TOYOTA AVENSIS 2005 Service Repair Manual

A77472
Thrust Direction
Axial Direction
Front
A
B
10 mm
(0.39 in.)
A78295
30.4 mm
(1.1968 in.)
A36650
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±57
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
14. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
86.000 to 86.013 mm (3.3858 to 3.3863 in.)
Maximum diameter: 86.013 mm (3.3863 in.)
If the diameter is greater than maximum, replace the cylinder
block.
15. INSPECT PISTON DIAMETER
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 30.4 mm (1.1968 in.)
from the piston head.
Piston diameter:
85.927 to 85.937 mm (3.3829 to 3.3833 in.)
16. INSPECT PISTON CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.063 to 0.086 mm (0.0025 to 0.0034 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)
(b) If the clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder
block.
17. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the piston ring and the wall of the ring groove.
Ring groove clearance:
Piston Ringmm (in.)
No. 10.020 to 0.007 (0.0008 to 0.0028)
No. 20.020 to 0.006 (0.0008 to 0.0024)
Oil ring (Side rail)0.070 to 0.150 (0.0028 to 0.0059)

A77473Piston Ring4.5 mm
(1.77 in.)
EM2552
A13490
EM0227
A01185
14±58
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
18. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 4.5 mm (1.77 in.) from the top of the
cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No. 2 0.47 to 0.62 mm (0.0185 to 0.0244 in.)
Oil (side rail) 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum end gap:
No. 1 0.89 mm (0.0350 in.)
No. 2 1.37 mm (0.0539 in.)
Oil (side rail) 0.73 mm (0.0287 in.)
19. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
piston bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.009 mm (0.8660 to 0.8665 in.)
(c) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
(d) Subtract the piston pin diameter measurement from the
piton pin hole diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)

A77474
Piston Bushing
Inside Diameter
Mark
Front Mark
Connecting Rod
Bushing Inside Diameter MarkFront Mark
Z00064
Z00065
A01470
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±59
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(e) If the oil clearance is greater than maximum, replace the
connecting rod. If necessary, replace the piston and pis-
ton pin as a set.
(f) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
(g) If the oil clearance is greater than maximum, replace the
connecting rod. If necessary, replace the connecting rod
and piston pin as a set.
20. INSPECT CONNECTING ROD SUB±ASSY
(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
(b) If out±of alignment is greater than maximum, replace the
connecting rod assembly.
(1) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
(c) If twist is greater than maximum, replace the connecting
rod assembly.
21. INSPECT CONNECTING ROD BOLT
(a) Using a vernier calipers, measure the tension portion di-
ameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
(b) If the diameter is less than minimum, replace the bolt.

A13859
A38182
ZF6928
EM6347A15065
14±60
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
22. INSPECT CRANKSHAFT
(a) Using a dial indicator and V±blocks, measure the circle
runout as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 in.)
(b) Using a micrometer, measure the diameter of each main
journal.
Diameter: 54.988 to 55.000 (2.1648 to 2.06535 in.)
(c) Check each main journal for taper and out±of±round as
shown.
Maximum taper and out ±of± round:
0.003 mm (0.0001 in.)
HINT:
Markmm (in.)
054.998 to 55.000 (2.16528 to 2.16535)
154.996 to 54.998 (2.16520 to 2.16528)
254.994 to 54.996 (2.16512 to 2.16520)
354.992 to 54.994 (2.16504 to 2.16512)
454.990 to 54.992 (2.16496 to 2.16504)
554.988 to 54.990 (2.16490 to 2.16496)
(d) Using a micrometer, measure the diameter of each crank
pin.
Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.)
(e) Check each crank pin for taper and out±of±round as
shown.
Maximum taper and out±of±round:
0.003 mm (0.0001 in.)
23. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.

A77273
Upper SideBottom Side
{mm} 6 (Ring Pin A)
5 (Ring Pin B)
A53029
A77274
Plastigage
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±61
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
24. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap into the ring pin.
Standard protrusion:
Ring pin A 6 mm (0.236 in.)
Ring pin B 5 mm (0.197 in.)
25. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE:

Clean the backside of the bearing and the bearing
surface of the bearing cap and keep them free of oils.

The bearing cap bolts are tightened in 2 progressive
steps.
(a) Clean each main journal and bearing.
(b) Install the upper bearing with an oil groove on cylinder
block.
(c) Install the lower bearing on the bearing cap sub assem-
bly.
(d) Place the crankshaft on the cylinder block.
(e) Lay a strip of Plastigage across each journal.
SST 09011±38121

A77275Front Mark and Journal Number
A77475


10    
A77470
90

Engine FrontPaint
Mark
A13855
14±62
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(f) Examine the front marks and install the bearing caps on
the cylinder block.
(g) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.
(h) Using several steps, tighten the bolts with the specified
torque in the sequence shown in the illustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(i) Retighten the bolts in the same way as above with the
specified torque.
Torque: 40 N
m (408 kgf
cm, 29 ft
lbf)
(j) Place the front mark on each bearing cap bolt head with
paint.
(k) Retighten the bearing cap bolts by 90
in the same se-
quence as step (h).
(l) Check that each painted mark is now at a 90
angle to the
front.
NOTICE:
Do not turn the crankshaft.
(m) Remove the bearing caps.
(n) Measure the Plastigage at its widest point.
Standard oil clearance:
0.017 to 0.040 mm (0.0007 to 0.0016 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
NOTICE:
Completely remove the Plastigage.

A77276
Mark
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±63
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(o) If using a standard bearing, replace it with one having the
same number as old one. If the number of the bearing
cannot be determined, select a proper bearing by putting
together the numbers imprinted on the cylinder block and
the crankshaft. The total number of this will determine an
applicable bearing among the 4 standard bearings,
marked º1º, º2º, º3º and º4º. For the details about selec-
tion, refer to the table and hint below.
Cylinder block
+
Crankshaft
0 to 23 to 56 to 89 to 11
Replacement
bearing
number
º1ºº2ºº3ºº4º
HINT:
EXAMPLE
Cylinder block with imprinted number º4º
Crankshaft with imprinted number º3º
º4º + º3º = º7º
Select the bearing with marked º3º
Reference:
ItemMarkmm (in.)
Cylinder block main journal bore diameter (A)
0
1
2
3
4
5
659.000 to 59.002 (2.08683 to 2.32291)
59.003 to 59.004 (2.08694 to 2.32299)
59.005 to 59.006 (2.08701 to 2.32307)
59.007 to 59.009 (2.08708 to 2.32318)
59.010 to 59.011 (2.08718 to 2.32326)
59.012 to 59.013 (2.08725 to 2.32334)
59.014 to 59.016 (2.08733 to 2.32346)
Crankshaft main journal diameter (B)
0
1
2
3
4
554.998 to 55.000 (1.94528 to 2.16535)
54.996 to 54.998 (1.94521 to 2.16527)
54.994 to 54.996 (1.94514 to 2.16519)
54.992 to 54.994 (1.94507 to 2.16511)
54.990 to 54.992 (1.94500 to 2.16504)
54.988 to 54.990 (1.94493 to 2.16496)
Standard bearing center wall thickness
1
2
3
41.993 to 1.996 (0.07846 to 0.07858)
1.996 to 1.999 (0.07858 to 0.07870)
1.999 to 2.002 (0.07870 to 0.07882)
2.002 to 2.005 (0.07882 to 0.07894)
26. INSTALL TIGHT PLUG
(a) Apply adhesive around tight plugs.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent.

A77484
Engine FrontEngine Rear
A77476
Front Side
B
18
9
A (M16)31.5
A
16
20
B (M10)84
Exhaust SideC
A
9 14
27.5
C (M6) 14±64
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(b) Using SST, push in the tight plugs as shown in the illustra-
tion.
SST 09950±60010 (09951±00200), 09950±70010
(09951±07100)
Standard depth:
Engine front 1.7 to 2.7 mm (0.067 to 0.106 in.)
Engine rear 2.2 to 3.2 mm (0.087 to 0.126 in.)
27. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Stud bolt B 10N
m (97 kgf
cm, 84 in.
lbf)
Stud bolt C 5.0N
m (51 kgf
cm, 44 in.
lbf)

A77477
Back Side
BB
A8
15
B 10
22A
Bottom Side
7.5 (Pin A)
12 (Pin B)
A
A
Front Side
A
A13857
A77478
Front Mark
Front Mark
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±65
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
28. INSTALL STRAIGHT PIN
(a) Using a plastic±faced hammer, tap into the straight pin.
Standard protrusion
Pin A 7.5 mm (0.295 in.)
Pin B 12 mm (0.472 in.)
29. INSTALL PISTON
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
(b) Gradually heat the piston to 80 to 90
C (176 to 194
F).
(c) Align the front mark of the piston with the front mark lo-
cated on the connecting rod, and push in the piston with
your thumb.
(d) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.

A77479
Upward
No. 1
No. 2
Painted Mark
Code Mark (2T)
A77480
Front
Side Rail UpperSide Rail Lower
No. 2 Expander
Compression No. 1 and
A53029
A33379
14±66
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
30. INSTALL PISTON RING SET
(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 painted mark facing right side.
NOTICE:
Install the compression ring No. 2 with the code mark (2T)
upward.
(c) Position the piston rings so that the ring ends are as
shown.
31. INSTALL CRANKSHAFT BEARING
(a) Install the upper bearing with an oil groove on cylinder
block.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the cylinder block and keep them free of oils.
32. INSTALL CRANKSHAFT BEARING NO.2
(a) Install the lower bearing on bearing cap.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the cylinder block and keep them free of oils.