2AZ-FE Engine Mechanical: Removal & Installation Scion xB II

INSTALLATION

1. INSTALL FAN AND GENERATOR V BELT Using SST and 19 mm socket wrench, loosen the V-ribbed belt tensioner arm clockwise, then install the fan and generator V belt. SST 09216-42010 (09216-04010) NOTE: Be sure to connect SST and the tools so that they are in line during use. When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly. After the tensioner is fully retracted, do not apply any more force than is necessary.
2. INSTALL REAR ENGINE UNDER COVER RH

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1. REMOVE REAR ENGINE UNDER COVER RH
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See «REMOVAL»(ref-289750-S15841887892008070700000) )
3. REMOVE IGNITION COIL ASSEMBLY (See «REMOVAL»(ref-289750-S15841887892008070700000) )
4. REMOVE SPARK PLUG (See «REMOVAL»(ref-289750-S15841887892008070700000) )
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See «REMOVAL»(ref-289749-S14214901592008070700000) )
6. SET NO. 1 CYLINDER TO TDC / COMPRESSION (See «REMOVAL»(ref-289749-S14214901592008070700000) )
7. CHECK VALVE CLEARANCE Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (cold) VALVE CLEARANCE SPECIFICATION Item Specified Condition Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.) Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression. Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (cold) VALVE CLEARANCE SPECIFICATION Item Specified Condition Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.) Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
8. ADJUST VALVE CLEARANCE Set No. 1 cylinder to TDC/compression (See «REMOVAL»(ref-289749-S14214901592008070700000) ). Remove the No. 1 chain tensioner (See «REMOVAL»(ref-289749-S14214901592008070700000) ). Loosen the camshaft timing sprocket (See «REMOVAL»(ref-289749-S14214901592008070700000) ). Remove the No. 2 camshaft (See «REMOVAL»(ref-289749-S14214901592008070700000) ). Remove the camshaft (See «REMOVAL»(ref-289749-S14214901592008070700000) ). Remove the valve lifters. Using a micrometer, measure the thickness of the removed valve lifters. Calculate the thickness of a new lifter so that the valve clearance comes within the specified values. New lifter thickness THICKNESS SPECIFICATION Item Specification Intake A = B + (C - 0.24 mm (0.0095 in.)) Exhaust A = B + (C - 0.43 mm (0.0169 in.)) THICKNESS SPECIFICATION A New lifter thickness B Used lifter thickness C Measured valve clearance CALCULATION EXAMPLE (Intake): Measured intake valve clearance = 0.40 mm (0.0158 in.) (Measured - Specification = Excess clearance) (a)0.40 mm (0.0158 in.) - 0.24 mm (0.0095 in.) = 0.16 mm (0.0063 in.) Measured used lifter thickness = 5.250 mm (0.2067 in.) New lifter thickness = 5.410 mm (0.2130 in.) (Excess clearance + Used lifter thickness = Ideal new lifter) (a)0.16 mm (0.0063 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.) Closest new lifter = 5.420 mm (0.2134 in.) Select No. 42 lifter 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.), from 5.060 to 5.740 mm (0.1992 to 0.2260 in.). The identification number inside the valve lifters shows the value to 2 decimal places. (The illustration shows 5.420 mm (0.2134 in.) Valve lifter selection chart (intake). New lifter thickness NEW LIFTER THICKNESS Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) - - Standard intake valve clearance (cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter. Valve lifter selection chart (exhaust). New lifter thickness NEW LIFTER THICKNESS Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) Lifter No. Thickness mm (in.) 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) - - Standard exhaust valve clearance (cold): 0.38 to 0.48 mm (0.0150 to 0.0189 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.510 mm (0.020 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 42 lifter. Install the selected valve lifter. Install the camshaft (See «INSTALLATION»(ref-289749-S09751370922008070700000) ). Install the No. 2 camshaft (See «INSTALLATION»(ref-289749-S09751370922008070700000) ). Install the No. 1 chain tensioner (See «INSTALLATION»(ref-289749-S09751370922008070700000) ).
9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-289749-S09751370922008070700000) )
10. INSTALL SPARK PLUG (See «INSTALLATION»(ref-289750-S12175651402008070700000) )
11. INSTALL IGNITION COIL ASSEMBLY (See «INSTALLATION»(ref-289750-S12175651402008070700000) )
12. INSPECT FOR ENGINE OIL LEAK
13. INSPECT IGNITION TIMING (See «ON-VEHICLE INSPECTION»(ref-289749-S22193950772008070700000) )
14. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-289750-S12175651402008070700000) )
15. INSTALL REAR ENGINE UNDER COVER RH

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1. REMOVE REAR ENGINE UNDER COVER RH
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See «REMOVAL»(ref-289750-S15841887892008070700000) )
3. REMOVE IGNITION COIL ASSEMBLY (See «REMOVAL»(ref-289750-S15841887892008070700000) )
4. REMOVE SPARK PLUG (See «REMOVAL»(ref-289750-S15841887892008070700000) )
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Remove the 2 ventilation hoses from the cylinder head. Remove the 2 bolts and separate the 2 wire harness brackets. Remove the 8 bolts and 2 nuts, and then remove the cylinder head cover and gasket.
6. SET NO. 1 CYLINDER TO TDC / COMPRESSION Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned. Check that each timing mark on the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft pulley by 1 revolution (360°) to align the timing marks as above. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket.
7. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (See «REMOVAL»(ref-289749-S04498049602008070700000) )
8. LOOSEN CAMSHAFT TIMING GEAR OR SPROCKET While holding the No. 2 camshaft with a wrench, loosen the No. 2 camshaft timing set bolt.
9. REMOVE NO. 2 CAMSHAFT Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt. Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket. Remove the camshaft timing sprocket from the timing chain.
10. REMOVE CAMSHAFT In several steps, uniformly loosen and remove the 10 bearing caps bolts in the sequence shown in the illustration. Remove the 5 bearing caps. Remove the camshaft and camshaft timing gear while holding the timing chain by hand. Tie the timing chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover.
11. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate. Cover all the oil ports with vinyl tape except the advance side port shown in the illustration. Apply air pressure of 150 kPa (1.5 kgf/cm 2 , 22 psi) to the oil path, then turn the camshaft timing gear to the advance direction (counterclockwise) by hand. CAUTION: Cover the paths with a piece of cloth to avoid oil splashes. HINT: Depending on the air pressure, the camshaft timing gear may turn to the advance side without applying force by hand. Also, if the pressure is difficult to apply because of air leakage from the port, the lock pin may be difficult to release. Remove the flange bolt of the camshaft timing gear. NOTE: Be sure not to remove the other 4 bolts. When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.