TOYOTA AVENSIS 2005 Service Repair Manual

A87939
6mm
Hexagon
Wrench
A87944
A09502
A09501
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−47
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
8. REMOVE CYLINDER BLOCK OIL ORIFICE
(a) Using a hexagon wrench (6 mm), remove the oil orifice.
9. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the No. 1 and No.
2 piston ring and oil ring.
NOTICE:
Try to keep the piston ring expansion as small as possible.
(b) Remove the coil by hand.
HINT:
Arrange the piston rings in the correct order.
10. REMOVE W/PIN PISTON SUB−ASSY
(a) Using a small screwdriver, pry the snap rings off the pis-
ton.
(b) Gradually heat the piston up to approximately 60_C
(140_F).
(c) Using a plastic−faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:
SThe piston and pin are a matched set.
SArrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

A09453
10mm
(0.39 in)
10mm
(0.39 in)
A09455
1
2 Front
Thrust
Direction
Axial
Direction1
2
A
B
C
A88537
14 mm
(0.55 in.) 14−48
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
11. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the warpage on the surface which contacts the cylin-
der head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder
block.
12. INSPECT CYLINDER BORE DIAMETER
(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:
82.200 to 82.400 mm (3.2362 to 3.2441 in.)
If the diameter is greater than maximum, replace the cylinder
block.
13. INSPECT W/PIN PISTON SUB−ASSY
(a) Using a micrometer, measure the piston diameter at a
right angle to the piston pin center line and 14 mm (0.55
in.) from the skirt bottom edge.
Piston diameter:
82.118 to 82.132 mm (3.2330 to 3.2335 in.)

A09693
EM0227
Z00064
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−49
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(b) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.068 to 0.140 mm (0.0027 to 0.0055 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons. If necessary, replace the cylinder block.
(c) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
31.015 to 31.027 mm (1.2211 to 1.2215 in.)
(d) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
31.000 to 31.012 mm (1.2205 to 1.2209 in.)
(e) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 to 0.019 mm (0.0002 to 0.0007 in.)
If the oil clearance is greater than maximum, replace the con-
necting rod. If necessary, replace the piston and piston pin as
a set.
14. INSPECT CONNECTING ROD SUB−ASSY
(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Inspect the misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the alignment is greater than maximum, replace the connect-
ing rod assembly.

Z00065
A87945
A88538
11 0 m m
(4.33 in.)
EM7639
14−50− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(2) Inspect the twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than maximum, replace the connecting rod
assembly.
15. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between a
new piston ring and wall of the ring groove.
Ring groove clearance:
No. 10.11 to 0.15 mm (0.0043 to 0.0059 in.)
No. 20.075 to 0.115 mm (0.0030 to 0.0045 in.)
Oil0.03 to 0.07 mm (0.0012 to 0.0028 in.)
If the clearance is not as specified, replace the piston.
16. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring until it is a little below
the bottom of the ring travel, 110 mm (4.33 in.) from the
top of the cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 10.27 to 0.39 mm (0.0106 to 0.0514 in.)
No. 20.39 to 0.54 mm (0.0154 to 0.0213 in.)
Oil0.20 to 0.40 mm (0.0079 to 0.0157 in.)
Maximum end gap:
No. 10.82 mm (0.0323 in.)
No. 21.00 mm (0.0394 in.)
Oil0.90 mm (0.0354 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.

A09491
20 mm (0.79 in.)
A56040
A56041
A09474
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−51
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
17. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter.
Standard diameter:
8.0 to 8.3 mm (0.315 to 0.327 in.)
If the diameter is less than minimum, replace the connecting rod
bolt.
18. INSPECT CRANKSHAFT
(a) Place the crankshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.025 mm (0.0010 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(c) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
56.992 to 57.010 mm (2.2438 to 2.2445 in.)
Crank pin diameter:
50.482 to 50.500 mm (1.9875 to 1.9882 in.)
If the diameter is not as specified, replace the crankshaft.
(d) Check each main journal and crank pin for taper and out−
of−round as illustrated.
Maximum taper and out−of−round:
0.01 mm (0.0004 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
19. INSPECT CYLINDER BLOCK OIL ORIFICE
(a) Check the oil orifice for clogging.
If necessary, replace the oil orifice.
20. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Clean each main journal and bearing.

A56038
A56042
A56039Groove
A09512
Groove
A09499
Plastigage
14−52− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(b) Install the bearing on the cylinder block and bearing cap.
HINT:
Each upper bearing has an oil groove and oil hole and each low-
er bearing does not.
(1) Align the bearing claw with the claw groove of the
cylinder clock, then push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the
main bearing cap, then push in the 5 lower bear-
ings.
(c) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
(d) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.
(e) Place the crankshaft on the cylinder block.
(f) Lay a strip of Plastigage across each journal.

A56043
A09497
A09500
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−53
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(g) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(h) Apply a light coat of engine oil to the threads and under
the heads of the main bearing cap bolts.
(i) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several steps.
Torque: 115 N
m (1,173 kgf
cm, 85 ft
lbf)
NOTICE:
Do not turn the crankshaft.
(j) Remove the bearing cap.
(k) Measure the Plastigage at its widest point.
Standard oil clearance:
0.032 to 0.100 mm (0.0013 to 0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ing. If necessary, replace the crankshaft.

A09688
No. 1No. 2
No. 3
No. 4
No. 5No. 1
No. 2No. 3
No. 4
No. 5
Mark
1, 2 or 3
Mark
0, 1 or 2Mark
1, 2, 3, 4 or 5
14−54− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(l) If using the standard bearing, replace it with one having
the same number. If the number of the bearing cannot be
determined, find the correct number of the bearing by ad-
ding together the numbers imprinted on the cylinder block
and crankshaft, then select the bearing with the same
number as the total. There are 5 sizes of standard bear-
ings, marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly.
Number Marked
Cylinder BlockCrankshaftUse Bearing
101
112
123
202
213
224
303
314
325
HINT:
EXAMPLE
Cylinder block ”2” + Crankshaft ”1” = Total number 3 (Use bear-
ing ”3”)
Cylinder block main journal bore diameter:
Mark ”1”61.000 to 61.006 mm (2.4016 to 2.4018 in.)
Mark ”2”61.006 to 61.012 mm (2.4018 to 2.4020 in.)
Mark ”3”61.012 to 61.018 mm (2.4020 to 2.4023 in.)
Crankshaft main journal diameter:
Mark ”0”57.004 to 57.010 mm (2.2443 to 2.2445 in.)
Mark ”1”56.998 to 57.004 mm (2.2440 to 2.2443 in.)
Mark ”2”56.992 to 56.998 mm (2.2438 to 2.2440 in.)
Standard size bearing center wall thickness:
Mark ”1”1.976 to 1.979 mm (0.0778 to 0.0779 in.)
Mark ”2”1.979 to 1.982 mm (0.0779 to 0.0780 in.)
Mark ”3”1.982 to 1.985 mm (0.0780 to 0.0781 in.)
Mark ”4”1.985 to 1.988 mm (0.0781 to 0.0783 in.)
Mark ”5”1.988 to 1.991 mm (0.0783 to 0.0784 in.)
(m) Completely remove the Plastigage.

A59623
Intake Side:
Front Side:Exhaust Side:
Rear Side:
1.5 mm
(0.059 in.)2.0 mm
(0.079 in.)2.0 mm
(0.079 in.)
A
BA 1.5 mm
(0.059 in.)
B 2.0 mm
(0.079 in.)
A
A
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−55
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
21. INSTALL TIGHT PLUG
(a) Apply adhesive around new tight plugs.
Adhesive: Part No.08833−00070, THREE BOND 1324
or equivalent.
(b) Using SST, tap in the tight plugs as shown tn the illustra-
tion.
SST 09950−60010 (09951−00350), 09950−70010
(09951−07100)
Standard depth:
2.0 mm (0.079 in.) for intake side
2.0 mm (0.079 in.) for exhaust side
1.5 mm (0.059 in.) for front side
1.5 mm (0.059 in.) for rear side A
2.0 mm (0.079 in.) for rear side B

A87940
Cylinder Head Side: Lower Side:
Front Side:
A
11 mm (0.433 in.)
20 mm
(0.787 in.)
14 mm (0.55 in.) 8mm
(0.315 in.)
AAA
B B
Protrusion Height: 5.0 mm (0.197 in.)
Protrusion Height: 13 mm (0.512 in.)
BA 14−56
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
22. INSTALL RING PIN
(a) Using a plastic−faced hammer, tap in new ring pins until
their protrusion heights are as specified.