TOYOTA AVENSIS 2003 Service Repair Manual

1509S±01
A78491
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Exhaust Pipe Assy Front
Compression Spring Floor Panel Brace Front


Exhaust Pipe
Gasket
43 (440, 32)

Exhaust Pipe Gasket
30 (302, 22)
43 (440, 32)Compression Spring
Exhaust Pipe Assy Tail
w/ HID Sensor:
Heated Oxygen Sensor
44 (449, 33)44 (449, 33)
RHD:
Front Floor Footrest
Clip
Floor Carpet Assy Front Heated Oxygen Sensor
w/o HID Sensor:
±
EXHAUST EXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
15±1
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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1509T±01
A78493
A78494
(c)
(d)
A78495
A78496
15±2
±
EXHAUSTEXHAUST PIPE ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR) (See page 76±32) 2. REMOVE HEATED OXYGEN SENSOR (W/O HIDSENSOR)
(a) Using a clip remover, remove the 2 clips.
(b) Open the floor carpet.
(c) Disconnect the heated oxygen sensor connector.
(d) Remove the grommet.
(e) Remove the heated oxygen sensor.
3. REMOVE HEATED OXYGEN SENSOR (W/ HID SENSOR)
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the heated oxygen sensor.
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A77865
A77866
(a)(a)
(b)(b)
(b)
±
EXHAUST EXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
15±3
AVENSIS REPAIR MANUAL (RM1018E)
4. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts, and then remove the floor panel
brace front.
5. REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 bolts and 2 compression springs.
(b) Remove the exhaust pipe tail from the 3 exhaust pipe supports.
(c) Remove the gasket from the exhaust pipe front.
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A78492
(a)(a)
(b)
(b)
A77857
A78440
New Gasket
15±4
±
EXHAUST EXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs.
(b) Remove the exhaust pipe front from the 2 exhaust pipe supports.
(c) Remove the gasket from the exhaust manifold.
7. INSTALL EXHAUST PIPE ASSY FRONT
(a) Compression spring inspection (1) Using vernier calipers, measure the free length ofthe compression spring.
Minimum length: 41.5 mm (1.634 in.)
If the free length is less than minimum, replace the compression
spring.
(b) Install a new gasket to the exhaust manifold as shown in the illustration.
(c) Install the exhaust pipe front to the 2 exhaust pipe sup-
ports.
(d) Tighten the 2 compression springs and 2 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
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A77857
A78440
New Gasket
±
EXHAUST EXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
15±5
AVENSIS REPAIR MANUAL (RM1018E)
8. INSTALL EXHAUST PIPE ASSY TAIL
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 38.5 mm (1.516 in.)
If the free length is less than minimum, replace the compression
spring.
(b) Install a new gasket to the exhaust pipe front as shown in the illustration.
(c) Install the exhaust pipe tail to the 3 exhaust pipe supports.
(d) Tighten the 2 compression springs and 2 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
9. INSTALL HEATED OXYGEN SENSOR (W/O HID SENSOR) Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)
10. INSTALL HEATED OXYGEN SENSOR (W/ HID SENSOR) Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)
11. CHECK FOR EXHAUST GAS LEAKS
12. INSTALL FLOOR PANEL BRACE FRONT
Torque: 30 N
m (302 kgf
cm, 22 ft
lbf)
13. INSTALL FRONT FLOOR FOOTREST (W/O HID SENSOR)
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160AO±01
B10233Hole
±
COOLING WATER PUMP ASSY (1ZZ±FE/3ZZ±FE)
16±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
WATER PUMP ASSY (1ZZ±FE/3ZZ±FE)
INSPECTION
1. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
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140KO±01
A62767
Compression Ring No.1Compression Ring No.2 Oil Ring (Side Rail)
 Snap Ring Piston
Piston Pin
Snap Ring
 Bush
Connecting Rod
Connecting Rod Bearing
Cylinder Block Sub±assy
Crankshaft BearingCrankshaft Bearing Cap Sub±assy
Crankshaft Bearing
Crankshaft Thrust Washer Upper
Key
Crankshaft
Connecting Rod Bearing
Connecting Rod Bearing Cap
Oil Ring (Expander)
See page 14±39
1st 44 (449, 33)
2nd Turn 90

See page 14±39
1st 20 (204, 15)
2nd Turn 90

19 (194, 14)
 Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
11 (112, 8)
5.0 (51, 44 in.
lbf)
Ring Pin
Straight Pin
Ring Pin
Straight Pin
Crankshaft
Thrust Washer Upper
Straight Pin
Ring Pin
Straight Pin
14±38
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
COMPONENTS
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140KP±01
A01155
A01156
A01159
Plastigage
A62797
Front
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±39
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.160 ± 0.342 mm (0.063 ± 0.0135 in.)
Maximum thrust clearance: 0.342 mm (0.0135 in.)
2. INSPECT CONNECTING ROD BEARING OIL CLEARANCE
NOTICE:
Do not turn the crankshaft.
(a) Using marking paint, write the matched cylinder number on each connecting rod and cap.
HINT:
The match marks on the connecting rods and caps are for en-
suring correct reassembly.
(b) Using SST, remove the 2 connecting rod cap bolts. SST 09205±16010
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of Plastigage across the crank pin.
(f) Check that the protrusion of the connecting rod cap is fac- ing in the correct direction.
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A01163
A62798
Paint Mark
90

Front
A01160
A62799
Mark
1, 2 or 3
A01166
14±40
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(g) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(h) Using SST, tighten the bolts in several passes by the spe-
cified torque.
SST 09205±16010
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(i) Mark the front of the connecting cap bolts with paint.
(j) Retighten the cap bolts by 90  as shown in the illustration.
(k) Check that the crankshaft turns smoothly.
(l) Remove the 2 bolts, connecting rod cap and lower bear- ing.
(m) Measure the Plastigage at its widest point. Standard oil clearance:
0.028 ± 0.060 mm (0.0011 ± 0.0024 in.)
Maximum oil clearance: 0.080 mm (0.0031 in.)
NOTICE:
Remove the Plastigage completely after the measurement.
(n) If replacing a bearing, select a new one having the same
number as marked on the connecting rod. There are 3
sizes of standard bearings, marked º1º, º2º and º3º ac\
-
cordingly.
Reference:
Standard bearing center wall thickness
Markmm (in.)
11.486 ± 1.490 (0.0585 ± 0.0587)
21.490 ± 1.494 (0.0587 ± 0.0588)
31.494 ± 1.498 (0.0588 ± 0.0590)
3. REMOVE PISTON SUB±ASSY W/CONNECTING ROD
(a) Using a ride reamer, remove all the carbon from the topof the cylinder.
(b) 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.
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A01175
A01192
A01179
A62800
SST
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±41
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
4. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearing from the connecting rod and crankshaft\
.
5. REMOVE PISTON RING SET
HINT:
Take care not to misplace the piston rings on both the match
with the piston and the direction of the rings.
(a) Using a piston ring expander, remove the 2 compressionrings.
(b) Remove the 2 side rails and oil ring by hand.
6. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
7. REMOVE W/PIN PISTON SUB±ASSY
(a) Gradually heat the piston to 80 ± 90 C (176 ± 194 F).
(b) Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Arrange the piston, pins, ring, connecting rod and bear-
ings in the correct order.
8. REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bushing. SST 09222±30010
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