TOYOTA AVENSIS 2003 Service Repair Manual

A64006
V±ribbed Belt
Tensioner Assy
Camshaft Bearing Cap No. 1Camshaft Timing Gear
or SprocketCamshaft Timing Gear Assy
Chain Tensioner
Assy No. 1 Camshaft
Camshaft No. 2
Camshaft Bearing Cap No. 3
69 (704, 51)
29 (296, 21)
9.0 (92, 80 in.

lbf)
23 (235, 17)
54 (551, 40)
54 (551, 40)
13 (133, 10)
N´m (kgf´cm, ft´lbf) : Specified torque
Timing Chain Sub±assy
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
14±63
AVENSIS REPAIR MANUAL (RM1018E)
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141CK±01
A78459
A76713
A64023
A65078
14±64
±
ENGINE MECHANICALCAMSHAFT(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE UNDER COVER RH (See page 14±27) 3. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove and the 2 screw and 2 clips and detach the en-gine under cover No.2.
4. DISCONNECT COIL, IGNITION
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.
(d) Remove the 4 bolts and the 4 ignition coils.
5. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head cover.
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A64058
A64856
A60622
A01045
A64005
±
ENGINE MECHANICALCAMSHAFT(1ZZ±FE/3ZZ±FE)
14±65
AVENSIS REPAIR MANUAL (RM1018E)
6.DISCONNECT VENTILATION HOSE NO.2
(a)Disconnect the ventilation hose from the cylinder head
cover.
7.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts, and 3 clamp brackets.
(b)Remove the cylinder head cover.
8.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
9. REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
10. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly and loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
11. REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine. Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.
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A62185
MarkMark
Mark Timing Chain
Cover Surface
Timing
Notch
A11858
A62186
Paint Mark
A62178
Push
14±66
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley to align the timing notch with timing mark º0º of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock- et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
13. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, then remove the V±ribbed belt tensioner.
HINT:
Jack up and down to remove the bolt.
14. REMOVE CAMSHAFT
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the timing chain and the camshaft timing sprockets.
(c) Remove the 2 nuts and the chain tensioner.
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A62187
Hold
Tighten
A62188
24 5 3 1
A32124
A6218924 31
A32125
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
14±67
AVENSIS REPAIR MANUAL (RM1018E)
(d) Hold the camshaft with a wrench, loosen the camshaft
timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.
(e) Using several steps, loosen the camshaft bearing cap bolts on No. 2 camshaft in the sequence shown in the il-
lustration. Remove the bearing caps.
(f) Remove the camshaft timing gear as shown in the illustra- tion.
(g) Using several steps, loosen the camshaft bearing cap bolts on camshaft in the sequence shown in the illustra-
tion. Remove the bearing caps.
(h) Remove the camshaft as holding the timing chain.
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A32556
A62190
Advance
Side Path
Retard Side
Path
Open
Close
Rubber
Vinyl Tape
Open Close
A62191
Advanced
Side Path
Retard
Side Path
14±68
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(i) Tie the timing chain with a string as shown in the illustra- tion.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
15. INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Check the lock of camshaft timing gear.
(1) Clamp the camshaft in a vice, and confirm the cam-shaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
(b) Release lock pin. (1) Cover 4 oil paths of the cam journal with vinyl tapeas shown in the illustration.
HINT:
The one of the 2 glooves on the cam journal is for retards (up-
per) and the rest is for advances (lower). Each groove has the
2 oil paths. Plug one of the oil paths for each groove with rubber
pieces before wrapping the cam journal with the tape. (2) Punctuate the tape for the advance oil path and for
the retard oil path in the opposite side from the ad-
vance as shown in the illustration.
(3) Put air pressure into two broken paths (the advance side path and the retard side path) with about 150
kPa {1.5 kgf
cm}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.
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A62192
Hold Pressure
DecompressAdvanced
Side Path
Retard
Side Path
A62190
Advance
Side Path
Retard Side
Path
Open
Close
Rubber
Vinyl Tape
Open Close
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
14±69
AVENSIS REPAIR MANUAL (RM1018E)
(4) Confirm if the camshaft timing gear assembly re-
volves in the timing advance direction when weak-
ening the air pressure of the timing retard path.
HINT:
When the lock pin is released, the camshaft timing gear re-
volves in the advance direction. (5) When the camshaft timing gear comes to the most
advanced position, take out the air pressure of the
timing retard side path, and then take out that of tim-
ing advance side path.
CAUTION:
Camshaft timing assembly gear occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released first. It often causes the breakage of
the lock pin.
(c) Check smooth revolution (1) Revolve the camshaft timing gear assembly withinthe movable range [20
(40
CA)] except for the
most retarded position several times, and check the
smooth revolution.
CAUTION:
Be sure to perform this check by hand, instead of air pres-
sure.
(d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear assembly is
locked at the most retarded position.
16. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Clamp the camshaft in a vice, and confirm that the gear is locked.
CAUTION:
Be careful not to damage the camshaft.
(b) Cover 4 oil paths of cam journal with vinyl tape as shown
in the illustration.
HINT:
The one of the 2 glooves on the cam journal is for retards (up-
per) and the rest is for advances (lower). Each groove has the
2 oil paths. Plug one of the oil paths for each groove with rubber
pieces before wrapping the cam journal with the tape. (1) Punctuate the tape for the advance oil path and for
the retard oil path in the opposite side from the ad-
vance as shown in the illustration.
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A62191
Advanced
Side Path
Retard
Side Path
A62192
Hold Pressure
Decompress Advanced
Side Path
Retard
Side Path
A62193
Straight Pin
Fringe Bolt
A62194
Straight Pin
Key Groove
14±70
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1.5
kgf
cm}.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
(d) Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air
pressure of the timing retard path.
HINT:
When the lock pin is released, the camshaft timing gear re-
volves in the advance direction.
(e) When the camshaft timing gear comes to the most ad- vanced position, take out the air pressure of the timing re-
tard side path, next, take out that of timing advance side
path.
CAUTION:
Camshaft timing gear assembly occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released first. It often causes the breakage of
the lock pin.
(f) Remove the fringe bolt of camshaft timing gear assembly.
NOTICE:

Be sure not to remove the other 4 bolts.

In case of 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 assembly and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly clockwise (as shown in the illustration) while pushing it lightly against
the camshaft. Push further at the position where the pin
gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
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A62195
Painted Link
Timing Mark
A62196
4123
A62197
Painted Link
Timing Mark
A32124
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
14±71
AVENSIS REPAIR MANUAL (RM1018E)
(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 assembly can move to the retard angle side (the right angle) and is locked at
the most retarded position.
18. INSTALL CAMSHAFT
(a) Install the timing chain on the camshaft timing gear with the painted links aligned with the timing marks on the
camshaft timing gear as shown in the illustration.
(b) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(c) Put the camshaft No.2 on the cylinder head with the painted links of the chain aligned with the timing mark on
the camshaft timing gear.
(d) Tighten the camshaft timing gear set bolt temporarily.
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A621983124
5
6 7
A62187
Hold
Tighten
A62185
Mark Mark
Mark Timing Chain
Cover Surface
Groove
A62177
Raise
Push
Hook
Pin
14±72
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(e) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(f) Install the bearing cap No. 1. Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)
(g) Hold the camshaft with a wrench, tighten the camshaft timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the valve lifter.
(h) Check that the match marks on the 2 camshaft sprockets are aligned with each other and are aligned with the
painted links of the timing chain as shown in the illustra-
tion. Also, check the timing notch is aligned with the timing
mark º0º of the chain cover.
(i) Install chain tensioner. (1) Check that the O±ring is clean, and set the hook asshown in the illustration.
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