180 Rsi 2zz Ge Valve Clearance

PCV Hose Tube Assembly i i ! !

ECT Sensor

Sensorfilter Toyota Zz2 Engine

Oil Filter ♦ Gasket

Camshaft Position Sensor

ECT Sensor

Camshaft Position Sensor

2zz Intake Manifold

Spacer

Throttle Position ♦Grommet Sensor Connector

Spacer

Oil Filter ♦ Gasket

Injector Connector Accelerator Control Cable Bracket ft

Vacuum Hose

Intake Manifold

Intake Manifold

2zz Intake Manifold

Injector Connector Accelerator Control Cable Bracket

Water Bypass Hose

[ N-m (kgt-cm, ft-ibf) : Specified torque N ♦ NorWeusable pail

A103W

2ZZ-GE:

No. 2 Cylinder Head Cover 1

Wire Harness Protector

Delivery Pipe and Fuel Tube Assembly

2000 Toyota Celica Inlet Hose

Wire Harness Protector

Delivery Pipe and Fuel Tube Assembly

Injector Connector

Accelerator Control Cable Bracket

Generator Bracket

Intake Manifold Insulator

Injector Connector

Intake Manifold

Accelerator Control Cable Bracket

Generator Bracket

IAC Valve Connector Throttle Body

Intake Manifold Insulator

[N-m (kgf-cmJHbf) : Specified torque N ♦ Nori-reusablfTpart

1ZZ-FE:

Cylinder Head Cover

Gasket -

2zz Intake Manifold

No. 1 Camshaft Bearing Cap

Exhaust Camshaft Camshaft Timing Sprocket

«« Engine [45(460,33) Mounting Bracket""" ^ -----——

13033."» | valve Lifter No. 3 Camshaft j § Bearin9 Cap ¿, Keeper

Valve

Spring

M v Spring Seat / \ Valve Guide

Bushing

No. 1 Camshaft Bearing Cap

Valve Spring Seat Toyota 3rz

M v Spring Seat / \ Valve Guide

Bushing

Radiator Hose

N-m (kgf-cm, ft-lbf) ] : Specified torque n ♦ Non-reusable part

Chain Vibration Damper - Crankshaft Position Sensor

Radiator Hose

/• <. " ' - ♦ Cylinder Head j,;,- Gasket

N-m (kgf-cm, ft-lbf) ] : Specified torque n ♦ Non-reusable part iSrf, n & j

Crank Angle Sensor Plate

Chain Vibration Damper - Crankshaft Position Sensor

2ZZ-GE:

Cylinder Head Cover—

Cylinder Head Cover—

Ventilation

No. 1 Camshaft Bearing Cap Exhaust Camshaft-~___ Camshaft Timing Sprocket-

No. 3 Camshaft

Bearing Cap i3

RH Engine Mounting Bracket-

No. 1 Camshaft Bearing Cap Exhaust Camshaft-~___ Camshaft Timing Sprocket-

Bearing Cap i3

Intake Camshaft

No. 3 Camshaft

Intake Camshaft

Drive Belt Tensioner ;

See page EM-61

1st | 35(375,26} | 2nd Turn 180°

Drive Belt Tensioner ;

Toyota 2zz Valve Adjustment Cups

^-♦Cylinder Head Gasket

Pulley

Crank Angle Sensor Plate Chain Vibration Damper

Crankshaft Position Sensor

^-♦Cylinder Head Gasket i

Pulley j~Nm (kgf-cm,Ttlbf) | : Specified torque N ♦ Norv-reusable part

Crank Angle Sensor Plate Chain Vibration Damper

Crankshaft Position Sensor

2ZZ-GE

Valve Rocker Arm

Rocker No. 2 Shaft

Oü Pressure Switch

Oil Control Valve Housing f'9.0 (92,80 in. ibf)

Rocker No. 1 Shaft

Oil Control Valve for VVTL

Cylinder Head

Cylinder Head

Vvtl Controls

Oil Control Valve for VVTL

Oü Control Valve for VVT

Oü Control Valve for VVT

♦ Gasket f~N-m (kgt-cm, ft-lbf)"] : Specified torque . ♦ Non-reusâbfë part

REMOVAL

1. REMOVE BATTERY

2. REMOVE ECU BOX (See page EM-74)

3. DRAIN ENGINE COOLANT

4. DISCONNECT ENGINE COOLANT RESERVOIR

5. REMOVE AIR CLEANER ASSEMBLY

6. DISCONNECT ACCELERATOR CABLE

7. REMOVE DRIVE BELT AND ALTERNATOR (See page CH-7)

8. REMOVE EXHAUST PIPE (See page EM-74)

Imagenes Manchas Tinta

REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts and exhaust manifold stay.

(b) Remove the 6 bolts and upper heat insulator.

(c) Remove the 5 nuts, exhaust manifold and gasket.

(d) Remove the 3 bolts and lower heat insulator.

REMOVE EXHAUST MANIFOLD

(a) Remove the 4 bolts and exhaust manifold stay.

(b) Remove the 5 bolts and upper heat insulator.

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2zz Alternator Wiring

Remove the 3 bolts, 2 nuts, exhaust manifold and gasket. Remove the 4 bolts and lower heat insulator. REMOVE IGNITION COIL (See page IG-6) REMOVE SPARK PLUG (See page IG-1) REMOVE PCV HOSES

REMOVE THROTTLE BODY (See page SF-36) REMOVE INJECTOR (See page SF-21)

1ZZ-FE:

DISCONNECT ENGINE WIRE FROM CYLINDER HEAD

Disconnect the ECT sensor connector. Disconnect the camshaft position sensor connector. Disconnect the oil control valve for VVT connector. Disconnect the 2 ground wires.

Disconnect the 2 clamps and engine wire protector from the intake manifold.

2ZZ-GE:

DISCONNECT ENGINE WIRE FROM CYLINDER HEAD

Disconnect the ECT sensor connector. Disconnect the camshaft position sensor connector. Disconnect the oil control valve for VVT connectors. Disconnect the oil control valve for VVTL connectors. Disconnect the oil pressure switch connector. Disconnect the 2 ground wires. Remove the 2 bolts, and disconnect the engine wire. Remove the intake manifold No. 2 insulator. 1ZZ-FE:

REMOVE INTAKE MANIFOLD

Disconnect the EVAP hose for ORVR. Disconnect the brake booster vacuum hose. Remove the 4 bolts, 2 nuts, intake manifold, 2 wire harness stays and gasket.

REMOVE INTAKE MANIFOLD

(a) Disconnect the EVAP hose for ORVR.

(b) Disconnect the brake booster vacuum hose.

(c) Remove the bolt and disconnect the No. 1 ventilation pipe and oil dipstick and guide.

(d) Remove the 2 bolts, nut and stay.

(e) Remove the 4 bolts, 2 nuts, intake manifold and gasket.

(f) Remove the intake manifold insulator.

20. REMOVE CAMSHAFT POSITION SENSOR

21. REMOVE ECT SENSOR

22. REMOVE PCV VALVE AND GROMMET

23. REMOVE OIL FILLER CAP

24. REMOVE CAMSHAFT TIMING SPROCKETS (See page IG-9}

2zz Intake Manifold

REMOVE CAMSHAFT

Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts.

Depression And Suicide

REMOVE CAMSHAFT

Uniformly loosen and remove the 20 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps intake and exhaust camshaft.

27. REMOVE CYLINDER HEAD

(a) Disconnect the upper radiator hoses from the water hose union.

(b) Disconnect the heater water hose from the water hose union.

(c) Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and piate washers.

NOTICE:

Head warpage or cracking could result from removing botts in an incorrect order.

(d) Remove the boit holding the water bypass pipe to the cylinder head.

2000 Toyota Celica Cylinder Head

(e) Lift the cyiinder from the dowefs on the cylinder block and replace the cylinder head on wooden blocks on a bench.

HINT:

If the cylinder head is difficult to lift off, pry between the cylinder head and cyiinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

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DISASSEMBLY

1. REMOVE OIL CONTROL VALVE for VVT

Remove the bolt and cam timing oil control valve.

2. REMOVE OIL CONTROL VALVE FILTER

Remove the bolt, gasket and oil control valve filter.

How Replace Lifters Toyota Rsi

REMOVE OIL CONTROL VALVE HOUSING

(a) Remove the bolt and oil control vaive for VVTL.

(b) Using SST, remove the oil pressure switch. SST 09816-30010

(c) Remove the 3 bolts, 2 nuts, oil control vaive housing and gasket.

(d) Remove the oil control valve filter.

How Replace Lifters Toyota RsiHow Replace Lifters Toyota Rsi

REMOVE VALVE ROCKER ARM

(a) Remove the 2 bolts, rocker No. 1 and No. 2 shafts.

(b} Remove the 8 valve rocker arm.

HINT:

Arrange the rocker arms in the correct order.

5. REMOVE VALVE LIFTERS HINT:

Arrange the valve lifters in the correct order.

6. REMOVE VALVES

(a) Using SST, compress the valve spring and remove the 2 keepers.

SST 09202-70020 (09202-00020)

(b) Remove the spring retainer.

(c) Remove the vaive spring.

(d) Remove the valve.

Using needle—nose pliers, remove the oil seal.

(f) Using compressed air and magnetic linger, remove the spring seat by blowing air.

HINT:

Arrange the valves, valve springs, spring seats, and spring retainers in the correct order.

INSPECTION

1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK

(a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove ail the carbon from the piston surface.

Borregos Para Dibujar

(b) Using a gasket scraper, remove at! the gasket material from the cylinder block surface.

(c) Using compressed air, blow carbon and oil from the bolt holes.

CAUTION:

Protect your eyes when using high pressure compressed air.

2. REMOVE GASKET MATERIAL

Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

NOTICE:

Be careful not to scratch the cylinder block contact surface.

Calligraphie Arabe

3. CLEAN COMBUSTION CHAMBERS

Using a wire brush, remove all the carbon from the combustion chambers.

NOTICE:

Be careful not to scratch the cylinder block contact surface.

4. CLEAN CYLINDER HEAD

Using a soft brush and solvent, thoroughly clean the cylinder head.

Cylinder Block Side

Intake M inifold Side

Cylinder Block Side

Exhaust Manifold Side

2zz Intake Manifold

Exhaust Manifold Side

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5. CLEAN VALVE GUIDE BUSHINGS

Using a valve guide bushing brush and solvent, clean all the guide bushings.

6. INSPECT FOR FLATNESS

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for war-page.

Maximum warpage: 0.05 mm (0.0020 in.)

If warpage is greater than maximum, replace the cylinder head.

7. INSPECT FOR CRACKS

Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

8. CLEAN VALVES

(a) Using a gasket scraper, chip off any carbon from the valve head.

(b) Using a wire brush, thoroughly clean the valve.

9. INSPECT VALVE STEMS AND GUIDE BUSHINGS

(a) Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 1ZZ-FE 5.510 - 5.530 mm (0.2169 - 0.2177 in.) 2ZZ-GE 5.500 - 5.518 mm (0.2165 - 0.2172 in.)

(b) Using a micrometer, measure the diameter of the valve stem.

Valve stem diameter: 1ZZ-FE

Intake 5.470 - 5.485 mm (0.2154 - 0.2159 in.) Exhaust 5.465 - 5.480 mm (0.2152 - 0.2157 in.) 2ZZ-GE

Intake 5.460 ~ 5.475 mm (0.21496 - 0.21555 in.) Exhaust 5.445-5.470 mm (0.21437 - 0.21535 in.)

(c) Subtract the vaive stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance:

1ZZ-FE

Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.) 2ZZ-GE

Intake 0.025 - 0.058 mm (0.00098 - 0.00228 in.) Exhaust 0.030 - 0.063 mm (0.00118 - 0.00248 in.) Maximum oil clearance: 1ZZ-FE

Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) 2ZZ-GE

If the clearance is greater than maximum, replace the valve and guide bushing.

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44.5°

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(a) Check the vaive is ground to the correct valve face angle. Valve face angle: 44.5°

(b) Check that the surface of the valve for wear. If the valve face is worn, replace the valve.

Margin Thickness

Margin Thickness

Overall Length

(c) Check the valve head margin thickness.

Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.7 mm (0.028 in.)

If the margin thickness is less than minimum, replace the valve.

(d) Check the valve overall length. Standard overall length: 1ZZ-FE

Intake 88.65 mm (3.4902 in.) Exhaust 88.69 mm (3.4917 in.) 2ZZ-GE

Intake 111.3 mm (4.382 in.) Exhaust 111.7 mm (4.398 in.) Minimum overall length: 1ZZ-FE

Intake 88.35 mm (3.4783 in.) Exhaust 88.39 mm (3.4799 in.) 2ZZ-GE

Intake 110.9 mm (4.366 in.) Exhaust 111.3 mm (4.382 in.)

If the overall length is less than minimum, replace the valve.

(e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.

Exhaust Valve Stem Tip Wear Kx250

11. INSPECT AND CLEAN VALVE SEATS

(a) Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

(b) After resurfacing the valve seat 45°, measure the residuary width of the valve seat 45°,

Minimum residuary length: Intake 3.3 mm (0.130 in.) Exhaust 3.2 mm (0.126 in.)

If the valve seat 45° residuary widfh less than minimum, replace the cylinder head.

(c) Check the valve seating position.

Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve.

(d) Check the valve face and seat for the following:

If blue appears 360" around the face, the valve is concentric, if not, replace the valve.

If blue appears 360" around the valve seat, the guide and face are concentric. If not, resurface the seat.

Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 In.) If not, correct the valve seats as follows:

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(1) If the seating is too high on the vafve face, use 30c and 45° cutters to correct the seat.

(2) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.

(e) Hand-lap the valve and valve seat with an abrasive compound.

(f) After hand-lapping, clean the valve and valve seat.

12. INSPECT VALVE SPRINGS

(a) Using a steel square, measure the deviation of the valve spring.

Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2°

If the deviation is greater than maximum, replace the valve spring.

(b) Using vernier calipers, measure the free length of the valve spring. Free length:

Intake 46.4 mm (1.830 in.) Exhaust 46.5 mm (1.831 in.)

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(c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 1ZZ-FE

2ZZ-GE

intake

Exhaust

208.2 - 229.8 N (21.2 - 23.4 kgf, 47.6 - 52.6 Ibf) at 38.5 mm (1.516 in.) Maximum working tension: 1ZZ-FE

2ZZ-GE

Intake

Exhaust

495.5 - 548.5 N (50.5 - 55.9 kgf, 111.3 - 123.2 Ibf) at 28.5 mm (1.122 in.)

If the installed tension is not as specified, replace the valve spring

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13. INSPECT CAMSHAFT FOR RUNOUT

(a) Place the camshaft on V-blocks.

(b) Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout: 0.03 mm (0.0012 in.)

If the circle runout is greater than maximum, replace the camshaft.

14. INSPECT CAM LOBES

Using a micrometer, measure the cam lobe height. Standard cam lobe height: 1ZZ-FE:

Intake 44.333 - 44.433 mm (1.7454 -1.7493 in.) Exhaust 43.761 - 43.861 mm (1.7229 - 1.7268 in.) 2ZZ-GE: INTAKE

No. 1 40.607 - 40.707 mm (1.59586 - 1.59979 in.) No. 2 38.769 - 38.869 mm (1.52362 - 1.52755 in.) 2ZZ-GE: EXHAUST

No. 1 40.019-40.119 mm (1.57275-1.57668 in.) NO. 2 38.863 - 38.963 mm (1.52732 - 1.53125 in.) Minimum cam iobe height: 1ZZ-FE:

Intake 44.18 mm (1.7394 in.) Exhaust 43.61 mm (1.7169 in.) 2ZZ-GE; Intake

No.1 40.45 mm (1.5925 in.) No.2 38.61 mm (1.5201 in.) Exhaust

Sf the cam iobe height is iess than minimum, replace the camshaft.

15. INSPECT CAMSHAFT JOURNALS

Using a micrometer, measure the journal diameter. 1ZZ-FE:

No.1 journal diameter:

Others journal diameter:

2ZZ-GE:

No.1 journal diameter:

Other journal diameter:

If the journal diameter is not as specified, check the oil clearance.

16. INSPECT CAMSHAFT JOURNAL CLEARANCE

(a) Clean the bearing caps and camshaft journals.

(b) Place the camshafts on the cylinder head.

(c) Lay a strip of Piastigage across each of the camshaft journal.

Repairing Camshaft Journal

(d) install the bearing caps (See page EM-65). Torque:

1ZZ-FE:

No.1 23 Nm (235 kgfcm, 17 ft-lbf) No.3 13 N m (133 kgf cm, 10 ft-lbf) 2ZZ-GE: 18.5 N m (189 kgf cm, 14 ft lbf) NOTICE:

Do not turn the camshaft.

(e) Remove the bearing caps.

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(f) Measure the piastigage at its widest point. 1ZZ-FE:

Standard oil clearance:

Maximum oil clearance:

2ZZ-GE:

Standard oil clearance:

No. 1 journal 0.035 - 0.076 mm (0.00138-0.00299 in.) Other journal 0.035 - 0.072 mm (0.00138 - 0.00283 in.) Maximum oil clearance: 0.10 mm (0.039 in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.

(g) Completely remove the Piastigage.

(h) Remove the camshafts.

17. INSPECT CAMSHAFT THRUST CLEARANCE

(a) install the camshafts. (See page EM-65)

(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

1ZZ-FE:

Standard thrust clearance:

Maximum thrust clearance:

2ZZ-GE:

Standard thrust clearance: 0.04 - 0.14 mm (0.0016 - 0,0055 in.) Maximum thrust clearance: 0.15 mm (0.0059 in.)

If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.

(c) Remove the camshafts.

18. INSPECT VALVE TIMING CONTROLLER ASSEMBLY

(a) Apply vinyl tape to all the ports except the one indicated by the arrow in the illustration.

NOTICE:

Do not apply tape in the range from the tip of the camshaft to 18 mm from that tip.

(b) install the valve timing controller assembly. Torque: 47 N m (480 kgf-cm, 35 ft-lbf)

NOTICE:

Do not push valve timing controller assembly to the camshaft forcibly when installing it.

(c) Check that the valve timing controller assembly will not turn.

(d) Wind tape around the tip of the air gun and apply air of approx. 100 kPa (1 kgf/cm2,14 psi) to the port of the camshaft. NOTICE:

When the oil splashes, wipe it off with a shop rag and the iikes.

HINT:

Perform this in order to release the lock pin for the maximum delay angle locking.

(e) Under the condition of (d), turn the valve timing controller assembly to the advance angel side (the arrow marked direction in the illustration) with your hand. Standard: Must turn

HINT:

Depending on the air pressure, the valve timing controller assembly wii! turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.

(f) Except the position where the lock pin meets at the maximum delay angle, let the valve timing controller assembly turn back and forth and check the movable range and that there is no disturbance.

Standard: Movable smoothly in the range about 30°

(g) Turn the valve timing controller assembly with your hand and lock it at the maximum delay angel position.

INSPECT VALVE LIFTERS AND LIFTER BORES

(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 - 31.025 mm (1.2205 - 1.2215 in.)

(b) Using a micrometer, measure the lifter diameter. Lifter diameter:

(c) Subtract the lifter diameter measurement from the lifter bore diameter measurement.

Standard oil clearance: 0.024 - 0.059 mm (0.0009 - 0.0023 in.) Maximum oil clearance: 0.079 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.

How Replace Lifters Toyota Rsi

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