2003 TOYOTA AVENSIS length

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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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 diameter Standard Minimum
Undercut depth Standard Minimum
0.05 mm (0.0020 in.)
28 mm (1.102 in.)
27 mm (1.063 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
Starter yoke assy
Brush length StandardMinimum
14 mm (0.551 in.)
9 mm (0.354 in.)
Starter brush holder assy
Brush length StandardMinimum
14 mm (0.551 in.)
9 mm (0.354 in.)
Generator rotor assy
Coil resistance at 20
C (68
F)
Slip ring diameter Standard
Minimum
2.1 ± 2.5

14.2 ± 14.4 mm (0.559 ± 0.567 in.)
12.8 mm (0.504 in.)
Generator brush holder assy
Exposed brush length StandardMinimum
9.5 ± 11.5 mm (0.374 ± 0.453 in.)
1.5 mm (0.059 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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A62758
Slip Ring
A62759
Slip Ring
Rotor
A62760
A62761
B
P4
E
P2P1
B
P1 P2 P3P4
E
A62762
19±12
±
STARTING & CHARGING GENERATOR ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
7. INSPECT GENERATOR ROTOR ASSY
(a) Using an ohmmeter, check that there is continuity be- tween the slip rings.
Standard resistance: 2.1 ± 2.5
at 20
C (68
F)
(b) Using an ohmmeter, check that there is no continuity be- tween the slip ring and rotor.
(c) Using a vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 ± 14.4 mm (0.559 ± 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
8. INSPECT GENERATOR HOLDER W/RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the B or E terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step (a).
(c) Check that one shows continuity and the other shows no continuity.
9. INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Using a vernier calipers, measure the exposed brush length.
Standard exposed length:
9.5 ± 11.5 mm (0.374 ± 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
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A62224
A37017
A37020
A62225
Free
Lock
A33580
±
STARTING & CHARGING STARTER ASSY (1ZZ±FE/3ZZ±FE)
19±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
8. INSPECT BRUSH
(a) Using a vernier calipers, measure the brush length. Standard length: 14 mm (0.551 in.)
Minimum length: 9 mm (0.354 in.)
9. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using an ohmmeter, check that there is no continuity be- tween the positive (+) and negative (±) brush holders.
10. INSPECT STARTER CLUTCH SUB±ASSY
(a) Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counter-
clockwise and check that it locks.
11. INSPECT MAGNET STARTER SWITCH ASSY
(a) Push in the plunger and check that it returns quickly to its original position.
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A79148
SST
A79149
SST
16±48
±
COOLINGWATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
39.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69) 40. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the water pump replaced, must re-
place fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a) Temporarily install the new fuel inlet pipe.
(b) Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe to the injec- tion pump side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
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170FW±01
A56222
A56223
17±12
±
LUBRICATION OIL FILTER SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of nat\
ural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used \
engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or\
sol-
vents.

In order to preserve the environment, used oil and used oil filter must be\
disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil. Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter. SST 09228±06501
4. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn. SST 09228±06501
5. ADD ENGINE OIL
(a) Fill with fresh engine oil. Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. \
qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp.\
qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK
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