Page 3465 of 5135
01±10
± INTRODUCTIONTERMS
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)Abbreviations Meaning
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PTCPositive Temperature Coefficient
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRSRigid Rear Suspension
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TFTToyota Free±Tronic
Page 3466 of 5135
± INTRODUCTIONTERMS
01±11
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)Abbreviations Meaning
TISTotal Information System For Vehicle Development
T/MTransmission
TMCTOYOTA Motor Corporation
TMMKTOYOTA Motor Manufacturing Kentucky, Inc.
TRCTraction Control System
TURBOTurbocharge
TWCThree±Way Catalyst
U/DUnderdrive
U/SUndersize
VCVVacuum Control Valve
VENTVentilator
VINVehicle Identification Number
VPSVariable Power Steering
VSCVehicle Stability Control
VSVVacuum Switching Valve
VTVVacuum Transmitting Valve
VVT±iVariable Valve Timing±intelligent
w/With
WGNWagon
W/HWire Harness
w/oWithout
WU±TWCWarm Up Three±way Catalytic Converter
WU±OCWarm Up Oxidation Catalytic Converter
1stFirst
2ndSecond
2WDTwo Wheel Drive Vehicle (4 x 2)
3rdThird
4thFourth
4WDFour Wheel Drive Vehicle (4 x 4)
4WSFour Wheel Steering System
5thFifth
Page 3467 of 5135
141BV±01
A77366
Intake Valve Guide Bush
Non±reusable part Valve Stem Oil O Seal or RingValve Lifter
Valve Retainer Lock
Retainer
Inner Compression Spring
Valve Spring Seat
Exhaust Valve Guide Bush
Stud Bolt
Cylinder Head Assy
Intake Valve Exhaust Valve Ring w/ Head Pin
14±38
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
CYLINDER HEAD ASSY
COMPONENTS
Page 3468 of 5135
190OI±01
A81555
A82635
A82636
A82637
19±2
± STARTING & CHARGINGSTARTER ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
OVERHAUL
1. REMOVE REPAIR SERVICE STARTER KIT
(a) Remove the nut, and disconnect the lead wire from the re-
pair service starter kit.
(b) Remove the 3 nuts holding the repair service starter kit to
the starter housing.
(c) Remove the repair service starter kit.
(d) Remove the return spring and plunger.
2. REMOVE STARTER YOKE ASSY
(a) Using a torx driver T25, remove the 2 through bolts and
pull out the starter yoke together with the starter commu-
tator end frame.
(b) Remove the starter yoke from the starter commutator end
frame.
3. REMOVE STARTER ARMATURE ASSY
(a) Remove the starter armature assy from the starter yoke assy.
Page 3469 of 5135
A79722
A82638
A82639
A82640
A82641
Terminal C
Terminal 50Continuity
± STARTING & CHARGINGSTARTER ASSY
19±3
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
4. REMOVE STARTER ARMATURE PLATE
(a) Remove the armature plate from the starter yoke.
5. REMOVE STARTER BRUSH HOLDER ASSY
(a) Remove the 2 screws and brush holder assy from the
commutator end frame.
6. REMOVE PLANET GEAR
(a) Remove the 3 planet gears from the repair service starter
kit.
7. INSPECT REPAIR SERVICE STARTER KIT
(a) Check the plunger.
(1) Push in the plunger and check that it returns quickly
to its original position.
If necessary, replace the repair service starter kit.
(b) Check the pull±in coil for open circuit.
(1) Using an ohmmeter, check that there is continuity
between terminals 50 and C.
If there is no continuity, replace the repair service starter kit.
Page 3470 of 5135
A82642
Terminal 50Continuity
A82643
Continuity
A82644No Continuity
A82645
A82646
29mm 19±4
± STARTING & CHARGINGSTARTER ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(c) Check if the hold±in coil has an open circuit.
(1) Using an ohmmeter, check that there is continuity
between terminal 50 and the switch body.
If there is no continuity, replace the repair service kit.
8. INSPECT STARTER ARMATURE ASSY
(a) Check the commutator for open circuit.
(1) Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segments, replace the ar-
mature.
(b) Check the commutator for ground.
(1) Using an ohmmeter, check that there is no continu-
ity between the commutator and the armature coil
core.
If there is continuity, replace the armature.
(c) Check the commutator for dirty or burned surface.
If the surface is dirty or burnt, smooth the surface with 400±grit
sandpaper.
(d) Check for the commutator circuit runout.
(1) Place the commutator on V±blocks.
(2) Using a dial indicator, measure the circle runout.
Standard runout: 0.02 mm (0.0008 in.)
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than maximum, replace the armature.
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard length: 29 mm (1.142 in.)
Minimum length: 28 mm (1.102 in.)
If the diameter is less than minimum, replace the armature.
Page 3471 of 5135
A82647
Length
A82648
No Continuity
A82649
Free Lock
A82650
Apply Grease
A82651
± STARTING & CHARGINGSTARTER ASSY
19±5
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
9. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the starter brush
holder assy.
(b) Check the brush holder.
(1) Using an ohmmeter, check that there is no continu-
ity between the positive (+) and negative (±) brush
holders.
If there is continuity, repair or replace the starter commutator
end frame assy.
10. INSPECT REPAIR SERVICE STARTER KIT
(a) Check the starter clutch.
(1) Rotate the clutch pinion gear counterclockwise and
check that it turns freely. Try to rotate the clutch pin-
ion gear clockwise and check that it locks.
If necessary, replace the repair service starter kit.
11. INSTALL PLANET GEAR
(a) Apply grease to the planet gears and pin parts of the plan-
etary shaft.
(b) Install the 3 planet gears.
12. INSTALL STARTER BRUSH HOLDER ASSY
(a) Install the brush holder to the starter armature assy.
Page 3472 of 5135
A82652
A82653
A82654
KeywayKey
A81586
Keyway Key
A82636
19±6
± STARTING & CHARGINGSTARTER ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
13. INSTALL STARTER COMMUTATOR END FRAME
ASSY
(a) Install the commutator end frame with the 2 screws.
14. INSTALL STARTER ARMATURE ASSY
(a) Align the rubber with the convex cutout of starter yoke.
(b) Install starter armature with the brush holder to the starter
yoke.
15. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter yoke.
(b) Align the keyway of the starter plate with the key inside the
starter yoke, and install the starter plate.
16. INSTALL STARTER YOKE ASSY
(a) Align the key of the starter yoke with the keyway located
on the starter drive housing.
(b) Using a torx driver T25, install the starter yoke with the 2
through bolts.
Torque: 6.0 Nm (61 kgfcm, 53 in.lbf)
17. INSTALL REPAIR SERVICE STARTER KIT
(a) Apply grease to the plunger and hook.
(b) Set the plunger and hook of the repair service starter kit
to the drive lever.
(c) Install the plunger and return spring.