2003 TOYOTA AVENSIS Service Repair Manual

load capacity oil capacities lug pattern ABS coolant capacity oil dipstick

Page 833 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 0300O±02
03±4
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
ENGINE MECHANICAL
SERVICE DATA
Chain sub±assy
Length at 16 links Maximum
112.6 mm (4.433 in.)

0300O±02
03±4
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
ENGINE MECHANICAL
SERVICE DATA
Chain sub±assy
Length at 16 links Maximum
112.6 mm (4.433 in.)
Camshaft timing gear or sprocket
Diameter (w/ chain) Minimum
97.3 mm (3.831 in.)
Crankshaft timing gear or sprocket
Diameter (w/ chain) Minimum
51.6 mm (2.032 in.)
Chain tensioner slipper
Wear Maximum
1.0 mm (0.039 in.)
Chain vibration damper No. 1
Wear maximum
1.0 mm (0.039 in.)
Cylinder head set bolt
Length Standard Maximum
156.0 ± 159.0 mm (6.142 ± 6.260 in.)
159.5 mm (6.280 in.)
Camshaft
Circle runout Maximum
Lobe height Standard Intake
Exhaust
Minimum Intake Exhaust
Journal diameter No. 1 Others
Thrust clearance Standard
Maximum
Oil clearance Standard Maximum
0.03 mm (0.0012 in.)
44.333 ± 44.433 mm (1.7454 ± 1.7493 in.)
43.761 ± 43.861 mm (1.7229 ± 1.7268 in.)
44.18 mm (1.7394 in.)
43.61 mm (1.7169 in.)
34.449 ± 34.465 mm (1.3563 ± 1.3569 in.)
22.949 ± 22.965 mm (0.9035 ± 0.9041 in.)
0.040 ± 0.095 mm (0.0009 ± 0.0023 in.)
0.110 mm (0.0043 in.)
0.035 ± 0.072 mm (0.0014 ± 0.0028 in.)
0.10 mm (0.0039 in.)
Valve clearance (Cold) Intake
Exhaust0.15 ± 0.25 mm (0.006 ± 0.010 in.)
0.25 ± 0.35 mm (0.010 ± 0.014 in.)
Cylinder head sub±assy
Warpage Maximum Cylinder block side Intake manifold side
Exhaust manifold side
0.05 mm (0.0020 in.)
0.10 mm (0.0040 in.)
0.10 mm (0.0040 in.)
Valve guide bushing
Inside diameter
Oil clearance Standard Intake Exhaust
Maximum Intake Exhaust
Bore diameter
Protrusion height
5.510 ± 5.530 mm (0.2169 ± 0.2177 in.)
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
0.08 mm (0.0031 in.)
0.01 mm (0.0039 in.)
10.285 ± 10.306 mm (0.4049 ± 0.4057 in.)
8.7 ± 9.1 mm (0.342 ± 0.358 in.)
Valve stem
Diameter Intake Exhaust
5.470 ± 5.485 mm (0.2154 ± 0.2159 in.)
5.465 ± 5.480 mm (0.2152 ± 0.2158 in.)
Inner compression spring
Free length
Deviation Maximum
Angle (reference) Maximum
43.40 mm (1.7087 in.)
2.0 mm (0.078 in.)
2
Valve
Overall length Standard Intake
Exhaust
Minimum Intake Exhaust
Head margin thickness Standard
Minimum
88.65 mm (3.4902 in.)
88.69 mm (3.4917 in.)
88.35 mm (3.4874 in.)
88.39 mm (3.4799 in.)
1.0 mm (0.039 in.)
0.7 mm (0.028 in.)
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Page 834 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual ±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
Valve lifter
Diameter
Bore diameter
Oil clearance Standard
Maximum
30.966 ± 30.976 mm (1.2191 ± 1.2195

±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
Valve lifter
Diameter
Bore diameter
Oil clearance Standard
Maximum
30.966 ± 30.976 mm (1.2191 ± 1.2195 in.)
31.000 ± 31.025 mm (1.2205 ± 1.2215 in.)
0.024 ± 0.059 mm (0.0016 ± 0.0037 in.)
0.1 mm (0.0039 in.)
Straight pin
Protrusion height
5 mm (0.20 in.)
Union protrusion
Protrusion height Standard A B
C
29 mm (1.14 in.)
66.5 mm (2.62 in.)
24 mm (0.95 in.)
Connecting rod sub±assy
Thrust clearance Standard Maximum
Oil clearance Standard Maximum
Out±of alignment Maximum per/100 mm (3.94 in.)
Twist Maximum per/100 mm (3.94 in.)
0.160 ± 0.342 mm (0.063 ± 0.0135 in.)
0.342 mm (0.0135 in.)
0.028 ± 0.060 mm (0.0011 ± 0.0024 in.)
0.080 mm (0.0031 in.)
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
Connecting rod bearing
Center wall thickness Reference Mark 1 Mark 2
Mark 3
1.486 ± 1.490 mm (0.0585 ± 0.0587 in.)
1.490 ± 1.494 mm (0.0587 ± 0.0588 in.)
1.494 ± 1.498 mm (0.0588 ± 0.0590 in.)
Crankshaft
Thrust clearance StandardMaximum
Circle runout Maximum
Main journal diameter Maximum taper and out±of±round
Oil clearance Standard Maximum
0.04 ± 0.24 mm (0.0016 ± 0.0094 in.)
0.30 mm (0.0118 in.)
0.03 mm (0.0012 in.)
47.988 ± 48.000 mm (1.8893 ± 1.8898 in.)
0.02 mm (0.0008 in.)
0.013 ± 0.030 mm (0.0005 ± 0.0012 in.)
0.05 mm (0.0020 in.)
Cylinder block sub±assy
Warpage Maximum
Bore diameter StandardMaximum
0.05 mm (0.0020 in.)
79.000 ± 79.013 mm (3.1073 ± 3.1108 in.)
79.013 mm (3.1108 in.)
Piston
Diameter (at 29.8 mm (1.173 in.) from the piston head) 1ZZ±FE 3ZZ±FE
Oil clearance Standard 1ZZ±FE 3ZZ±FE
Maximum 1ZZ±FE
3ZZ±FE
78.925 ± 78.935 mm (3.1073 ± 3.1077 in.)
78.955 ± 78.965 mm (3.1085 ± 3.1089 in.)
0.065 ± 0.088 mm (0.0026 ± 0.0035 in.)
0.035 ± 0.058 mm (0.0014 ± 0.0023 in.)
0.088 mm (0.0035 in.)
0.058 mm (0.0023 in.)
Piston ring
Groove clearance No. 1 No. 2
End gap Standard No. 1 No. 2
Maximum No. 1
No. 2
0.020 ± 0.070 mm (0.0008 ± 0.0028 in.)
0.030 ± 0.070 mm
0.25 ± 0.35 mm (0.0098 ± 0.0138 in.)
0.35 ± 0.50 mm (0.0138 ± 0.0197 in.)
0.74 mm (0.029 in.)
0.89 mm (0.035 in.)
Piston pin
Diameter
20.004 ± 20.013 mm (0.7876 ±0.7879 in.)
Connecting rod bolt
Diameter Standard Maximum
6.6 ±6.7 mm (0.260 ± 0.264 in.)
6.4 mm (0.252 in.)
Crank pin
DiameterMaximum taper and out±of±round
43.992 ± 44.000 mm (1.7320 ± 1.7323 in.)
0.02 mm (0.0008 in.)
Crankshaft bearing cap set bolt
Diameter Standard Maximum
7.3 ± 7.5 mm (0.287 ± 0.295 in.)
7.2 mm (0.283 in.)
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Page 835 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 03±6
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
Straight pin
Timing chain or belt cover sub±assy x cylinder block sub±assy
length 15 mm (0.59 in.)
len

Page 836 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 030K6±01
03±2
±
SERVICE SPECIFICATIONS STANDARD BOLT
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHex

Page 837 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 0300Q±02
03±10
±
SERVICE SPECIFICATIONS STARTING & CHARGING
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
STARTING & CHARGING
SERVICE DATA
Starter armature assy
Circle runout Maximum
Commutator dia

Page 838 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 0300R±02
±
SERVICE SPECIFICATIONS STARTING & CHARGING
03±11
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
Starter commutator end frame assy x St

Page 839 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
Cylinder block water drain cock sub±assy

0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
Cylinder block water drain cock sub±assy x Cylinder block sub±assy\
2020415
Oil strainer sub±assy x Cylinder block sub±assy9.09280 in. lbf
Oil pan sub±assy x Cylinder block sub±assy9.09280 in.lbf
Oil pan drain plug x Oil pan sub±assy3737727
Oil filter union x Cylinder block sub±assy3030622
Oil pump assy x Cylinder block sub±assy9.09280 in.lbf
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90500
Turn 9036
Turn 90
Oil control valve filter x Cylinder head sub±assy3030622
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in. lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing gear or sprocket x Camshaft No. 25455140
Camshaft, Camshaft No. 2 x Cylinder head sub±assy Bearing cap No. 1
Bearing cap No. 323
13235
13317
10
Chain vibration damper No. 1 x Cylinder head sub±assy9.09280 in.lbf
Chain vibration damper No. 1 x Cylinder block sub±assy9.09280 in.lbf
Chain tensioner slipper x Cylinder block sub±assy1919414
Timing chain or belt cover sub±assy x Cylinder head sub±assy1313310
Timing chain or belt cover sub±assy x Cylinder block sub±assy M6
M813
19133
19410
14
Chain tensioner assy No. 1 x Cylinder head sub±assy9.09280 in.lbf
Crankshaft pulley x Crankshaft1381,407102
Water pump assy x Cylinder block sub±assy1111 28
Water pump assy x Timing chain or belt cover sub±assy9.09280 in.lbf
Cylinder head cover sub±assy x Cylinder head sub±assy w/o washer
w/ washer11
9.011 2 928
80 in. lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Spark plug x Cylinder head sub±assy2525518
Stud bolt
Timing chain or belt cover sub±assy x Cylinder head sub±assy
length 89 mm (3.50 in.)
length 53.5 mm (2.11 in.)
Cylinder head cover sub±assy x Cylinder head sub±assy
Intake manifold x Cylinder head sub±assy
Exhaust manifold x Cylinder head sub±assy
9.5
5.0
5.0
9.5
9.597
51
51
97
9784 in. lbf
44 in. lbf
44 in. lbf
84 in. lbf
84 in. lbf
W/ Head taper screw plug No. 2 x Cylinder head sub±assy4444933
Crankshaft bearing cap sub±assy x Cylinder block sub±assy M10 1st
2nd3rd
M822
44
Turn 90 19224
449
Turn 90 19416
33
Turn 90 14
Connecting rod x Connecting rod cap 1st
2nd20
Turn 90204
Turn 9015
Turn 90
Stud bolt
Water by±pass pipe No. 1 x Cylinder block sub±assy
Water inlet x Cylinder block sub±assy
Oil strainer sub±assy x Cylinder block sub±assy
Oil pan sub±assy x Cylinder block sub±assy
Knock control sensor x Cylinder block sub±assy
5.0
5.0
5.0
5.0 1151
51
51
51
11 244 in. lbf
44 in. lbf
44 in. lbf
44 in. lbf
8
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Page 840 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 190A9±01
A62217
Generator PulleyGenerator Drive End Frame
Terminal Insulator
Generator Rotor Assy Washer
Generator Rectifier End Frame Generator
Cord Clip
Generator Plate SealGenerator Holder W/ Rec

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