TOYOTA AVENSIS 2005 Service Repair Manual

A64817
A64978
Oil Groove
Claw
A64979
Oil Groove
Claw
A64977
Upper Side Rail
Front
MarkCompression No. 2
Lower Side Rail Compression No. 1
and Expander
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–75
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(i) Tighten the 10 other bolts for the bearing cap.
Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)
33. INSTALL CONNECTING ROD BEARING
(a) Align the connecting rod bearing claw with the oil groove
of the connecting rod cap.
(b) Install the connecting rod bearing onto the connecting rod
cap.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
(c) Align the connecting rod bearing claw with the oil groove
of the connecting rod.
(d) Install the connecting rod bearing onto the connecting
rod.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
34. INSTALL CONNECTING ROD SUB–ASSY
(a) Position the piston rings so that the ring ends are as
shown.
(b) Apply engine oil to the cylinder walls, pistons, and sur-
faces of the connecting rod bearings.

A62813
Front Mark
Piston Ring
Compressor
A65713
Front Mark
A65714
SST
A65715
Paint Mark90 Engine
Front
A64845
14–76
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(c) Using a piston ring compressor, correctly push the num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
(d) Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, then install the connecting rod.
NOTICE:
Match the numbered connecting rod cap with the same
numbered connecting rod.
(e) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(f) Apply a light coat of engine oil to the threads and the bot-
tom of the heads of the connecting rod cap bolts.
(g) Using SST, tighten the bolts in several passes to the spe-
cified torque.
SST 09205–16010
Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf)
(h) Mark the front of the connecting cap bolts with paint.
(i) Retighten the cap bolts by an additional 90 as shown in
the illustration.
(j) Check that the crankshaft turns smoothly.
35. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB–ASSY
(a) Apply adhesive to 2 or 3 threads of the cylinder block wa-
ter drain cock, then install it within 3 minutes as shown in
the illustration.
Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf)
Adhesive:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent

A95730
9090
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–77
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(b) After applying the specified torque, rotate the cylinder
block water drain cock clockwise until its drain port faces
downward.
NOTICE:
Do not put into coolant for at least an hour after instal-
lation.
Do not rotate the drain union more than 360 in (b),
and never loosen it after setting the union correctly.

141TJ–01
A84914
Compression Ring No. 1Compression Ring No. 2 Oil Ring (Side Rail)

Snap Ring Piston
Piston Pin

Snap Ring
Connecting Rod Bearing
Cylinder Block Sub–assy
Crankshaft BearingCrankshaft Bearing Cap Sub–assy
Crankshaft Bearing
Crankshaft Thrust Washer Upper
Key
Crankshaft
Connecting Rod Bearing
Connecting Rod Bearing Cap
Oil Ring (Expander)
See page 14–51
1st 44 (449, 33)
2nd Turn 90 
1st 20 (204, 15)
2nd Turn 90
19 (194, 14)

Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torque Crankshaft
Thrust Washer Upper
Connecting Rod25 (255, 18)
Cylinder Block Water Drain Cock Sub–assy
See
page 14–51
14–50
–
ENGINE MECHANICAL CYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
CYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
COMPONENTS

141TN–01
A62766

Exhaust Valve Guide Bush
w/ Head Taper Screw Plug No. 2

Gasket
Intake Valve
Exhaust ValveCylinder Head Sub–assy Valve Lifter
Valve Spring Retainer Lock
Valve Spring Retainer
Inner Compression Spring

Valve Stem Oil O Seal or Ring
Valve Spring Seat

Intake Valve Guide Bush

Non–reusable part
N·m (kgf·cm, ft·lbf)
: Specified torque
44 (449, 33)
9.5 (97, 84 in.⋅lbf)
9.5 (97, 84 in.⋅lbf)
5.0 (51, 44 in.⋅lbf)
9.5 (97, 84 in.⋅lbf)

Ring Pin
5.0 (51, 44 in.⋅lbf)

Union

Union

Union
x8
x2 x5
x8
x8 Stud Bolt
Stud Bolt
Stud Bolt
Stud BoltStud Bolt x8
x8
x8
x8
x8
x8x8
x8
x8
x8
x8
x8
x8
– ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE)
14–37
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE)
COMPONENTS