TOYOTA AVENSIS 2003 Service Repair Manual

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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A62193
Straight Pin
Fringe Bolt
A62815
Mesh
A62816
37 9 62
481051
B08737
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±9
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(g) Remove the fringe bolt of camshaft timing gear assembly.
NOTICE:

Be sure not to remove the other 4 bolts.

In case of reusing the camshaft timing gear, release
the strait pin locking first, and then install the gear.
20. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt and camshaft timing oil control valve. 21. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the bolt, gasket and oil control valve filter.
22. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using a bi±hexagon wrench 10, uniformly loosen and re-move the 10 cylinder head bolts, in several passes, in the
sequence shown. Remove the 10 cylinder head bolts and
plate washers.
NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cracking could result from remov-
ing bolts in an incorrect order.
23. REMOVE CYLINDER HEAD GASKET
(a) Remove the gasket from the cylinder block.
24. REMOVE OIL PUMP ASSY
(a) Remove the 5 bolts, oil pump and gasket.
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A62817SST
A62202
Cut Position
A01153
A01456
14±10
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
25. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter. SST 09228±06501
26. REMOVE OIL FILTER UNION
(a) Using a socket hexagon wrench 12, remove the oil filter union. 27. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If there is, mend it with a sandpaper (# 400).
28. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket from the oil pan. 29. REMOVE OIL PAN SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Insert the blade of SST between the bearing cap sub±as-sembly and oil pan, and cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the oil pan contact surface of the
bearing cap sub±assembly and the oil pan flange.
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A62818
Raise
Move
Lock
A62819
Measuring Area
012345 16
A30206
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±11
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
30. REMOVE OIL STRAINER SUB±ASSY
(a) Remove the bolt, 2 nuts, oil strainer and gasket.
31. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Remove the cylinder block water drain cock from the cylinder block.
32. INSPECT CHAIN TENSIONER ASSY NO.1
(a) Check that the plunger moves smoothly when the ratchetpawl is raised with your finger.
(b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move
when pushed with your finger.
33. INSPECT CHAIN SUB±ASSY
(a) Using a spring tension gauge and vernier calipers, pull the timing chain with 140 N (4.3 kgf, 315 lb) and measure
the length of it.
Maximum chain elongation : 112.6 mm (4.433 in.)
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
34. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di- ameter with the chain.
Minimum sprocket diameter (w / chain):
97.3mm (3.831 in.)
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.
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EM2378
A32118
A32119
A62820
Overall Length
14±12
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
35. INSPECT C RANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di- ameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.
Minimum sprocket diameter (w / chain):
51.6mm (2.032 in.)
36. INSPECT CHAIN TENSIONER SLIPPER
(a) Using a vernier calipers, measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 in.)
37. INSPECT CHAIN VIBRATION DAMPER NO.1
(a) Using a vernier calipers, measure the vibration damper wears.
Maximum wear: 1.0 mm (0.039 in.)
38. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length:
156.0 ± 159.0 mm (6.142±6.260 in.)
Maximum bolt length: 159.5 mm (6.280 in.)
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EM1628
EM2011
EM2538
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±13
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
39. INSPECT CAMSHAFT
(a) Inspect camshaft for runout.
(1) Place the camshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
(b) Inspect cam lobes. (1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.333 ± 44.433 mm (1.7454 ± 1.7493 in.)
Exhaust 43.761 ± 43.861 mm (1.7229 ± 1.7268 in.)
Minimum cam lobe height:
Intake 44.18 mm (1.7394 in.)
Exhaust 43.61 mm (1.7169 in.)
(c) Inspect camshaft journals. (1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
34.449 ± 34.465 mm (1.3563 ± 1.3569 in.)
Others journal diameter:
22.949 ± 22.965 mm (0.9035 ± 0.9041 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
40. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Apply two or three threads of adhesive to the drain union, and install i\
t within 3 minutes. Torque: 20 N
m (204 kgf
cm15 ft
lbf)
(b) After applying the specified torque, rotate the drain union clockwise until i\
ts drain port faces downward.
NOTICE:

Do not put into coolant in an hour after the installation.

Do not rotate the drain union more than 360 in (b), and never loosen it after setting the union
correctly.
41. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 nuts and a bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
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A62821
Seal Width 4 ± 5 mm
6 mm Seal Packing
A62822
SST
A62817SST
14±14
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
42. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing material from the contact sur- face.
(b) Apply seal packing in the shape of bead (Diameter 3.5 mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

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

Do not put into engine oil within 2 hours after instal-
ling.
(c) Install the oil pan with the 14 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
43. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install it. Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
44. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crank shaft.
45. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter union. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
46. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501
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A30890
A62826
Lot No.
A62816
84 2 59731610
A62823
Paint Mark
90 
Front
A62815
Mesh
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±15
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
47. INSTALL OIL PUMP ASSY
(a) Engage the spline teeth of the oil pump drive rotor with the
large teeth of the crankshaft, and side the oil pump.
(b) Install the oil pump with the 5 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
48. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE:

Pay attention to the installation direction.

Place the cylinder head quietly in order not to damage
the gasket with the bottom part of the head.
49. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Using a bi±hexagon wrench 10, install and uniformly tight- en the 10 cylinder head bolts with plate washers, in sever-
al passes, in the sequence shown.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90  in the numerical or-
der shown.
(e) Check that the point marked bolts are moved at 90 
angle.
50. INSTALL OIL CONTROL VALVE FILTER
(a) Confirm that the filter is clear.
(b) Install the oil control valve filter to the cylinder head.
(c) Place a new gasket on the bolt, and install it. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
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A62824
Straight Pin
Key Groove
A32167
A62150
14±16
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Install a new O±ring to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
52. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc- tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
(e) Check that the camshaft timing gear assembly can move to the retard angle side (the right angle), and is locked at
the most retarded position.
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and install the camshaft tim- ing gear.
Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
NOTICE:
Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT
(a) Apply light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.
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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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