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 — if any step makes you unsure, stop and get a professional. Wear safety glasses, gloves, and use rated jack stands; never rely on a jack alone. Follow factory service manual torque specs for your exact model and recheck fasteners after the first 100–200 miles.
- Identify your vehicle’s suspension before starting (important because installation steps and required tools differ): many Toyota vehicles with 1RZ/2RZ engines use independent front suspension (struts or torsion bars) and a solid rear axle with leaf springs. Confirm whether your front is a strut-coil setup, a torsion-bar setup, and whether the rear is leaf springs or coils.
Tools — what they are, why you need them, and how to use them
- Hydraulic floor jack
- What: Low-profile jack to lift the vehicle.
- Why: Lifts the vehicle so you can support it on stands.
- How to use: Place on a factory jacking point, pump handle to raise until contact, then lift slightly more to slide jack stands under. Never work under a car supported only by the jack.
- Jack stands (pair for each end being worked)
- What: Rated stands that support weight safely.
- Why: Provide secure, stable support while you work.
- How to use: Set to equal height and place under secure frame or axle points; lower the vehicle onto the stands gently.
- Wheel chocks
- What: Blocks to prevent rolling.
- Why: Prevents the vehicle from moving while lifted.
- How to use: Place behind/forward wheels that remain on the ground.
- Socket set (metric), ratchet, extension bars
- What: Metric sockets (10mm–24mm commonly needed), breaker-length ratchet or 3/8", 1/2" drive.
- Why: Remove wheels, strut bolts, U-bolts, and other suspension fasteners.
- How to use: Use correct-sized sockets; sit square to bolt to avoid rounding heads. Use extensions to reach recessed fasteners.
- Breaker bar
- What: Long-handled bar for extra leverage.
- Why: Break loose tight, rusted, or high-torque nuts/bolts.
- How to use: Fit proper socket and apply steady force; avoid sudden jerks.
- Torque wrench (click-type, appropriate range)
- What: Tool to tighten bolts to specific torque values.
- Why: Ensures correct clamping — critical for safety.
- How to use: Set required torque, tighten slowly until click; follow sequence in manual.
- Spring compressor (strut spring compressor)
- What: Heavy-duty clamps or threaded compressors made for coil springs.
- Why: Compresses coil spring safely to remove/fit strut assemblies.
- How to use: Fit evenly on opposite coils, compress slowly and evenly, keep hands clear. If unsure or spring is corroded, do not proceed — springs can release with deadly force. Consider professional help.
- Ball joint separator / pickle fork / tie-rod end tool
- What: Tools to separate ball joints and tie rod ends from steering knuckles.
- Why: Needed when removing struts or control arms.
- How to use: Fit between joint and press or strike as instructed; support the hub to avoid damage.
- Pry bar(s)
- What: Strong steel bar for leverage.
- Why: Help free stubborn components and align parts for reassembly.
- How to use: Use controlled pressure; protect mounting points with wood block if needed.
- Hammer and dead-blow hammer
- What: For persuading stuck components.
- Why: Loosen rusted bolts and seats.
- How to use: Tap sharply for stuck items; use dead-blow to avoid damage.
- Penetrating oil (e.g., PB Blaster), wire brush
- What: Lubricant and cleaning tools.
- Why: Soften rusted nuts/bolts and clean threads.
- How to use: Spray on bolts and let soak; wire-brush threads before reinstall.
- C-clamp or large vise (for compressing small springs or isolators)
- What: General clamp.
- Why: Helpful to compress strut top or isolator if no spring compressor for small jobs.
- How to use: Use with care only for small tasks — do not substitute for proper spring compressor where needed.
- Torque-angle gauge (optional)
- What: For bolts requiring torque+angle tightening.
- Why: Some suspension bolts use torque+angle spec.
- How to use: Follow factory instructions.
- Torsion bar unloading tool (only if your front uses torsion bars)
- What: Special tool to relieve torsion bar preload.
- Why: Required to safely lower or remove torsion bars without damaging components or risking injury.
- How to use: Follow tool instructions and factory manual strictly; this is advanced — seek a shop if unsure.
- Bench vise or press (optional for swapping bushings)
- What: Used to press bushings/ball joints if needed.
- Why: Some kits require replacing bushings or ball joints which may require pressing.
- How to use: Use appropriate adapters and follow press safety.
Lowering kit types and what they change (pick the kit matching your suspension)
- Front lowering springs (for strut-coil front)
- What they are: Shorter or lower-rate coil springs that lower ride height.
- Why they’re used: Lowers center height, preserves strut geometry more than cutting springs.
- Replacement considerations: Use matched shocks/struts designed for lowered height or adjustable coilovers. Replace spring isolators and bump stops if worn.
- Drop spindles or strut spacers
- What: Drop spindles change spindle location to lower ride height without altering coil springs; strut spacers lift top mounts for a lift rather than lowering.
- Why: Drop spindles maintain spring geometry — often used for front lowering on solid-axle setups.
- Replacement considerations: Spindles may require new wheel bearings/seals if removed; torque and alignment critical.
- Torsion bar lowering key (for torsion-bar front)
- What: Keys that change torsion bar anchor point to lower the front.
- Why: Adjusts preload to lower the vehicle; requires torsion bar unloading tool.
- Replacement considerations: Inspect torsion bar splines and bushings. Professional alignment required.
- Rear lowering blocks (for live axle with leaf springs)
- What: Thicker or flipped blocks between axle and leaf spring U-bolts to lower the axle (or flipped blocks to raise).
- Why: Easy, inexpensive way to lower axle relative to spring perch.
- Replacement considerations: New U-bolts sized for block thickness are required; shocks often must be shortened or replaced.
- Shortened leaf springs or re-arched leaf packs
- What: Leaf packs with fewer leaves or different arch to lower axle.
- Why: Permanent lowering with better ride control than blocks.
- Replacement considerations: Requires U-bolts, new bushings, matched shock length, and alignment. Professional fitment recommended.
- Drop shackles or shackle repositioning
- What: Changed shackles to change spring angle and lower or raise the rear.
- Why: Sometimes used on vans/trucks to alter height.
- Replacement considerations: Inspect shackles and bushings; may change spring/shock geometry.
Step-by-step high-level procedure (use correct kit instructions and factory manual torque specs)
- Preparation and safety set-up
- Park on flat level ground, engage parking brake, chock rear wheels.
- Loosen wheel lug nuts slightly while car is on ground.
- Jack the vehicle at the recommended jacking point, raise and support with jack stands on solid frame or axle perch.
- Remove wheels and secure steering/rotational components with bungee cords if needed.
- Front strut / coil spring lowering (common procedure)
- Remove wheel and inspect top mount access point in engine bay or strut tower.
- Support the lower control arm with a secondary jack or stand to keep hub from dropping when you unbolt the strut.
- Remove lower strut-to-knuckle bolts (use penetrating oil and breaker bar if needed).
- Remove sway-bar end link and ABS/brake line brackets attached to the strut.
- Remove top strut nuts from strut tower (hold strut piston from turning or use appropriate tool).
- Remove strut assembly from vehicle.
- Compress the coil spring using a certified spring compressor — place compressors opposite each other, tighten evenly until spring is relaxed on top mount.
- Swap springs with the lowering springs: install new spring with new isolators/bump stops as provided.
- Slowly decompress spring ensuring it seats correctly in top and bottom perches.
- Reinstall strut assembly into vehicle, loosely fit top nuts, then align bottom to knuckle and install bolts.
- Torque all fasteners to factory specs with a torque wrench. Repeat on other side.
- Note: Replace shocks/struts if required by the kit — shorter springs on stock shocks can cause the shock to bottom out early.
- Front torsion-bar lowering (if applicable)
- If vehicle has torsion bars, use the torsion bar unloading tool to relieve preload from the crossmember.
- Remove adjustment bolt and slide torsion bar out of key and adjust with lowering key as per kit instructions.
- Re-tension and check spline engagement; never reinstall without proper tool and torque.
- Inspect bushings and replace if worn. This is advanced — consider a shop if unfamiliar.
- Rear leaf-spring lowering with blocks or new leaf springs
- Support axle with a jack and remove U-bolts (penetrating oil beforehand). Do not let axle drop uncontrolled — support with jack.
- If using lowering blocks: position new block between axle perch and spring, align center pins, fit new longer U-bolts and torque to spec.
- If replacing leaf springs: unbolt front and rear spring hangers and remove spring; install new spring and new bushings as needed, fit with new U-bolts, torque to spec.
- If using shackle changes, remove shackles and replace with kit parts; fit new bushings.
- Replace or shorten shock absorbers if they will bottom out or be too long — shocks are frequently required when lowering.
- Reassembly and immediate checks
- Reinstall wheels and torque lug nuts to manufacturer specs with torque wrench.
- Lower vehicle to ground and settle suspension by rocking gently.
- Check brake line routing and ABS sensor wires; ensure no binding or excessive tension. If lines are tight, replace with longer hoses or add brackets as required by the kit.
- Check bump stops: if lowered significantly, shorter bump stops or new mounts may be needed to prevent damage.
Essential replacement parts commonly required when lowering
- Shocks/struts matched to lowered ride height
- Why: Stock shocks are valved and length-designed for stock ride height; lowering can cause poor damping and premature bottoming.
- New U-bolts (for leaf-spring axle setups)
- Why: Blocks or thicker plates require longer U-bolts; used U-bolts may be stretched or corroded.
- Spring isolators, top mounts, bump stops
- Why: These rubber parts compress/age and should be replaced when changing springs to avoid noise and improper seating.
- Brake lines or hose extensions/brackets (if needed)
- Why: Significant drop may pull on lines; replace or fit longer hoses to avoid overstretching.
- Ball joints, tie-rod ends, bushings (inspect and replace if worn)
- Why: Lowering alters geometry and stresses worn components; replace worn components to maintain handling and safety.
- Torsion bar keys or new torsion bars (if torsion-bar modification)
- Why: Kit may include keys; inspect torsion bar for wear.
- Wheel bearings/seals or spindle components (if drop spindles are used and disassembled)
- Why: Disassembly may disturb bearings/seals; replacement prevents leaks or premature wear.
- Alignment/camber/caster adjustment shims or adjustable control arms (if necessary)
- Why: Lowering changes geometry and camber/caster; adjustments required to keep tires from excessive wear and to keep steering stable.
Alignment and post-installation service
- Always perform a full 4-wheel alignment immediately after lowering.
- Why: Lowering changes camber, caster, and toe; improper alignment causes tire wear and unsafe handling.
- Re-torque all suspension fasteners after the first 100–200 miles and periodically after.
- Why: Fasteners can settle as bushings compress and components seat.
- Test drive carefully at low speed first; listen for rubbing, binding, or unusual noises.
Common risks and why professional help is sometimes required
- Compressed springs store lethal energy; improper use of spring compressors can cause catastrophic injury.
- Torsion bar systems require special unloading tools and knowledge to avoid injury or damage.
- Incorrect installation can lead to loss of steering control or premature component failure.
- Suspension geometry changes can cause undesirable handling or tire wear — alignment shops have proper equipment for corrections.
Final quick checklist before starting
- Confirm suspension type (strut vs. torsion bar, leaf vs. coil rear).
- Get the correct lowering kit for that suspension and vehicle year.
- Gather the tools above, plus any special kit hardware and a factory service manual or torque chart.
- Plan for an alignment appointment right after installation.
- You can do this as a capable DIYer with proper tools and caution, but for spring compressors, torsion bars, or if you lack a torque wrench/alignment access, get a professional install. rteeqp73
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