TOYOTA AVENSIS 2003 Service Repair Manual

A77389
Timing MarksMark Links
Timing Mark
A77290
Hold
Stopper
A32629
A77390Seal Packing
14±148
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Align the mark links (gold or yellow colored links) with each timing mark located on the camshaft timing gears,
and install the chain.
43. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
44. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
(b) Check that the chain tensioner slipper is hold on the cylin- der block stopper.
45. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
46. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the chain cover within 3 minutes after applying
seal packing.

Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing
chain cover.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent.
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A77391
Seal Packing
4mm
2.5 mm
A
A
AA

3 to 4 mm
A77251
Nut
Nut
C
C C
C
B
B
B
B B
B
B
B
AC
A13759
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±149
AVENSIS REPAIR MANUAL (RM1018E)
(c) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to
0.157 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent
(d) Install the timing chain cover with the 14 bolts and 2 nuts. Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in.
lbf)
Bolt B 21 N
m (214 kgf
cm, 15 ft
lbf)
Bolt C 43 N
m (438 kgf
cm, 32 ft
lbf)
Nut 9.0 N
m (92 kgf
cm, 80 in.
lbf)
47. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the bolt and nut. Torque: 60 N
m (610 kgf
cm, 44 ft
lbf)
NOTICE:
As the drive tensioner should be fastened together with the
timing chain cover, so be sure install it within 15 minutes
after the timing chain cover is installed.
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A77392
Seal Packing6mm
A64641
A77393
SST
A77394
Raise
Pin Hook
Push
14±150
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
48. INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b) Apply a continuous bead (Diameter 3 mm to 4 mm (0.157 in.)) of seal packing as shown in the illustration, and install
the oil pan.
Seal packing: part No. 08826 ± 00080 or equivalent
(c) Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
49. INSTALL CRANKSHAFT POSITION SENSOR 50. INSTALL CRANKSHAFT PULLEY
(a) Using SST, tighten the set bolt.SST 09213±54015 (91651±60855), 09330±00021
Torque: 170 N
m (1,733 kgf
cm, 125 ft
lbf)
51. 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 located in
position.
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A77395
Engine
Front
A77396
Hook
PinTurn
Disconnect
A77397
Push Turn
Plunger
A77398
A
B
A
A
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±151
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install a new gasket chain tensioner with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is released wile inserting, apply the hook again,
and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise, and check that the
hook is disengaged from the plunger knock pin.
(d) Turn the crankshaft clockwise, and check that the plunger is extended.
52. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
53. INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
54. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.
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A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(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 5 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c)install the cylinder head cover with the 8 bolts and 2 nuts. Torque:
Bolt A 11 N
m (112 kgf
cm, 8 ft
lbf)
Bolt B 14 N
m (143 kgf
cm, 10 ft
lbf)
Bolt C 21 N
m (214 kgf
cm, 15 ft
lbf)
Nut 11 N
m (112 kgf
cm, 8 ft
lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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141BC±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)
14±218
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1AZ±FSE)
COMPONENTS
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A77319
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket Cooler Bracket
(LHD Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant Suction Hose No. 1
(LHD 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)
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FSE)
14±219
AVENSIS REPAIR MANUAL (RM1018E)
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A77374
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
Cylinder Head Cover Sub±assy
11 (115, 8.0)
Ventilation Hose No. 1

Gasket
Fuel Tube Sub±assy

Gasket
Fuel Pipe
Sub±assy No. 1
Fuel Pressure
Pulsation Damper
Assy
Fuel Pump Assy

Gasket14 (143, 10)
Ignition Control
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)

O±ring
Ventilation Hose No. 2
33 (331, 24)
25 (255, 18)
Fuel Pipe No. 1

Fuel Injector
Back±up Ring No. 1

Fuel Injector Back±up
Ring No. 3

Fuel Injector
Back±up Ring No. 2
30 (306, 22)
14±220
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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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)
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FSE)
14±221
AVENSIS REPAIR MANUAL (RM1018E)
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141CH±01
A79321
ClipEngine Room Side Cover RH
Retainer
Clip
Radiator Cover Assy
Clip Engine Under Cover RH Engine Under Cover No. 1
Clip
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±45
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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