compression ratio TOYOTA AVENSIS 2003 Service Service Manual

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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140KL±01
A62179
A62185
MarkMark
Mark Timing Chain
Cover Surface
Groove
14±4
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE OIL FILLER CAP SUB±ASSY
(a) Remove the oil filler cap from the cylinder head cover.
2. REMOVE OIL FILLER CAP GASKET
(a) Remove the gasket from the oil filler cap.
3. REMOVE VENTILATION VALVE SUB±ASSY
(a) Remove the ventilation valve from the cylinder head cover.
4. REMOVE SPARK PLUG
(a) Using a spark plug wrench, remove the 4 spark plugs.
5. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 9 bolts, 2 seal washer, 2 nuts and cylinder head cover.
6. REMOVE CYLINDER HEAD COVER GASKET
(a) Remove the gasket from the cylinder head cover. 7. REMOVE WATER PUMP ASSY
(a) Remove the 6 bolts, water pump and O±ring.
8. REMOVE CRANKSHAFT PULLEY
(a) Set No. 1 cylinder to TDC/compression.(1) Turn the crankshaft pulley, and align its groove with
timing mark º0º of the timing chain cover.
(2) Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line
on the timing chain cover surface as shown in the
illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
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A62190
Advance
Side Path
Retard Side
Path
Open
Close
Rubber
Vinyl Tape
Open Close
A62191
Advanced
Side Path
Retard
Side Path
A62192
Hold Pressure
Decompress Advanced
Side Path
Retard
Side Path
14±8
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
19. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Grip the camshaft with a vice, and confirm that the gear is locked.
CAUTION:
Be careful not to damage the camshaft.
(b) Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.
HINT:
Two advance side paths are provided in the groove of the cam-
shaft. Plug one of the path with a rubber piece.
(c) Break through the tapes of the advance side path and the retard side path on the opposite side of the groove.
(d) Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1.5 kgf/
cm
2}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.
(e) Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air
pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear revolves in
the advance direction.
(f) When the camshaft timing gear comes to the most ad- vanced position, take out the air pressure of the timing re-
tard side path, and then, takeout that of timing advance
side path.
CAUTION:
Camshaft timing gear assembly occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before retard side paths. It often
causes the breakage of the lock pin.
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A62825
62 4 8
51 3 7
11
10 9
A10079
Mark
A62170
Set KeyUpward
A62171
Yellow
Color Line
Timing Mark
A62172
SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±17
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(c) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 23 N
m (235 kgf
cm, 17 ft
lbf)
Bearing cap No. 3 13 N
m (133 kgf
cm, 10 ft
lbf)
55. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression. (1) Turn the hexagonal wrench head portion of thecamshafts, and align the point marks of the cam-
shaft timing gears.
(2) Using a crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
(b) Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
(c) Using a SST, install the sprocket. SST 09223±22010
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A62185
MarkMark
Mark Timing Chain
Cover Surface
Groove
A01131
A01132
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±21
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
64. INSPECT VALVE CLEARANCE
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley, and align its groove with
timing mark º0º of the timing chain cover.
(2) Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line
on the timing chain cover surface as shown in the
illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
(b) Check only the valves indicated. (1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust 0.25 ± 0.35 mm (0.010 ± 0.014 in.)
(c) Turn the crankshaft 1 revolution (360
) and set No. 4 cyl-
inder to TDC/compression.
(d) Check only the valves indicated. (1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust 0.25 ± 0.35 mm (0.010 ± 0.014 in.)
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A62186
Paint Mark
A62187
Fix
Tighten
A62188
24 5 3 1
A32124
A6218924 31
14±22
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
65. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the timing chain and camshaft tim- ing sprockets.
(c) Remove the 2 bolts and chain tensioner.
(d) Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.
(e) Loosen the camshaft bearing cap bolts on No. 2 camshaft in the order as shown in the illustration in several passes,
and remove the caps.
(f) Remove the camshaft timing gear as shown in the illustra- tion.
(g) Loosen the camshaft bearing cap bolts on camshaft in the order as shown in the illustration in several passes, and
remove the caps.
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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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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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A77392Seal Packing6mm
A64641
17±10
±
LUBRICATIONOIL PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
43.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
44. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
45.INSTALL CHAIN SUB±ASSY (See page 14±139)
46. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
47.INSTALL CHAIN TENSIONER SLIPPER (See page 14±139)
48.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±139)
49.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
50.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
51. INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b) Apply seal packing in the shape of bead (Diameter 3 to 4
mm (0.157 in.)) as shown in the illustration, and install the
oil pan.
Seal Packing: Part No. 08826 ± 00080 or equivalent
(c) Insert the oil pan with 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
52.INSTALL CRANKSHAFT POSITION SENSOR (See page 14±139)
53.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST 09213±54015 (91651±60855), 09330±00021
54.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
55. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
56.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
57.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
58. INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
59. INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
60. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
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A77392Seal Packing6mm
A64641
±
LUBRICATIONOIL PUMP ASSY(1AZ±FSE)
17±17
AVENSIS REPAIR MANUAL (RM1018E)
46.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
47.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
48.INSTALL CHAIN SUB±ASSY (See page 14±139)
49.INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
50.INSTALL CHAIN TENSIONER SLIPPER (See page 14±139)
51.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±139)
52.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
53.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
54.INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a)Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b)Apply seal packing in the shape of bead (Diameter 3 to 4
mm (0.157 in.)) as shown in the illustration, and install the
oil pan.
Seal Packing: Part No. 08826 ± 00080 or equivalent
(c)Insert the oil pan with 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
55.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
56.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST 09213±54015 (91651±60855), 09330±00021
57. INSTALL CHAIN TENSIONER ASSY NO.1
58. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
60.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
61. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
62. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
63. INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
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