TOYOTA AVENSIS 2003 Service Repair Manual

A62791
14 mm25 mm
9 mm
A
B
C
A62792
Adhesive
A62793
B A
C
A62794
SST
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±35
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
24. INSTALL UNION
(a) Mark the standard position away from the edge, onto the
water hose union as shown in the illustration.
(b) Apply adhesive to the water hose union hole of the cylin- der head.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent.
(c) Using a press, press in a new water hose union until the standard marks come to the level of the cylinder head sur-
face.
Standard protrusion:
A 29 mm (1.14 in.)
B 66.5 mm (2.62 in.)
C 24 mm (0.95 in.)
NOTICE:

Install the water hose union within 3 minutes after ap-
plying adhesive.

Do not put into coolant within an hour after installing.
25. INSTALL VALVE GUIDE BUSH
(a) Gradually heat the cylinder head to 80 ± 100 C (176 ±
212 F).
(b) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height.
SST 09201±10000, 09201±01055, 09950±70010 (09951±07100)
Protrusion height: 8.7 ± 9.1 mm (0.342 ± 0.358 in.)
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A62795
Exhaust
Intake Mark
ºNOKº
Black Surface
Gray Surface
A62796
SST
A01065
A62780
SST
A07307
14±36
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
26. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil on the valve stem oil seals.
NOTICE:
Be very careful to assemble the oil seal for intake and ex-
haust. Assembling the wrong one may cause a failure.
HINT:
The intake valve stem oil seal is gray and the exhaust valve
stem oil seal is black.
(b) Using SST, push in a new valve stem oil seal. SST 09201±41020
27. INSTALL INNER COMPRESSION SPRING
(a) Install the valve, spring seat, valve spring, and spring re- tainer.
(b) Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202±70020 (09202±00010)
(c) Using a plastic hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to
ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
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±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±37
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
28. INSTALL W/HEAD TAPER SCREW PLUG NO.2
(a) Using a socket hexagon wrench 10, install the taper screw plug with a ne\
w gasket.
Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)
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140KJ±01
A62768
Oil Filler Cap Sub±assy
Gasket
Ventilation Valve
Sub±assy
Seal Washer
Cylinder Head Cover
Sub±assy Gasket Spark Plug
Water Pump Assy
Crankshaft Pulley
9.0 (92, 80 in.

lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
11 (112, 8)
25 (255, 18)

O±ring
11 (112, 8)
138 (1,407, 102)
9.0 (92, 80 in.
lbf)

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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A62769
Camshaft Bearing Cap No. 1
Camshaft Timing Gear or Sprocket
Camshaft Timing Gear Assy Camshaft Bearing Cap
No. 3
Camshaft No.2 Camshaft
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover Sub±assy
Chain Tensioner
Slipper
Crankshaft Position Sensor
Plate No. 1Chain Vibration Damper No. 1
Crankshaft Timing Gear
13 (133, 10)
23 (235, 17)
54 (551, 40)
54 (551, 40)
Chain Sub±assy
19 (194, 14)
9.0 (92, 80 in.

lbf)
9.0 (92, 80 in.
lbf)
13 (133, 10)
19 (194, 14)

Oil Seal

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
14±2
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
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A62770
Cylinder Head Sub±assyOil Control Valve Filter Gasket
 Gasket 
O±ring
Camshaft Timing
Oil Control Valve Assy
Cylinder Block Sub±assy  Oil Seal
Oil Pump Assy 
Gasket
Oil Strainer Sub±assy Oil Filter Sub±assy

Gasket
 Gasket
1st 49 (500, 36)
2nd Turn 90
See page 14±4
Plate Washer
30 (306, 22)9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)30 (306, 22)
Oil Filter Union
37 (377, 27)
Oil Pan Drain Plug
9.0 (92, 80 in.
lbf)
 Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
20 (204, 15)
Cylinder Block
Water Drain Cock Sub±assy
Oil Pan Sub±assy
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±3
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
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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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A62837SST
A10076
A30848
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Using SST, remove the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
(c) Remove the crankshaft pulley from the crankshaft.
9. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and chain tensioner.
NOTICE:
Be sure not to revolve the crank shaft without the chain tensioner. 10. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 11 bolts and nuts.
(b) Remove the timing chain cover by prying the portions be- tween the cylinder head and cylinder block with a screw±
driver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
11. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a screwdriver remove the oil seal.
12. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Remove the crankshaft position sensor plate from the crankshaft.
13. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.
14. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolts and chain vibration damper.
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A30857
A62814
4
2531
A32167
A62190
Advance
Side Path
Retard Side
Path
Open
Close
Rubber
Vinyl Tape
Open Close
14±6
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. REMOVE CHAIN SUB±ASSY
(a) Using screwdrivers, ply out the timing chain with the crankshaft timing gear as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution for
valves not to touch the pistons.
16. REMOVE CAMSHAFT
(a) Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the
9 bearing caps, intake and exhaust camshafts.
17. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and remove the bolt and camshaft timing gear.
NOTICE:
Be careful not to damage the camshaft.
18. INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Check the lock of camshaft timing gear. (1) Grip the camshaft with a vice, and confirm the cam-
shaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
(b) Release lock pin. (1) Cover 4 oil paths of cam journal with vinyl tape asshown 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. (2) Break through the tapes of the advance side pathand the retard side path on the opposite side of the
groove.
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A62191
Advanced
Side Path
Retard
Side Path
A62192
Hold Pressure
Decompress Advanced
Side Path
Retard
Side Path
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(3) Put air pressure into two broken paths (the advance
side path and the retard side path) with about 150
kPa {1.5 kgf
cm}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.
(4) Confirm if the camshaft timing gear assembly re-volves in the timing advance direction when weak-
ening the air pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear, revolves in
the advance direction. (5) When the camshaft timing gear comes to the mostadvanced position, take out the air pressure of the
timing retard side path, and then, take out that of
timing advance side path.
CAUTION:
Camshaft timing assembly gear occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before retard side path. It often
causes the breakage of the lock pin.
(c) Check smooth revolution (1) Revolve the camshaft timing gear assembly withinthe movable range except for the most retarded
position several times, and check the smooth revo-
lution.
CAUTION:
Be sure to perform this check by hand, instead of air pres-
sure.
(d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear assembly islocked at the most retarded position.
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