2003 TOYOTA AVENSIS length

A62818
Raise
Move
Lock
A62819
Measuring Area
012345 16
A30206
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±11
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
30. REMOVE OIL STRAINER SUB±ASSY
(a) Remove the bolt, 2 nuts, oil strainer and gasket.
31. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Remove the cylinder block water drain cock from the cylinder block.
32. INSPECT CHAIN TENSIONER ASSY NO.1
(a) Check that the plunger moves smoothly when the ratchetpawl is raised with your finger.
(b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move
when pushed with your finger.
33. INSPECT CHAIN SUB±ASSY
(a) Using a spring tension gauge and vernier calipers, pull the timing chain with 140 N (4.3 kgf, 315 lb) and measure
the length of it.
Maximum chain elongation : 112.6 mm (4.433 in.)
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
34. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di- ameter with the chain.
Minimum sprocket diameter (w / chain):
97.3mm (3.831 in.)
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.
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EM2378
A32118
A32119
A62820
Overall Length
14±12
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
35. INSPECT C RANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di- ameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.
Minimum sprocket diameter (w / chain):
51.6mm (2.032 in.)
36. INSPECT CHAIN TENSIONER SLIPPER
(a) Using a vernier calipers, measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 in.)
37. INSPECT CHAIN VIBRATION DAMPER NO.1
(a) Using a vernier calipers, measure the vibration damper wears.
Maximum wear: 1.0 mm (0.039 in.)
38. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length:
156.0 ± 159.0 mm (6.142±6.260 in.)
Maximum bolt length: 159.5 mm (6.280 in.)
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A62837SST
A62180
DisconnectHook
Pin Turn
A62181
Plunger
Turn
Push
A10085
A62179
A
ABB
B
B
14±20
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
62. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt. SST 09960±10010 (09962±01000, 09963±01000)
Torque: 138 N
m (1,407 kgf
cm, 102 ft
lbf)
(c) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
(d) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released from the knock pin and the plunger springs out.
63. INSTALL WATER PUMP ASSY
(a) Place a new O±ring on the timing chain cover.
(b) Install the water pump with the 6 bolts. Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in
lbf)
Bolt B 11 N
m (112 kgf
cm, 8 ft
lbf)
HINT:
Each bolt length is indicated in the illustration.
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±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±9
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)Abbreviations Meaning
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/TManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
NO.Number
O2SOxygen Sensor
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
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L1L2
D02612
L2
L1
D01201
L2
L1
D01202
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
01±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
NOTICE:
Do the torque checking with the lower limit value of the torque toleranc\
e.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets: When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always\
use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:(1) In case of tightening by extending the entire lengthof the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
lbf 
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that\
vaporized fuel fills those places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,and do not spray much water so as to prevent slipping.
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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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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.)
length 12 mm (0.47 in.)
Transaxle housing x Cylinder block sub±assy
Cylinder head sub±assy x Cylinder block sub±assy
Crankshaft bearing cap sub±assy x Cylinder block sub±assy
Oil pump assy x Cylinder block sub±assy
Driveshaft bracket x Cylinder block sub±assy
5 mm (0.20 in.)
6 mm (0.24 in.)
12 mm (0.47 in.)
7 mm (0.28 in.)
7.5 mm (030 in.)
10 mm (0.39 in.)
8 mm (0.31 in.)
Connecting rod small end bush
Oil clearance
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
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0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
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 90
500
Turn 90
36
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 90
204
Turn 90
15
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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