TOYOTA AVENSIS 2003 Service Repair Manual

A77345
Timing
Marks
Timing
Marks
A77286
Push
A77412
HoldLoosen
A77294
15973
481062
A52473
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FSE)
14±241
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that each timing mark of the camshaft timing gears
is aligned with each timing mark located on the No. 1 and
No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
13. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner and a gasket.
NOTICE:
Do not turn the crankshaft.
14. REMOVE NO.2 CAMSHAFT
(a) Hold the No. 2 camshaft with a wrench on the hexagonal lobe, and loosen the camshaft timing gear set bolt.
NOTICE:
Be careful not to damage the cylinder head and valve lifter
with the wrench.
(b) Using several steps, loosen and remove the 10 camshaft bearing cap bolts uniformly in the sequence shown in the
illustration.
(c) Remove the 5 camshaft bearing caps.
(d) Raising the No. 2 camshaft, remove the set bolt.
(e) Remove the camshaft timing gear from the No. 2 cam- shaft with with the timing chain wrapped.
(f) Remove the camshaft timing gear from the timing chain.
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A77309
15973
481062
A56228
A77413
Advance
Side Port
A31032
14±242
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 10 camshaft bearing cap bolts uniformly in the sequence shown in the
illustration.
(b) Remove 5 camshaft bearings.
(c) Remove the camshaft.
(d) Tie the timing chain as shown in the illustration.
NOTICE:

Be careful not to drop anything inside the timing
chain cover.

Do not expose the chain to water, and prevents dust.
16. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Clamp the camshaft in a vise, and make sure the cam- shaft timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except an advance side port shown in the illustration.
(c) Put air pressure into the oil port with 150 kpa (1.5 kgf/cm
2
21 psi), and turn the camshaft timing gear to the advance
direction (counterclockwise) by hand.
CAUTION:
Cover the ports with shop rag to avoid oil splashing.
HINT:
Depending on the air pressure, the camshaft timing gear will
turn to the advance angle side without applying force by hand.
Also, under the condition that the pressure can be hardly ap-
plied because of the air leakage from the port, there may be the
case that the lock pin could be hardly released.
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A32639
A77414
Straight
Pin
Key
Groove
A77284
A77415Bearing Cap No. 1 Bearing Cap No. 3
5
312 4
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FSE)
14±243
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove a fringe bolt of camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If reusing the camshaft timing gear, release the
straight pin lock first, and then install the gear.
17. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc- tion (as shown in the illustration) while lightly pushing it to-
ward the camshaft. Push further at the position where the
pin gets into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right direction).
(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
(e) Check that the camshaft timing gear can move to the re-
tard angle side (to the right direction), and is locked at the
most retarded position.
18. INSTALL CAMSHAFT
(a) Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.
(b) Install the timing chain on the camshaft timing gear, with
the painted links aligned with the timing marks on the
camshaft timing gear.
(c) Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
19. INSTALL NO.2 CAMSHAFT
(a) Put the No. 2 camshaft on the cylinder head with the painted links of chain aligned with the timing mark on the
camshaft timing gear.
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A52473
A77416
Bearing Cap No. 2 Bearing Cap No. 3
531 2 4
A77417
TightenHold
A77345
Timing
Marks
Timing
Marks
A77394
Raise
Pin Hook
Push
14±244
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Raising the No. 2 camshaft, tighten the set bolt temporari- ly.
(c) Examine the from marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(d) Hold the camshaft with a wrench on the hexagonal lobe, and tighten the camshaft timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the cylinder head and valve lifter.
(e) Check that the match marks on the timing chain and the camshaft timing gears are positioned as shown in the il-
lustration
20. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap- ply the hook to the pin so that the plunger is locked in posi-
tion.
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A77395
Engine
Front
A77396
HookPinTurn
Disconnect
A77397
Push Turn
Plunger
±
ENGINE MECHANICALCAMSHAFT(1AZ±FSE)
14±245
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket chain tensioner No. 1 with 2 nuts.
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
NOTICE:
If the hook is disengaged while installing, apply the hook
again, and then resume the installation.
(c)Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d)Turn the crankshaft clockwise, and check the plunger is extended.
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
22.INSTALL FUEL PUMP ASSY (See page 11±52)
23.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
24.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
25.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
26. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
27. CHECK FOR ENGINE OIL LEAKS
28. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
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141C7±01
A79426N´m (kgf´cm, ft´lbf): Specified torque
8.0 (82, 71 in.
lbf)
7.0 (71, 62 in.
lbf)
39 (398, 29)
72 (734, 53)
Engine Cover No. 1 Engine Room Cover Side
Radiator Support Opening Cover
Power Steering
Idle Pulley Bracket
Engine Under Cover Sub±assy No. 1
Air Cleaner Cap w/ Hose
Air Cleaner Element
AIr Cleaner Case
Engine Under Cover RH
V (Cooler
Compressor to
Crankshaft
Pulley) Belt No. 1 Clip
Clip
Retainer
Clip
Clip
14±314
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1CD±FTV)
COMPONENTS
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A79427N´m (kgf´cm, ft´lbf): Specified torque
52 (530, 38)52 (530, 38)
52 (530, 38)
Injector DriverEngine Mounting Insulator Sub±assy RH
Vacuum Reservoir Sub±assy
Union To Connector Tube Hose
Air Tube No. 1
25 (255, 18)
8.3 (85, 73 in.´lbf)
25 (255, 18)
5.0 (51, 44 in.´lbf)
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±315
AVENSIS REPAIR MANUAL (RM1018E)
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A61211
: Specified torqueN´m (kgf´cm, ft´lbf)
* Replace only if damaged Timing Belt No. 2 Cover
Transverse Engine
Engine Mounting Bracket
Seal Washer
Timing Belt No.1 Cover
Crankshaft Pulley
Seal Washer
x 5
Generator V belt
Glow Plug
Screw Grommet
Timing Belt Guide Timing Belt
* Gasket
x 7
Glow Plug Assy
* Gasket
Timing Chain Cover Plate
Timing Belt
Tensioner
180 (1,837, 133)
21 (214, 15)
9.0 (92, 80 in.´lbf)
37 (375, 27)
64 (650, 47)
2.2 (22, 19 in.´lbf)
7.4 (76, 66 in.´lbf)
7.4 (76, 66 in.´lbf)
Idler Pulley
40 (408, 30)Glow Plug
No.1 Connector
14±316
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79428
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
18 (184, 13)
27 (270, 20)22 (224, 16)13 (135, 9.7)

Gasket

O±ring
Fuel Injector
Back±up Ring No. 1



Injection Nozzle Seat
8.8 (90, 78 in.
lbf)

Oil Seal
8.8 (90, 78 in.
lbf)
20 (204, 15)
Washer
Nozzle Holder Clamp Nozzle Leakage
Pipe Assy
Injector Assy Cylinder Head Cover Sub±assy
Gasket
Camshaft Bearing Cap No. 2 Camshaft Camshaft
Camshaft Carrier
Camshaft Oil Seal
Retainer
88 (899, 65)
Camshaft Timing Pulley Set Key
20 (204, 15)
* 42 (428, 31)
46 (469, 34)
Injection Pipe
Clamp No. 2
Injection Pipe
Sub±assy


O±ring
21 (214, 15)
Vacuum Pump Assy
5.0 (51, 44 in.
lbf)

Nozzle Holder Seal
* Use SST
* 42 (428, 31)
46 (469, 34)
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±317
AVENSIS REPAIR MANUAL (RM1018E)
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141C8±01
SSTA61187
14±318
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
9.REMOVE AIR TUBE NO.1 (See page 14±270)
10.REMOVE INJECTOR DRIVER (See page 14±286)
11. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH (See page 14±307)
15.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
16.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
17.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
19. REMOVE TIMING BELT GUIDE
20.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
23.REMOVE TIMING BELT (See page 14±307)
24.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
25. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the timing pulley.
HINT:
Using a plastic±faced hammer, tap out the pulley.
(c) Remove the set key.
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