TOYOTA AVENSIS 2003 Service Repair Manual

010BI±01
Z11554
Seal Lock Adhesive
01±4
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
PRECAUTION
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES.
(a) When foreign substances such as dust, grain of sand or metallic dust enter i\
nside of engine, it often causes functional failure of the engine.
(1) Precaution before disassembly.

Remove adequately all sand and mud adhere to the outside of engine.
(2) Precaution at reassembly.

Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS.
(a) The existence of scratches on the contact and revolving surfaces often c\
auses oil leak and seisure. (1) Precautions at disassembly and reassembly.

When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).

When fix the parts to the vise, do not directly catch it in the vise. Fix th\
e parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS.
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas- sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:

Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.\
) is prohibited:

Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS.
(a) Each parts needs to be reassembled as the same position and direction as\
it disassembled. (1) Precautions at disassembly and reassembly.

Follow the directions when the manual designates to mark the matchmark and/or \
direction
mark.

Disassembled parts needs to be put in order as disassembled, not to chan\
ge position and/
or direction.

Follow the directions when the manual instructs the position and directi\
on.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE.
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED.
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES.
8. NON±REUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW PARTS.
9. BASIC REPAIR HINT
(a) Precoated Parts:(1) Precoated parts are bolts, nuts, etc. that are coatedwith a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
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L1L2
D02612
L2
L1
D01201
L2
L1
D01202
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
01±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
NOTICE:
Do the torque checking with the lower limit value of the torque toleranc\
e.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets: When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always\
use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:(1) In case of tightening by extending the entire lengthof the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
lbf 
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that\
vaporized fuel fills those places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,and do not spray much water so as to prevent slipping.
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D01563
D25081
Flat Spring Clamp
Clamp Track
01±6
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(3) Never use any electric equipment like an electric motor or a working light as they may cause spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKEPARTS
(a) If any metal tip is mixed in the inlet pass, that may give a bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts, close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of inserting portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force to the arrow mark direction after the installation.
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1706D±01
A62218
Oil Pump relief Valve PlugOil Pump Relief Valve Spring Oil Relief Valve
Oil Pump Body Oil Pump Driven RotorOil Pump Drive Rotor
Oil Pump Cover
37 (377, 27)
10 (102, 7)
N´m (kgf´cm, ft´lbf) : Specified torque
±
LUBRICATION OIL PUMP ASSY (1ZZ±FE/3ZZ±FE)
17±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OIL PUMP ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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1700D±03
B00307
Oil Jet
A32175
A32176
A32178
17±2
±
LUBRICATION OIL PUMP ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE OIL PUMP DRIVE AND DRIVEN ROTORS
(a) Remove the 3 screws and oil pump cover.
(b) Remove the oil pump drive and driven rotors from the oil pump.
2. REMOVE VALVE, OIL PUMP RELIEF
(a) Remove the plug, spring and valve from the oil pump. 3. INSPECT OIL JET
(a) Check the oil jet for damage or clogging.
4. INSPECT OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil, and checkthat it falls smoothly into the valve hole by its own weight.
5. INSPECT ROTOR TIP CLEARANCE
(a) Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance:
0.040 ± 0.160 mm (0.0016 ± 0.0063 in.)
Maximum tip clearance: 0.160 mm (0.0063 in.)
6. INSPECT ROTOR SIDE CLEARANCE
(a) Using a feeler gauge and precision straight edge, mea- sure the clearance between the 2 rotors and precision
straight edge.
Standard side clearance:
0.025 ± 0.071 mm (0.0010 ± 0.0028 in.)
Maximum side clearance: 0.071 mm (0.0028 in.)
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A32177
A62219
Mark
±
LUBRICATION OIL PUMP ASSY (1ZZ±FE/3ZZ±FE)
17±3
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
7. INSPECT BODY CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the driven rotor and oil pump body.
Standard body clearance:
0.260 ± 0.325 mm (0.0102 ± 0.0128 in.)
Maximum body clearance: 0.325 mm (0.0128 in.)
8. INSTALL OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil, and insert oil pump relief v\
alve and spring to the valve hole.
(b) Install the oil pump relief valve plug. Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
9. INSTALL OIL PUMP DRIVE AND DRIVEN ROTORS
(a) Coat the oil pump drive and driven rotors with engine oil, and place it into the oil pump with marks facing the oil
pump cover side.
(b) Install the oil pump cover with the 3 screw. Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)
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0214A±01
±
PREPARATION ENGINE MECHANICAL
02±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
ENGINE MECHANICAL
PREPARATION
SST
09011±3812112 mm Socket Wrench for 12
Pointed HeadCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09032±00100Oil Pan Seal CutterPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09201±01055Valve Guide Bushing Remover &
Replacer 5.5CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09201±10000Valve Guide Bushing Remover &
Replacer SetCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09201±41020Valve Stem Oil Seal ReplacerCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09202±70020Valve Spring CompressorCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09202±00010)AttachmentCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09205±16010Cylinder Head Bolt WrenchCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09222±30010Connecting Rod Bushing Remover
& ReplacerCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09223±15030Oil Seal & Bearing ReplacerPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09223±22010Crankshaft Front Oil Seal
ReplacerPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09228±06501Oil Filter WrenchPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
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02±2
±
PREPARATION ENGINE MECHANICAL
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
09950±70010Handle SetPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09951±07100)Handle 100PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09960±10010Variable Pin Wrench SetPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
(09962±01000)Variable Pin Wrench Arm AssyPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
(09963±01000)Pin 10PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
Recomended Tools
09040±00011Hexagon Wrench SetPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09043±20100)Socket Hexagon Wrench 10CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09043±20120)Socket Hexagon Wrench 12PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
(09043±20100)Socket Hexagon Wrench 10CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09043±50100Bi±hexagon Wrench 10 mmPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
08826±00100ºSeal Packing 1282B,º
THREE BOND 1282B or equivalent
(FIPG)PARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
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±
PREPARATION ENGINE MECHANICAL
02±3
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
08833±00070ºAdhesive 1324,º
THREE BOND 1324 or equivalentCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
CYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
Equipment
Wooden block
Spring tension gauge
Vernier calipers
V±block
Dial indicator
Micrometer
Torque wrench
Heater
Precision straight edge
Feeler gauge
Caliper gauge
Steel square
Plastigage
Valve seat cutter
Ride reamer
Piston ring expander
Plastic hammer
Cylinder gauge
Connecting rod aligner
Piston ring compressor
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02149±01
02±4
±
PREPARATION LUBRICATION
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
LUBRICATION
PREPARATION
Equipment
Feeler gauge
Precision straight edge
Torque wrench
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