T-SB-0030-15
Service Bulletin Details
Public Details for: T-SB-0030-15
Tsb: note-service bulletin no. T-sb-0158-14, "2az engine oil consumption inspection procedure," must be performed first before continuing with the procedure in this bulletin. Some 2006 - 2013 model year vehicles equipped with the 2az engine
- 2013 - 2012 - 2011 - 2010 - 2009 - 2008 - 2007 - 2006 -
Models from 2013
2013 TOYOTA MATRIX |
Models from 2012
2012 TOYOTA MATRIX |
Models from 2008
2008 TOYOTA CAMRY |
2008 TOYOTA CAMRY HYBRID |
2008 TOYOTA CAMRY SOLARA |
2008 TOYOTA RAV4 |
Models from 2007
2007 TOYOTA CAMRY |
2007 TOYOTA CAMRY HYBRID |
2007 TOYOTA CAMRY SOLARA |
2007 TOYOTA RAV4 |
Models from 2006
2006 TOYOTA RAV4 |
T-SB-0030-15 Rev1 May 26, 2015 2AZ Engine Oil Consumption Repair Procedure Service Category Engine/Hybrid System Section Engine Mechanical Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2007 – 2011 Camry HV Engine(s): 2AZ VDS(s): BB3EK, BB46K 2007 – 2009 Camry Engine(s): 2AZ VDS(s): BE46K 2009 – 2011 Corolla Engine(s): 2AZ VDS(s): BE40E, BE4EE 2009 – 2013 Matrix Engine(s): 2AZ VDS(s): GE40E, KE40E, KE42E, KE4EE, LE40E, LE4EE, ME4EE 2006 – 2008 RAV4 Engine(s): 2AZ VDS(s): BD31V, BD32V, BD33V, BD34V, BD35V, ZD31V, ZD32V, ZD33V, ZD34V, ZD35V 2007 – 2008 Solara Engine(s): 2AZ VDS(s): CE30P REVISION NOTICE October 9, 2015 Rev1: • The Parts Information and Repair Procedure sections have been updated. Any previous printed versions of this bulletin should be discarded. © 2015 Toyota Motor Sales, USA Page 1 of 28 Rev1 T-SB-0030-15 May 26, 2015 Page 2 of 28 2AZ Engine Oil Consumption Repair Procedure SUPERSESSION NOTICE The information contained in this bulletin supersedes SB No. T-SB-0094-11. • Applicability has been updated to include 2010 – 2011 model year Corolla and 2010 – 2013 model year Matrix vehicles. • The Title has been updated. • The Production Change Information section has been removed. Service Bulletin No. T-SB-0094-11 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this bulletin before proceeding. Introduction NOTE Service Bulletin No. T-SB-0158-14, “2AZ Engine Oil Consumption Inspection Procedure,” MUST be performed first BEFORE continuing with the procedure in this bulletin. Some 2006 – 2013 model year vehicles equipped with the 2AZ engine may exhibit engine oil consumption. The piston assembly has been changed to minimize oil consumption. Use the following Repair Procedure to address this condition. Warranty Information OP CODE DESCRIPTION MODEL Camry EG9014 ENGINE 2AZ-FE DRIVETRAIN – TIME OFP 14.8 13211-0H040-A0 13211-0H040-B0 13211-0H040-C0 13211-0H041-A0 13211-0H041-B0 13211-0H041-C0 13211-28110-A0 13211-28110-B0 13211-28110-C0 13211-28111-A0 13211-28111-B0 13211-28111-C0 13211-28112-A0 13211-28112-B0 13211-28112-C0 R & R Piston and Ring Set Camry HV 2AZ-FXE – © 2015 Toyota Motor Sales, USA 15.5 13211-28120-A0 13211-28120-B0 13211-28120-C0 13211-28121-A0 13211-28121-B0 13211-28121-C0 T1 T2 11 99 Rev1 T-SB-0030-15 May 26, 2015 Page 3 of 28 2AZ Engine Oil Consumption Repair Procedure Warranty Information (Continued) OP CODE DESCRIPTION MODEL ENGINE Corolla DRIVETRAIN TIME OFP – 14.2 2WD 14.2 4WD 14.7 2WD 15.6 4WD 16.3 13211-28110-A0 13211-28110-B0 13211-28110-C0 13211-28111-A0 13211-28111-B0 13211-28111-C0 13211-28112-A0 13211-28112-B0 13211-28112-C0 Matrix EG9014 R & R Piston and Ring Set RAV4 2AZ-FE Solara – 16.3 T1 T2 11 99 13211-0H040-A0 13211-0H040-B0 13211-0H040-C0 13211-0H041-A0 13211-0H041-B0 13211-0H041-C0 APPLICABLE WARRANTY • This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date. • Warranty application is limited to occurrence of the specified condition described in this bulletin. Parts Information Required Kit Part Numbers MODEL KIT PART NUMBER KIT PART NAME* Camry 04004-11228 1 Camry HV 04004-11428 1 Corolla 04004-11628 Matrix 04004-11728 RAV4 04005-42128 1 Solara 04004-12228 1 QTY 1 Repair Kit, Piston Ring 1 * See Kit Contents table for individual parts included in each kit. Additional Required Parts MODEL PART NUMBER PART NAME QTY ALL 90915-YZZF1 Filter, Oil 1 ALL (except Camry HV) 04004-79128-#0 Piston 4 © 2015 Toyota Motor Sales, USA Rev1 T-SB-0030-15 May 26, 2015 Page 4 of 28 2AZ Engine Oil Consumption Repair Procedure Parts Information (Continued) MODEL PART NUMBER PART NAME QTY Camry HV 13211-28150-#0 Piston 4 17177-28040 Gasket, Intake Manifold to Head 1 17171-28020 Gasket, Intake Manifold to Exhaust Manifold Intake Runner 1 Camry (PZEV Only) Additional Parts: Only As Needed PART NUMBER PART NAME MODEL 13251-0H030-#0 ALL QTY NEW PREVIOUS 13201-09790-#0 13201-09791-#0 Pin, Piston 13201-29686-#0 As Needed Rod Sub-assy, Connecting 13201-29686-#0 13281-0H031-0# Bearing, Connecting Rod 8 (if Needed) Kit Contents NOTE This is NOT a list of individual parts to order for this Repair Procedure. This is only a list of parts included in the required kit. Please consult the above required parts sections for ordering details. MODEL KIT PART NUMBER Camry Camry HV Corolla Matrix RAV4 Solara 04004-11228 04004-11428 04004-11628 04004-11728 04005-42128 04004-12228 PART NUMBER PART NAME 13011-28260 Ring Set, Piston 1 1 1 1 1 1 15708-28011 Nozzle Sub-assy, Oil, No.1 4 4 4 4 4 4 11115-28040 Gasket, Cylinder Head 1 1 1 1 1 1 11213-28021 Gasket, Cylinder Head Cover 1 1 1 1 1 1 12157-10010 Gasket (for Transfer Drain Plug) / Gasket, No. 2 (for Transfer Case) – – – 2 2 – 13552-28010 Gasket (for Chain Tensioner) 1 1 1 1 1 1 16258-28040 Gasket (for Oil Cooler Pipe Union Bolt) 1 – 1 – – – 17173-28010 Gasket, Exhaust Manifold 1 1 1 1 1 1 QUANTITY (per Kit) 17177-28031 1 1 1 1 1 1 1 – – – – – – – 1 1 1 – 1 1 – – – 1 Gasket, Intake Manifold to Head 17177-28040 17451-28070 Gasket, Exhaust Pipe 90917-06090 © 2015 Toyota Motor Sales, USA Rev1 T-SB-0030-15 May 26, 2015 Page 5 of 28 2AZ Engine Oil Consumption Repair Procedure Parts Information (Continued) MODEL KIT PART NUMBER PART NUMBER PART NAME 94185-60800 Bolt (Front Exhaust Pipe No. 1 Support Bracket) Camry Camry HV Corolla Matrix RAV4 Solara 04004-11228 04004-11428 04004-11628 04004-11728 04005-42128 04004-12228 QUANTITY (per Kit) 90917-06078 2 2 – – – 2 – – 1 1 1 – 1 1 – – – 1 Gasket, Exhaust Pipe, Center 90917-06076 90177-22001 Nut (for Front Axle Shaft) 2 2 2 2 2 2 90119-10461 1 1 1 1 1 1 90901-19060 Bolt (for Drive Shaft Bearing Bracket Setting No. 1) – – – 1 – – 90311-38098 Seal, Oil (for Timing Chain Case) 1 1 1 1 1 1 90311-89010 Seal, Engine Rear Oil 1 1 1 1 1 1 90430-12031 Gasket (for Oil Pan Drain Plug) 1 1 1 1 1 1 90430-18008 Gasket, Drain Plug, etc. 2 3 2 2 1 2 – 1 – – – – 2 – 2 2 1 2 90468-04193 Clip (Transmission Control Cable) 90468-14016 90520-22025 Ring, Hole Snap (for Piston Pin) 8 8 8 8 8 8 90520-38015 Ring, Hole Snap (for Front Drive Shaft RH) 1 1 1 1 2 1 – – – – 1 – 1 1 1 1 1 1 – – 2 2 – – 2 2 – – 2 2 90520-33008 90521-33002 Ring, Hole Snap (for Front Drive Shaft LH) 95381-03020 Pin, Cotter (Tie Rod) 95381-03025 96721-19010 Ring, O (for Oil Level Gage Guide) 1 1 1 1 1 1 96761-24020 Ring, O (for Cylinder Block to Crankcase Stiffener) 1 1 1 1 1 1 G1917-32010 Ring, O (for Camshaft Timing Oil Control Valve) 1 1 1 1 1 1 © 2015 Toyota Motor Sales, USA Rev1 T-SB-0030-15 May 26, 2015 Page 6 of 28 2AZ Engine Oil Consumption Repair Procedure Required Tools & Equipment TOOLS & MATERIAL PART NUMBER QUANTITY Three Bond 1324 or Equivalent – As Needed FIPG Sealant or Equivalent 00295-00103 As Needed Super Long Life Coolant (SLLC) 00272-SLLC2 6.6 U.S. qts. (6.2 liters) – Camry, Camry HV, RAV4, Solara 4.5 U.S. qts. (4.3 liters) – Corolla, Matrix 4.0 U.S. qts. (3.8 liters) ILSAC GF-4 Multi-grade SAE 0W-20 or 5W-20 Green Plastigage™ – As Needed Cylinder Ridge Reamer – 1 Torque Yield Wrench – 1 Precision Straight Edge – 1 Piston Heater – 1 Piston Ring Compressor – 1 Torque Wrench – 1 Large Brass Punch – 1 Piston Ring Expander – 1 Thread Chaser – 1 Feeler Gauge – 1 Caliper Gauge – 1 Micrometer – 1 Vernier Caliper – 1 Engine Stand – 1 SPECIAL SERVICE TOOLS (SST) PART NUMBER QTY Gasket Seal Cutter 09032-00100 1 NOTE Additional SSTs may be ordered by calling 1-800-933-8335. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 7 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure NOTE Verify that Service Bulletin No. T-SB-0158-14, “2AZ Engine Oil Consumption Inspection Procedure,” has been performed BEFORE continuing with this bulletin. Replace the piston and piston ring set. 1. Remove the engine assembly and place on an engine stand. Refer to the Technical Information System (TIS), applicable model and model year Repair Manual: NOTE Removal and replacement of automatic transmission fluid is unnecessary and is NOT covered under this bulletin. • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Removal” NOTE Removal of the oil cooler pipe (with oil cooler) is necessary, replacement gasket is included in parts kit. • 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV: Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical: Engine Assembly: Removal” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Removal” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Removal” • 2006 / 2007 / 2008 RAV4: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Removal” NOTE Do NOT remove No. 1 and No. 2 water by-pass pipes. Gaskets are NOT included in parts kits. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 8 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) • 2007 / 2008 Solara: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Removal” 2. Remove the cylinder head assembly. Refer to TIS, applicable model and model year Repair Manual: • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head: Removal” • 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV: Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical: Cylinder Head: Removal” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head Gasket: Removal” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head Gasket: Removal” • 2006 / 2007 / 2008 RAV4: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head: Removal” • 2007 / 2008 Solara: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Disassembly” 3. Remove the pistons from the connecting rods. A. Remove the oil pan drain plug and gasket. Figure 1. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 9 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) B. Remove the oil pan sub-assembly. (1) Remove the 12 bolts and 2 nuts. Figure 2. (2) Insert the blade of the Gasket Seal Cutter between the crankcase and oil pan. Cut through the sealer and remove the oil pan. Figure 3. SST: 09032-00100 NOTICE Be careful NOT to damage the contact surfaces of the crankcase, chain cover, and oil pan. 1 © 2015 Toyota Motor Sales, USA Gasket Seal Cutter T-SB-0030-15 Rev1 May 26, 2015 Page 10 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) C. Remove the engine rear oil seal. Figure 4. (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver (with a taped tip), pry out the oil seal. NOTICE After removing the oil seal, check the crankshaft for damage. If the crankshaft is damaged, smooth the surface with 400-grit sandpaper. 1 Cut Position D. Remove the stiffening crankcase assembly. NOTICE Remove the stiffening crankcase as a unit. Do NOT separate the halves of the assembly, exposing the balance shaft bearings. (1) Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. Figure 5. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 11 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (2) Using a screwdriver (with a taped tip), remove the crankcase by prying between the crankcase and cylinder block. Figure 6. NOTICE Be careful NOT to damage the contact surfaces of the crankcase and cylinder block. 1 (3) Remove the O-ring from the cylinder block. Protective Tape Figure 7. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 12 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) E. Remove the piston sub-assemblies with connecting rod. (1) Using a ridge reamer, remove all the carbon from the top of the cylinder. Figure 8. (2) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Figure 9. HINT The matchmarks on the connecting rods and caps are provided for ensuring correct reassembly. 1 (3) Using a 12 mm socket wrench, uniformly loosen the 2 bolts. Matchmark Figure 10. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 13 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (4) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by moving the connecting rod cap right and left. HINT Keep the lower bearing inserted in the connecting rod cap. (5) Inspect the connecting rod oil clearance. 1. Clean the crank pin and bearing. 2. Check the crank pin and bearing for pitting and scratches. 3. Lay a strip of Plastigage™ on the crank pin. Figure 11. 1 Plastigage™ 4. Check that the front mark of the connecting rod cap is facing forward. Figure 12. 1 © 2015 Toyota Motor Sales, USA Front Mark T-SB-0030-15 Rev1 May 26, 2015 Page 14 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) 5. Install and alternately tighten the bolts of the connecting rod cap in several steps. Figure 13. Torque: 25 N*m (250 kgf*cm, 18 ft*lbf) NOTE The connecting cap bolts should be tightened in 2 progressive steps. 6. Mark the front of the connecting rod cap bolts with paint. Retighten the cap bolts by 90◦ as shown in the illustration. Figure 14. 1 Paint Mark 2 90◦ 3 Engine Front © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 15 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) 7. Remove the 2 bolts and connecting rod cap. 8. Measure the Plastigage™ at its widest point. Standard Oil Clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 in.) Maximum Oil Clearance: 0.08 mm (0.0032 in.) If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. NOTE Completely remove the Plastigage™ after the measurement. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 16 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) HINT If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing’s standard thickness is indicated by a 1, 2, or 3 mark on its surface. Figure 15. Standard Connecting Rod Large End Bore Diameter: MARK SPECIFIED CONDITION Mark 1 51.000 to 51.007 mm (2.0079 to 2.0082 in.) Mark 2 51.008 to 51.013 mm (2.0082 to 2.0084 in.) Mark 3 51.014 to 51.020 mm (2.0084 to 2.0087 in.) Standard Connecting Rod Bearing Thickness: MARK SPECIFIED CONDITION Mark 1 1.485 to 1.488 mm (0.0585 to 0.0586 in.) Mark 2 1.489 to 1.491 mm (0.0586 to 0.0587 in.) Mark 3 1.492 to 1.494 mm (0.0587 to 0.0588 in.) Standard Crankshaft Pin Diameter: MARK SPECIFIED CONDITION Mark 1 Mark 2 47.990 to 48.000 (1.8894 to 1.8898 in.) Mark 3 © 2015 Toyota Motor Sales, USA 1 Plastigage™ 2 1, 2, or 3 Mark T-SB-0030-15 Rev1 May 26, 2015 Page 17 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (6) Push the piston, connecting rod assembly, and upper bearing through the top of the cylinder block. HINT • Keep the bearing, connecting rod, and cap together. • Arrange the piston and connecting rod assemblies in the correct order. (7) Repeat for the other 3 piston/connecting rod assemblies. F. Remove the connecting rod bearings. HINT Arrange the removed parts in the correct order. G. Inspect the cylinder bore for abnormal damage. Visually check the cylinder bore for the presence of crosshatch. • If the cylinder bore has visible crosshatch, the cylinder block is OK to re-use. • Confirm that only light vertical marks are present, if any. NOTE • It is normal for an in-service block to have light markings present from carbon and should NOT be interpreted as excessive cylinder wall scratches. • ONLY replace the short block if multiple, severe scratches are present. • Do NOT hone the cylinder walls. H. Using a screwdriver, pry out the 2 piston pin hole snap rings. Figure 16. HINT If necessary, sublet the following specialized and precision operations to a local engine machining shop. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 18 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) I. Remove the piston. (1) Gradually heat the piston to approximately 176◦ to 194◦F (80◦ to 90◦C). Figure 17. HINT If necessary, sublet the following specialized and precision operations to a local engine machining shop. (2) Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. Figure 18. NOTICE • The piston, pin and connecting rod are a matched set. • Arrange the pistons, pins, rings, connecting rods, and bearings in the correct order. For additional information, refer to TIS, applicable model and model year Repair Manual: • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Disassembly” • 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV: Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical: Engine Unit: Disassembly” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Disassembly” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Block: Disassembly” © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 19 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Disassembly” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Block: Disassembly” • 2006 / 2007 / 2008 RAV4: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Disassembly” • 2007 / 2008 Solara: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Disassembly” 4. Inspect piston, pin, connecting rod and bearings to determine replacement part numbers and measure to determine if parts are suitable for re-use. NOTE The following steps are required to determine the correct replacement part numbers. HINT If necessary, sublet the following specialized and precision operations to a local engine machining shop. © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 20 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) Figure 19. A. Inspect the piston bore diameter mark located on the top face in order to determine correct replacement parts. Piston type will be: A, B, or C. A B NOTE Due to carbon build up, piston face may need to be cleaned before reading designated piston type. If piston type cannot be found, reference connecting rod. 1 2 PART NUMBER CAMRY, COROLLA, MATRIX, RAV4, SOLARA CAMRY HV 04004-79128-A0 13211-28150-A0 04004-79128-B0 13211-28150-B0 04004-79128-C0 13211-28150-C0 2 3 NOTE Although B” pistons are the most commonly used in production, any engine can have any combination of all 3 pistons (A, B, C). The approximate production mix for pistons is as follows: A = 4%, B = 92%, C = 4%. A TMMK Made B TMC Made 1 Front Mark 2 Piston Pin Bore Diameter Mark 3 Connecting Rod © 2015 Toyota Motor Sales, USA 1 T-SB-0030-15 Rev1 May 26, 2015 Page 21 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (1) Using a micrometer, measure the piston pin diameter. Figure 20. Standard Piston Pin Diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) Ensure the connecting rod small end bore diameter measurement is within specification for the piston bore diameter mark inspected previously. If the diameter is NOT as specified, replace the piston pin. 1 NOTE Piston pin type is a matched set with the piston and connecting rod. For example: if the piston removed has a "B" marking, the piston pin diameter should be 22.001 - 22.003 mm 2 1 1 5 mm (0.20 in.) 2 30 mm (1.18 in.) PART NUMBER SPECIFIED CONDITION 13251-0H030-A0 21.997 to 22.000 mm (0.8660 to 0.8661 in.) 13251-0H030-B0 22.001 to 22.003 mm (0.8662 to 0.8663 in.) 13251-0H030-C0 22.004 to 22.006 mm (0.8663 to 0.8664 in.) © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 22 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (2) Using a caliper gauge, measure the connecting rod small end bore diameter. Figure 21. Standard Connecting Rod Small End Bore Diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Ensure the connecting rod small end bore diameter measurement is within specification for the piston bore diameter mark inspected previously. If the diameter is NOT as specified, replace the piston pin. NOTE Connecting Rod type is a matched set with the piston and piston pin. For example: if the piston removed has a "B" marking, the connecting rod small end bore diameter should be 22.009 - 22.011 mm. PART NUMBER SPECIFIED CONDITION PREVIOUS NEW 13201-09790-A0 13201-29686-A0 22.005 to 22.008 mm (0.8663 to 0.8665 in.) 13201-09790-B0 13201-29686-B0 22.009 to 22.011 mm (0.8665 to 0.8666 in.) 13201-09790-C0 13201-29686-C0 22.012 to 22.014 mm (0.8666 to 0.8667 in.) B. Inspect the connecting rod bolt. Figure 22. Using vernier calipers, measure the tension portion diameter of the bolt. Standard Diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum Diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the connecting rod bolt. For additional information, refer to TIS, applicable model and model year Repair Manual: • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Inspection” © 2015 Toyota Motor Sales, USA Rev1 T-SB-0030-15 May 26, 2015 Page 23 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) • 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV: Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical: Engine Unit: Inspection” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Block: Inspection” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Block: Inspection” • 2006 / 2007 / 2008 RAV4: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Inspection” • 2007 / 2008 Solara: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Inspection” 5. Install the NEW pistons and rings and reassemble the engine in reverse order of disassembly. NOTE 3 piece oil control ring installation procedure is NOT included in the Repair Manual. Follow the steps below to install the piston rings and refer to the repair manual for all other reassembly steps. A. Install Piston Ring Set. Figure 23. 1 2 3 1 Upper Oil Ring Side Rail 2 Oil Ring Expander 3 Lower Oil Lower Oil Ring Side Rail © 2015 Toyota Motor Sales, USA Rev1 T-SB-0030-15 May 26, 2015 Page 24 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (1) Install the oil ring expander and 2 oil ring side rails by hand. NOTE When installing oil expander ring, do NOT overlap the ends. Figure 24. 1 2 3 4 5 1 Push Oil Ring Expander Surface Into Piston With Thumb 2 Normal Condition 3 Align End of Ring © 2015 Toyota Motor Sales, USA 4 NG Condition 5 Do NOT Overlap T-SB-0030-15 Rev1 May 26, 2015 Page 25 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (2) Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring with the code mark positioned as shown in the illustration. Figure 25. NOTE Install the No. 2 compression ring with the code mark facing upward. 3 1 2 A A Code Mark 1 No. 1 Compression Ring 2 No. 2 Compression Ring 3 Upward © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 26 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) (3) Position the piston rings so that the ends are as shown in the illustration. Figure 26. A 3 1 5 7 6 2 4 B 3 1 5 7 2 6 4 A TMC Made B TMMK Made 1 No. 1 Compression Ring 2 No. 2 Compression Ring 3 Oil Ring Expander 4 Upper Side Rail – Oil Control Ring 5 Lower Side Rail – Oil Control Ring 6 Front Mark 7 Front Side © 2015 Toyota Motor Sales, USA T-SB-0030-15 Rev1 May 26, 2015 Page 27 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) B. Install the NEW pistons and reassemble the engine in reverse order of disassembly. For additional information, refer to TIS, applicable model and model year Repair Manual: • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Reassembly” • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head: Installation” • 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV: Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical: Engine Unit: Reassembly” • 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV: Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical: Cylinder Head: Installation” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Block: Reassembly” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Reassembly” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head Gasket: Installation” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Block: Reassembly” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Reassembly” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head Gasket: Installation” • 2006 / 2007 / 2008 RAV4: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Reassembly” • 2006 / 2007 / 2008 RAV4: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder Head: Installation” © 2015 Toyota Motor Sales, USA Rev1 T-SB-0030-15 May 26, 2015 Page 28 of 28 2AZ Engine Oil Consumption Repair Procedure Repair Procedure (Continued) • 2007 / 2008 Solara: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Unit: Reassembly” 6. Install the engine assembly. Refer to TIS, applicable model and model year Repair Manual: • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Installation” • 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV: Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical: Engine Assembly: Installation” • 2009 / 2010 / 2011 Corolla: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Installation” • 2009 / 2010 / 2011 / 2012 / 2013 Matrix: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Installation” • 2006 / 2007 / 2008 RAV4: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Installation” • 2007 / 2008 Solara: Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine Assembly: Installation” 7. Test drive the vehicle to verify normal operation. © 2015 Toyota Motor Sales, USA