Toyota 2AZ-FE Engine Workshop Manual

Factory repair and maintenance manual for the 2AZ-FE gasoline engine. This 2.4-liter engine was installed on many Toyota models, including Camry, RAV4, Highlander, Harrier, Estima, Alphard, Corolla and others.

Manual contents:

• Detailed design of the 2AZ-FE engine.
• Step-by-step procedures for disassembly and assembly.
• Repair of the timing belt, cylinder head and cylinder block.
• Lubrication, cooling, intake and exhaust systems.
• Electrical diagrams, sensors and engine management systems.
• Diagnostics and troubleshooting.
• Adjustment standards, tightening torques and technical data.

Rav4 06 Engine 2AZ-FE Starting Download

Rav4 06 Engine 2AZ-FE Lubrication Download

Rav4 06 Engine 2AZ-FE Ignition Download

Rav4 06 Engine 2AZ-FE Fuel Download

Rav4 06 Engine 2AZ-FE Exhaust Download

Rav4 06 Engine 2AZ-FE Engine Mechanical Download

Rav4 06 Engine 2AZ-FE Engine Control System Download

Rav4 06 Engine 2AZ-FE Emission Control Download

Rav4 06 Engine 2AZ-FE Cooling Download

Rav4 06 Engine 2AZ-FE Charging Download

The Toyota 2AZ-FE engine is reliable, but requires attention to the cooling system, timing belt and oil consumption. With timely maintenance, the resource is 300,000+ km.

Increased oil consumption

• Reason: coking of oil scraper rings and crankcase ventilation.
• Symptoms: blue smoke, constant need to top up oil.
• Solution: replacing rings, overhaul of the CPG, sometimes replacing the cylinder head.

Burnt head gasket

• Reason: engine overheating or poor quality of fasteners.
• Symptoms: emulsion in oil, bubbles in the expansion tank, loss of power.
• Solution: replacing the gasket, milling the head, installing reinforced bolts.

Increased vibration at idle

• Reason: wear of engine mounts, contamination of the throttle or injectors.
• Solution: replacing the supports, cleaning the throttle and fuel system.

Worn threads of cylinder head bolts (strip threads)

• Reason: design feature of the block (aluminum).
• Symptoms: antifreeze leak, overheating.
• Solution: install repair studs (helicoil).

Noise and knocking in the timing belt

• Cause: timing chain or tensioner wear.
• Symptoms: metallic ringing during cold start, phase error.
• Solution: replace the chain, tensioner and shoes.

Problems with the cooling system

• Cause: weak radiator, pump leak.
• Symptoms: overheating, constant loss of antifreeze.
• Solution: replace the radiator, pipes, water pump.

Increased fuel consumption

• Cause: dirty injectors, MAF, lambda probes.
• Symptoms: loss of traction, black exhaust, mixture errors.
• Solution: clean or replace sensors, injectors.