Toyota 1AZ-FSE

The Toyota 1AZ-FSE is a 2,0 l (1998 cc, 121.93 cu-in) straight-four 4-stroke natural aspirated gasoline engine from Toyota AZ-family. This engine was manufactured by Toyota Motor Company from 2000 to 2009 in Japan.

The Toyota 1AZ-FSE features a lightweight aluminum block with cast-iron cylinder liners and aluminum head with two camshafts (DOHC) and four valves per cylinder. The 1AZ-FSE engine has slant-squish combustion chambers, offset cylinder and crank centers, VVT-i (Variable Valve Timing with intelligence) for the intake side and Toyota’s D-4 direct injection system.

An 86.0 mm (3.39 in) cylinder bore and 86.0 mm (3.39 in) piston stroke give the motor a total of 1,998 cc (121.93 cu-in) of displacement. Compression ratio rating is 9.8:1, 10:5:1 to 11.0:1 (depends on the year and car model).

It produces from 150 PS (110 kW; 148 HP) at 6,000 rpm to 155 PS (114 kW; 153 HP) at 6,000 rpm of maximum horsepower and from 192 Nm (19.6 kg·m; 141.7 ft·lb) at 4,000 rpm to 200 Nm (20.4 kg·m; 147.6 ft·lb) at 4,000 rpm of peak torque.

The breakdown of the engine code is as follows:

• 1 – 1-st generation engine
• AZ – Engine family
• F – Economy narrow-angle DOHC
• S – Gasoline direct injection system (D-4)
• E – Multi Point Fuel Injection

General information

Cylinder block

The 1AZ-FSE has an open-deck die-cast aluminum cylinder block with cast-in iron liners and a die-cast aluminum lower crankcase and a stamped oil pan. The forged steel crankshaft is fully balanced with eight counterweights and supported by five main bearings.

A helical gear pressed in No. 3 counterweight drives twin contra-rotating balance shafts in the shaft housing within the lower crankcase. The engine used aluminum pistons with two compression and single oil ring. The cylinder bore is 86.0 mm (3.39 in) and the piston stroke is 86.0 mm (3.39 in). Compression ratio rating is 9.8:1, 10:5:1 to 11.0:1.

Main bearing cap bolts tightening procedure and torque specs:

• Step 1: 40 Nm; 4.0 kg·m; 29.5 ft·lb
• Step 2: Turn all bolts 90°

After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

Connecting rod bearing bolts

• Step 1: 24.5 Nm; 2.5 kg·m; 18 ft·lb
• Step 2: Turn bolts 90°

Drive plate (A/T) fixing bolts

• 83 Nm; 8.5 kg·m; 61 ft·lb

Cylinder head

The cylinder head is made of strong, light aluminum alloy which gives it good cooling efficiency. Each camshaft is supported by five bearings. The dual overhead camshafts are driven by a single-stage roller chain. The camshafts act on four valves per cylinder via bucket tappets. Valve diameters are 34.0 mm (1.3 in) for intake and 29.5 mm (1.2 in) for exhaust, with 8.0 mm (0.3 in) lift for both intake and exhaust valves.

Head tightening procedure and torque specs:

• Step 1: 79 Nm; 8.0 kg·m; 58 ft·lb
• Step 2: Turn all bolts 90°

Camshaft timing gear assy bolt

• 54 Nm; 5.5 kg·m; 40 ft·lb

Camshaft bearing cap bolts

• № 1:30 Nm; 3.0 kg·m; 22 ft·lb
• Other:9 Nm; 0.9 kg·m; 6.4 ft·lb

Maintenance data

Valve clearance adjustment data

Calculate the thickness of new adjusting valve lifter so valve clearance comes within specified values.

R = Thickness of removed valve lifter
N = Thickness of new valve lifter
M = Measured valve clearance

Intake:
N = R + [M – 0.24 mm (0.009 in)]
Exhaust:
N = R + [M – 0.35 mm (0.014 in)]

Valve lifters are available in 35 sizes to range from 5.06 mm (0.1992 in) to 5.74 mm (0.2260 in), in steps of 0.02 mm (0.0008 in).

Example (intake valve):
R = 5.12 mm
M = 0.45 mm
N = 5.12 + (0.45 – 0.35) = 5.22 mm, so we need a valve lifter 5.22 mm (0.2055 in).

Vehicle applications

Author: Sergei Wers
About: Co-founder and CEO of a multi-brand auto repair shop (engine repair, chassis repair, body repair and painting) for over 15 years. I have been developing internet sites with technical specifications for more than seven years.