TOYOTA AVENSIS 2003 Service Repair Manual

A01191
A01038
Seal Packing
A62801
793
481062
15
A62806
Paint Mark
Front 90

14±52
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(c) Install the 2 thrust washers under the No. 3 journal posi- tion of the cylinder block with the oil grooves facing out-
ward.
(d) Apply engine oil to upper bearing and install the crank- shaft on the cylinder block.
(e) Apply a light coat of engine oil on the bolt threads, the bolt seats, and the bearings of the bearing cap sub±assy.
(f) Apply seal packing in the shape of bead (Diameter 2.5 ± 3.5 mm (0.08 ± 0.12 in.) consequently as shown in the il-
lustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the bearing cap sub±assembly within 3 min-
utes after applying seal packing.

Do not put into engine oil within 2 hours after the
installation.
(g) 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)
(h) Mark the front of the bearing cap sub±assy bolts with paint.
(i) Retighten the bearing cap sub±assy bolts by 90  as
shown in the illustration.
(j) Check that the painted mark is now at a 90  angle to the
front.
(k) Tighten 10 other bolts for the bearing cap.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
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A62813
Front Mark
A62797
Front
A01163
A62798
Paint Mark
90

Front
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±53
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
37. INSTALL CONNECTING ROD SUB±ASSY
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(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) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.
NOTICE:

Clean the backside and the surface of the connecting
rod cap bearing and let not stick the oils and fats.

Match the numbered connecting rod cap with the
same numbered connecting rod.
(e) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(f) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(g) 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)
(h) Mark the front of the connecting cap bolts with paint.
(i) Retighten the cap bolts by 90  as shown in the illustration.
(j) Check that the crankshaft turns smoothly.
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140KM±01
A62766
Valve Lifter
Valve Spring Retainer Lock Valve Spring Retainer
Inner Compression Spring

Valve Stem Oil O Seal or Ring
Valve Spring Seat

Exhaust Valve Guide Bush
W/ Head Taper Screw Plug No. 2
Gasket
Intake Valve Exhaust ValveCylinder Head Sub±assy
Valve Lifter
Valve Spring Retainer Lock
Valve Spring Retainer
Inner Compression Spring

Valve Stem Oil O Seal or Ring
Valve Spring Seat

Intake Valve Guide Bush

Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque
44 (449, 33)
9.5 (97, 84 in.
lbf)
9.5 (97, 84 in.
lbf)
5.0 (51, 44 in.
lbf)
9.5 (97, 84 in.
lbf)
Ring Pin
Union
5.0 (51, 44 in.
lbf)
Union
Union
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±27
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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140KN±01
A62780
SST
A62781
SST
14±28
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE W/HEAD TAPER SCREW PLUG NO.2
(a) Using a socket hexagon wench 10, remove the taper screw plug and gasket.\
2. REMOVE VALVE LIFTER
(a) Remove the 16 valve lifters from the cylinder head. 3. REMOVE INNER COMPRESSION SPRING
(a) Using SST, compress the valve spring and remove the 2keepers, the retainer, and the spring seat.
SST 09202±70020 (09202±00010)
4. REMOVE INTAKE VALVE
(a) Remove the 8 intake valves from the cylinder head.
5. REMOVE EXHAUST VALVE
(a) Remove the 8 exhaust valves from the cylinder head.
6. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Remove the 16 valve stem oil seals from the valve guide bush.
7. REMOVE VALVE SPRING SEAT
(a) Remove the 16 valve spring seats from the cylinder head. 8. REMOVE VALVE GUIDE BUSH
(a) Heat the cylinder head to 80 ± 100
C (176 ± 212
F).
(b) Using SST, tap out the valve guide bush.
SST 09201±10000, 09201±01055, 09950±70010 (09951±07100)
9. REMOVE STUD BOLT
(a) Remove the 11 stud bolts from the cylinder head.
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A01075
A01071
A62782
A62783
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±29
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
10. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side0.05 mm (0.0020 in.)
Intake manifold side0.10 mm (0.0040 in.)
Exhaust manifold side0.10 mm (0.0040 in.)
11. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
12. INSPECT VALVE GUIDE BUSHING OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the valve guide bush.
Busing inside diameter:
5.510 ± 5.530 mm (0.2169 ± 0.2177 in.)
(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
Intake 5.470 ± 5.485 mm (0.2154 ± 0.2159 in.)
Exhaust 5.465 ± 5.480 mm (0.2152 ± 0.2158 in.)
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A01445
EM0801
A62784
Deviation
14±30
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.
Standard oil clearance:
Intake 0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
Exhaust 0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.01 mm (0.0039 in.)
13. INSPECT VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame- ter of the cylinder head.
Diameter: 10.285 ± 10.306 mm (0.4049 ± 0.4057 in.)
(b) If the bushing bore diameter of the cylinder head is great- er than 10.306 mm (0.4057 in.), machine the bushing
bore to the dimension of 10.335 ± 10.356 mm (0.4068 ±
0.4077 in.) to install a over size bushing.
HINT:
bushing bore diameter mm (in.)
Bushing size
10.285 ± 10.306
(0.4049 ± 0.4057)Use STD
10.335 ± 10.356
(0.4068 ± 0.4077)Use O/S 0.05
14. INSPECT INNER COMPRESSION SPRING
(a) Using a vernier caliper, measure the free length of the valve spring.
Free length: 43.40 mm (1.7087 in.)
(b) Using a steel square, measure the deviation of the valve spring.
Maximum deviation: 2.0 mm (0.078 in.)
Maximum angle (reference): 2

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EM2534
A62785
Margin
Thickness
EM2534
A62785
Margin
Thickness
A62786
Width
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±31
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSPECT INTAKE VALVE
(a) Using a vernier calipers, check the valve overall length.
Standard overall length: 88.65 mm (3.4902 in.)
Minimum overall length: 88.35 mm (3.4784 in.)
(b) Using a vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
16. INSPECT EXHAUST VALVE
(a) Using a vernier calipers, check the valve overall length. Standard overall length: 88.69 mm (3.4917 in.)
Minimum overall length: 88.39 mm (3.4799 in.)
(b) Using a vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
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A62787
1.0 ± 1.4 mm30


45


A62788
1.0 ± 1.4 mm 60


45

P16860
A01080
14±32
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the valve face with the width between 1.0 ± 1.4 mm
(0.039 ± 0.055 in.).
18. REPAIR VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 30
and
45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 75
and 45

cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com- pound.
(d) Check the valve seating position.
19. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter. Lifter diameter:
30.966 ± 30.976 mm (1.2191 ±1.2195 in.)
20. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter:
31.000 ± 31.025 mm (1.2205 ± 1.2215 in.)
(b) Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance:
0.024 ± 0.059 mm (0.0009 ± 0.0023 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)
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A01455
A62789
Plastigage
A01454
A01453
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±33
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
21. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the 2 camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 ± 0.095 mm (0.0016 ± 0.0037 in.)
Maximum thrust clearance: 0.110 mm (0.0043 in.)
(c) If the thrust clearance is greater than maximum, replace the cylinder head. If damages are found on the camshaft
thrust surfaces, the camshaft also has to be replaced.
22. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour- nal.
(d)Install the bearing caps (See page 14±4). Torque:
No. 1 23 N
m (235 kgf
cm, 17 ft
lbf)
No. 3 13 N
m (132 kgf
cm, 10 ft
lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the plastigage at its widest point.
Standard oil clearance:
0.035 ± 0.072 mm (0.0014 ± 0.0028 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
NOTICE:
Completely remove the Plastigage after the measuring.
If the oil clearance is greater than maximum, replace the cylin-
der head.
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A62790
AB
F
D
C
E
24.5
A B
D
E C F
16 89 34.5
9 53.5
16.5
1238.5 22.5
12
48.5
5
38.5
21.5
12
[mm]C
Front side:
Exhaust side: Intake side:
Upper side:
14±34
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
23. INSTALL STUD BOLT AND RING PIN
(a) Install the 11 stud bolts to cylinder head, Torque:
Stud bolt A, D and E 9.5 N
m (97, 84 in.
lbf)
Stud bolt B and C 5.0 N
m (51, 44 in.
lbf)
(b) Using a plastic hammer, install the new 2 ring pins to the cylinder head. Standard protrusion: 5 mm (0.020 in.)
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