TOYOTA AVENSIS 2003 Service Repair Manual

A62801
793
481062
15
A01195
A32142
14±42
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
9. REMOVE CRANKSHAFT BEARING CAP SUB ASSY
(a) Remove the 10 bearing cap bolts.
(b) Uniformly loosen the 10 bearing cap sub±assy bolts, in several passes, in the sequence shown in the illustration.
SST 09011±38121
(c) Using a screwdriver, remove the bearing cap sub±assem- bly by prying the indicated portions between the cylinder
block and bearing cap sub±assembly. Remove the 5 low-
er main bearings.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and bearing cap sub±assembly.
10. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 ± 0.24 mm (0.0016 ± 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
(b) If the thrust clearance is greater than maximum, measure the thrust washer thickness. If the thickness is not speci-
fied, replace the thrust washer.
Thrust washer thickness:
2.430 ± 2.480 mm (0.0957 ± 0.0976 in.)
11. REMOVE CRANKSHAFT THRUST WASHER UPPER
(a) Remove the crankshaft thrust washer from the cylinder block.
12. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper main bearings and 2 thrust washers from the cylinder \
block.
NOTICE:
Arrange the main bearings and thrust washers in the correct order.
13. REMOVE CRANKSHAFT BEARING
(a) Remove the crankshaft bearing from the cylinder block.
14. REMOVE STUD BOLT
(a) Remove the 9 stud bolts from the cylinder block.
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A01169
A62802
Thrust Direction
Axial Direction
A
B 10 mm 10 mm
C
A62803
29.8 mm
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±43
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
16. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame- ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
79.000 ± 79.013 mm (3.1102 ± 3.1108 in.)
Maximum diameter: 79.013 mm (3.1108 in.)
If the diameter is greater than the maximum, replace the cylin-
der block.
17. INSPECT PISTON DIAMETER
(a) Using a micrometer, measure the piston diameter at a right angle to the piston pin hole, and at the piston of 29.8
mm (1.173 in.) from the piston head.
Piston diameter:
1ZZ±FE 78.925 ± 78.935 mm (3.1073 ± 3.1077 in.)
3ZZ±FE 78.955 ± 78.965 mm (3.1085 ± 3.1089 in.)
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A62804
A62805
A01171
A01170
14±44
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
18. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter\
measurement. Standard oil clearance:
1ZZ±FE 0.065 ± 0.088 mm (0.0026 ± 0.0035 in.)
3ZZ±FE 0.035 ± 0.058 mm (0.0014 ± 0.0023 in.)
Maximum oil clearance:
1ZZ±FE 0.088 mm (0.0035 in.)
3ZZ±FE 0.058 mm (0.0023 in.)
If the oil clearance is greater than maximum, replace all the 4 pistons. I\
f necessary, replace the cylinder block.
19. INSPECT CONNECTING ROD SUB±ASSY
(a) Using a connecting rod aligner and feeler gauge, checkthe connecting rod alignment.
(1) Check for out±of±alignment.
Maximum out±of alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out±of alignment is greater than maximum, replace the con-
necting rod assembly.
(2) Check for twist.
Maximum twist:
0.05mm (0.0020 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
20. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.
Ring groove clearance:
No. 1 0.020 ± 0.070 mm (0.0008 ± 0.0028 in.)
No. 2 0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
21. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bot- tom of the ring travel, that means 100 mm (3.94 in.) from
the top of the cylinder block.
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EM7639
EM0227
A01470
A11783
ZF6927
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±45
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1 0.25 ± 0.35 mm (0.0098 ± 0.0138 in.)
No. 2 0.35 ± 0.50 mm (0.0138 ± 0.0197 in.)
Maximum end gap:
No. 1 0.74 mm (0.029 in.)
No. 2 0.89 mm (0.035 in.)
22. INSPECT PISTON PIN
(a) Using a micrometer, measure the piston pin diameter. Piston pin diameter:
20.004 ± 20.013 mm (0.7876 ± 0.7879 in.)
NOTICE:
Push the piston pin into the matched piston.
23. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion diam- eter of the bolts.
Standard diameter:
6.6 ± 6.7 mm (0.260 ± 0.264 in.)
Maximum diameter: 6.4 mm (0.252 in.)
(b) If the diameter is less than minimum, replace the bolt.
24. INSPECT CRANKSHAFT
(a) Using a dial indicator and V±blocks, measure the circle runout, as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 in.)
(b) Using a micrometer, measure the diameter of each main journal at the points shown in the illustration.
Diameter: 47.988 ± 48.000 mm (1.8893 ± 1.8898 in.)
(c) Check each main journal for taper and out±of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
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ZF6928
A01194
A11780
Plastigage
A62801
793
481062
15
A62806
Paint Mark
Front 90


14±46
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration.
Diameter: 43.992 ± 44.000 mm (1.7320 ± 1.7323 in.)
(e) Check each crank pin for taper and out±of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
25. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier caliper, measure the tension portion diame- ter of the bolts.
Standard diameter: 7.3 ± 7.5 mm (0.287 ± 0.295 in.)
Minimum diameter: 7.2 mm (0.283 in.)
26. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Clean each main journal and bearing.
(b) Place the crankshaft on the cylinder block.
(c) Lay a strip of Plastigage across each journal.
(d) Using SST, tighten the bolts in several passes, in the se- quence shown, by the specified torque.
SST 09011±38121
Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)
(e) Mark the front of the bearing cap sub±assembly bolts with paint.
(f) Retighten the bearing cap sub±assy bolts by 90
as
shown in the illustration.
(g) Check that the painted mark is now at a 90
angle to the
front.
NOTICE:
Do not turn the crankshaft.
(h) Remove the bearing cap sub±assy.
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A11781
A62807
Mark 0, 1, 2,
3, 4, 5 or 6
Mark 0, 1,
2, 3, 4 or 5
Mark
0, 1, 2, 3, or 4
No. 1 No. 2
No. 3
No. 5 No. 6
No. 2
No. 5
No. 3 No. 1
No. 4
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±47
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
0.013 ± 0.030 mm (0.0005 ± 0.0012 in.)
Minimum oil clearance: 0.05 mm (0.0020 in.)
NOTICE:
Completely remove the plastigage
(j) If replacing a bearing, select a new one having the same number. If the number of the bearing cannot be deter-
mined, calculate the correct use bearing number by ad-
ding together the numbers imprinted on the cylinder block
and crankshaft, then select a new bearing having the cal-
culated number. There are 4 sizes of standard bearings,
marked º1º, º2º, º3º and º4º accordingly.
Cylinder block (A)
+
Crankshaft (B)
0±23±56±89±11
Use bearingº1ºº2ºº3ºº4º
HINT:
EXAMPLE:
Cylinder block º4º (A) + Crankshaft º3º (B) = Total number 7 (Use
bearing º3º)
ItemMarkmm (in.)
Cylinder block main journal bore diameter (A)
º0º
º1º
º2º
º3º
º4º
º5º
º6º52.000 ± 52.003 (2.0472 ± 2.0473)
52.003 ± 52.005 (2.0473 ± 2.0474)
52.005 ± 52.007 (2.0474 ± 2.0475)
52.007 ± 52.010 (2.0475 ± 2.0476)
52.010 ± 52.012 (2.0476 ± 2.0477)
52.012 ± 52.014 (2.0477 ± 2.0478)
52.014 ± 52.016 (2.0478 ± 2.0479)
Crankshaft main journal diameter (B)
º0º
º1º
º2º
º3º
º4º
º5º47.998 ± 48.000 (1.8897 ± 1.8898)
47.996 ± 47.998 (1.8896 ± 1.8897)
47.994 ± 47.996 (1.8895 ± 1.8896)
47.992 ± 47.994 (1.8894 ± 1.8895)
47.990 ± 47.992 (1.8893 ± 1.8894)
47.988 ± 47.990 (1.8892 ± 1.8893)
Standard bearing center wall thickness
º1º
º2º
º3º
º4º1.994 ± 1.997 (0.0785 ± 0.0786)
1.997 ± 2.000 (0.0786 ± 0.0787)
2.000 ± 2.003 (0.0787 ± 0.0789)
2.003 ± 2.006 (0.0789 ± 0.0790)
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A62883
AAB CD
ABC D
Upper side: Lower side: Intake side:
16.59 27.5
13
822.5 18.5
9 31.5 16
10
48
[mm]
A62884
Front side: Upper side:
A C
C
AB C 6
10
7
B
[mm]
14±48
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
27. INSTALL STUD BOLT
(a) Install the 9 stud bolt to the cylinder block. Torque:
Stud bolt A, B and C 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Stud bolt D 11 N
m (112 kgf
cm, 8 ft
lbf)
28. INSTALL RING PIN
(a) Using a plastic hammer, install the 5 ring pins to the cylinder block. Standard protrusion:
Ring pin A 6 mm (0.24 in.)
Ring pin B 10 mm (0.39 in.)
RIng pin C 7 mm (0.28 in.)
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A62885
Front side:
Rear side: Lower side:
Exhaust side:
5 7.5
812
AB CD [mm]
D
A
BC
A62809
Oil Hole
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±49
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
29. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, install the 9 straight pins to the cylinder block.
Standard protrusion:
Straight pin A 5 mm (0.20 in.)
Straight pin B 7.5 mm (0.30 in.)
Straight pin C 8 mm (0.31 in.)
Straight pin D 12 mm (0.47 in.)
30. INSTALL CONNECTING ROD SMALL END BUSH
(a) Align the oil hole of a new bushing with the one of the con-necting rod.
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A62800
SST
A36991
A01193
A62810
Front Mark
(Cavity)
(Protrusion)
A01192
14±50
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Using SST and a press, press into the small end bushing. SST 09222±30010
(c) After installing the bushing, check that the oil hole of the
connecting rod is aligned with the hole of the small end
bushing and that the oil clearance measured on both
sides of connecting rod are equal.
(d) Horn the connecting rod end bushing to obtain the stan- dard specified oil clearance.
Oil clearance: 0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
HINT:
When pushing the piston pin with engine oil applied into the
connecting rod with thumb, the piston pin is supposed to have
a little resistance to insert at normal room temperature.
31. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is aligned with the pin hole
cutout portion of the piston.
32. INSTALL W/PIN PISTON SUB±ASSY
(a) Gradually heat the piston to 80 ± 90
C (176±194
F).
(b) Align the front marks on the piston with connecting rod,
and push in the piston with your thumb.
33. INSTALL PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is aligned with the pin hole
cutout portion of the piston.
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A62811
Cord Mark
A62812
Upper Side Rail
Front Compression No. 2
Lower Side Rail
Compression No. 1
or Expander
A01188
A01190
A01189
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±51
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
34. INSTALL PISTON RING SET
HINT:
In case of reusing the piston rings, install them to the matched
pistons with the surfaces faced correctly.
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark (No.2 only): T or 2R
(c) Position the piston rings so that the ring ends are as shown.
35. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod and let not stick the oils and fats.
36. INSTALL CRANKSHAFT
(a) Install the upper bearing with an oil groove on cylinder block.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the bearing cap and let not stick the oils and fats.
(b) Install the lower bearing on the bearing cap sub±assy.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the bearing cap and let not stick the oils and fats.
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