piston TOYOTA AVENSIS 2005 Service Owner's Guide

D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:
D26804
42±18
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE CLUTCH RELEASE CYLINDER ASSY
(EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type:
Remove the 3 bolts, clutch release cylinder assy, and
clutch line bracket.
(b) 1AZ±FE/1AZ±FSE Engine Type:
Remove the 3 bolts and clutch release cylinder assy.
6. REMOVE CLUTCH RELEASE CYLINDER ASSY
(1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, remove the 2 bolts
and clutch release cylinder assy.
7. REMOVE CLUTCH RELEASE CYLINDER KIT
(a) Remove the boot from the cylinder body.
(b) Remove the push rod from the cylinder body.
(c) Remove the piston from the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(d) Remove the spring from the cylinder body.
(e) Remove the bleeder plug cap from the bleeder plug.
8. REMOVE RELEASE CYLINDER BLEEDER PLUG
9. INSTALL RELEASE CYLINDER BLEEDER PLUG
Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)

CL0672
D26804
D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:(1)
(1)
(1)
(1)
(2) (2)
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
42±19
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL CLUTCH RELEASE CYLINDER KIT
(a) Install the bleeder plug cap to the bleeder plug.
(b) Install a new spring to the cylinder body.
(c) Coat the parts with lithium soap base glycol grease, as
shown in the illustration.
(d) Install the piston to the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(e) Install the push rod to the cylinder body.
(f) Install the boot to the cylinder body.
11. INSTALL CLUTCH RELEASE CYLINDER ASSY
(1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, install the clutch re-
lease cylinder assy with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
12. INSTALL CLUTCH RELEASE CYLINDER ASSY
(EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type:
(1) Install the clutch release cylinder and clutch line
bracket with the 2 bolts.
Torque: 14 N
m (141 kgf
cm, 10 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(b) 1AZ±FE/1AZ±FSE Engine Type:
(1) Install the clutch release cylinder with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)

4202X±03
D30055Lithium soap glycol grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part 1CD±FTV Engine Type:
Bleeder PlugRelease Cylinder Body
Piston
Push RodBoot Bleeder Plug
Cap
8.4 (85, 74 in.
lbf)
Wire Harness ClampClutch Accumulator Assy
Spring
1AZ±FSE/1AZ±FE Engine Type:
15 (155, 11)
12 (120, 9)


12 (120, 9)
Release Cylinder Body
12 (120, 9)
Release Cylinder Body
Clutch Line Clamp
Clutch Line Bracket
15 (155, 11)
12 (122, 9)
5.0 (51, 44 in.
lbf)1ZZ±FE/3ZZ±FE Engine Type:
15 (155, 11)Clutch Line Clamp
14 (141, 10)
15 (155, 11)
12 (120, 9)
42±16
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH RELEASE CYLINDER ASSY (MTM)
COMPONENTS

750NB±01
B65104
AB ab 75±48
± ENGINE HOOD/DOORBACK DOOR STAY
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
Use the same procedures on the RH side as on the LH side.
1. DISPOSE OF BACK DOOR STAY ASSY LH
(a) Horizontally fix the stay in a vise with the piston±rod pulled
out.
(b) Wearing safety glasses, gradually cut a part between A
and B as shown in the illustration using a metal saw to
gradually release the gas.
Standard dimension:
a80 mm (3.15 in.)
b20 mm (0.80 in.)
NOTICE:
Although the gas inside the stay is colorless, odorless and
harmless, there is a possibility that metal debris from cut-
ting could be blown out. Therefore, cover it with clothes or
thr like.

A77470
90
Engine FrontPaint
Mark
A38162
A77471
Mark
1, 2 or 3
Mark
1, 2 or 3
A13469
14±54
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(i) Place the front mark on each connecting rod cap bolt
head with paint.
(j) Retighten the cap bolts by 90 as shown in the illustration.
NOTICE:
Do not turn the crankshaft.
(k) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the Plastigage.
(m) If replacing the bearing, replace it with one having the
same number as marked on the connecting rod. There
are 3 sizes of standard bearings, marked º1º, º2º and º3º
accordingly.
HINT:
Standard bearing center wall thickness.
Mark 11.485 to 1.488 mm (0.0585 to 0.0586 in.)
Mark 21.488 to 1.491 mm (0.0586 to 0.0587 in.)
Mark 31.491 to 1.494 mm (0.0587 to 0.0588 in.)
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.

Store the piston and connecting rod assemblies in correct
order so they can be returned to the original locations
when re±installing.
4. REMOVE CONNECTING ROD BEARING

A14289
A13861
A01178
A01179
A13851
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±55
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
5. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
6. REMOVE PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 to 90 C (176 to 194 F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Store the pistons, pins, rings, connecting rods and bear-
ings in correct order so that they can be returned to the
original locations when re±assembling.
7. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.040 to 0.240 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
(b) If the thrust clearance is greater than maximum, replace
the thrust washers as a set.
Thrust washer thickness:
1.930 to 1.980 mm (0.0760 to 0.0780 in.)

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.

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.