Page 745 of 2234
A77857
A78440
New Gasket
±
EXHAUST EXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
15±5
AVENSIS REPAIR MANUAL (RM1018E)
8. INSTALL EXHAUST PIPE ASSY TAIL
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 38.5 mm (1.516 in.)
If the free length is less than minimum, replace the compression
spring.
(b) Install a new gasket to the exhaust pipe front as shown in the illustration.
(c) Install the exhaust pipe tail to the 3 exhaust pipe supports.
(d) Tighten the 2 compression springs and 2 bolts. Torque: 43 N m (440 kgf cm, 32 ftlbf)
9. INSTALL HEATED OXYGEN SENSOR (W/O HID SENSOR) Torque: 44 N m (449 kgf cm, 33 ftlbf)
10. INSTALL HEATED OXYGEN SENSOR (W/ HID SENSOR) Torque: 44 N m (449 kgf cm, 33 ftlbf)
11. CHECK FOR EXHAUST GAS LEAKS
12. INSTALL FLOOR PANEL BRACE FRONT
Torque: 30 N m (302 kgf cm, 22 ftlbf)
13. INSTALL FRONT FLOOR FOOTREST (W/O HID SENSOR)
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Page 746 of 2234
160AO±01
B10233Hole
±
COOLING WATER PUMP ASSY (1ZZ±FE/3ZZ±FE)
16±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
WATER PUMP ASSY (1ZZ±FE/3ZZ±FE)
INSPECTION
1. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
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Page 747 of 2234
140KO±01
A62767
Compression Ring No.1Compression Ring No.2 Oil Ring (Side Rail)
Snap Ring Piston
Piston Pin
Snap Ring
Bush
Connecting Rod
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±39
1st 44 (449, 33)
2nd Turn 90
See page 14±39
1st 20 (204, 15)
2nd Turn 90
19 (194, 14)
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
5.0 (51, 44 in. lbf)
5.0 (51, 44 in.lbf)
5.0 (51, 44 in. lbf)
11 (112, 8)
5.0 (51, 44 in. lbf)
Ring Pin
Straight Pin
Ring Pin
Straight Pin
Crankshaft
Thrust Washer Upper
Straight Pin
Ring Pin
Straight Pin
14±38
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
COMPONENTS
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Page 748 of 2234

140KP±01
A01155
A01156
A01159
Plastigage
A62797
Front
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±39
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.160 ± 0.342 mm (0.063 ± 0.0135 in.)
Maximum thrust clearance: 0.342 mm (0.0135 in.)
2. INSPECT CONNECTING ROD BEARING OIL CLEARANCE
NOTICE:
Do not turn the crankshaft.
(a) Using marking paint, write the matched cylinder number on each connecting rod and cap.
HINT:
The match marks on the connecting rods and caps are for en-
suring correct reassembly.
(b) Using SST, remove the 2 connecting rod cap bolts. SST 09205±16010
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of Plastigage across the crank pin.
(f) Check that the protrusion of the connecting rod cap is fac- ing in the correct direction.
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Page 749 of 2234

A01163
A62798
Paint Mark
90
Front
A01160
A62799
Mark
1, 2 or 3
A01166
14±40
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(g) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(h) Using SST, tighten the bolts in several passes by the spe-
cified torque.
SST 09205±16010
Torque: 20 N m (204 kgf cm, 15 ftlbf)
(i) Mark the front of the connecting cap bolts with paint.
(j) Retighten the cap bolts by 90 as shown in the illustration.
(k) Check that the crankshaft turns smoothly.
(l) Remove the 2 bolts, connecting rod cap and lower bear- ing.
(m) Measure the Plastigage at its widest point. Standard oil clearance:
0.028 ± 0.060 mm (0.0011 ± 0.0024 in.)
Maximum oil clearance: 0.080 mm (0.0031 in.)
NOTICE:
Remove the Plastigage completely after the measurement.
(n) 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 º1º, º2º and º3º ac\
-
cordingly.
Reference:
Standard bearing center wall thickness
Markmm (in.)
11.486 ± 1.490 (0.0585 ± 0.0587)
21.490 ± 1.494 (0.0587 ± 0.0588)
31.494 ± 1.498 (0.0588 ± 0.0590)
3. REMOVE PISTON SUB±ASSY W/CONNECTING ROD
(a) Using a ride reamer, remove all the carbon from the topof 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.
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Page 750 of 2234

A01175
A01192
A01179
A62800
SST
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±41
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
4. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearing from the connecting rod and crankshaft\
.
5. REMOVE PISTON RING SET
HINT:
Take care not to misplace the piston rings on both the match
with the piston and the direction of the rings.
(a) Using a piston ring expander, remove the 2 compressionrings.
(b) Remove the 2 side rails and oil ring by hand.
6. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
7. REMOVE W/PIN PISTON SUB±ASSY
(a) Gradually heat the piston to 80 ± 90 C (176 ± 194 F).
(b) Using a plastic hammer and brass bar, lightly tap out the piston pin and 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 CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bushing. SST 09222±30010
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Page 751 of 2234

A62801
793
481062
15
A01195
A32142
14±42
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
9. REMOVE CRANKSHAFT BEARING CAP SUB ASSY
(a) Remove the 10 bearing cap bolts.
(b) Uniformly loosen the 10 bearing cap sub±assy bolts, in several passes, in the sequence shown in the illustration.
SST 09011±38121
(c) Using a screwdriver, remove the bearing cap sub±assem- bly by prying the indicated portions between the cylinder
block and bearing cap sub±assembly. Remove the 5 low-
er main bearings.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and bearing cap sub±assembly.
10. 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 ± 0.24 mm (0.0016 ± 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
(b) If the thrust clearance is greater than maximum, measure the thrust washer thickness. If the thickness is not speci-
fied, replace the thrust washer.
Thrust washer thickness:
2.430 ± 2.480 mm (0.0957 ± 0.0976 in.)
11. REMOVE CRANKSHAFT THRUST WASHER UPPER
(a) Remove the crankshaft thrust washer from the cylinder block.
12. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper main bearings and 2 thrust washers from the cylinder \
block.
NOTICE:
Arrange the main bearings and thrust washers in the correct order.
13. REMOVE CRANKSHAFT BEARING
(a) Remove the crankshaft bearing from the cylinder block.
14. REMOVE STUD BOLT
(a) Remove the 9 stud bolts from the cylinder block.
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Page 752 of 2234

A01169
A62802
Thrust Direction
Axial Direction
A
B 10 mm 10 mm
C
A62803
29.8 mm
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±43
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
16. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame- ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
79.000 ± 79.013 mm (3.1102 ± 3.1108 in.)
Maximum diameter: 79.013 mm (3.1108 in.)
If the diameter is greater than the maximum, replace the cylin-
der block.
17. INSPECT PISTON DIAMETER
(a) Using a micrometer, measure the piston diameter at a right angle to the piston pin hole, and at the piston of 29.8
mm (1.173 in.) from the piston head.
Piston diameter:
1ZZ±FE 78.925 ± 78.935 mm (3.1073 ± 3.1077 in.)
3ZZ±FE 78.955 ± 78.965 mm (3.1085 ± 3.1089 in.)
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