2005 TOYOTA AVENSIS Service Repair Manual

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Page 5121 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual A01170
11 0 m m
(4.33 in.)
EM7639
A62804
A62805
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–65
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
19. INSPECT PISTON RING END GAP

Page 5122 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual A01470
A64828
ZF6927
ZF6928
14–66
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
21. INSPECT CONNECTING ROD BOLT
(a) Using vernier cali

Page 5123 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual 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
(RM1

Page 5124 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual 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�

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)

Page 5125 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual A64972
8
155
(0.197)
(mm (in.))12
(0.472) 7.5
(0.295)8
(0.315) Front Side:
Bearing Cap Lower Side:Lower Side: Rear Side:
10
22
1510
146
ABCD A
BC
D
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3

Page 5126 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual A64973
Front Side: Upper Side:
AB
B
ABC6
(0.236)7
(0.276)10
(0.394)
C
(mm (in.)) Bearing Cap Front Side:
14
1213
129
15 14–70
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3

Page 5127 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual A64974
Intake Side:
Bearing Cap Lower Side:Upper Side:
A
D
E
DC B
ABCDE
(mm)15
1238.515
1052.5
14
931.512
927.5 10
822.5
A64975
End Gap
End Gap
Pin Hole
Cutout Portion
– ENGINE MECHANICALCYLINDER BL

Page 5128 of 5135

TOYOTA AVENSIS 2005 Service Repair Manual 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 ENG

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