TOYOTA AVENSIS 2003 Service Repair Manual

A79143
SST
A09656
A79144
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
14±319
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE INJECTION PIPE SUB±ASSY NO.1
(See page 11±60)
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or a
plastic bag.
27.REMOVE INJECTION PIPE SUB±ASSY NO.2(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
28.REMOVE INJECTION PIPE SUB±ASSY NO.3(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
29.REMOVE INJECTION PIPE SUB±ASSY NO.4(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
30. REMOVE VACUUM PUMP ASSY
(a) Remove vacuum hose.
(b) Remove vacuum pump oil hose.
(c) Remove the 2 bolts and the vacuum pump assembly.
31. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
32. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, the cylinder head cover and thegasket.
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A09668
A09650
5
6
4 2
1
12 3
1011
13
8
7
15
14
9
A09619
SST
A09620
14±320
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
33.REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11±60)
34.REMOVE INJECTOR ASSY (See page 11±60)
HINT:
Since each injector assembly has a characteristic fuel injecting behavior, store them in correct order so that
they can be returned to the original locations when re±assembling. 35. REMOVE CAMSHAFT OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by pryingbetween the oil seal retainer and the camshaft bearing
cap.
36. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 15 bearing cap bolts uniformly in the sequence shown in the illustra-
tion.
(b) Remove the 5 bearing caps and the camshaft sub±assy.
37. REMOVE NO.2 CAMSHAFT
(a) Remove the camshaft sub±assy and the camshaft carrier. 38. REMOVE CAMSHAFT OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
39. INSTALL CAMSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-face is flush with the camshaft oil seal retainer edge.
SST 09223±46011
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90

A09683
TDC Mark
Dot Mark
A09624
A09625
A09626
Alignment Mark
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±321
AVENSIS REPAIR MANUAL (RM1018E)
40. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set
the dot mark of the crankshaft timing pulley at the position
of 90
BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
41. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, damage to the cylinder head or
the camshaft may result. To avoid this, the following proce-
dures should be carried out.
(a) Place the camshaft carrier on the cylinder head.
(b) Install the camshaft sub±assy No. 1.
(c) Apply engine oil to the cam and gear of the camshaft, and the journal of the camshaft carrier.
(d) Place the intake camshaft on the camshaft carrier as
shown in the illustration so that the No. 3 and No. 4 of cyl-
inder cam lobes face downward.
42. INSTALL NO.2 CAMSHAFT
(a) Install the camshaft sub±assy No. 2.
(b) Apply engine oil to the cam and gear of the camshaft, and the journal of the camshaft carrier.
(c) Engage the exhaust camshaft gear and the intake cam- shaft gear by aligning the alignment marks on each gear.
(d) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.
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A09601
Seal Packing
A09627
A09650
12
3
5
49
6
8
7
13
10
11
15
14 12
A09600
Seal Width
2 to 4 mm
Seal Packing
14±322
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(e)Install the camshaft bearing caps. (1)Remove any oil packing (FIPG) material from theNo. 5 camshaft bearing cap.
(2)Apply seal packing to the No. 5 camshaft bearing cap as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(3)Place the 5 bearing caps in their proper locations.
(4)Using several steps, install and tighten the 15 bear- ing cap bolts uniformly in the sequence shown in the
illustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
43.INSPECT VALVE CLEARANCE (See page 14±270)
44.ADJUST VALVE CLEARANCE (See page 14±270) 45. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the oil seal
retainer and the cylinder block.
(1) Thoroughly clean all components to remove all theloose material.
(2) Using non±residue solvent, clean both sealing sur- faces.
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 2 to 4 mm(0.08 to 0.16 in.) opening.
(2) Parts must be assembled within 15 minutes of ap- plication. Otherwise the material must be removed
and reapplied.
(3) Immediately remove nozzle from the tube and rein- stall the cap.
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A62592
SST
A09663
:Seal Packing
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
14±323
AVENSIS REPAIR MANUAL (RM1018E)
(c)Install the oil seal retainer with the 4 bolts. Tighten the 4
bolts uniformly in several steps.
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
46.INSTALL CAMSHAFT TIMING PULLEY
(a)Install the pulley set key to the groove of the camshaft.
(b)Align the keyway of the timing pulley with the key located on the camshaft, slide the pulley into place.
(c)Using SST, install the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
47.INSTALL CAMSHAFT POSITION SENSOR (See page 10±63)
48.INSTALL INJECTOR ASSY (See page 11±60)
49.INSTALL NOZZLE LEAKAGE PIPE ASSY(See page 11±60) SST09992±00242
50.INSTALL CYLINDER HEAD COVER SUB±ASSY
(a)Remove any old packing (FIPG) material.
(b)Apply seal packing to the cylinder head.Seal packing: Part No. 08826±00080 or equivalent
(c)Install the gasket to the cylinder head cover.
(d)Install the cylinder head cover with the 10 bolts.
Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
51.INSTALL NOZZLE HOLDER SEAL
(a)Install 4 new nozzle holder seals.
52.INSTALL VACUUM PUMP ASSY Torque: 21 N
m (214 kgf
cm,15 ft
lbf)
53.INSTALL INJECTION PIPE SUB±ASSY NO.1(See page 11±60)
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
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A79147
Fulcrum
Length
30 cm
SST
14±324
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c)Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST09023±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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d)Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST09023±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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e)Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
54.INSTALL INJECTION PIPE SUB±ASSY NO.2 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
55.INSTALL INJECTION PIPE SUB±ASSY NO.3 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56.INSTALL INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
57.INSTALL TIMING BELT(See page 14±307)
58.CHECK VALVE TIMING(See page 14±307)
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±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±325
AVENSIS REPAIR MANUAL (RM1018E)
59.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
60.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
61.INSTALL TIMING BELT GUIDE(See page 14±307)
62.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
63.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
64.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
65.INSTALL CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021
66.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
67.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
68. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
69.INSTALL INJECTOR DRIVER (See page 14±286)
70.INSTALL AIR TUBE NO.1 (See page 14±270)
71. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
72.INSTALL AIR CLEANER ASSY (See page 14±286)
73. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
74. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
75.CHECK FOR FUEL LEAKS(See page 11±60)
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141CJ±01
A79321
ClipEngine Room Side Cover RH
Retainer
Clip
Radiator Cover Assy
Clip Engine Under Cover RH Engine Under Cover No. 1
Clip
14±60
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1ZZ±FE/3ZZ±FE)
COMPONENTS
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A76710
Fan and Generator V BeltCylinder Head Cover No. 2
Clip
Engine Mounting
Insulator RH
N´m (kgf´cm, ft´lbf) : Specified torque
7.0 (71, 62 in.
lbf)
52 (530, 38)
52 (530, 38)
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
14±61
AVENSIS REPAIR MANUAL (RM1018E)
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A76709
Ventilation Hose No. 2Clamp Bracket
Ventilation Hose
Ignition Coil Assy
Engine Wire
Clamp Bracket
Clamp Bracket
Gasket
Cylinder Head Cover
Sub±assy
Seal Washer
N´m (kgf´cm, ft´lbf) : Specified torque
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
11 (112, 8)
11 (112, 8)11 (112, 8)
11 (112, 8)
14±62
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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