TOYOTA AVENSIS 2005 Service Repair Manual

A95721
Matchmark
A95723
SST
A01159
Plastigage
A95727
Front Mark
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–55
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(d) Measure the oil clearance of the No. 1 and No. 4 cylin-
ders.
NOTICE:
Do not turn the crankshaft during the measurement.
(1) Using marking paint, write the matched cylinder
number on each connecting rod and cap.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring correct reassembling.
(2) Using SST, remove the 4 bolts and 2 connecting rod
caps as shown.
SST 09205–16010
(3) Clean the crank pin and bearing.
(4) Check the crank pin and bearing for pitting and
scratches.
(5) Lay a strip of Plastigage across the crank pin.
(6) Check that the front marks of the connecting rod
cap are facing in the correct direction.
(7) Apply a light coat of engine oil to the threads and un-
der the heads of the connecting rod cap bolts.

A95723
SST
A65715
Paint Mark90 Engine
Front
A95723
SST
14–56
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(8) Using SST, tighten the 2 bolts in several passes to
the specified torque.
SST 09205–16010
Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf)
(9) Mark the front of the connecting cap bolts with paint.
(10) Retighten the cap bolts by an additional 90 as
shown in the illustration.
(11) Check that the crankshaft turns smoothly.
(12) Remove the 4 bolts and 2 connecting rod caps.

A01160
A95729
Connecting Bearing Cap: Connecting Bearing:
TAIHO Mark Lot. Number Mark
TAIHO Made
FEDERAL MOGUL
/GLYCO Made
MarkMark
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–57
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(13) Measure the Plastigage at its widest point.
Standard oil clearance:
0.028 to 0.060 mm (0.0011 to 0.0024 in.)
Maximum oil clearance: 0.080 mm (0.0031 in.)
NOTICE:
Remove the Plastigage completely after the measurement.
If the oil clearance is greater than maximum, re-
place the connecting rod bearing.
If necessary, grind or replace the crankshaft.
HINT:
The TAIHO mark is either on the claw side or the opposite
side.
If replacing a bearing, select a new one having the same
number as marked on the connecting rod. There are 3
sizes of standard bearings, marked ”1”, ”2” and ”3” ac-
cordingly.
ItemMarkSpecification
Connecting rod bearing cap
bore diameter1
2
347.000 to 47.008 mm (1.8504 to 1.8507 in.)
47.009 to 47.016 mm (1.8507 to 1.8510 in.)
47.017 to 47.024 mm (1.8511 to 1.8513 in.)
Connecting rod bearing
thickness1
2
31.486 to 1.490 mm (0.0585 to 0.0587 in.)
1.491 to 1.494 mm (0.0587 to 0.0588 in.)
1.495 to 1.498 mm (0.0589 to 0.0590 in.)
Crankshaft pin outer diame-
ter–43.992 to 44.000 mm (1.7320 to 1.7323 in.)

A01166
A64813
A64814
A64815
A01175
Piston Ring
Expander
14–58
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
4. REMOVE CONNECTING ROD SUB–ASSY
(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.
5. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearing from the connecting
rod cap.
(b) Remove the connecting rod bearing from the connecting
rod.
6. 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.

A01192
A63898
A01179
A64817
A64968
793
481062
15
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–59
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
7. REMOVE W/PIN PISTON SUB–ASSY
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Heat the piston up to 80 to 90C (176 to 194F).
(c) Using a plastic hammer and brass bar, lightly tap out the
piston pin, then remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the piston, pins, ring, connecting rod and bear-
ings in the correct order.
8. REMOVE CRANKSHAFT
(a) Remove the 10 bolts from the crankshaft bearing cap.
(b) Uniformly loosen the 10 bearing cap bolts in several
passes in the sequence shown in the illustration.

A95732
Crankshaft
Bearing Cap
A64820
A32142
A64821
14–60
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(c) Using a screwdriver, remove the crankshaft bearing cap
by prying the indicated portions between the cylinder
block and bearing cap.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and bearing cap.
(d) Remove the crankshaft from the cylinder block.
9. 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:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum,
measure the thrust washer thickness.
If the thickness is not as specified, replace the thrust
washer.
HINT:
Thrust washer thickness: 2.430 to 2.480 mm (0.0957 to 0.0976
in.).
10. REMOVE CRANKSHAFT THRUST WASHER UPPER
(a) Remove the 2 crankshaft thrust washers from the cylinder
block.

A64822
A64823
A64969
Crankshaft Bearing Cap Side: Intake Side: Upper Side:
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–61
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
11. REMOVE CRANKSHAFT BEARING
(a) Remove the 5 crankshaft bearings from the cylinder
block.
NOTICE:
Arrange the main bearings and thrust washers in the cor-
rect order.
(b) Remove the 5 crankshaft bearings from the crankshaft
bearing cap.
NOTICE:
Arrange the main bearings and thrust washers in the cor-
rect order.
12. REMOVE STUD BOLT
(a) Using Torx socket wrenches E5 and E7, remove the 9
stud bolts.

A64825
A95449
Axial Direction
A
B10 mm (0.394 in.) Thrust Direction
A95733
13.0 mm
(0.512 in.) 14–62
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
13. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the warpage on the surface which comes into con-
tact with the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder
block.
14. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A and B in the thrust and axial directions.
Standard diameter:
79.000 to 79.013 mm (3.1102 to 3.1107 in.)
Maximum diameter: 79.133 mm (3.1155 in.)
If the average diameter of 4 positions is greater than maximum,
replace the cylinder block.
15. INSPECT W/PIN PISTON SUB–ASSY
(a) For engine type 1ZZ–FE.
(1) Using a micrometer, measure the diameter of the
piston. Align the micrometer so it is 13.0 mm (0.512
in.) from the bottom of the piston and at right angles
(90) to the piston pin holes as illustrated.
Piston diameter:
78.955 to 78.965 mm (3.1085 to 3.1089 in.)
If the diameter is not as specified, replace the piston.

A95733
13.5 mm
(0.531 in.)
A13490
EM0227
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–63
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(b) For engine type 3ZZ–FE.
(1) Using a micrometer, measure the diameter of the
piston. Align the micrometer so it is 13.5 mm (0.531
in.) from the bottom of the piston and at right angles
(90) to the piston pin holes as illustrated.
Piston diameter:
78.960 to 78.975 mm (3.1087 to 3.1091 in.)
If the diameter is not as specified, replace the piston.
16. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.073 to 0.096 mm (0.0029 to 0.0038 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace all of the piston assembly.
If necessary, replace the cylinder block.
17. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the piston pin bore diam-
eter.
Piston pin bore diameter:
20.006 to 20.015 mm (0.7876 to 0.7880 in.)
Markmm (in.)
A20.006 to 20.009 (0.7876 to 0.7878)
B20.010 to 20.012 (0.7878 to 0.7879)
C20.013 to 20.015 (0.7879 to 0.7880)
If the diameter is not as specified, replace the piston assembly.
(b) Using a micrometer, measure the piston pin outer diame-
ter.
Piston pin outer diameter:
20.004 to 20.013 mm (0.7876 to 0.7879 in.)
Markmm (in.)
A20.004 to 20.007 (0.7876 to 0.7877)
B20.008 to 20.010 (0.7877 to 0.7878)
C20.011 to 20.013 (0.7878 to 0.7879)
If the diameter is not as specified, replace the piston assembly.

A01185
A64970
Front Mark
Connecting Rod
Small End
Bore Diameter
MarkPiston Pin
Bore Diameter
Mark
Front Mark
Piston:
Connecting Rod:
A01171
14–64
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(c) Using a caliper gauge, measure the connecting rod small
end bore diameter.
Connecting rod small end bore diameter:
20.012 to 20.021 mm (0.7879 to 0.7882 in.)
Markmm (in.)
A20.012 to 20.015 (0.7879 to 0.7880)
B20.016 to 20.018 (0.7880 to 0.7881)
C20.019 to 20.021 (0.7881 to 0.7882)
If the diameter is not as specified, replace the connecting rod
assembly.
(d) Subtract the piston pin outer diameter measurement from
the piston pin bore diameter measurement.
Standard oil clearance:
–0.001 to 0.017 mm (–0.00004 to 0.0007 in.)
Maximum oil clearance: 0.017 mm (0.0007 in.)
If the oil clearance is greater than maximum, re-
place the connecting rod assembly.
If necessary, replace the piston pin.
(e) Subtract the piston pin outer diameter measurement from
the connecting rod small end bore diameter measure-
ment.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.011 mm (0.0004 in.)
If the oil clearance is greater than maximum, re-
place the connecting rod assembly.
If necessary, replace the connecting rod and piston
pin.
18. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the new piston ring and wall of the ring groove.
Ring groove clearance:
ItemSpecification
No. 1 ring0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No. 2 ring0.03 to 0.07 mm (0.0012 to 0.0028 in.)
Oil ring0.03 to 0.11 mm (0.0012 to 0.0043 in.)
If the groove clearance is not as specified, replace the piston
assembly.