Engine Oil Consumption TOYOTA 2AZ-FE

T-SB-0094-11 August 11, 2011
2AZ-FE Engine Oil Consumption
Service
Category Engine/Hybrid System
Section Lubrication 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 Corolla Engine(s): 2AZ

VDS(s): BE40E
2009 Matrix Engine(s): 2AZ

VDS(s): GE40E, KE40E, LE40E
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
Introduction
Some 2006 – 2011 model year vehicles equipped with the 2AZ-FE 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.
© 2011 Toyota Motor Sales, USA Page 1 of 24

T-SB-0094-11 August 11, 2011 Page 2 of 24
Production Change Information
This TSB applies to:

• ALL 2007 – 2008 MY Solara vehicles.
• Vehicles produced BEFORE the Production Change Effective VINs shown below.
MODEL DRIVETRAIN PLANT PRODUCTION CHANGE EFFECTIVE VIN
TMMK Line 1 4T1BE46K#9U402467

TMMK Line 2 4T1BE46K#9U916988
Camry 2AZ-FE
SIA 4T4BE46K#9R131092
Tsutsumi JTNBE46K#93174340
TMMK 4T1BB##K#BU138556
Camry HV 2AZ-FXE
Tsutsumi JTNBB##K#B3054292
NUMMI 1NXBE40E#9Z087463
Corolla
TMMC 2T1BE40E#9C026707
Matrix 2AZ-FE TMMC 2T1#E40E#9C010829
Tahara JTM#D3#V#85209466
RAV4
Shokki JTM#D3#V#86088135
Warranty Information
DRIVE-
OP CODE DESCRIPTION MODEL ENGINE TIME OFP T1 T2
TRAIN
Camry 2AZ-FE – 14.8 13211-#####-#0

Camry HV 2AZ-FXE – 15.5 13211-28120-#0
Corolla – 14.2
R & R Piston and 2WD 14.2

EG9014 Matrix 11 99
Ring Set 4WD 14.7
2AZ-FE 13211-#####-#0
2WD 15.6
RAV4
4WD 16.3
Solara – 16.3
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.
© 2011 Toyota Motor Sales, USA

Parts Information
PREVIOUS PART CURRENT PART

MODEL ENGINE PART NAME QTY
NUMBER NUMBER
11115-28040 Same Gasket, Cylinder Head 1

Gasket, Cylinder Head
11213-0H010 Same 1
Cover
13011-0H030 13011-0H031 Ring Set, Piston (NAP*) 1
13011-28160 13011-28161 Ring Set, Piston (CBU**) 1
15193-0H010 Same Gasket, Oil Pump 1
22271-0D051 Same Throttle Body Gasket 1
Camry, 90080-31073 Same Seal, Engine Rear Oil 1

Camry HV, Ring, Hole Snap (for
Corolla, 90520-A0004 Same 8
ALL Piston Pin)
Matrix,
RAV4, O-Ring, Cylinder Block to
96761-24020 Same 1
Solara Crankcase Stiffener
13251-0H030-#0 Same Pin, Piston As Needed
13201-09790-#0 Rod Sub-Assy,
Same As Needed
13201-29686-#0 Connecting
8
13281-0H030-0# Same Bearing, Connecting Rod
(As Needed)
Gasket, Exhaust Manifold
17173-0H020 17173-28010 1
to Head
90915-YZZF1 Same Filter, Oil 1
Camry, 13211-0H040-#0 13211-0H041-#0 Piston (NAP*) 4
Corolla,
Matrix, 13211-28110-#0
RAV4, 13211-28112-#0 Piston (CBU**) 4
13211-28111-#0
Solara
Camry 2AZ-FE
(Non-PZEV),
Corolla, Gasket, Intake Manifold
17177-0H010 Same 1
Matrix, to Head, No. 1
RAV4,
Solara
Gasket, Intake Manifold
17171-28020 Same to Exhaust Manifold 1
Camry 2AZ-FE (Intake Runner)
(PZEV) (PZEV)
Gasket, Intake Manifold
17177-28040 Same 1
to Head, No. 1

Parts Information (Continued)
PREVIOUS PART CURRENT PART

MODEL ENGINE PART NAME QTY
NUMBER NUMBER
13211-28120-#0 13211-28121-#0 Piston 4

Camry HV 2AZ-FXE Gasket, Intake Manifold
17177-0H010 Same 1
to Head, No. 1
* NAP engines have serial numbers starting with the numbers 7, 8, or 9.

** CBU engines have serial numbers starting with the letters H, J, K, or numbers between 0 – 6.
Figure 1. 2AZ-FE Engine Serial Number Location Figure 2. 2AZ-FXE Engine Serial Number Location
Required Tools & Equipment
TOOLS & MATERIAL PART NUMBER QUANTITY
Three Bond 1324 or Equivalent – As Needed

FIPG Sealant or Equivalent 08826-00080 As Needed
6.6 U.S. qts.
Super Long Life Coolant (SLLC) 00272-SLLC2
(6.2 liters)
Camry,
– Camry HV, 4.5 U.S. qts.
RAV4, (4.3 liters)
ILSAC GF-4 Multi-grade SAE 0W-20 or 5W-20 Solara
– Corolla, 4.0 U.S. qts.

Matrix (3.8 liters)
Green Plastigage™ – As Needed
Cylinder Ridge Reamer – 1
Torque Yield Wrench – 1
Precision Straight Edge – 1
Piston Heater – 1

Required Tools & Equipment (Continued)
TOOLS & MATERIAL PART NUMBER QUANTITY
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
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.

Inspection Procedure
NOTE
In some cases, a P030# (cylinder # misfire detected) DTC may also be set as a result of oil
consumption.
Perform an oil consumption test to determine the consumption rate.

1. Confirm the engine oil level is full.
2. Mark the oil dipstick to indicate the current level.
3. Replace the oil dipstick.
4. Mark the oil dipstick, oil drain plug, and oil fill cap to prevent/indicate tampering during the test.
HINT
Use tape, sealer, cable ties, or equivalent to mark the oil dipstick, oil drain plug, and oil fill cap.
5. Advise the customer to drive the vehicle normally for 1,200 miles and return for inspection.
6. Determine the quantity of oil that was consumed in 1,200 miles.
Was the oil level more than 1 quart low after 1,200 miles of normal driving?
• YES — Go to the Repair Procedure.
• NO — This TSB does NOT apply. Warranty guideline for acceptable oil consumption is
1 quart per 1,200 miles of operation. No warranty claim should be filed.

Repair Procedure
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:
• 2007 / 2008 / 2009 Camry:
Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical:
Engine Assembly: Removal”
• 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 Corolla / Matrix:
Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Engine
• 2006 / 2007 / 2008 RAV4:
Engine Assembly: Removal”
• 2007 / 2008 Solara:
2. Remove the cylinder head assembly.
Refer to TIS, applicable model and model year Repair Manual:
• 2007 / 2008 / 2009 Camry:
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”
Engine/Hybrid System – Engine Mechanical – “2AZ-FE Engine Mechanical: Cylinder
Head Gasket: Removal”
• 2006 / 2007 / 2008 RAV4:
Cylinder Head: Removal”
• 2007 / 2008 Solara:
Unit: Disassembly”

Repair Procedure (Continued)
3. Remove the pistons from the connecting rods.
A. Remove the oil pan drain plug and gasket. Figure 3.
B. Remove the oil pan sub-assembly.
(1) Remove the 12 bolts and 2 nuts. Figure 4.

(2) Insert the blade of the SST between the Figure 5.

crankcase and oil pan. Cut through the
sealer and remove the oil pan.
NOTICE
Be careful NOT to damage the contact
surfaces of the crankcase, chain
cover, and oil pan.
1 SST (P/N 09032-00100)
C. Remove the oil pump assembly by removing Figure 6.

the 3 bolts and gasket.

D. Remove the engine rear oil seal. Figure 7.
(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
E. 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 Figure 8.

in the sequence shown in the illustration.

(2) Using a screwdriver (with a taped tip), Figure 9.

remove the crankcase by prying between
the crankcase and cylinder block.
NOTICE
Be careful NOT to damage the contact
surfaces of the crankcase and cylinder
block.
1 Protective Tape
(3) Remove the O-ring from the cylinder Figure 10.

block.

F. Remove the piston sub-assemblies with connecting rod.
(1) Using a ridge reamer, remove all the Figure 11.

carbon from the top of the cylinder.
(2) Check that the matchmarks on the Figure 12.

connecting rod and cap are aligned to
ensure correct reassembly.
HINT
The matchmarks on the connecting
rods and caps are provided for
ensuring correct reassembly.
1 Matchmark
(3) Using a 12 mm socket wrench, uniformly Figure 13.

loosen the 2 bolts.

(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 14.
1 Plastigage™
4. Check that the front mark of the connecting rod cap is facing forward.
Figure 15.
1 Front Mark

5. Install and alternately tighten the bolts of the connecting rod cap in several steps.
Figure 16.
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 17.
1 Paint Mark
2 90◦
3 Engine Front

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.

HINT
Figure 18.
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.
Standard Connecting Rod Large End

Bore Diameter:
MARK SPECIFIED CONDITION
51.000 to 51.007 mm
Mark 1
(2.0079 to 2.0082 in.)
51.008 to 51.013 mm
Mark 2
(2.0082 to 2.0084 in.)
51.014 to 51.020 mm
Mark 3
(2.0084 to 2.0087 in.)
Standard Connecting Rod Bearing

Thickness:

1 Plastigage™
1.485 to 1.488 mm
Mark 1
(0.0585 to 0.0586 in.) 2 1, 2, or 3 Mark
1.489 to 1.491 mm
Mark 2
(0.0586 to 0.0587 in.)
1.492 to 1.494 mm
Mark 3
(0.0587 to 0.0588 in.)
Standard Crankshaft Pin

Diameter:
Mark 1
47.990 to 48.000
Mark 2
(1.8894 to 1.8898 in.)
Mark 3

(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.

G. Remove the connecting rod bearings.
HINT
Arrange the removed parts in the correct order.
H. Inspect the cylinder block for warpage. Figure 19.
Using a precision straightedge and feeler

gauge, measure the warpage of the surface
that is in contact with the cylinder head gasket.
Camry, Camry HV, Corolla, Matrix, RAV4, Solara:
Maximum Warpage: 0.05 mm (0.002 in.)
If the warpage is greater than the maximum,

replace the short block assembly.

I. Inspect the cylinder bore. Figure 20.
Visually check the cylinder bore for the

presence of crosshatch and/or vertical
scratches.
• If the cylinder bore has visible crosshatch
and no vertical scratches, the cylinder
block is OK to re-use.
• If vertical scratches are present and
can be felt with a fingernail, or if the
crosshatch is not visible, replace the short
block assembly.
J. Using a screwdriver, pry out the 2 piston pin Figure 21.

hole snap rings.
HINT
If necessary, sublet the following
specialized and precision operations to a
local engine machining shop.
K. Remove the piston.
(1) Gradually heat the piston to Figure 22.

approximately 176 to 194◦F
(80 to 90◦C).

(2) Using a plastic hammer and brass bar, Figure 23.

lightly tap out the piston pin and remove
the connecting rod.
NOTE
• The piston and pin 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 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”
Block: Disassembly”
• 2006 / 2007 / 2008 RAV4:
Engine Unit: Disassembly”
• 2007 / 2008 Solara:
4. Measure and inspect the piston pin, connecting rod, and bearings to determine replacement part
numbers and 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.
A. Inspect the original piston pin oil clearance to determine the correct replacement piston
part number below.
(1) Using a caliper gauge, measure the Figure 24.

piston pin bore diameter.
Standard Piston Pin Bore Diameter:
22.001 to 22.010 mm (0.8662 to 0.8665 in.)
PART NUMBER
CAMRY, COROLLA, MATRIX, RAV4, SOLARA SPECIFIED CONDITION
CAMRY HV
NAP* CBU**
22.001 to 22.004 mm
13211-0H041-A0 13211-28112-A0 13211-28121-A0
(0.8662 to 0.8663 in.)
22.005 to 22.007 mm
13211-0H041-B0 13211-28112-B0 13211-28121-B0
(0.8663 to 0.8664 in.)
22.008 to 22.010 mm
13211-0H041-C0 13211-28112-C0 13211-28121-C0
(0.8665 to 0.8665 in.)
* NAP engines have serial numbers starting with the numbers 7, 8, or 9.

** CBU engines have serial numbers starting with the letters H, J, K, or numbers between 0 – 6.

Figure 25. 2AZ-FE Engine Serial Number Location Figure 26. 2AZ-FXE Engine Serial Number Location
(2) Using a micrometer, measure the piston Figure 27.

pin diameter.
Standard Piston Pin Diameter: 21.997 to
22.006 mm (0.8660 to 0.8664 in.)
If the diameter is NOT as specified,

replace the piston pin.
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.)

(3) Using a caliper gauge, measure the Figure 28.

connecting rod small end bore diameter.
Standard Connecting Rod Small End
Bore Diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
If the diameter is NOT as specified,

replace the connecting rod.
PART NUMBER SPECIFIED CONDITION
13201-09790-A0 22.005 to 22.008 mm (0.8663 to 0.8665 in.)

13201-09790-B0 22.009 to 22.011 mm (0.8665 to 0.8666 in.)
13201-09790-C0 22.012 to 22.014 mm (0.8666 to 0.8667 in.)
B. Inspect the connecting rod bolt. Figure 29.
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.
• 2007 / 2008 / 2009 Camry:
Engine Unit: Inspection”
• 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”
Block: Inspection”

• 2006 / 2007 / 2008 RAV4:

Engine Unit: Inspection”
• 2007 / 2008 Solara:
Unit: Inspection”
5. Install the new pistons and rings and reassemble the engine in reverse order of disassembly.
• 2007 / 2008 / 2009 Camry:
Engine Unit: Reassembly”
• 2007 / 2008 / 2009 Camry:
Cylinder Head: Installation”
• 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV:
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 Corolla / Matrix
Block: Reassembly”
Unit: Reassembly”
Head Gasket: Installation”
• 2006 / 2007 / 2008 RAV4:
Engine Unit: Reassembly”
• 2006 / 2007 / 2008 RAV4:
Cylinder Head: Installation”
• 2007 / 2008 Solara:
Unit: Reassembly”

6. Install the engine assembly.

Refer to TIS, applicable model and model year Repair Manual:
• 2007 / 2008 / 2009 Camry:
Engine Assembly: Installation”
• 2007 (to 10/06) / 2007 (10/06 & later) / 2008 / 2009 / 2010 / 2011 Camry HV:
Assembly: Installation”
• 2006 / 2007 / 2008 RAV4:
Engine Assembly: Installation”
• 2007 / 2008 Solara:
7. Test drive the vehicle to verify normal operation.

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T-SB-0094-11 August 11, 2011

2AZ-FE Engine Oil Consumption

Section Lubrication Market USA

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2007 – 2011 Camry HV Engine(s): 2AZ

2007 – 2009 Camry Engine(s): 2AZ

2009 Corolla Engine(s): 2AZ

2009 Matrix Engine(s): 2AZ

2006 – 2008 RAV4 Engine(s): 2AZ

2007 – 2008 Solara Engine(s): 2AZ

© 2011 Toyota Motor Sales, USA Page 1 of 24

2AZ-FE Engine Oil Consumption

Production Change Information

This TSB applies to:

TMMK Line 1 4T1BE46K#9U402467

Camry 2AZ-FE – 14.8 13211-#####-#0

R & R Piston and 2WD 14.2

• Warranty application is limited to occurrence of the specified condition described in this

© 2011 Toyota Motor Sales, USA

2AZ-FE Engine Oil Consumption

PREVIOUS PART CURRENT PART

11115-28040 Same Gasket, Cylinder Head 1

Camry, 90080-31073 Same Seal, Engine Rear Oil 1

© 2011 Toyota Motor Sales, USA

2AZ-FE Engine Oil Consumption

Parts Information (Continued)

PREVIOUS PART CURRENT PART

13211-28120-#0 13211-28121-#0 Piston 4

* NAP engines have serial numbers starting with the numbers 7, 8, or 9.

Required Tools & Equipment

TOOLS & MATERIAL PART NUMBER QUANTITY

Three Bond 1324 or Equivalent – As Needed

– Corolla, 4.0 U.S. qts.

© 2011 Toyota Motor Sales, USA

2AZ-FE Engine Oil Consumption

Required Tools & Equipment (Continued)

TOOLS & MATERIAL PART NUMBER QUANTITY

Piston Ring Compressor – 1

SPECIAL SERVICE TOOLS (SST) PART NUMBER QTY

Gasket Seal Cutter* 09032-00100 1

© 2011 Toyota Motor Sales, USA

2AZ-FE Engine Oil Consumption

Perform an oil consumption test to determine the consumption rate.

© 2011 Toyota Motor Sales, USA

2AZ-FE Engine Oil Consumption

Replace the piston and piston ring set.

© 2011 Toyota Motor Sales, USA

2AZ-FE Engine Oil Consumption

Repair Procedure (Continued)

3. Remove the pistons from the connecting rods.

A. Remove the oil pan drain plug and gasket. Figure 3.

B. Remove the oil pan sub-assembly.

(1) Remove the 12 bolts and 2 nuts. Figure 4.

© 2011 Toyota Motor Sales, USA

2AZ-FE Engine Oil Consumption

Repair Procedure (Continued)

(2) Insert the blade of the SST between the Figure 5.

1 SST (P/N 09032-00100)

C. Remove the oil pump assembly by removing Figure 6.

© 2011 Toyota Motor Sales, USA

Torque: 25 Nm (250 kgfcm, 18 ft*lbf)