TOYOTA AVENSIS 2005 Service Repair Manual

A62196
4123
A62197
Painted Link
Timing Mark
A32124
A621983124 5 67
A62187
Fix
Tighten 14±24
± ENGINE MECHANICALPARTIAL 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.

A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Groove
A62177
Raise
Push
Hook
Pin
A62178
Push
A62180
Disconnect
Hook
Pin Turn
± ENGINE MECHANICALPARTIAL 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 as
shown 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.

A62181
Plunger
Turn
Push
A10085
A62182
Seal Packing
14±26
± ENGINE MECHANICALPARTIAL 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)

0214S±01
02±2
± PREPARATIONENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
ENGINE MECHANICAL
PREPARATION
SST
09032±00100Oil Pan Seal CutterPARTIAL ENGINE ASSY(1CD±FTV)
09201±10000Valve Guide Bushing Remover &
Replacer SetCYLINDER HEAD ASSY(1CD±FTV)
(09201±01060)Valve Guide Bushing Remover &
Replacer 6CYLINDER HEAD ASSY(1CD±FTV)
09202±70020Valve Spring CompressorCYLINDER HEAD ASSY(1CD±FTV)
(09202±00010)AttachmentCYLINDER HEAD ASSY(1CD±FTV)
09223±15030Oil Seal & Bearing ReplacerPARTIAL ENGINE ASSY(1CD±FTV)
09223±46011Crankshaft Front Oil Seal
ReplacerPARTIAL ENGINE ASSY(1CD±FTV)
09248±55050Valve Clearance Adjust Tool SetPARTIAL ENGINE ASSY(1CD±FTV)
(09248±05510)Valve Lifter PressPARTIAL ENGINE ASSY(1CD±FTV)
(09248±05520)Valve Lifter StopperPARTIAL ENGINE ASSY(1CD±FTV)
09316±60011Transmission & Transfer Bearing
ReplacerPARTIAL ENGINE ASSY(1CD±FTV)
(09316±00011)Replacer PipePARTIAL ENGINE ASSY(1CD±FTV)

± PREPARATIONENGINE MECHANICAL
02±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(09316±00021)Replacer ºAºPARTIAL ENGINE ASSY(1CD±FTV)
09950±50013Puller C SetPARTIAL ENGINE ASSY(1CD±FTV)
(09951±05010)Hanger 150PARTIAL ENGINE ASSY(1CD±FTV)
(09952±05010)Slide ArmPARTIAL ENGINE ASSY(1CD±FTV)
(09953±05010)Center Bolt 100PARTIAL ENGINE ASSY(1CD±FTV)
(09953±05020)Center Bolt 150PARTIAL ENGINE ASSY(1CD±FTV)
(09954±05021)Claw No.2PARTIAL ENGINE ASSY(1CD±FTV)
09950±60010Replacer SetCYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
(09951±00210)Replacer 21CYLINDER HEAD ASSY(1CD±FTV)
(09951±00350)Replacer 35CYLINDER BLOCK(1CD±FTV)
09950±70010Handle SetCYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09951±07100)Handle 100CYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetPARTIAL ENGINE ASSY(1CD±FTV)

02±4
± PREPARATIONENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(09962±01000)Variable Pin Wrench Arm AssyPARTIAL ENGINE ASSY(1CD±FTV)
(09963±01000)Pin 10PARTIAL ENGINE ASSY(1CD±FTV)
09992±00242Turbocharger Pressure GaugePARTIAL ENGINE ASSY(1CD±FTV)
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)CYLINDER HEAD ASSY(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
08826±00100ºSeal Packing 1282B,º
THREE BOND 1282B or equivalent
(FIPG)PARTIAL ENGINE ASSY(1CD±FTV)
08833±00070ºAdhesive 1324,º
THREE BOND 1324 or equivalentCYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
Equipment
V±block
Piston ring compressor
Piston ring expander
Valve seat cutter
Hexagon wrench (6 mm)
Hexagon wrench (8 mm)
Connecting rod aligner
Cylinder gauge
Dial indicator
Feeler gauge
Micrometer
Precision straight edge
Steel square
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Slide calipers
Wooden block
Spring tester
Plastigage
Heater

030KT±01
± SERVICE SPECIFICATIONSINTAKE
03±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
V Band8.38574 in.´lbf
Compressor housing x Bearing housing4.74842 in.´lbf
Turbocharger actuator x Compressor housing7.88069 in.´lbf
Compressor inlet elbow x Compressor housing2323517

140DS±02
A09477
A09488
A09492
A09494
Plastigage
14±40
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.08 ± 0.30 mm (0.0031 ± 0.0118 in.)
Maximum thrust clearance: 0.40 mm (0.0157 in.)
If the thrust clearance is greater then maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using 2 removed connecting rod cap bolts, remove the
connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pits and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Lay a strip of plastigage across the crank pin.

A09514
Front Mark
(Protrusion)
A09493
90

90

A09490
Front
Painted Mark
A09495
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±41
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(g) Match the numbered connecting rod cap with the con-
necting rod.
(h) Install the connecting rod cap with the front mark facing
forward.
(i) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(j) Install and alternately tighten the 2 cap bolts in several
passes.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
If any of the cap bolts does not meet the torque specification,
replace the connecting rod cap bolts.
(k) Mark the front of the cap bolt with the paint.
(l) Retighten the cap bolts 90
as shown.
(m) Check that the painted mark is now at a 90
angle to the
front.
NOTICE:
Do not turn the crankshaft.
(n) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
(o) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 ± 0.056 mm (0.0015 ± 0.0022 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.

A09472
No.1
No.2
No.3
No.4
Mark
0,1 or 2Mark
1, 2, 3, 4 or 5Mark
1, 2 or 3
A56037
Ridge reamer
14±42
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(p) If using a standard bearing, replace it with one having the
same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together
the numbers imprinted on the crankshaft and connecting
rod cap, then select the bearing with the same number as
the total. There are 5 sizes of standard bearings, marked
º1º, º2º, º3º, º4º and º5º accordingly.
Connecting rod capCrankshaftUse bearing
101
112
123
202
213
224
303
314
325
HINT:
EXAMPLE: Connecting rod cap º2º + Crankshaft º1º
= total number 3 (Use bearing º3º)
Connecting rod big end inside diameter:
Mark º1º53.500 ± 53.506 mm (2.1063 ± 2.1065 in.)
Mark º2º53.506 ± 53.512 mm (2.1065 ± 2.1068 in.)
Mark º3º53.512 ± 53.518 mm (2.1068 ± 2.1070 in.)
Crankshaft crank pin diameter:
Mark º0º50.494 ± 50.500 mm (1.9880 ± 1.9882 in.)
Mark º1º50.488 ± 50.494 mm (1.9877 ± 1.9880 in.)
Mark º2º50.482 ± 50.488 mm (1.9875 ± 1.9877 in.)
Standard sized bearing center wall thickness:
Mark º1º1.478 ± 1.481 mm (0.0582 ± 0.0583 in.)
Mark º2º1.481 ± 1.484 mm (0.0583 ± 0.0584 in.)
Mark º3º1.484 ± 1.487 mm (0.0584 ± 0.0585 in.)
Mark º4º1.487 ± 1.490 mm (0.0585 ± 0.0587 in.)
Mark º5º1.490 ± 1.493 mm (0.0587 ± 0.0588 in.)
(q) Completely remove the Plastigage.
3. REMOVE PISTON SUB±ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearing, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.
4. REMOVE CONNECTING ROD BEARING