TOYOTA AVENSIS 2005 Service Repair Manual

A57510
Engine FrontEngine Rear
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±53
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
Reference:
ItemMarkmm (in.)
Cylinder block main journal bore diameter (A)
0
1
2
3
4
5
659.000 ± 59.002 (2.32283 ± 2.32291)
59.003 ± 59.004 (2.32295 ± 2.32299)
59.005 ± 59.006 (2.32303 ± 2.32307)
59.007 ± 59.009 (2.32311 ± 2.32318)
59.010 ± 59.011 (2.32322 ± 2.32326)
59.012 ± 59.013 (2.32330 ± 2.32334)
59.014 ± 59.016 (2.32338 ± 2.32346)
Crankshaft main journal diameter (B)
0
1
2
3
4
554.998 ± 55.000 (2.16527 ± 2.16535)
54.996 ± 54.998 (2.16519 ± 2.16527)
54.994 ± 54.996 (2.16511 ± 2.16519)
54.992 ± 54.994 (2.16503 ± 2.16511)
54.990 ± 54.992 (2.16496 ± 2.16504)
54.988 ± 54.990 (2.16488 ± 2.16496)
Standard bearing center wall thickness
1
2
3
41.993 ± 1.996 (0.07846 ± 0.07858)
1.996 ± 1.999 (0.07858 ± 0.07870)
1.999 ± 2.002 (0.07870 ± 0.07882)
2.002 ± 2.005 (0.07882 ± 0.07894)
27. INSTALL TIGHT PLUG
(a) Apply adhesive around tight plugs.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent.
(b) Using SST, into the tight plugs as shown in the illustration.
SST 09950±60010 (09951±00200), 09950±70010
(09951±07100)
Standard depth:
Engine front 1.7 ± 2.7 mm (0.067 ± 0.106 in.)
Engine rear 2.2 ± 3.2 mm (0.087 ± 0.126 in.)

A
BC
A
A (M6)
B (M10)C (M6) 18
931.584 16
20
9 14
27.5A
BC
A
B (M10)C (M6) 18
931.584 16
20
9 14
27.5
A57547
Front SideExhaust Side
A
B 810
15227.5 (Pin A)
12 (Pin B) BB
AA
A
A
A57512
Back SideFront SideBottom Side 14±54
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
28. 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)
29. 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.)

P12418A32958
A57513
Front Mark
Front Mark
No. 1
No. 2
A57514
Code Mark (2N) Upward
Painted Mark
No. 2
A57515
Front
Side Rail UpperSide Rail Lower
Expander
Compression No. 1 and
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±55
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
30. INSTALL PISTON
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
(b) Gradually hat the piston to 80 ± 90
C (176 ± 194
F).
(c) Align the front marks on the piston with 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.
31. 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 point mark facing right side.
NOTICE:
Install the compression ring No. 2 with the code mark (2N)
facing upward.
(c) Position the piston rings so that the ring ends are as
shown.

A53029
A33379
A13501
A13868
14±56
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
32. 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 let not stick the oils and fats.
33. 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 bearing cap and let not stick the oils and fats.
34. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
35. INSTALL CRANKSHAFT
(a) Apply engine oil to upper bearing and install the crank-
shaft on the cylinder block.
(b) Apply engine oil to lower bearing.
(c) Examine the front marks and install the bearing caps on
the cylinder block.
(d) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.

A13987
1
2 3
45
6 7
89
10 7
90
A57516
Engine FrontPaint
Mark
A57517
Claw
A57518
Front Mark
Front
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±57
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(e) Tighten the blots in several passes, in the sequence
shown, by the specified torque.
Torque: 20 N
m (205 kgf
cm, 15 ft
lbf)
(f) Tighten the bolts in several passes, in the sequence
shown, by the specified torque.
Torque: 40 N
m (410 kgf
cm, 30 ft
lbf)
(g) Mark the front of the bearing cap bolts with paint.
(h) Retighten the bearing cap bolts by 90 in the numerical
order shown.
(i) Check that the painted mark is now at a 90angle to the
front.
(j) Check the crankshaft turns smoothly.
36. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the bearing cap and let not stick the oils and fats.
37. INSTALL PISTON
NOTICE:
The connecting rod cap bolts are tightened in 2 progres-
sive steps.
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.

A13874
90

A57516
Engine FrontPaint
Mark 14±58
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(d) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(e) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(f) Tighten the bolts in several passes by the specified
torque.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
(g) Mark the front of the connecting cap blots with paint.
(h) Retighten the cap bolts by 90
as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
SST 09011±38121, 99999±60012

140DV±01
SST
A57488Wooden Blocks
SST
A57489Wooden Blocks
A13356
14±30
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
CYLINDER HEAD ASSY (1AZ±FE)
OVERHAUL
1. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
2. REMOVE INTAKE VALVE
(a) Using SST and wooden blocks, compress and remove
the 8 valve spring retainer locks.
SST 09202±70020 (09202±00010)
(b) Remove the parts below from the cylinder head.
1Retainer
2Valve spring
3Intake valve
HINT:
Arrange the removed parts in the correct order.
3. REMOVE EXHAUST VALVE
(a) UsIng SST and wooden blocks, compress and remove
the 8 valve spring retainer locks.
SST 09202±70020 (09202±00010)
(b) Remove the parts below from the cylinder head.
1Retainer
2Valve spring
3Exhaust valve
4. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle±nose pliers, remove the oil seals.
5. REMOVE VALVE SPRING SEAT
6. REMOVE STUD BOLT

A57490
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A13365
EM0183A57491
Width
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±31
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
7. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side 0.08 mm (0.0031 in.)
Intake manifold side 0.08 mm (0.0031 in.)
Exhaust manifold side 0.08 mm (0.0031 in.)
8. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the intake ports, exhaust
ports and cylinder surface for cracks.
9. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360
around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360
around the valve sat, the guide
and face are concentric. If not, resurface the seat.
(3) Check that the sat contact is in the middle of the
valve face with the width between 1.0 ± 1.4 mm
(0.039 ± 0.055 in.).

1.0±1.4mm
45

30

A53031
1.0±1.4mm
75

45

A53032
A36626
A36627
14±32
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
10. REPAIR VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth seats.
(a) If the seating is too high on the valve face, use 30
and
45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 75
and 45

cutters to correct the seat.
(c) Hand±lap the valve and valve sat with an abrasive com-
pound.
(d) Check the valve seating position.
11. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
Intake 0.040 ± 0.095 mm (0.0016 ± 0.0037 in.)
Exhaust 0.080 ± 0.135 mm (0.0032 ± 0.0053 in.)
Maximum thrust clearance:
Intake 0.11 mm (0.0043 in.)
Exhaust 0.15 mm (0.0059 in.)
(c) If the thrust clearance is greater than maximum, replace
the cylinder head. If the thrust surface is damaged, re-
place the camshaft.
12. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of plastigage across each of the camshaft jour-
nal.

A32645
A36628
A57492Number MarkNumber Mark
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±33
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(d) Install the bearing caps.
Torque:
29.5 N
m (300 kgf
cm, 22 ft
lbf) for No. 1
29.5 N
m (300 kgf
cm, 22 ft
lbf) for No. 2
9 N
m (90 kgf
cm, 80 in.
lbf) for No. 3
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing cap, and measure the plastigage at
its widest point.
Standard oil clearance:
Intake No. 1 journal bearing mark 1
0.007 ± 0.038 mm (0.0028 ± 0.00150 in.)
Exhaust No. 1 journal
0.040 ± 0.079 mm (0.0016 ± 0.003 in.)
Other journals
0.025 ± 0.062 mm (0.00098 ± 0.00244 in.)
Maximum oil clearance:
Intake No. 1 journal 0.07 mm (0.0028 in.)
Other journals 0.10 mm (0.0039 in.)
NOTICE:
Completely remove the plastigage after the inspection.
(f) If the oil clearance is greater than maximum, replace the
camshaft. If necessary, replace the cylinder head.
(g) If the oil clearance on No.1 journal is greater than maxi-
mum, choose and replace the bearing.
Cylinder head journal bore diameter
Mark º1º40.000 ± 40.008 mm (1.57480 ± 1.57511 in.)
Mark º2º40.009 ± 40.017 mm (1.57515 ± 1.57547 in.)
Mark º3º40.018 ± 40.025 mm (1.57551 ± 1.57578 in.)
Standard bearing center wall thickness
Mark º1º2.000 ± 2.004 mm (0.07874 ± 0.07890 in.)
Mark º2º2.005 ± 2.008 mm (0.07894 ± 0.07905 in.)
Mark º3º2.009 ± 2.012 mm (0.07909 ± 0.07921 in.)
Camshaft journal diameter
35.971 ± 35.985 mm (1.41648 ± 1.41673 in.)