Toyota 1AZ-FSE

Toyota 1AZ-FSEThe 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

Engine Specifications
Engine code1AZ-FSE
LayoutFour stroke, Inline-4 (Straight-4)
Fuel typeGasoline (petrol)
Production2000-2009
Displacement2.0 L, 1,998 cc (121.93 cu in)
Fuel systemToyota D-4 direct injection system
Power adderNone
Power output 150 PS (110 kW; 148 HP) at 6,000 rpm
152 PS (112 KW; 150 HP) at 6,000 rpm
155 PS (114 kW; 153 HP) at 6,000 rpm
Torque output 192 Nm (19.6 kg·m; 141.7 ft·lb) at 4,000 rpm
198 Nm (20.2 kg·m; 146.1 ft·lb) at 4,000 rpm
200 Nm (20.4 kg·m; 147.6 ft·lb) at 4,000 rpm
Firing order1-3-4-2
Dimensions (L x W x H):
Weight

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.

Cylinder block
Cylinder block alloyAluminium
Compression ratio:9.8:1, 10.5:1 or 11:1
Cylinder bore:86.0 mm (3.39 in)
Piston stroke:86.0 mm (3.39 in)
Number of piston rings (compression / oil):2 / 1
Number of main bearings:5
Cylinder inner diameter (standard):86.000-86.013 mm (3.3858-3.3863 in)
Piston skirt diameter (standard):85.940-85.950 mm (3.3834-3.3838 in)
Piston pin outer diameter:22.000 mm (0.8661 in)
Piston ring side clearance:Top0.020-0.070 mm (0.0008-0.0028 in)
Second0.020-0.060 mm (0.0008-0.0024 in)
Piston ring end gap:Top0.30-0.40 mm (0.0118-0.0157 in)
Second0.47-0.62 mm (0.0185-0.0244 in)
Oil0.10-0.35 mm (0.0039-0.0138 in)
Crankshaft main journal diameter:54.998-55.000 mm (2.1652-2.1653 in)
Crankpin diameter:47.990-48.000 mm (1.8894-1.8898 in)

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.

Cylinder head
Valve Arrangement:DOHC, chain drive
Valves:16 (4 valves per cylinder)
Valve head diameter:INTAKE34.0 mm (1.3385 in)
EXHAUST29.5 mm (1.1614 in)
Valve length:INTAKE101.71 mm (4.004 in)
EXHAUST101.15 mm (3.982 in)
Valve stem diameter:INTAKE5.470-5.485 mm (0.2153-0.2159 in)
EXHAUST5.465-5.480 mm (0.151 – 0.2157 in)
Valve spring free length:45.7 mm (1.799 in)
Camshaft cam height:INTAKE45.510-45.610 mm (1.7917-1.7957 in)
EXHAUST45.983-46.083 mm (1.8103-1.8143 in)
Outer camshaft journal diameter:№135.971-35.985 mm (1.4162-1.4167 in)
№2, 3, 4, 522.959-22.975 mm (0.9039-0.9045 in)

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 (HOT)
Intake valve0.19-0.29 mm (0.007-0.011 in)
Exhaust valve0.30-0.40 mm (0.012-0.016 in)
Idle speed650±50 rpm
Ignition timing Since 2001: 4-12°
Since 2004: 8-16°
Compression pressure
Standard13.0 kg/m2 / 200 rpm
Minimun11.0 kg/m2 / 200 rpm
Compression differential limit between cylinders1.0 kg/m2 / 200 rpm
Oil system
Oil consumption , L/1000 km (qt. per miles)up to 0.5 (1 qt. per 1200 miles)
Recommended engine oil 5W-20, 5W-30, 10W-30
Oil type APISJ
Engine oil capacity (Refill capacity) With filter change 4.2 l
Without filter change 4.0 l
Oil change interval, km (miles)10,000 (6,000)
Oil Pressure, kPa (bar, kg/cm 2, psi) Idle speed: More than 60 (0.6, 0.61, 9)
2,000 rpm: More than 270 (2.7, 2.8, 39)
Ignition system
Spark plugDENSO: SK20BGR11
Spark plug gap1.1 mm (0.043 in)

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

ModelYears Produced
Toyota Avensis
Toyota Avensis Verso
Toyota Noah
Toyota Voxy
Toyota RAV4
Toyota Gaia
Toyota Isis
Toyota Ipsum
Toyota Caldina
Toyota Wish
Toyota Allion
Toyota Premio
Toyota Opa
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6 Comments

  1. There is plenty of those engine even here in Zambia but I have no idea where Samoa is. Here they cost about $1000 for a 1az-fse engine. You also have the option of getting a subassembled one ( it will not have ignition coils, starter motor, alternator, aircon compressor, power steering sometimes intake and exhaust manifolds are removed) at about $700. This option is Good if you have the old engine.

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