2AZ-FE ENGINE MECHANICAL

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Sylvia Harrell
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1 ENGINE 2Z-FE ENGINE MECHNICL EG-33 2Z-FE ENGINE MECHNICL ENGINE COVER The engine cover is made of nylon resin, and sound insulation material (urethane foam) is placed between the engine cover and the cylinder head cover to improve sound insulation performance. Urethane Foam - Cross Section 0300EG40C CYLINDER HED COVER lightweight magnesium alloy diecast cylinder head cover is used. The cylinder head cover gasket and the spark plug gasket are integrated to reduce the number of parts. crylic rubber, which excels in heat resistance and reliability, is used for the cylinder head cover gasket. Cylinder Head Cover Cylinder Head Cover Gasket 185EG35 The shape of the PCV (Positive Crankcase Ventilation) baffle plate has been modified to enhance oil flow volume.

2 EG-34 ENGINE 2Z-FE ENGINE MECHNICL CYLINDER HED The cylinder head, which is made of aluminum, has a pentroof-type combustion chamber. The spark plug is located in the center of the combustion chamber in order to improve the engine s anti-knocking performance. Through the adoption of taper squish combustion chambers, the engine knocking resistance is reduced and fuel efficiency is ensured. Upright intake ports are used to improve intake efficiency. The routing of the water jacket in the cylinder head is optimized to ensure the cooling performance. In addition, a water bypass passage is provided below the exhaust ports to reduce the number of parts and achieve weight reduction. Injector EX IN EX Taper Squish Bypass Passage 208EG67 IN 198EG29 - Cross Section

3 ENGINE 2Z-FE ENGINE MECHNICL EG-35 CYLINDER HED GSKET steel-laminate type cylinder head gasket is used. shim is used around the cylinder bore of the gasket to help enhance sealing performance and durability. Cylinder Bore Outside Front Shim - Cross Section 0300EG41C long with modifying the engine coolant passage, the shape of the cylinder head gasket has been modified as shown below: 07 Models 06 Models 0300EG29C

4 EG-36 ENGINE 2Z-FE ENGINE MECHNICL CYLINDER BLOCK The cylinder block is made of aluminum alloy. Producing the thin cast-iron liners and aluminum alloy cylinder block as a unit realizes a compact design. The liner is thin, and reboring is not possible. The oil filter and the air conditioning compressor bracket are integrated with the crankcase. The water pump swirl chamber, the thermostat housing and the rear oil seal retainer are integrated with the cylinder block to reduce the number of parts. Water Pump Swirl Chamber Crankshaft Bearing Cap Thermostat Housing ir Conditioning Compressor Bracket Crankcase Plastic Region Tightening Bolts Oil Filter Bracket 0300EG04C

5 ENGINE 2Z-FE ENGINE MECHNICL EG-37 ir passage holes are provided in the bulkhead of the cylinder block. s a result, the air at the bottom of the cylinder flows smoother, and pumping loss (back pressure at the bottom of the piston generated by the piston s reciprocal movement) is reduced to improve the engine s output. : ir Flow ir Passage Holes ir Passage Holes 0300EG05C Piston-cooling oil jets have been added to enhance lubrication performance. Oil Jet 0300EG06C water jacket spacer is provided in the water jacket. s a result, the viscosity of the engine oil that acts as a lubricant between the bore walls and the pistons is lower, thus friction is reduced. Water Jacket Spacer 0300EG07C

6 EG-38 ENGINE 2Z-FE ENGINE MECHNICL PISTON The pistons are made of aluminum alloy. The tops of the pistons use a taper squish shape to allow fuel combustion efficiency. The piston skirts are coated with resin to reduce friction losses. Full-floating piston pins are used. Due to increased machining precision of the cylinder bore diameter, it is not necessary to produce pistons with different diameters. Taper Squish Shape Resin Coating Resin Coating View from the Top 0300EG09C The thickness and tension of the top and 2nd piston rings have been reduced in order to reduce friction. The shape of the pistons has been modified to change the compression ratio. 07 Models 06 Models 0300EG10C

7 ENGINE 2Z-FE ENGINE MECHNICL EG-39 CONNECTING ROD The connecting rods and caps are made of high-strength steel for weight reduction. Nutless-type plastic region tightening bolts are used on the connecting rods to achieve a lighter design. The connecting rod bearings are reduced in width to reduce friction. Plastic Region Tightening Bolts 208EG61

8 EG-40 ENGINE 2Z-FE ENGINE MECHNICL CRNKSHFT The crankshaft has five journals and eight balance weights. The crankshaft is made of forged steel. The crankshaft bearings are reduced in width to reduce friction. Surface roughness of the pins and journals has been reduced to reduce friction. The balance shaft drive gear is installed onto the crankshaft. Balance Shaft Drive Gear Oil Hole Balance Weight 208EG68 The crankshaft bearing groove is deeper in the middle of the bearing than at the ends. This enhances engine oil lubrication in the middle of the bearing. Bearing Edge Crankshaft Bearing Groove Bearing Center Crankshaft Bearing 0300EG11C

9 ENGINE 2Z-FE ENGINE MECHNICL EG-41 BLNCE SHFT Balance shafts are used to reduce vibration. direct-drive gear that is installed on the crankshaft acts also as a counterweight. In addition, a resin gear is used on the driven side to suppress noise and offer lightweight design. Balance Shaft Drive Gear Crankshaft Balance Shaft No.2 Balance Shaft No.1 Resin Gear Resin Gear Balance Shaft Housing 0300EG12C The balance ratio of the balance shafts has been enhanced to reduce noise.

10 EG-42 ENGINE 2Z-FE ENGINE MECHNICL VLVE MECHNISM 1. General The valve mechanism uses a VVT-i (Variable Valve Timing-intelligent) system to achieve lower fuel consumption and higher engine performance, and to reduce exhaust emissions. For details of VVT-i control, refer to page EG-23. Intake and exhaust efficiency is increased due to larger total port areas. The intake and exhaust camshafts are driven by a timing chain. long with increase in the amount of valve lift, a shimless type valve lifter is used. This valve lifter raises the cam contact surface. Intake Valves Chain Tensioner VVT-i Controller Intake Camshaft Exhaust Camshaft Camshaft Valve Lifter Exhaust Valves Chain Slipper Chain Damper 0300EG13C Service Tip The adjustment of the valve clearance is accomplished by selecting and replacing the appropriate valve lifters. total of 35 valve lifters are available in mm ( in.) increments, from mm (0.199 in.) to mm (0.226 in.). For details, refer to the 2007 tc Repair Manual (Pub. No. RM0300U).

11 ENGINE 2Z-FE ENGINE MECHNICL EG Valve Timing Intake Valve Exhaust Valve Open Close Open Close 3 to 43 BTDC 65 to 25 BDC 45 BBDC 3 TDC TDC VVT-i Operation Range Intake Valve Opening ngle Exhaust Valve Opening ngle 65 VVT-i Operation Range 25 BDC EG14C The profile of the intake camshaft has been modified to enhance output by increasing the valve operation angle and valve lift. Models 07 Models 06 Models Open 3 to 43 BTDC 3 to 43 BTDC Valve Operation ngle Close 65 to 25 BDC 60 to 20 BDC Valve Lift mount mm (in.) 10.0 (0.39) 9.4 (0.37) The diameter of the intake valve springs has been reduced to accommodate increased valve lift, without changing the seat pressure. The exhaust valves are heat-treated to enhance thermal resistance.

12 EG-44 ENGINE 2Z-FE ENGINE MECHNICL 3. Camshaft The intake camshaft is provided with a timing rotor to trigger the camshaft position sensor. In conjunction with the adoption of the VVT-i system, an oil passage is provided in the intake camshaft in order to supply engine oil pressure to the VVT-i system. VVT-i controller is installed on the front of the intake camshaft to vary the timing of the intake valves. Timing Rotor VVT-i Controller Intake Camshaft Exhaust Camshaft Timing Sprocket 181EG11 4. Timing Chain and Chain Tensioner The timing chain uses a roller chain with a pitch of 8.0 mm (0.315 in.) to make the engine more compact. The main timing chain is lubricated by an oil jet. The chain tensioner uses a spring and oil pressure to maintain proper chain tension at all times. The chain tensioner suppresses noise generated by the timing chain. The chain tensioner is a ratchet type with a non-return mechanism. To achieve excellent serviceability, the chain tensioner is constructed so that it can be removed and installed from the outside of the timing chain cover. Chain Tensioner Cam Spring Cam Chain Damper Spring Plunger Chain Slipper Oil Jet 0300EG15C

13 ENGINE 2Z-FE ENGINE MECHNICL EG-45 SERPENTINE BELT DRIVE SYSTEM 1. General ccessory components are driven by a serpentine belt consisting of a single V-ribbed belt. It reduces the overall engine length, weight and number of engine parts. n automatic tensioner eliminates the need for tension adjustment. Idler Pulley for utomatic Tensioner Generator Pulley Power Steering Pump Pulley Water Pump Pulley Crankshaft Pulley ir Conditioning Compressor Pulley 198EG11 2. utomatic Tensioner The automatic tensioner consists of an idler pulley and a tensioner. The idler pulley maintains belt tension using the force of the spring that is located in the tensioner. rm Idler Pulley - Cross Section Tensioner 258RV77

ENGINE 1ZZ-FE ENGINE DESCRIPTION EG-1 ENGINE - 1ZZ-FE ENGINE

EG-1 ENGINE - 1ZZ-FE ENGINE ENGINE 1ZZ-FE ENGINE DESCRIPTION The VVT-i (Variable Valve Timing-intelligent) system, the DIS (Direct Ignition System), and a plastic intake manifold have been used on the