TOYOTA AVENSIS 2003 Service Repair Manual

A62178
Push
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
A11858
A64005
±
ENGINE MECHANICALCAMSHAFT(1ZZ±FE/3ZZ±FE)
14±73
AVENSIS REPAIR MANUAL (RM1018E)
(2)Apply engine oil to the chain tensioner and install it
with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
(3)Turn the crankshaft counter clockwise, and take thehook off the knock pin to release the plunger.
(4)Turn the crankshaft clockwise, and check that the plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
19.ADJUST VALVE CLEARANCE(See page 14±6)
20. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
21. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
http://vnx.su

A62182
Seal Packing
A65687
AA
A
A
A
A
A
A
BB
A
A64023
14±74
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
22. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il- lustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover and 3 cable brackets with the 9 bolts, 2 seal washers and 2 nuts. Tighten the bolts
and nuts uniformly in the several steps.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for A
9.0 N
m (92 kgf
cm, 80 in
lbf) for B
23. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
http://vnx.su

A76713
A78459
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
14±75
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
24. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
25. CHECK FOR ENGINE OIL LEAKS
http://vnx.su

141B7±01
A77310
Engine Cover Sub±assy No. 1
Radiator Support
Opening Cover
Engine Room
Cover Side
Fan and Generator V Belt
Engine Under Cover RH
Engine Under Cover LH
N´m (kgf´cm, ft´lbf): Specified torque
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±135
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1AZ±FE)
COMPONENTS
http://vnx.su

A77319
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
Cooler Bracket
(LHD (w/ Air Conditioner)
Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant
Suction Hose No. 1
(LHD (w/ Air Conditioner)
Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator ASSY
Exhaust Pipe Assy Front
43 (440, 32)

Gasket
43 (440, 32)
7.0 (71, 62 in.
lbf)
52 (530, 38)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
Vane Pump Assy
37 (377, 27)
14±136
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

A77320
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
Ignition Coil Assy
9.0 (90, 80 in.
lbf)
14 (143, 10)
11 (115, 8.0)
Cylinder Head Cover Sub±assy

Gasket
11 (115, 8.0)
Ventilation Hose
Ventilation Hose No. 2
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±137
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

A77321
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
43 (440, 32)

Gasket
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover
Sub±assy
Crankshaft Position
Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt
Tensioner Assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
43 (440, 32)
170 (1,735, 125)
Crank Shaft Pulley

Oil Seal
43 (440, 32)
Chain Sub±assy
Chain Tensioner
Slipper
Chain Vibration
Damber No. 1
Crankshaft
Timing Gear
or Sprocket
19 (195, 14)
Crankshaft Position
Sensor Plate No. 1
Timing Chain Guide
Oil Pump
Drive Gear
12 (122, 9.0)
Spring
Chain Tensioner
Oil Pump Drive Shaft Gear
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
30 (301, 22)
No. 2 Chain Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
14±138
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

141B8±01
A77281
A77292
A77299
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
14±139
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE ENGINE UNDER COVER LH
6.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining the engine oil.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
7.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
8.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
9.REMOVE GENERATOR ASSY (See page 19±20)
10.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
11. SEPARATE VANE PUMP ASSY
(a) Remove the 2 through bolts and separate the vane pump.
12. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove 3 bolts and separate the return tube as shownin the illustration.
http://vnx.su

A77303
A77308
A77306
A77307
14±140
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
13. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
14. SEPARATE VANE PUMP OIL RESERVOIR ASSY
NOTICE:
Do not disconnect the 2 hoses. 15. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil pump reservoir bracket No.1.
16. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the clamp and engine wire.
17. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove the bolt and the engine service cover bracket RH. 18. REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a) Remove the bolt and cooler bracket.
http://vnx.su

A77283
A77284
A77285
Unleaded Gasoline
Timing
Marks

eaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±141
AVENSIS REPAIR MANUAL (RM1018E)
19. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the bolt and the engine service cover bracket RH.
20. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
21. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Disconnect the 2 PCV hoses from the cylinder head cov-er.
(b) Remove the 8 bolts and 2 nuts, and then remove the cylin- der head cover and gasket.
22. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its timing notch with timing mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing gear are aligned with the timing marks 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.
http://vnx.su