Page 17 of 2000
ENGINE - 2AZ-FE ENGINE
01NEG37Y
Mesh Type Gasket
01NEG38Y
TWC EG-20
4. Intake Manifold
The intake manifold has been made of plastic to reduce the weight and the amount of heat transferred from
the cylinder head. As a result, it has become possible to reduce the intake air temperature and improve the
intake volumetric efficiency.
A mesh type gasket is used, in order to reduce the intake noise.
5. Exhaust Manifold
A stainless steel exhaust manifold is used for improving the warm-up of TWC (Three-Way Catalytic
converter) and for weight reduction.
Page 18 of 2000
ENGINE - 2AZ-FE ENGINE
01MEG33Y
Ball Joint
Spring
Gasket
BoltSub Muffler
Ball Joint
Main Muffler
TWC Ball JointEG-21
6. Exhaust Pipe
The exhaust pipe uses two ball joints in order to achieve a simple construction and ensured reliability.
The TWC can improve exhaust emission by optimizing the cell density and the wall thickness.
Page 19 of 2000
ENGINE - 2AZ-FE ENGINE
01MEG30Y
Fuel Pump Assembly
Fuel Filter
Pressure Regulator
Quick Connector
Injector
Fuel Tank
Canister EG-22
FUEL SYSTEM
1. General
The fuel returnless system is used to reduce evaporative emissions.
A fuel cut control is used to stop the fuel pump when the SRS airbag is deployed in a front or side collision.
For details, see page EG-53.
A quick connector is used in the fuel main pipe to improve serviceability.
The 12-hole type fuel injector is used.
The ORVR (On-board Refueling Vapor Recovery) system is used. For details, see page EG-54.
Page 20 of 2000
ENGINE - 2AZ-FE ENGINE
185EG16
Pulsation
Dumper
Pressure Regulator
Fuel Pump
AssemblyFuel Tank
Fuel Filter
Fuel Pump
DR011EG18
EG-23
2. Fuel Returnless System
Fuel returnless system is used to reduce the evaporative emission. As shown below, by integrating the fuel
filter and pressure regulator with fuel pump assembly, the fuel return system in which the fuel returns from
the engine area is discontinued and temperature rise inside the fuel tank is prevented.
3. Fuel Injector
The 12-hole type injector is used. By modifying its
injector nozzle to a taper shape, this injector has
achieved high atomizing performance of fuel. In
addition, the injector provides good performance
with the lightweight moving parts and the
optimized magnetic circuit.
Page 21 of 2000
ENGINE - 2AZ-FE ENGINE
165EG25
Camshaft
Position
Sensor
Crankshaft
Position
Sensor
Va r i o u s
SensorG2
NE
ECMIGT1
IGT2
IGT3
IGT4
IGF+BIgnition Coil
(with Igniter)
No.1 Cylinder
No.2 Cylinder
No.3 Cylinder
No.4 Cylinder
185EG38
0.7 mm
(0.028 in.)
Iridium Tip EG-24
IGNITION SYSTEM
1. General
A DIS (Direct Ignition System) is used. The DIS improves the ignition timing accuracy, reduces
high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor.
The DIS in this engine is an independent ignition system which has one ignition coil (with igniter) for each
cylinder.
Iridium-tipped spark plugs are used.
2. Spark Plug
Iridium-tipped spark plugs are used to improve ignition performance while maintaining the same durability
of the platinum-tipped spark plugs.
Specifications
DENSOSK20R11
NGKIFR6A11
Plug Gap1.0 - 1.1 mm
(0.039 - 0.043 in.)
Page 22 of 2000

ENGINE - 2AZ-FE ENGINE
206EG40206EG41
206EG42
Stator Segment
ConductorStator
Joined
Joined Segment
Conductor SystemSegment
ConductorStator
StatorConductor
Wire
Conductor Wire
A
AA - A Cross
Section
Segment Conductor Type GeneratorB
BB - B Cross
Section
Conventional Type GeneratorWinding System
Stator
Segment
Conductor
Cross Section
Stator of Segment Conductor Type GeneratorEG-25
CHARGING SYSTEM
1. Segment Conductor Type Generator
A compact and lightweight segment conductor type generator that generates high amperage output in a
highly efficient manner is used.
This generator has a joined segment conductor system in which multiple segment conductors are welded
together to form the stator. Compared to the conventional winding system, the electrical resistance is
reduced due to the shape of the segment conductors, and their arrangement helps to make the generator
compact.
Specifications
Ty p eSE0
Rated Voltage12 V
Rated Output100 A
Initial Output Starting SpeedMax. 1,500 rpm
Page 23 of 2000
ENGINE - 2AZ-FE ENGINE
01NEG45Y
RegulatorB
M
IG
RLO
L
Ignition Switch
To Discharge
Wa r n i n g L i g h t
Generator
ECM
281EG13
281EG12
Coil SpringPulley
Helical Coil Type One-way Clutch EG-26
Wiring Diagram
2. Generator Pulley
A helical coil type one-way clutch is used on the generator pulley in order to reduce the load that acts on
the auxiliary equipment belt.
The pulley mounting nut and the generator pulley have been integrated to achieve a compact construction.
Page 24 of 2000

ENGINE - 2AZ-FE ENGINE
01NEG46Y
ArmatureSurface Commutator
Permanent Magnet
Brush
LengthEG-27
STARTING SYSTEM
1. General
A compact and lightweight PS (Planetary reduction-Segment conductor motor) type starter is used.
Because the PS type starter contains an armature that uses square-shaped conductors, and its surface
functions as a commutator, it has resulted in both improving its output torque and reducing its overall
length.
In place of the field coil used in the conventional type starter, the PS type starter uses two types of
permanent magnets: main magnets and interpolar magnets. The main magnets and interpolar magnets
have been efficiently arranged to increase the magnetic flux and to shorten the length of the yoke.
Specifications
Starter TypePS Type
Rating Output1.7 kW
Rating Voltage12 V
Length*1mm (in.)128 (5.04)
Weight g (lb)2950 (6.50)
Rotational Direction*2Counterclockwise
*1: Length from the mounted area to the rear end of the starter
*
2: Viewed from pinion side