Toyota 1RZ 1RZ-E 2RZ 2RZ-E engine factory workshop and repair manual
Toyota 1RZ 1RZ-E 2RZ 2RZ-E engine factory workshop and repair manual download
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Introduction
Engine Mechanical
EFI system
Fuel System
Cooling System
Lubrication System
Ignition System
Starting System
Charging System
Service Specifications
Torgue settings
SST and SSM
Engine
Diagonostics
Emission Control
Electronic Fuel Injection
Cooling
The 1RZ is a 2.0 L (1,998 cc) version built from 1989. Bore is 86 mm and stroke is 86 mm.
The 1RZ-E is the fuel-injected version of the 1RZ. With a 9.0 to 1 compression ratio, output is 101–108 hp at 5,400 rpm with 118–123 lb·ft (161–167 N·m) of torque at 2,800 rpm.
The 2RZ is a 2.4 L (2,438 cc) version. Bore is 95 mm and stroke is 86 mm; a variety of combination of heads and fuel delivery systems were available.
2RZ-E This is an SOHC engine with two valves per cylinder. Valve adjustment is by shim over bucket. Output is 120 PS (88 kW) at 5,200 rpm. Originally manufactured with a carburetor induction system, it was later upgraded to Electronic Fuel Injection, with the -E suffix added to the engine designation. Toyota specified unleaded fuel with a rating of at least 91 RON (Research Octane Rating) in Australia.
1989–2004 Toyota HiAce
1998–2005 Toyota Revo
1998–2001 Toyota Hilux
2000–2004 Toyota Kijang
1995–2004 Toyota Tacoma 4x2
Toyota 1RZ 1RZ-E 2RZ 2RZ-E factory workshop and repair online download
- Safety first
- Wear safety glasses to protect eyes from cleaner spray and debris.
- Wear nitrile or mechanic gloves to protect skin from solvents and grime.
- Work in a well-ventilated area; throttle-body / carb cleaner is flammable and gives off fumes — no smoking or open flames.
- Disconnect the negative battery terminal before unplugging electrical connectors or doing major work to avoid shorts and accidental cranking.
- What the part is and where it usually is
- The idle air control valve (IACV), sometimes called an idle speed control valve or bypass valve, is mounted on or next to the throttle body. On 1RZ / 1RZ‑E / 2RZ / 2RZ‑E engines it will be a small solenoid/valve assembly bolted to the throttle body with an electrical connector and usually a small gasket or O‑ring.
- Its job is to let a small, controlled amount of air bypass the throttle plate to regulate idle speed.
- Basic tools you should have (detailed descriptions and how to use them)
- Metric socket set (commonly 8, 10, 12 mm sockets)
- Purpose: remove bolts that hold the valve and air intake hoses.
- How to use: fit the correct socket onto a ratchet, place on bolt head and turn counterclockwise to loosen. Use an extension to reach recessed bolts.
- 3/8" or 1/4" ratchet
- Purpose: drive the sockets to remove and install bolts.
- How to use: set the ratchet direction switch for loosen/tighten, apply steady force; avoid sudden jerks.
- Extension bars
- Purpose: reach bolts set deep in recesses.
- How to use: attach between socket and ratchet to gain length.
- Combination screwdrivers (flathead and Phillips)
- Purpose: loosen hose clamps or remove small screws.
- How to use: match tip size to screw, press firmly and turn; for hose clamps, pry flathead gently if they’re spring-style.
- Pliers (regular and needle-nose)
- Purpose: remove spring-type hose clamps, pull vacuum lines, handle small items.
- How to use: grip the clamp/line and squeeze/rotate while pulling to remove.
- Torx/Allen bits (if required)
- Purpose: some throttle bodies use Torx or hex bolts.
- How to use: pick matching bit, fit into bolt, and turn with driver or socket adapter.
- Clean rags or shop towels
- Purpose: wipe off dirt and soak up cleaner.
- How to use: keep valve faces and passages clean; plug openings with a rag to prevent debris falling in.
- Throttle body / carburetor cleaner (spray)
- Purpose: dissolves carbon and varnish on the valve and passages.
- How to use: spray onto the valve pintle/intake passages; allow dwell, then wipe with a clean rag. Do not spray electrical connectors; avoid prolonged soaking of rubber seals.
- Small brush (nylon or brass)
- Purpose: scrape off stubborn carbon without damaging metal.
- How to use: gently brush the valve seat/pintle and passages after applying cleaner.
- Pick or small screwdriver (for gasket/O‑ring removal)
- Purpose: help remove old gasket or O‑ring without gouging surfaces.
- How to use: gently pry out gasket; avoid scratching mating surfaces.
- Digital multimeter (recommended extra tool)
- Purpose: check IACV electrical resistance, connector power/ground to diagnose electrical faults.
- How to use: set to Ohms to check coil resistance (compare to spec if you have it), set to DC voltage to check for battery voltage and ground with ignition on. If unsure, follow meter manual.
- OBD-II scanner (recommended extra tool)
- Purpose: read and clear idle-related fault codes; monitor engine RPM and sensors while testing.
- How to use: plug into the vehicle diagnostic port, read stored codes, clear after repairs, and observe live data while engine idles.
- New gasket or O‑ring (replacement part)
- Purpose: prevents air leaks after reassembly.
- How to use: replace old gasket with new one when re-installing the valve; seat evenly.
- Small torque wrench (optional but recommended)
- Purpose: tighten bolts to correct spec without overtightening.
- How to use: set desired torque per service manual and tighten bolts evenly.
- Basic procedure to clean and inspect the IACV (beginner-friendly)
- Prepare: park level, set parking brake, engine cool or at indicated temperature in manual for service, disconnect battery negative terminal.
- Locate the IACV on the throttle body: trace intake plumbing to the throttle body; the IACV is bolted to it and has a wiring connector.
- Disconnect electrical connector: press the lock tab and pull straight off; work slowly to avoid breaking the clip.
- Remove intake duct or air hose as needed: loosen hose clamps with screwdriver or pliers and slide hose off to gain access.
- Unbolt the IACV: use the correct socket/bit to remove mounting bolts; keep bolts and any spacers together on a rag.
- Remove the IACV and inspect:
- Check for carbon build-up on the pintle/valve or inside the passages.
- Inspect O‑ring or gasket for hardening, cracking, or deformation — if present, replace.
- Inspect connector and wiring for corrosion or damaged insulation.
- Clean the valve and passages:
- Use throttle-body/carbon cleaner and a lint-free rag. Spray cleaner onto the pintle and passages, allow to soak briefly, brush gently, then wipe.
- Do not spray cleaner into the electrical connector. Avoid soaking rubber parts long-term.
- If carbon is heavy, repeat until surfaces are free of heavy deposits.
- Reinstall with new gasket if required:
- Fit new gasket/O‑ring, place the valve back and hand-start bolts to avoid cross-threading, then snug evenly. If you have a torque wrench follow factory torque; if not, tighten snugly but don’t overtighten — overtightening can strip threads or crack the throttle body.
- Reconnect electrical connector and intake hose, reconnect negative battery terminal.
- Start engine and observe idle:
- Let engine reach operating temperature; observe idle smoothness and RPM.
- If codes were present, use OBD-II scanner to check and clear codes; some ECUs relearn idle after a drive cycle.
- How to use the extra diagnostic tools (brief)
- Digital multimeter
- Measure resistance across the IACV terminals (power off); compare to spec if available — a completely open circuit indicates internal failure.
- With ignition on and engine off, measure voltage at the connector terminals to confirm power and ground; no power can mean a wiring or fuse issue.
- OBD-II scanner
- Read stored fault codes, freeze-frame data and monitor live RPM and sensor readings; clear codes after successful repair and recheck.
- When replacement is required and why
- Signs you need to replace the IACV
- Valve mechanically stuck or physically damaged (broken pintle, cracked housing).
- Cleaning does not fix poor idle, hunting, stalling, or inability to idle.
- Electrical failure: multimeter shows open circuit/incorrect resistance, or no change when commanded (and wiring/fuse are okay).
- Vacuum or air leaks around the valve due to a ruined gasket/O‑ring that cannot seal even when reinstalled.
- What replacement parts might be needed
- Replacement IACV assembly specific to 1RZ / 1RZ‑E / 2RZ / 2RZ‑E (OEM or equivalent aftermarket). Common manufacturers: Toyota OEM, Denso, Standard Motor Products — match by engine code and year.
- New gasket or O‑ring (often supplied with the new valve; buy separately if not).
- If electrical connector or wiring are corroded/damaged, replacement connector/pigtail or minor wiring repair may be required.
- Why replacement might be preferable to cleaning
- Severe internal wear, seized motor, or electrical failure cannot be fixed by cleaning.
- On older parts, the cost of diagnostic time and repeated cleaning may exceed the cost of a new valve.
- Common beginner mistakes to avoid
- Do not force connectors or bolts — use correct tool size and steady pressure.
- Do not leave intake openings uncovered — cover with a clean rag to prevent debris from falling in.
- Do not use harsh tools to scrape mating surfaces — avoid gouging throttle body.
- Do not run the engine immediately after heavy cleaning that may have sprayed solvent into intake; allow solvent to evaporate or follow cleaner instructions.
- If cleaning doesn’t fix the problem (next steps)
- Use an OBD-II scanner to read/clear codes and monitor live data.
- Test electrical supply to the IACV with a multimeter.
- Replace the valve and gasket if it fails electrical tests or remains problematic after cleaning.
- If replacement fails to correct idle, check for vacuum leaks, throttle position sensor issues, or other intake/ignition/fuel problems.
- Parts sourcing and tips
- Give engine code, year, and vehicle model to parts supplier to get the correct IACV.
- OEM part or reputable aftermarket brand (Denso, Standard) recommended for reliability.
- Buy a replacement gasket/O‑ring even if you hope to reuse the old one — they’re inexpensive and prevent leaks.
- Final checks after repair
- Confirm no vacuum leaks around the throttle body/IACV.
- Verify smooth idle and that any previous fault codes are cleared or do not return.
- Take a short drive and let ECU relearn idle characteristics; recheck after a day.
- Quick tool-use reminders (very brief)
- Socket + ratchet: turn counterclockwise to loosen, clockwise to tighten; use correct size.
- Screwdriver: match head, turn gently; keep screwdriver aligned with screw.
- Pliers: pinch and pull; use needle-nose for small clips.
- Multimeter: read manual; set correct mode (Ohms for resistance, DC volts for power checks).
- Throttle cleaner: spray, wait, brush, wipe; avoid soaking rubber and connectors.
- Final note
- Cleaning the IACV is a common first step and often fixes idle problems caused by carbon. Replace the valve if it is electrically faulty, physically damaged, or does not respond after cleaning. rteeqp73
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