Piston TOYOTA AVENSIS 2005 Service Repair Manual

A95733
13.5 mm
(0.531 in.)
A13490
EM0227
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–63
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(b) For engine type 3ZZ–FE.
(1) Using a micrometer, measure the diameter of the
piston. Align the micrometer so it is 13.5 mm (0.531
in.) from the bottom of the piston and at right angles
(90) to the piston pin holes as illustrated.
Piston diameter:
78.960 to 78.975 mm (3.1087 to 3.1091 in.)
If the diameter is not as specified, replace the piston.
16. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.073 to 0.096 mm (0.0029 to 0.0038 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace all of the piston assembly.
If necessary, replace the cylinder block.
17. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the piston pin bore diam-
eter.
Piston pin bore diameter:
20.006 to 20.015 mm (0.7876 to 0.7880 in.)
Markmm (in.)
A20.006 to 20.009 (0.7876 to 0.7878)
B20.010 to 20.012 (0.7878 to 0.7879)
C20.013 to 20.015 (0.7879 to 0.7880)
If the diameter is not as specified, replace the piston assembly.
(b) Using a micrometer, measure the piston pin outer diame-
ter.
Piston pin outer diameter:
20.004 to 20.013 mm (0.7876 to 0.7879 in.)
Markmm (in.)
A20.004 to 20.007 (0.7876 to 0.7877)
B20.008 to 20.010 (0.7877 to 0.7878)
C20.011 to 20.013 (0.7878 to 0.7879)
If the diameter is not as specified, replace the piston assembly.

A01185
A64970
Front Mark
Connecting Rod
Small End
Bore Diameter
MarkPiston Pin
Bore Diameter
Mark
Front Mark
Piston:
Connecting Rod:
A01171
14–64
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(c) Using a caliper gauge, measure the connecting rod small
end bore diameter.
Connecting rod small end bore diameter:
20.012 to 20.021 mm (0.7879 to 0.7882 in.)
Markmm (in.)
A20.012 to 20.015 (0.7879 to 0.7880)
B20.016 to 20.018 (0.7880 to 0.7881)
C20.019 to 20.021 (0.7881 to 0.7882)
If the diameter is not as specified, replace the connecting rod
assembly.
(d) Subtract the piston pin outer diameter measurement from
the piston pin bore diameter measurement.
Standard oil clearance:
–0.001 to 0.017 mm (–0.00004 to 0.0007 in.)
Maximum oil clearance: 0.017 mm (0.0007 in.)
If the oil clearance is greater than maximum, re-
place the connecting rod assembly.
If necessary, replace the piston pin.
(e) Subtract the piston pin outer diameter measurement from
the connecting rod small end bore diameter measure-
ment.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.011 mm (0.0004 in.)
If the oil clearance is greater than maximum, re-
place the connecting rod assembly.
If necessary, replace the connecting rod and piston
pin.
18. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the new piston ring and wall of the ring groove.
Ring groove clearance:
ItemSpecification
No. 1 ring0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No. 2 ring0.03 to 0.07 mm (0.0012 to 0.0028 in.)
Oil ring0.03 to 0.11 mm (0.0012 to 0.0043 in.)
If the groove clearance is not as specified, replace the piston
assembly.

A01170
11 0 m m
(4.33 in.)
EM7639
A62804
A62805
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–65
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
19. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, which is 110 mm (4.33 in.) from the
top of the cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
ItemSpecification
No. 1 ring0.25 to 0.35 mm (0.0098 to 0.0138 in.)
No. 2 ring0.35 to 0.50 mm (0.0138 to 0.0197 in.)
Oil ring0.15 to 0.40 mm (0.0059 to 0.0157 in.)
Maximum end gap:
ItemSpecification
No. 1 ring1.05 mm (0.0413 in.)
No. 2 ring1.20 mm (0.0472 in.)
If the end gap is greater than maximum, replace the
piston ring.
If the end gap is greater than maximum, even with
a new piston ring, replace the cylinder block.
20. INSPECT CONNECTING ROD SUB–ASSY
(a) Using a connecting rod aligner and feeler gauge, check
the connecting rod alignment.
(1) Check for out–of–alignment.
Maximum out–of–alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the out–of–alignment is greater than maximum, replace the
connecting rod assembly.
(2) check for twist.
Maximum twist:
0.05mm (0.0020 in.) per 100 mm (3.94 in.)
If the twist is greater than maximum, replace the connecting rod
assembly.

A64974
Intake Side:
Bearing Cap Lower Side:Upper Side:
A
D
E
DC B
ABCDE
(mm)15
1238.515
1052.5
14
931.512
927.5 10
822.5
A64975
End Gap
End Gap
Pin Hole
Cutout Portion
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–71
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
27. INSTALL STUD BOLT
(a) Using Torx socket wrenches E5 and E7, install the 9 stud
bolts into the cylinder block.
Torque:
5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for A
11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) for B
5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for C
5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for D
5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for E
28. INSTALL W/PIN PISTON SUB–ASSY
(a) Using a small screwdriver, install a new snap ring onto
one end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is aligned with the pin
hole cutout portion of the piston.

A01187
A64976
Front
Mark
A96654
End Gap
End Gap
Pin Hole
Cutout Portion
A62811
Cord Mark
Piston Ring
Expander
14–72
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(b) Gradually heat the piston up to 80 to 90C (176 to 194F).
(c) Align the front marks on the piston with the connecting
rod, then push in the piston with your thumb.
(d) Using a small screwdriver, install a new snap ring onto
one end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is aligned with the pin
hole cutout portion of the piston.
29. INSTALL PISTON RING SET
HINT:
In case of reusing the piston rings, install them onto the
matched pistons with the surfaces facing upward correctly.
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark (No. 2 only): 2R

A64977
Upper Side Rail
Front
MarkCompression No. 2
Lower Side Rail Compression No. 1
and Expander
A01190
Oil Groove
A01189
A01191Oil Groove
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–73
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(c) Position the piston rings so that the ring ends are as
shown.
30. INSTALL CRANKSHAFT BEARING
(a) Install the upper bearing with an oil groove onto the cylin-
der block.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
(b) Install the lower bearing onto the bearing cap.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
31. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers onto the No. 3 journal position
of the cylinder block with the oil grooves facing outward.

A64817
A64978
Oil Groove
Claw
A64979
Oil Groove
Claw
A64977
Upper Side Rail
Front
MarkCompression No. 2
Lower Side Rail Compression No. 1
and Expander
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–75
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(i) Tighten the 10 other bolts for the bearing cap.
Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)
33. INSTALL CONNECTING ROD BEARING
(a) Align the connecting rod bearing claw with the oil groove
of the connecting rod cap.
(b) Install the connecting rod bearing onto the connecting rod
cap.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
(c) Align the connecting rod bearing claw with the oil groove
of the connecting rod.
(d) Install the connecting rod bearing onto the connecting
rod.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
34. INSTALL CONNECTING ROD SUB–ASSY
(a) Position the piston rings so that the ring ends are as
shown.
(b) Apply engine oil to the cylinder walls, pistons, and sur-
faces of the connecting rod bearings.

A62813
Front Mark
Piston Ring
Compressor
A65713
Front Mark
A65714
SST
A65715
Paint Mark90 Engine
Front
A64845
14–76
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(c) Using a piston ring compressor, correctly push the 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, then install the connecting rod.
NOTICE:
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 to the threads and the bot-
tom of the heads of the connecting rod cap bolts.
(g) Using SST, tighten the bolts in several passes to 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 an additional 90 as shown in
the illustration.
(j) Check that the crankshaft turns smoothly.
35. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB–ASSY
(a) Apply adhesive to 2 or 3 threads of the cylinder block wa-
ter drain cock, then install it within 3 minutes as shown in
the illustration.
Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
Adhesive:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent

141TJ–01
A84914
Compression Ring No. 1Compression Ring No. 2 Oil Ring (Side Rail)

Snap Ring Piston
Piston Pin

Snap Ring
Connecting Rod Bearing
Cylinder Block Sub–assy
Crankshaft BearingCrankshaft Bearing Cap Sub–assy
Crankshaft Bearing
Crankshaft Thrust Washer Upper
Key
Crankshaft
Connecting Rod Bearing
Connecting Rod Bearing Cap
Oil Ring (Expander)
See page 14–51
1st 44 (449, 33)
2nd Turn 90 
1st 20 (204, 15)
2nd Turn 90
19 (194, 14)

Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torque Crankshaft
Thrust Washer Upper
Connecting Rod25 (255, 18)
Cylinder Block Water Drain Cock Sub–assy
See
page 14–51
14–50
–
ENGINE MECHANICAL CYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
CYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
COMPONENTS