1AZ FE Engine

AZ series was introduced since 2000 – to gradually supplant the legendary S series, and for ten years remained the main mid-size engine of company. Installed in many initially FF C/D/E-class cars, vans, light- and medium-SUVs.

Engine Displacement, cm3 Bore x Stroke, mm Compression ratio Output, hp Torque, Nm RON Weight, kg EMS Standards Model Year
1AZ-FE 1998 86.0 x 86.0 9.8 147 / 6000 192 / 4000 95 117 EFI-L EEC AZT250 2003
9.8 152 / 6000 194 / 4000 95 131 EFI-L EEC ACA30 2006
9.5 137 / 5600 190 / 4000 95 112 LG EEC AZT250 2003
1AZ-FSE 1998 86.0 x 86.0 9.8 152 / 6000 200 / 4000 91 D-4 JIS AZT240 2000
10.5 155 / 6000 192 / 4000 91 D-4 JIS AZT240 2004
11.0 147 / 5700 196 / 4000 95 124 D-4 EEC AZT250 2003
11.0 149 / 5700 200 / 4000 95 D-4 EEC AZT220 2000
2AZ-FE 2362 88.5 x 96.0 9.6 160 / 5600 221 / 4000 91 EFI-L JIS ACM21 2002
9.8 170 / 6000 224 / 4000 91 138 EFI-L JIS ANH20 2008
2AZ-FSE 2362 88.5 x 96.0 11.0 163 / 5800 230 / 3800 95 D-4 JIS AZT250 2006
2AZ-FXE 2362 88.5 x 96.0 12.5 131 / 5600 190 / 4000 91 EFI-L JIS ATH10 2007
12.5 150 / 6000 190 / 4000 91 EFI-L JIS AHR20 2009
3AZ-FXE 2362 88.5 x 96.0 12.5 150 / 6000 187 / 4400 EFI-L CHN AHV40 2010

 

1AZ-FE engine can be seen as a simplified version of 2AZ-FE.

  • There is no balancing mechanism.
  • No oil nozzles in the block.
  • Pistons have larger skirt.

– For some regions specific modifications was produced – for leaded gasoline, without VVT, without converter and relative components.

1AZ-FSE (2.0 D-4) / 2AZ-FSE (2.4 D-4)

1AZ-FSE, 2AZ-FSE – transverse, with direct injection, for initially FF cars, vans and SUVs. Installed in: Allion/Premio 240, Avensis 220..250, Caldina 240, Gaia, Isis, Nadia, Noah/Voxy 60, Opa, RAV4 20, Vista 50, Wish 10.
By 2009 replaced by ZR engines with traditional multipoint injection (and Valvematic system).

There are some differences in the mechanical part of D-4 engines.

  • The higher the compression ratio.
  • The fuel injectors are mounted in cylinder head.
  • High pressure fuel pump is driven by additional cam on the inlet camshaft.
  • Variable valve timing range 43°.

– The pistons has the specify shape which help to lead the fuel spray to the area of the spark plug. The top ring groove has anti-wear alumite coating.

– Some models was equipped with oil cooler.

 

1 – water pump, 2 – bypass, 3 – to heater, 4 – to radiator, 5 – from ATF heater, 6 – to ATF heater, 7 – thermostat, 8 – drain, 9 – oil cooler, 10 – from radiator.

– Differences of version for Japanese domestic market (type’2004): a compression ratio 10.5 instead of 9.8, three-layer cylinder head gasket instead of a two-layer, other shape of the combustion chamber, additional channels for coolant between the cylinders, the other valve timing, intake valve lift 9.4 instead of 8.2 mm, exhaust – 8.0 instead of 8.6 mm, reduced by 1.1 mm piston height.

1AZ engine specs

Manufacturer Kamigo Plant Shimoyama Plant Also called Toyota 1AZ Production 2000-present Cylinder block alloy Aluminum Configuration Straight-4 Valvetrain DOHC 4 valves per cylinder Piston stroke, mm (inch) 86 (3.39) Cylinder bore, mm (inch) 86 (3.39) Compression ratio 9.6 9.8 10.5 11 Displacement 1998 cc (121.9 cu in) Power output 108 kW (145 HP) at 6,000 rpm 110 kW (150 HP) at 5,700 rpm 111 kW (150 HP) at 6,000 rpm 112 kW (152 HP) at 6,000 rpm Torque output 190 Nm (140 lb·ft) at 4,000 rpm 193 Nm (142 lb·ft) at 4,000 rpm 193 Nm (142 lb·ft) at 4,000 rpm 200 Nm (148 lb·ft) at 4,000 rpm Redline – HP per liter 72.6 75.1 75.1 76.1 Fuel type Gasoline Weight, kg (lbs) 131 (290) Fuel consumption, L/100 km (mpg) -City -Highway -Combined for RAV4 XA20 11.4 (20) 7.3 (32) 9.8 (24) Turbocharger Naturally aspirated Oil consumption , L/1000 km (qt. per miles) up to 1.0 (1 qt. per 750 miles) Recommended engine oil 0W-20 5W-20 Engine oil capacity, L (qt.) 4.2 (4.4) Oil change interval, km (miles) 5,000-10,000 (3,000-6,000) Normal engine operating temperature, °C (F) – Engine lifespan, km (miles) -Official information -Real – 300,000+ (180,000) Tuning, HP -Max HP -No life span loss 200+ –

1az-fe-engine-specs

The engine is installed in:

  • 2006–2009 Toyota Camry (Aurion version)
  • 2001–2003 Toyota RAV4
  • 2003-2006 Toyota RAV4 Euro
  • 2001–2009 Toyota Ipsum
  • Toyota Avensis
  • Toyota Avensis Verso
  • Toyota Noah/Voxy
  • Toyota RAV4
  • Toyota Gaia
  • Toyota Isis
  • Toyota Ipsum
  • Toyota Caldina
  • Toyota Wish
  • Toyota Allion
  • Toyota Premio
  • Toyota Opa

toyota-1az-fe-engine

ETCS (electronic throttle control)

Driven by motor with control unit commands. When starting the throttle is slightly opened to allow additional air intake, and then the opening angle decreases depending on the coolant temperature. At the homogeneous mode idling speed is adjusted by throttle moving, at LeanBurn mode – by fuel supply volume correction with constant throttle opening. In addition, ETCS performs traction control (TRC) function and some stabilization system (VSC) functions.

Driven by motor with control unit commands. When starting the throttle is slightly opened to allow additional air intake, and then the opening angle decreases depending on the coolant temperature. At the homogeneous mode idling speed is adjusted by throttle moving, at LeanBurn mode – by fuel supply volume correction with constant throttle opening. In addition, ETCS performs traction control (TRC) function and some stabilization system (VSC) functions.

SCV (swirl control valve) actuator. There is SCV block between the cylinder head and the inlet manifold, which closes one of two inlets channel to each cylinder, depending on the driving conditions. The flaps are driven by vacuum actuator.

1 – SCV actuator, 2 – SCV valve, 3 – MAP sensor.

– At low speed, low load, low coolant temperature SCV is closed, air flows through one port, that increases flow speed and forms a vortex in the cylinder, for better mixture turbulization.
– At high load, SCV opens and air flows through the both ports.

Considering the air supply system features, additional pressure sensor for the brake servo was implemented, to switch the mode that provides the specified vacuum level.

EGR system (domestic market)

Exhaust gas recirculation system of D-4 engines provides inlet of significant proportion of the exhaust gas at LeanBurn mode (much more than in traditional engines). It allows to low combustion temperature, decrease content of nitrogen oxides in the exhaust gases, reduce pumping losses at the inlet.

EGR valve is driven by DC step-motor, opening angle depends on the engine speed, coolant temperature, load and vehicle speed.

Exhaust gases from the valve flows into EGR aluminum manifold, which uniforms stream of gases in each cylinder. Both the valve and manifold are water cooled.

NOx-converter (domestic market)

In the exhaust pipe of Japanese models NOx converter is installed. LeanBurn mode is accompanied by an increased emission of NOx, than the nitric oxide reacts with oxygen of the exhaust gas (O2), and products are accumulated on the catalyst adsorbing material in the form of nitrates (NO2). At homogeneous mode, with sufficiently rich mixture, the content of CO and HC in the exhaust gases increases, with its involvement in the presence of platinum dioxide (NO2) is reduced to nitrogen (N2). Simultaneously with the accumulation of nitrogen oxides converter actively captures the sulphur, which takes the useful volume of the absorbent layer, so the system can to function normally only using low-sulphur gasoline.

Ignition system – DIS-4, spark plugs with iridium centre electrode (initially for overseas market – Denso SK20R11 / NGK IFR6A11, since MY2003 – Denso SK20BR11 with two additional side electrodes, for domestic market – SK20BGR11 – protruded in the combustion chamber due to long shroud).

Type’2004 differences: L-type control system with MAF sensor, ETCS actuator with throttle position sensor (Hall effect), absence of separate NO-converter.

 

Owner Experience

• The above mentioned typical defects of 2AZ-FE engines are relevant for -FSE engines, including the problem with the “drop head” failure (defective parts – 11400-28120, -28160, ~$5000-6000).

In addition, several specific points are added:

  1. The tendency to noticeable vibrations due to low nominal idle speed, drawdown further with minimum deviations of engine management system components operation. Sometimes the traction loss at medium speed occurs and driving performance is deteriorated. Often, the cause can not be found even by whole units replacement, although in some cases, cleaning of MAF sensor, throttle, SCV actuator, or replacement of VVT valve, ignition coil terminals, EGR forced clogging may be useful. To partially smooth discomfort from rpm subsidence helps replacement of the engine mounts (primarily – liquid filled).
  2. Direct injection and control system have no such critical defects as first generation (3S-FSE), and require less attention. Recommended to be extremely careful with brittle plastic parts of the injectors (~$300), sometime injectors required in case of coil deteriorating. Replacement of low-pressure electric pump and fuel tank filter often requires. Note formal recall campaigns concerning fuel pipe replacement and the fuel pump check valve for the Avensis 250.
  3. EGR operation traditionally causes a strong carbon deposits in the inlet – from the throttle to the SCV and valves, and therefore requires regular mechanical and chemical treatment. Otherwise, problems of rpm drawdown and cold start are inevitable. There is not EGR at -FSE engines for domestic market, but it does not eliminate the need for cleaning the intake of the oil sludge.

Summary

After more than ten years since the first AZ appearance we can evaluate the series as a whole.

Specs. Power output and torque – are consistent with the average level of asian analogs, and in most cases provides enough thrust-weight ratio (except perhaps medium-SUVs).

Direct injection. D-4 did not cause significant performance gain or improvement in fuel efficiency compare to conventional motors of AZ series, and performs primarily “environmental” objectives. But increased cost of maintenance and repair of the “excess” components is enough to once again make sure of worthlessness and harm of using direct injection engines on the low-forced natural aspirated engines. Although 1..2AZ-FSE are more reliable than a terrible 3S-FSE, ordinary 1..2AZ-FE with multipoint injection are less of a problem.

Not to mention that because of an incurable idling low rpm problem (with the attendant vibrations) such cars driving is uncomfortable. Small note – in 2008 the known asian auto-repairer wrote: “but the progress is not standing still, and MFI soon be will be replaced by DI”, but in reality the D-4 history has developed somewhat differently.

Repairability. From the point of view of the manufacturer AZ considered “disposable”, as well as all the modern engines without “oversize” concept. Of course, in despair, these engines are subjected to overhaul, with cylinder block liners replacement using non-original parts or matched counterparts from other brands. The minimum cost of such work, as usual, is comparable to the price of the used engine – $1500-2000, whereas in the top-workshops complete overhaul valued at $4000-5000. As with other aspects of maintainability, here things are good – 2AZ-FE and 1AZ-FSE and shipped both to the European and the domestic markets, which has removed a lot of problems with spare parts and “second hand” engines.

Reliability. In the aggregate of most specs AZ series could be considered not bad representatives of the “3rd wave” motors, but only one critical defect of the cylinder heads ever eliminated their reputation, becoming a congenital malformation of popular models (Camry 30, RAV4 20, Highlander 20…), and undermined confidence to even later modifications.

Part 1 2003 rav4 1az-fe repair and diagnosis of camshaft, engine valve head removal

Toyota Engine 1AZ FSE Repair Manual – DHTauto.com

Unstable 1AZ-FSE motor rotation

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