41 | Replace screws Thread repairs exclusively with Al Heli-coil. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 15 Nm | |||
| Torque angle | 90 ° | |||
| 5AZ Oil spray nozzles to engine block | N54 | Hollow bolt | 12 Nm | |
| 6AZ Screw plug, water drain | N54 | M14x1.5 | Replace seal | 25 Nm |
| 7AZ Screw plug, timing case upper section | N54 | M22x1.5 | Replace seal | 50 Nm |
| 8AZ Screw plug, timing case lower section | N54 | M16x1.5 | Replace seal | 30 Nm |
ENGINE BLOCK-TIGHTENING TORQUE SPECIFICATIONS
11 12 Cylinder Head With Cover
| Type | Thread | Description | Tightening Specification | |
|---|---|---|---|---|
| 1AZ Cylinder head bolt | N54 | M11 x 135 | Replace screws. | |
| Jointing torque | 30 Nm | |||
| 1st angle of rotation | 90 ° | |||
| 2. Angle of rotation | 90 ° | |||
| 3. Angle of rotation | 45 ° | |||
| 2AZ Cylinder head bolt | N54 | M9 x 95 M9 x 125 | Replace screws. | |
| Jointing torque | 30 Nm | |||
| 1st angle of rotation | 90 ° | |||
| 2. Angle of rotation | Omitted | |||
| 3. Angle of rotation | 45 ° | |||
| 3AZ Cylinder head bolt | N54 | M9 x 30 M9 x 70 | 22 Nm | |
| 4AZ Cylinder head cover to cylinder head. | N54 | M6 | 8.5 Nm | |
| 5AZ Metal bracket to cylinder head. | N54 | M6 x 16 | 8 Nm | |
| 6AZ Lifting eye to cylinder head. | N54 | M8 x 20 | 19 Nm | |
| 7AZ Ignition coil cover to cylinder head cover. | N54 | M6 x 20 | 4 Nm | |
| 8AZ Hexagon screw (2 x) Metal bracket for ignition coil cover to cylinder head cover. | N54 | M6 x 12 | 4 Nm |
CYLINDER HEAD WITH CYLINDER HEAD COVER-TIGHTENING TORQUE SPECIFICATIONS
| Type | Thread | Tightening Specification | |
|---|---|---|---|
| 11AZ Cylinder head cover | All | M6 | 10 Nm |
| All | M7 | 15 Nm | |
| M21 | M8 | 15 Nm | |
| 12AZ Oil trap to cylinder head cover | M21 | M8 | 17 Nm |
| 13AZ Timing case to cylinder head | All | M7 | 15 Nm |
| All | M8 | 20 Nm | |
| 14AZ Plug for oil channel (micro-encapsulated) | M47/M57 | M12 x 1.5 | 20 Nm |
| 15AZ Vent plugs to cylinder head (coolant) | M67 | 2 Nm |
CYLINDER HEAD WITH COVER-TIGHTENING TORQUE SPECIFICATIONS
11 13 Oil Sump
| Type | Thread | Description | Tightening Specification | |
|---|---|---|---|---|
| Optional extra designation: SA203 = All-wheel drive SA205 = Automatic transmission | ||||
| 1AZ Plug (1 x) Oil drain to oil sump. | N54 | M12 x 1.5 | Replace sealing ring. | 25 Nm |
| 2AZ ASA screw (20 x with optional extra SA203) (23 x with optional extra SA205) Oil sump (aluminum) to crankcase lower half. The end faces of the aluminum screw heads are painted blue. | N54 | M8 x 26 | Replace screw. Thread repairs exclusively with aluminum Heli-coil threaded insert. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 8 Nm | |||
| Torque angle | 90 ° | |||
| 3AZ ASA screw (5 x M8 x 112 with optional extra SA203) (2 x M8 x 112 with optional extra SA205) (3 x M8 x 92 with optional extra SA203 or SA205) Oil sump (aluminum) to crankcase lower half. The end faces of the aluminum screw heads are painted blue. | N54 | M8 | Replace screw. Thread repairs exclusively with aluminum Heli-coil threaded insert. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 8 Nm | |||
| Torque angle | 180 ° | |||
| 4AZ ASA screw (1 x M8 x 36 with optional extra SA203) Oil sump (aluminum) to crankcase lower half. The end faces of the aluminum screw heads are painted blue. | N54 | M8 | Replace screw. Thread repairs exclusively with aluminum Heli-coil threaded insert. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 8 Nm | |||
| Torque angle | 90 ° | |||
| 5AZ ASA screw (6 x without optional extra SA203) (7 x with optional extra SA203) Oil deflector to crankcase lower half. The end faces of the aluminum screw heads are painted blue. | N54 | M6 x 20 | Replace screw. Thread repairs exclusively with aluminum Heli-coil threaded insert. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 4 Nm | |||
| Torque angle | 90 ° | |||
| 6AZ ASA screw (3 x) Transmission to oil sump. | N54 | M8 x 50 | 19 Nm | |
| 7AZ Hexagon screw (1 x) Holder, transmission oil cooler line, to oil sump. | N54 | M6 x 30 | 8 Nm | |
| 8AZ Hexagon nut (3 x) Oil level sensor to oil sump. | N54 | M6 | 8 Nm | |
| 9AZ Transmission fluid cooler bracket to oil sump | N54 | M8 | 9 Nm |
OIL SUMP-TIGHTENING TORQUE SPECIFICATIONS
11 14 Case Covers
| Type | Thread | Description | Tightening Specification | |
|---|---|---|---|---|
| 1AZ Transmission cover plate to crankcase Aluminum screws/bolts are marked with blue paint. | N54 | M6x16 | Replace screws Thread repairs exclusively with Al Heli-coil Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 4 Nm | |||
| Torque angle | 45 ° |
CASE COVERS-TIGHTENING TORQUE SPECIFICATIONS
11 21 Crankshaft And Bearings
| Type | Thread | Description | Tightening Specification | |
|---|---|---|---|---|
| 1AZ Torsion damper (hub) to crankshaft (central bolt 12.9) | N54 | M16x80 | Replace screws Lightly oil screws and threads | |
| Jointing torque | 100 Nm | |||
| Torque angle | 360 ° |
CRANKSHAFT AND BEARINGS-TIGHTENING TORQUE SPECIFICATIONS
11 22 Flywheel
| Type | Thread | Description | Tightening Specification | |
|---|---|---|---|---|
| 1AZ Flywheel to crankshaft (automatic transmission) | N54 | M12x1.5x25.5 | Replace screws | |
| 1. Jointing torque | 30 Nm | |||
| 2. Final tightening | 125 Nm | |||
| 2AZ DM flywheel to crankshaft (manual transmission) | N54 | M12x1.5x 25.35 | Replace screw | 120 |
FLYWHEEL-TIGHTENING TORQUE SPECIFICATIONS
11 24 Connecting Rods And Bearings
| Type | Thread | Description | Tightening Specification | |
|---|---|---|---|---|
| 1AZ Connecting rod bolts | N54 | M9 | Replace, wash and oil screws | |
| Jointing torque | 20 Nm | |||
| Torque angle | 140 ° |
CONNECTING RODS AND BEARINGS-TIGHTENING TORQUE SPECIFICATIONS
11 28 V-Ribbed Belt With Tension And Deflection Element
| Type | Thread | Tightening Specifications | |
|---|---|---|---|
| 1AZ ISA screw (1 x) Belt tensioner with deflection pulley to engine block. | N54 | M10 x 110 | 40 Nm |
| 2AZ ISA screw (1 x) Deflection pulley 80 x 30 | N54 | M10 x 40 | 38 Nm |
| 3AZ ISA screw (1 x) Deflection pulley 90 x 30 | N54 | M10 x 40 | 38 Nm |
| 4AZ ASA screw (1 x) Belt tensioner to crankcase upper section. | N54 | M10 x 65 | 38 Nm |
| 5AZ Deflection pulley 65 x 33 | N54 | M10 x 65 | 40 Nm |
| 6AZ Deflection pulley 72 x 32 | N54 | M10 x 40 | 40 Nm |
| 7AZ ISA screw (1 x) Deflection pulley 73.8 x 24.92 to crankcase upper section. | N54 | M10 x 40 | 38 Nm |
V-RIBBED BELT WITH TENSION AND DEFLECTION ELEMENT-TIGHTENING TORQUE SPECIFICATIONS
11 31 Camshaft
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Upper and lower bearing strip of camshaft (steel screw 10.9) | N54 | M7x70 | Insert screws dry | |
| Jointing torque | 8 Nm | |||
| Torque angle | 60 ° | |||
| 2AZ Chain drive module to cylinder head | N54 | M6x35 | 8.5 Nm | |
| 3AZ Guide rail to crankcase | N54 | M8 | 20 Nm | |
| 4AZ Guide rail to cylinder head | N54 | M7 | 14 Nm | |
| 5AZ Chain tensioner to cylinder head | N54 | M22 x 1.5 | Replace sealing ring | 55 Nm |
| 6AZ Screw plug in cylinder head | N54 | M18x1.5 | 25 Nm |
CAMSHAFT-TIGHTENING TORQUE SPECIFICATIONS
11 36 Variable Camshaft Control
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ VANOS with sensor wheel to inlet and exhaust camshafts | N54 | M10x94 | Replace screw | |
| Jointing torque | 20 Nm | |||
| Torque angle | 180 ° | |||
| 2AZ Non-return valve VANOS to cylinder head | N54 | M14 x 1.5 | 13 Nm | |
| 3AZ Solenoid valve holder to cylinder head | N54 | M6x12 | 10 Nm |
VARIABLE CAMSHAFT CONTROL-TIGHTENING TORQUE SPECIFICATIONS
11 41 Oil Pump With Strainer And Drive
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Intake pipe to bedplate | N54 | M6x30 | Replace screws Thread repairs exclusively with Al Heli-coil. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 4 Nm | |||
| Torque angle | 100 ° | |||
| 2AZ Oil pump to bedplate | N54 | M8x123 | Replace screws Thread repairs exclusively with Al Heli-coil. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 10 Nm | |||
| Torque angle | 180 ° | |||
| N54 | M8x31 | Replace screws Thread repairs exclusively with Al Heli-coil. Jointing torque and angle of rotation must be observed without fail. | ||
| Jointing torque | 10 Nm | |||
| Torque angle | 90 ° | |||
| 3AZ Chain module to crankcase and oil pump | N54 | M6x16 | Replace screws Thread repairs exclusively with Al Heli-coil. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 4 Nm | |||
| Torque angle | 45 ° | |||
| 4AZ Sprocket to oil pump | N54 | M8 | Jointing torque | 20 Nm |
| Torque angle | 45 ° |
OIL PUMP WITH STRAINER AND DRIVE-TIGHTENING TORQUE SPECIFICATIONS
11 42 Oil Filter And Pipes
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Oil filter cap to oil filter housing | N54 | 25 Nm | ||
| 2AZ Oil filter housing to cylinder head | N54 | M8 x 78 M8 x 48 M8 x 28 | 22 Nm | |
| 3AZ Oil-coolant heat exchanger to oil filter housing. | N54 | M8 x 20 | 16 Nm | |
| 4AZ ISA screw (1 x) Assembly, oil feed line to crankcase top section | N54 | M8 x 35 | 19 Nm | |
| 5AZ ISA screw (1 x) Assembly, oil feed line to exhaust turbocharger | N54 | M6 x 12 | 8 Nm | |
| 6AZ Oil pressure line to crankcase | N54 | M8 x 12 | 20 Nm | |
| 7AZ ISA screw (2 x) Oil return line to exhaust turbocharger | N54 | M6 x 12 | 8 Nm | |
| 8AZ ISA screw (1 x) Oil return line to crankcase bottom section | N54 | M6 x 16 | 8 Nm | |
| 9AZ Oil feed to exhaust turbocharger | N54 | M6 x 12 | 8 Nm | |
| 10AZ Oil return to crankcase | N54 | M12 x 10 | 20 Nm | |
| 11AZ Screw plug to oil filter housing | N54 | M20 x 1.5 | Replace sealing ring | 50 Nm |
OIL FILTER AND PIPES-TIGHTENING TORQUE SPECIFICATIONS
11 51 Coolant Pump With Drive
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Coolant pump to crankcase | N54 | M8 x 26 | Replace screws. Thread repairs exclusively with aluminum Heli-coil threaded insert. Jointing torque and angle of rotation must be observed without fail. | |
| Jointing torque | 10 Nm | |||
| Torque angle | 90 ° | |||
| 2AZ ASA screw (3 x) Coolant pump to bracket. | N54 | M8 x 27 | 20.5 Nm | |
| 3AZ Hose clamp (1 x) Coolant hose between coolant pump and coolant thermostat. | N54 | L42-48 | 3 Nm | |
| 4AZ Hose clamp (1 x) Coolant hose between coolant pump and feed line. | N54 | L42-48 | 3 Nm |
COOLANT PUMP WITH DRIVE-TIGHTENING TORQUE SPECIFICATIONS
11 52 Fan
| Type | Tightening Specifications | |
|---|---|---|
| 1AZ Fan clutch on water pump Coupling nut (left-hand threads) | All | 40 Nm |
| M54 | 45 Nm | |
| 2AZ Fan to fan clutch | All | 10 Nm |
FAN-TIGHTENING TORQUE SPECIFICATIONS
11 53 Thermostat And Connections
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Thermostat housing to coolant pump. | N54 | M6 x 25 | 8 Nm | |
| 2AZ Thermostat housing to coolant pump. | N54 | M8 x 16 | 20 Nm | |
| 3AZ ASA screw (4 x) Assembly, feed line to crankcase top section | N54 | M6 x 20 | 9 Nm | |
| 4AZ Feed line to coolant pump. | N54 | L42-48 | Hose clamp | 3 Nm |
| 5AZ Feed line to thermostat | N54 | Hose clamp | 3 Nm | |
| 6AZ Coolant hose to cylinder head | N54 | M6 x 23 | 9 Nm | |
| 7AZ ISA screw (1 x) Coolant feed line to exhaust turbocharger | N54 | M6 x 12 | 8 Nm | |
| 8AZ ISA screw (1 x) Coolant return line to exhaust turbocharger | N54 | M6 x 12 | 8 Nm | |
| 9AZ ISA screw (1 x) Coolant return line to crankcase top section | N54 | M6 x 16 | 8 Nm | |
| 10AZ ISA screw (2 x) Coolant feed lines to assembly, feed line | N54 | M6 x 16 | 8 Nm | |
| 11AZ EJOT screw (1 x) Housing, coolant thermostat, to holder. | N54 | M5 x 21.8 | 9 Nm | |
| 12AZ Hose clamp (2 x) Coolant hose between coolant thermostat and radiator. | N54 | L42-48 | 3 Nm |
THERMOSTAT AND CONNECTIONS-TIGHTENING TORQUE SPECIFICATIONS
11 61 Intake Manifold
| Type | Thread | Tightening Specifications | |
|---|---|---|---|
| 1AZ Hexagon screw (1 x) Air intake manifold to cylinder head. | N54 | M7 x 50 | 15 Nm |
| 2AZ Hexagon nut (6 x) Air intake manifold to cylinder head. | N54 | AM7 | 15 Nm |
| 3AZ Hose clamp (1 x) Gaiter, rear charge-air duct to front charge-air duct. | N54 | L65-72 | 3 Nm |
INTAKE MANIFOLD-TIGHTENING TORQUE SPECIFICATIONS
11 62 Exhaust Manifold
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Exhaust manifold to cylinder head Coat screw connections with CRC copper paste | N54 | M8 | Replace nuts | 20 Nm |
EXHAUST MANIFOLD-TIGHTENING TORQUE SPECIFICATIONS
11 65 Turbocharger And Control
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Flange nut (with internal serrations) (8 x) Exhaust turbocharger to cylinder head | N54 | M7 | Replace flange nut. | 20 Nm |
| 2AZ ASA screw (4 x) Heat shield/retaining plate to crankcase top section | N54 | M6 x 16 | 8 Nm | |
| 3AZ ASA screw (4 x) Holder EPPC to cylinder head | N54 | M6 x 20 | 9 Nm | |
| 4AZ Bracket, air duct, compressor 2, to cylinder head | N54 | M6 x 15 | 9 Nm | |
| 5AZ Vacuum reservoir to bracket for vacuum reservoir | N54 | M8 | 20 Nm | |
| 6AZ Bracket, vacuum reservoir, to body | N54 | M6 x 14 | 5 Nm | |
| 7AZ Bracket to engine longitudinal member | N54 | M6 | 5 Nm | |
| 8AZ EPPC to bracket, EPPC, with heat shield | N54 | M6 | 5 Nm | |
| 9AZ Hexagon nut (3 x) Vacuum unit (wastegate valve) to bracket | N54 | M6 | 8 Nm | |
| 10AZ Lock nut to vacuum unit (wastegate valve) linkage | N54 | M6 | 7 Nm | |
| 11AZ Hexagon screw (2 x) Bracket, vacuum unit (wastegate valve), to turbocharger | N54 | M8 | 20 Nm | |
| 12AZ Band clamp (2 x) Charge-air duct to turbocharger. | N54 | M6 | Replace band clamp. | 3.5 Nm |
TURBOCHARGER AND CONTROL-TIGHTENING TORQUE SPECIFICATIONS
11 66 Vacuum Pump
| Type | Thread | Description | Tightening Specifications | |
|---|---|---|---|---|
| 1AZ Vacuum pump to crankcase | N54 | M6x40 | Flat mushroom head screw 10.9 Replace screws | 11 Nm |
| 2AZ Sprocket wheel to vacuum pump | N54 | M10x30 | Screw 12.9 washed and oiled | 66 Nm |
VACUUM PUMP-TIGHTENING TORQUE SPECIFICATIONS
11 72 Air Pump, Lines And Control Valves
| Type | Thread | Tightening Specifications | |
|---|---|---|---|
| 1AZ Secondary air valve to cylinder head | N52 | M6 | 8 Nm |
| 2AZ Secondary air pump to mounting bracket/pump carrier | N52 | M6 | 8 Nm |
| 3AZ Intake hose/intake line to body | N52 | M6 | 8 Nm |
AIR PUMP, LINES AND CONTROL VALVES-TIGHTENING TORQUE SPECIFICATIONS
11 78 Emissions Control, Control Sensor/Monitor Sensor
| Type | Thread | Tightening Specifications | |
|---|---|---|---|
| 1AZ Control sensor/monitor sensor | N54 | M18 x 1.5 | 50 Nm |
| 2AZ Bracket, oxygen sensor, to transmission | N54 | M8x16 | 20 Nm |
EMISSIONS CONTROL, CONTROL SENSOR/MONITOR SENSOR-TIGHTENING TORQUE SPECIFICATIONS