TOYOTA AVENSIS 2003 Service Repair Manual

0214A±01
±
PREPARATION ENGINE MECHANICAL
02±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
ENGINE MECHANICAL
PREPARATION
SST
09011±3812112 mm Socket Wrench for 12
Pointed HeadCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09032±00100Oil Pan Seal CutterPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09201±01055Valve Guide Bushing Remover &
Replacer 5.5CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09201±10000Valve Guide Bushing Remover &
Replacer SetCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09201±41020Valve Stem Oil Seal ReplacerCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09202±70020Valve Spring CompressorCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09202±00010)AttachmentCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09205±16010Cylinder Head Bolt WrenchCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09222±30010Connecting Rod Bushing Remover
& ReplacerCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09223±15030Oil Seal & Bearing ReplacerPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09223±22010Crankshaft Front Oil Seal
ReplacerPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09228±06501Oil Filter WrenchPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
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02±2
±
PREPARATION ENGINE MECHANICAL
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
09950±70010Handle SetPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09951±07100)Handle 100PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09960±10010Variable Pin Wrench SetPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
(09962±01000)Variable Pin Wrench Arm AssyPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
(09963±01000)Pin 10PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
Recomended Tools
09040±00011Hexagon Wrench SetPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09043±20100)Socket Hexagon Wrench 10CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09043±20120)Socket Hexagon Wrench 12PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
(09043±20100)Socket Hexagon Wrench 10CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09043±50100Bi±hexagon Wrench 10 mmPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
08826±00100ºSeal Packing 1282B,º
THREE BOND 1282B or equivalent
(FIPG)PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
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±
PREPARATION ENGINE MECHANICAL
02±3
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
08833±00070ºAdhesive 1324,º
THREE BOND 1324 or equivalentCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
Equipment
Wooden block
Spring tension gauge
Vernier calipers
V±block
Dial indicator
Micrometer
Torque wrench
Heater
Precision straight edge
Feeler gauge
Caliper gauge
Steel square
Plastigage
Valve seat cutter
Ride reamer
Piston ring expander
Plastic hammer
Cylinder gauge
Connecting rod aligner
Piston ring compressor
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02148±01
±
PREPARATION STARTING & CHARGING
02±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
STARTING & CHARGING
PREPARATION
SST
09286±46011Injection Pump Spline Shaft
PullerGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
09820±63010Alternator Pulley Set Nut Wrench
SetGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09820±06010)Alternator Rotor Shaft WrenchGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09820±06020)Alternator Pulley Set Nut 22 mm
WrenchGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
Recomended Tools
09011±12291Socket Wrench for 29 mm .GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
09082±00040TOYOTA Electrical TesterSTARTER ASSY
(1ZZ±FE/3ZZ±FE)
GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetSTARTER ASSY
(1ZZ±FE/3ZZ±FE)
GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
Equipment
Ohmmeter
Sandpaper
V±block
Dial indicator
Vernier calipers
Plastic hammer
Torque wrench
Wooden block
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0300O±02
03±4
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
ENGINE MECHANICAL
SERVICE DATA
Chain sub±assy
Length at 16 links Maximum
112.6 mm (4.433 in.)
Camshaft timing gear or sprocket
Diameter (w/ chain) Minimum
97.3 mm (3.831 in.)
Crankshaft timing gear or sprocket
Diameter (w/ chain) Minimum
51.6 mm (2.032 in.)
Chain tensioner slipper
Wear Maximum
1.0 mm (0.039 in.)
Chain vibration damper No. 1
Wear maximum
1.0 mm (0.039 in.)
Cylinder head set bolt
Length Standard Maximum
156.0 ± 159.0 mm (6.142 ± 6.260 in.)
159.5 mm (6.280 in.)
Camshaft
Circle runout Maximum
Lobe height Standard Intake
Exhaust
Minimum Intake Exhaust
Journal diameter No. 1 Others
Thrust clearance Standard
Maximum
Oil clearance Standard Maximum
0.03 mm (0.0012 in.)
44.333 ± 44.433 mm (1.7454 ± 1.7493 in.)
43.761 ± 43.861 mm (1.7229 ± 1.7268 in.)
44.18 mm (1.7394 in.)
43.61 mm (1.7169 in.)
34.449 ± 34.465 mm (1.3563 ± 1.3569 in.)
22.949 ± 22.965 mm (0.9035 ± 0.9041 in.)
0.040 ± 0.095 mm (0.0009 ± 0.0023 in.)
0.110 mm (0.0043 in.)
0.035 ± 0.072 mm (0.0014 ± 0.0028 in.)
0.10 mm (0.0039 in.)
Valve clearance (Cold) Intake
Exhaust0.15 ± 0.25 mm (0.006 ± 0.010 in.)
0.25 ± 0.35 mm (0.010 ± 0.014 in.)
Cylinder head sub±assy
Warpage Maximum Cylinder block side Intake manifold side
Exhaust manifold side
0.05 mm (0.0020 in.)
0.10 mm (0.0040 in.)
0.10 mm (0.0040 in.)
Valve guide bushing
Inside diameter
Oil clearance Standard Intake Exhaust
Maximum Intake Exhaust
Bore diameter
Protrusion height
5.510 ± 5.530 mm (0.2169 ± 0.2177 in.)
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
0.08 mm (0.0031 in.)
0.01 mm (0.0039 in.)
10.285 ± 10.306 mm (0.4049 ± 0.4057 in.)
8.7 ± 9.1 mm (0.342 ± 0.358 in.)
Valve stem
Diameter Intake Exhaust
5.470 ± 5.485 mm (0.2154 ± 0.2159 in.)
5.465 ± 5.480 mm (0.2152 ± 0.2158 in.)
Inner compression spring
Free length
Deviation Maximum
Angle (reference) Maximum
43.40 mm (1.7087 in.)
2.0 mm (0.078 in.)
2

Valve
Overall length Standard Intake
Exhaust
Minimum Intake Exhaust
Head margin thickness Standard
Minimum
88.65 mm (3.4902 in.)
88.69 mm (3.4917 in.)
88.35 mm (3.4874 in.)
88.39 mm (3.4799 in.)
1.0 mm (0.039 in.)
0.7 mm (0.028 in.)
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±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
Valve lifter
Diameter
Bore diameter
Oil clearance Standard
Maximum
30.966 ± 30.976 mm (1.2191 ± 1.2195 in.)
31.000 ± 31.025 mm (1.2205 ± 1.2215 in.)
0.024 ± 0.059 mm (0.0016 ± 0.0037 in.)
0.1 mm (0.0039 in.)
Straight pin
Protrusion height
5 mm (0.20 in.)
Union protrusion
Protrusion height Standard A B
C
29 mm (1.14 in.)
66.5 mm (2.62 in.)
24 mm (0.95 in.)
Connecting rod sub±assy
Thrust clearance Standard Maximum
Oil clearance Standard Maximum
Out±of alignment Maximum per/100 mm (3.94 in.)
Twist Maximum per/100 mm (3.94 in.)
0.160 ± 0.342 mm (0.063 ± 0.0135 in.)
0.342 mm (0.0135 in.)
0.028 ± 0.060 mm (0.0011 ± 0.0024 in.)
0.080 mm (0.0031 in.)
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
Connecting rod bearing
Center wall thickness Reference Mark 1 Mark 2
Mark 3
1.486 ± 1.490 mm (0.0585 ± 0.0587 in.)
1.490 ± 1.494 mm (0.0587 ± 0.0588 in.)
1.494 ± 1.498 mm (0.0588 ± 0.0590 in.)
Crankshaft
Thrust clearance StandardMaximum
Circle runout Maximum
Main journal diameter Maximum taper and out±of±round
Oil clearance Standard Maximum
0.04 ± 0.24 mm (0.0016 ± 0.0094 in.)
0.30 mm (0.0118 in.)
0.03 mm (0.0012 in.)
47.988 ± 48.000 mm (1.8893 ± 1.8898 in.)
0.02 mm (0.0008 in.)
0.013 ± 0.030 mm (0.0005 ± 0.0012 in.)
0.05 mm (0.0020 in.)
Cylinder block sub±assy
Warpage Maximum
Bore diameter StandardMaximum
0.05 mm (0.0020 in.)
79.000 ± 79.013 mm (3.1073 ± 3.1108 in.)
79.013 mm (3.1108 in.)
Piston
Diameter (at 29.8 mm (1.173 in.) from the piston head) 1ZZ±FE 3ZZ±FE
Oil clearance Standard 1ZZ±FE 3ZZ±FE
Maximum 1ZZ±FE
3ZZ±FE
78.925 ± 78.935 mm (3.1073 ± 3.1077 in.)
78.955 ± 78.965 mm (3.1085 ± 3.1089 in.)
0.065 ± 0.088 mm (0.0026 ± 0.0035 in.)
0.035 ± 0.058 mm (0.0014 ± 0.0023 in.)
0.088 mm (0.0035 in.)
0.058 mm (0.0023 in.)
Piston ring
Groove clearance No. 1 No. 2
End gap Standard No. 1 No. 2
Maximum No. 1
No. 2
0.020 ± 0.070 mm (0.0008 ± 0.0028 in.)
0.030 ± 0.070 mm
0.25 ± 0.35 mm (0.0098 ± 0.0138 in.)
0.35 ± 0.50 mm (0.0138 ± 0.0197 in.)
0.74 mm (0.029 in.)
0.89 mm (0.035 in.)
Piston pin
Diameter
20.004 ± 20.013 mm (0.7876 ±0.7879 in.)
Connecting rod bolt
Diameter Standard Maximum
6.6 ±6.7 mm (0.260 ± 0.264 in.)
6.4 mm (0.252 in.)
Crank pin
DiameterMaximum taper and out±of±round
43.992 ± 44.000 mm (1.7320 ± 1.7323 in.)
0.02 mm (0.0008 in.)
Crankshaft bearing cap set bolt
Diameter Standard Maximum
7.3 ± 7.5 mm (0.287 ± 0.295 in.)
7.2 mm (0.283 in.)
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03±6
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
Straight pin
Timing chain or belt cover sub±assy x cylinder block sub±assy
length 15 mm (0.59 in.)
length 12 mm (0.47 in.)
Transaxle housing x Cylinder block sub±assy
Cylinder head sub±assy x Cylinder block sub±assy
Crankshaft bearing cap sub±assy x Cylinder block sub±assy
Oil pump assy x Cylinder block sub±assy
Driveshaft bracket x Cylinder block sub±assy
5 mm (0.20 in.)
6 mm (0.24 in.)
12 mm (0.47 in.)
7 mm (0.28 in.)
7.5 mm (030 in.)
10 mm (0.39 in.)
8 mm (0.31 in.)
Connecting rod small end bush
Oil clearance
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
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0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Cylinder block water drain cock sub±assy x Cylinder block sub±assy\
2020415
Oil strainer sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan drain plug x Oil pan sub±assy3737727
Oil filter union x Cylinder block sub±assy3030622
Oil pump assy x Cylinder block sub±assy9.09280 in.
lbf
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Oil control valve filter x Cylinder head sub±assy3030622
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing gear or sprocket x Camshaft No. 25455140
Camshaft, Camshaft No. 2 x Cylinder head sub±assy Bearing cap No. 1
Bearing cap No. 323
13235
13317
10
Chain vibration damper No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block sub±assy9.09280 in.
lbf
Chain tensioner slipper x Cylinder block sub±assy1919414
Timing chain or belt cover sub±assy x Cylinder head sub±assy1313310
Timing chain or belt cover sub±assy x Cylinder block sub±assy M6
M813
19133
19410
14
Chain tensioner assy No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft pulley x Crankshaft1381,407102
Water pump assy x Cylinder block sub±assy1111 28
Water pump assy x Timing chain or belt cover sub±assy9.09280 in.
lbf
Cylinder head cover sub±assy x Cylinder head sub±assy w/o washer
w/ washer11
9.011 2 928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Spark plug x Cylinder head sub±assy2525518
Stud bolt
Timing chain or belt cover sub±assy x Cylinder head sub±assy
length 89 mm (3.50 in.)
length 53.5 mm (2.11 in.)
Cylinder head cover sub±assy x Cylinder head sub±assy
Intake manifold x Cylinder head sub±assy
Exhaust manifold x Cylinder head sub±assy
9.5
5.0
5.0
9.5
9.597
51
51
97
9784 in.
lbf
44 in.
lbf
44 in.
lbf
84 in.
lbf
84 in.
lbf
W/ Head taper screw plug No. 2 x Cylinder head sub±assy4444933
Crankshaft bearing cap sub±assy x Cylinder block sub±assy M10 1st
2nd3rd
M822
44
Turn 90
19224
449
Turn 90
19416
33
Turn 90
14
Connecting rod x Connecting rod cap 1st
2nd20
Turn 90
204
Turn 90
15
Turn 90

Stud bolt
Water by±pass pipe No. 1 x Cylinder block sub±assy
Water inlet x Cylinder block sub±assy
Oil strainer sub±assy x Cylinder block sub±assy
Oil pan sub±assy x Cylinder block sub±assy
Knock control sensor x Cylinder block sub±assy
5.0
5.0
5.0
5.0 1151
51
51
51
11 244 in.
lbf
44 in.
lbf
44 in.
lbf
44 in.
lbf
8
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030K5±01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess Bolt Stud Bolt
Weld BoltClass
4T
5T
6T
7T
8T
9T
10T 11 T
No Mark
w/ Washer No Mark
No Mark
w/ Washer
±
SERVICE SPECIFICATIONS STANDARD BOLT
03±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH
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030K7±01
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut Cold Forging Nut Cutting Processed Nut Class
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N
Old Standard Hexagon Nut
No Mark (w/ Washer)
No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
±
SERVICE SPECIFICATIONS STANDARD BOLT
03±3
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the \
greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
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