Toyota 2.4L (2RZ-FE) & 2.7L (3RZ-FE) Engine Service & Repair Manual

• • • IN-1 INTRODUCTION HOW TO USE THIS MANUAL IN - 2 IDENTIFICATION INFORMATION IN- 4 GENERAL REPAIR INSTRUCTIONS IN- 5 PRECAUTION IN - 8 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEM IN- 13 VEHICLE LIFT AND SUPPORT LOCATIONS IN- 30 ABBREVIATIONS USED IN THIS MANUAL IN - 31 GLOSSARY OF SAE AND TOYOTA TERMS IN- 33 STANDARD BOLT TORQUE SPECIFICATIONS IN- 36

GENERAL DESCRIPTION INOlO-01 HOW TO USE THIS MANUAL INDEX • INOZE-01 INTRODUCTION - HOW TO USE THIS MANUAL An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. IN-2 At the beginning of each section, a general Description is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. _-00 TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN -13. Be sure to read this before performing troubleshooting. tNOaJ-01 PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. REPAIR PROCEDURES Most repair operations. begin with an overview illustration. It identifies the components and • shows how the parts fit together. Example: • Nl1306 Clevis Pin .G..... l Clip t) Cl,v', I Lock Nut Snap Ring Washer Push Rod Piston ___ -"!U Tank Cylinder ®-------Filler Cap Float • Non-reusable part

INTRODUCTION - HOW TO USE THIS MANUAL IN-3 • • The procedures are presented in a step-by-step format: • The illustration shows what to do and where to do it. • The task heading tells what to do. • The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. IN02L-01 REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. IN02.M-OI SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the end of each section, for quick reference.

SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit). and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm. 22 ft.lbf) III02N-01 INOOI-OO HIOII-01 The vehicle identification number is stamped on the • vehicle identification number plate and certification label. A. Vehicle Identification Number Plate B. Certification Label The engine serial number is stamped on the engine block as shown. IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER INTRODUCTION - IDENTIFICATION INFORMATION IWOI'-OI CAUTIONS are presented in bold type. and indicate there is a possibility of injury to you or • other people. NOTICES are also presented in bold type. and indicate the possibility of damage to the components being repaired. HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. • • • 2RZ-FE, 3RZ-FE Engi-ne : CAUTIONS, NOTICES, HINTS: IN-4 5VZ-FE Engine: • N14492

INTRODUCTION - GENERAL REPAIR INSTRUCTIONS • • • IN0036 Seal Lock Adhesive FI1066 Zll554 IN-5 GENERAL REPAIR INSTRUCTIONS IN059-01 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in the appropriate order to facilitate reassembly. 3. Observe the following: (a) Before performing electrical work, disconnect the negative (-) terminal cable from the battery. (b) If it is necessary to disconnect the battery for inspection or repair, always disconnect the negative (-) terminal cable which is grounded to the vehicle body. (c) To prevent damage to the battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (d) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (e) Install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (f) Be sure the cover for the positive (+) terminal is properly in place. 4. Check hose and wiring connectors to make sure that they are secure and correct. 5. Non - reusable parts (a) Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. (b) Non-reusable parts are indicated in the compo- nent illustrations by the ••• symbol. 6. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.

Toyota 2.4L (2RZ-FE) & 2.7L (3RZ-FE) Engine Service & Repair Manual

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