TOYOTA AVENSIS 2005 Service Repair Manual

A59623
Intake Side:
Front Side:Exhaust Side:
Rear Side:
1.5 mm2.0 mm 2.0 mm
A
B
A 1.5 mm
B 2.0 mm
A
A
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±53
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
21. INSTALL TIGHT PLUG
(a) Apply adhesive around tight plugs.
Adhesive: Part No.08833 ± 00070, THREE BOND 1324
or equivalent.
(b) Using SST, tap to the tight plugs as shown tn the illustra-
tion.
SST 09950±60010 (09951±00350), 09950±70010
(09951±07100)
Standard depth:
Intake side: 2.0 mm (0.0787 in.)
Exhaust side: 2.0 mm (0.0787 in.)
Front side: 1.5 mm (0.0590 in.)
Rear side A: 1.5 mm (0.0590 in.)
B: 2.0 mm (0.0787 in.)

A56687
Cylinder Head Side: Lower Side:
Front Side:
A
B 11 m m20 mm
14 mm 8 mm
AAAA
B B
14±54
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
22. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap in new ring pins to the
specified protrusion height.
Protrusion height:
A: 7.0 mm (0.2755 in.)
B: 13 mm (0.5118 in.)

A56688
10 mm
22 mm7 mm
14 mm
11 m m
ABRear Side: Exhaust Side:
7 mm
C
B
A
C
A56689
Rear Side: Lower Side:
A
B
23 mm
A (M6)
B (M6)28 mm
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±55
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
23. INSTALL STRAIGHT PIN
(a) Using a plastic±faced hammer, tap in the straight pin.
Standard protrusion:
A: 13 mm (0.5118 in.)
B: 7.0 mm (0.2755 in.)
C: 5.0 mm (0.1968 in.)
24. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.

A09473
Hexagon
Wrench (6 mm)
A09503
A56044
A56045
A09510Groove
14±56
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
25. INSTALL CYLINDER BLOCK OIL ORIFICE
(a) Using a hexagon wrench (6 mm), install the oil orifice.
Torque: 9.0 N
m (92 kgf
cm, 78 in.
lbf)
26. INSTALL SUB±ASSY OIL NOZZLE NO.1
(a) Install the oil nozzle with the bolt. Install the 4 oil nozzles.
Torque: 7.4 N
m (76 kgf
cm, 67 in.
lbf)
27. INSTALL CRANKSHAFT
(a) Install the bearing on the cylinder block and bearing cap.
HINT:
Upper bearings have an oil groove and oil holes; lower bearings
do not.
(1) Align the bearing claw with the claw groove of the
cylinder block, and push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the
main bearing cap, and push in the 5 lower bearings.
(b) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.

A09512
Groove
A56048
A09497
A56046
A09506
Front Mark
(Arrow)
Front Mark
(Protrusion)
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±57
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.
(d) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and a font mark.
(e) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(f) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several passes.
Torque: 115 N
m (1,173 kgf
cm, 85 ft
lbf)
(g) Check that the crankshaft turns smoothly.
28. INSTALL W/PIN PISTON SUB±ASSY
(a) Install a new snap ring on one side of the piston pin hole.
(b) Gradually heat the piston to 60
C (140
F).
(c) Coat the piston pin and piston hole of the piston with en-
gine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin by hand.
(e) Install a new snap ring on the other side of the piston pin
hole.

A09508
A56047
Coil Joint
Oil Ring End
A09458
No.1
No.2Code Mark
Code Mark
A09507
Front
Mark
(Arrow)No.1
Compression
Ring
Oil Ring
No.2
Compression
Ring
Coil
14±58
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
29. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
30. INSTALL PISTON RING SET
(a) Install the coil by hand.
(b) Using a piston ring expander, install the oil ring.
HINT:
Face the end gap of the oil ring in the opposite direction coil
joint.
(c) Using a piston ring expander, install the No. 2 and No. 1
piston rings with the code mark facing upward.
Code mark:
No.11T
No.22T
NOTICE:
Make the expansion of the piston ring as small as neces-
sary.
(d) Position the piston rings so that the ring ends are as
shown.
31. INSTALL PISTON SUB±ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and sur-
faces of connecting rod bearings.
(b) Check the position of the piston ring ends.

A09511
Front Mark
(Arrow)
Front
Push
A09514
Front Mark
(Protrusion)
A09493
90

90

A09490
Painted Mark
Front
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±59
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
(d) Match the numbered connecting rod cap with the con-
necting rod.
(e) Install the connecting rod cap with the front mark facing
forward.
(f) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(g) Install and alternately tighten the 2 cap bolts in several
passes.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
If any of the cap bolts does not meet the torque specification,
replace the connecting rod cap bolts.
(h) Mark the front of the cap bolt with the paint.
(i) Retighten the cap bolts 90
as shown.
(j) Check that the painted mark is now at a 90
angle to the
front.
(k) Check that the crankshaft turns smoothly.

140DR±03
A56671
SST
A62594
SST
A09561
A09676
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±23
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
2. REMOVE INTAKE VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring and valve.
3. REMOVE EXHAUST VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring and valve.
4. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle±nose pliers, remove the oil seal.
5. REMOVE VALVE SPRING SEAT PLATE WASHER
(a) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.

A62595
A56049
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A09534
14±24
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
6. REMOVE SEMICIRCULAR PLUG
7. REMOVE W/HEAD TAPER SCREW PLUG NO.1
(a) Using a hexagon wrench (6mm), remove the 3 plugs.
SST 99999±70037
8. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side0.08mm (0.0031in.)
Intake manifold side0.20mm (0.0079in.)
Exhaust manifold side0.20mm (0.0079in.)
9. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using dye penetrant, check the intake ports, exhaust
ports and cylinder block contact surface for cracks.

EM2534
Z00052
A56051
Margin
Thickness
EM2534
Z00052
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±25
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
10. INSPECT INTAKE VALVE
(a) Check the valve overall length.
Standard overall length: 102.53 mm (4.0366 in.)
Minimum overall length: 102.10 mm (4.0197 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
(c) Check the valve head margin thickness.
Standard margin thickness: 0.9 mm (0.035 in.)
Minimum margin thickness: 0.6 mm (0.0247 in.)
11. INSPECT EXHAUST VALVE
(a) Check the valve overall length.
Standard overall length: 101.97 mm (4.0146 in.)
Minimum overall length: 101.55 mm (3.9980 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.960 ± 5.975 mm (0.2346 ± 0.2352 in.)