2005 TOYOTA AVENSIS oil

A01194
A11780
Plastigage
A64968
793
481062
15
A65715
Paint Mark90 Engine
Front
A64817
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–67
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
23. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolts.
Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 in.)
Minimum diameter: 7.3 mm (0.287 in.)
If the diameter is greater than minimum, replace the crankshaft
bearing cap set bolt.
24. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE:
Do not turn the crankshaft.
(a) Clean each main journal and bearing.
(b) Place the crankshaft on the cylinder block.
(c) Lay a strip of Plastigage across each journal.
(d) Using SST, tighten the bolts to the specified torque in the
several passes in the sequence shown.
Torque: 44 N⋅m (449 kgf⋅cm, 33 ft⋅lbf)
(e) Mark the front of the bearing cap bolts with paint.
(f) Retighten the bearing cap bolts by an additional 90 as
shown in the illustration.
(g) Check that the painted mark is now at a 90 angle to the
front.
(h) Tighten the 10 other bolts for the bearing cap.
Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)
(i) Remove the 10 bolts.

A64968
793
481062
15
A11781
A64971
Cylinder Block:
Crankshaft:
Bearing:No. 1 No. 2 No. 3 No. 4 No. 5
No. 2
No. 3
No. 5 No. 1
No. 4
Mark
14–68
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(j) Uniformly loosen the 10 bearing cap bolts in several
passes in the sequence shown in the illustration.
(k) Measure the Plastigage at its widest point.
Standard oil clearance:
0.015 to 0.032 mm (0.0006 to 0.0012 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
NOTICE:
Completely remove the Plastigage.
If the oil clearance is greater than minimum, replace
the crankshaft bearing.
If necessary, replace the crankshaft.
HINT:
If replacing a bearing, select a new one having the same num-
ber. If the number of the bearing cannot be determined, calcu-
late the correct use bearing number by adding together the
numbers imprinted on the cylinder block and crankshaft, then
select a new bearing having the calculated number. There are
4 sizes of standard bearings, marked ”1”, ”2”, ”3” and ”4” accord-
ingly.
Cylinder block (A)
+
Crankshaft (B)
0 to 23 to 56 to 89 to 11
Use bearing”1””2””3””4”
EXAMPLE:
Cylinder block ”3” (A) + Crankshaft ”4” (B) = Total number 7 (Use
bearing ”3”)
ItemMarkmm (in.)
Cylinder block journal bore
diameter (A)
”0”
”1”
”2”
”3”
”4”
”5”
”6”52.000 to 52.002 (2.0472 to 2.0473)
52.003 to 52.004 (2.0474 to 2.0474)
52.005 to 52.006 (2.0474 to 2.0475)
52.007 to 52.009 (2.0475 to 2.0476)
52.010 to 52.011 (2.0476 to 2.0477)
52.012 to 52.013 (2.0477 to 2.0478)
52.014 to 52.015 (2.0478 to 2.0478)
Crankshaft journal diameter
(B)
”0”
”1”
”2”
”3”
”4”
”5”47.999 to 48.000 (1.8897 to 1.8898)
47.997 to 47.998 (1.8896 to 1.8897)
47.995 to 47.996 (1.8896 to 1.8896)
47.993 to 47.994 (1.8895 to 1.8895)
47.991 to 47.992 (1.8894 to 1.8894)
47.988 to 47.990 (1.8893 to 1.8894)
Standard bearing center wall
thickness
”1”
”2”
”3”
”4”1.994 to 1.997 (0.0785 to 0.0786)
1.998 to 2.000 (0.0787 to 0.0787)
2.001 to 2.003 (0.0788 to 0.0789)
2.004 to 2.006 (0.0789 to 0.0790)

A01187
A64976
Front
Mark
A96654
End Gap
End Gap
Pin Hole
Cutout Portion
A62811
Cord Mark
Piston Ring
Expander
14–72
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(b) Gradually heat the piston up to 80 to 90C (176 to 194F).
(c) Align the front marks on the piston with the connecting
rod, then push in the piston with your thumb.
(d) Using a small screwdriver, install a new snap ring onto
one end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is aligned with the pin
hole cutout portion of the piston.
29. INSTALL PISTON RING SET
HINT:
In case of reusing the piston rings, install them onto the
matched pistons with the surfaces facing upward correctly.
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark (No. 2 only): 2R

A64977
Upper Side Rail
Front
MarkCompression No. 2
Lower Side Rail Compression No. 1
and Expander
A01190
Oil Groove
A01189
A01191Oil Groove
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–73
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(c) Position the piston rings so that the ring ends are as
shown.
30. INSTALL CRANKSHAFT BEARING
(a) Install the upper bearing with an oil groove onto the cylin-
der block.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
(b) Install the lower bearing onto the bearing cap.
NOTICE:
Do not apply engine oil to the bearing and its contact sur-
face.
31. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers onto the No. 3 journal position
of the cylinder block with the oil grooves facing outward.

A64820
A01038
Seal Packing
A64968
793
481062
15
A65715
Paint Mark90 Engine
Front
14–74
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
32. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, then install the
crankshaft onto the cylinder block.
(b) Apply a light coat of engine oil to the bolt threads, bolt
seats, and bearings of the bearing cap.
(c) Install the crankshaft onto the cylinder block.
(d) Apply a continuous bead of seal packing (Diameter; 2.5
to 3.5 mm (0.098 to 0.138 in.)) as shown in the illustration.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the bearing cap sub–assembly within 3 min-
utes after applying seal packing.
Do not put into engine oil for at least 2 hours after
installation.
(e) Tighten the bolts in several passes in the sequence
shown to the specified torque.
Torque: 44 N⋅m (449 kgf⋅cm, 33 ft⋅lbf)
(f) Mark the front of the bearing cap bolts with paint.
(g) Retighten the bearing cap bolts by an additional 90 as
shown in the illustration.
(h) Check that the painted mark is now at a 90 angle to the
front.

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

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