TOYOTA AVENSIS 2003 Service Repair Manual

A62173
Yellow Color MarkTiming Mark
A30867
A62174
SST
A62175
Seal Width
4 ± 5 mm
Seal Packing
14±18
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
56. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
57. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
58. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
59. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to the oil seal lip.
(b) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip off foreign materials.
60. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material from the contact sur- face.
http://vnx.su

A62176
Chain Cover
Groove
Cylinder Head
Groove Seal Width
4 ± 5 mm
A B
7 mm 4.5 mm 3 mm
6 mm
12 mm
B
A
A ± A B ± B A
A
A62177
Raise
Push
Hook
Pin
A62178
Push
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(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:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent
(c) Install the timing chain cover, with the 12 bolts and nut.
Torque:
M6 13 N
m (133 kgf
cm, 10 ft
lbf)
M8 19 N
m (194 kgf
cm, 14 ft
lbf)
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.
61. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check the O±ring is clean, and set the hook as shown in the illustration.
(b) Apply engine oil to the chain tensioner and install it with the 2 nuts..
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
When installing the tensioner, set the hook again if the
hook releases the plunger.
http://vnx.su

A62837SST
A62180
DisconnectHook
Pin Turn
A62181
Plunger
Turn
Push
A10085
A62179
A
ABB
B
B
14±20
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
62. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt. SST 09960±10010 (09962±01000, 09963±01000)
Torque: 138 N
m (1,407 kgf
cm, 102 ft
lbf)
(c) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
(d) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released from the knock pin and the plunger springs out.
63. INSTALL WATER PUMP ASSY
(a) Place a new O±ring on the timing chain cover.
(b) Install the water pump with the 6 bolts. Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in
lbf)
Bolt B 11 N
m (112 kgf
cm, 8 ft
lbf)
HINT:
Each bolt length is indicated in the illustration.
http://vnx.su

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.)
http://vnx.su

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.
http://vnx.su

A32125
A32556
A01082
A62195
Painted Link
Timing Mark
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±23
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(h) Remove the camshaft with holding the timing chain.
(i) Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(j) Remove the valve lifters.
(k) Using a micrometer, measure the thickness of the re- moved lifters.
(l) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Intake: A = B + (C ± 0.20 mm (0.008 in.))
Exhaust: A = B + (C ± 0.30 mm (0.012 in.))
HINT:

Select a new lifter with a thickness as close as possible
to the calculated values.

Lifter are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).
(m) As shown in the illustration, install the timing chain on the camshaft timing gear, with the painted links aligned with
the timing marks on the camshaft timing sprockets.
http://vnx.su

A62196
4123
A62197
Painted Link
Timing Mark
A32124
A621983124
5
6 7
A62187
Fix
Tighten
14±24
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(n) Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(o) Put the camshaft No.2 on the cylinder head with the painted links of the chain aligned with the timing mark on
the camshaft timing sprockets.
(p) Tighten the set bolt temporarily.
(q) Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(r) Install the bearing cap No. 1.
Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)
(s) Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the valve lifter.
http://vnx.su

A62185
MarkMark
Mark Timing Chain
Cover Surface
Groove
A62177
Raise
Push
Hook
Pin
A62178
Push
A62180
Disconnect
Hook
Pin Turn
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±25
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(t) Check the match marks on the timing chain and camshaft
timing sprockets, and then the alignment of the pulley
groove with timing mark of the chain cover as shown in the
illustration.
(u) Install chain tensioner. (1) Check the O±ring is clean, and set the hook asshown in the illustration.
(2) Apply engine oil to the chain tensioner and install it.
Torque: 9.0 N
m (92 kgf
cm, 80 in
lbf)
NOTICE:
When installing the tensioner, set the hook again if the
hook release the plunger.
(3) Turn the crankshaft counterclockwise, and discon-nect the plunger knock pin from the hook.
http://vnx.su

A62181
PlungerTurn
Push
A10085
A62182
Seal Packing
14±26
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(4) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released from the knock pin and the plunger springs out.
66. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Install the gasket to the cylinder head cover.
(b) Remove any old packing (FIPG) material.
(c) Apply seal packing to 2 locations as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not put into engine oil 2 hours after installing.
(d) Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts
Uniformly tighten the bolts and nuts, in the several
passes.
Torque:
w/o washer 11 N
m (112 kgf
cm, 8 ft
lbf)
w/ washer 9.0 N
m (92 kgf
cm, 80 in
lbf)
67. INSTALL SPARK PLUG
(a) Using a spark lug wrench, install the 4 spark plugs. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
http://vnx.su

010BJ±01
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TERMS (1ZZ±FE/3ZZ±FE)
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector
http://vnx.su