TOYOTA AVENSIS 2003 Service Repair Manual

A77327
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
9.0 (90, 80 in.
lbf)
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover Sub±assy
Crank Position Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt Tensioner
Sub±assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
170 (1,735, 125)
Crankshaft Pulley
Chain Sub±assy
43 (440, 32)
Chain Tensioner
Slipper
19 (195, 14)
Camshaft Position
Sensor Plate No. 1
Oil Pump
Drive Gear
Chain Vibration
Damper No. 1

Oil Seal
Timing Chain Guide
9.0 (90, 80 in.
lbf)
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
43 (440, 32)
43 (440, 32)
9.0 (90, 80 in.
lbf)
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±157
AVENSIS REPAIR MANUAL (RM1018E)
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A77326
Intake Manifold
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
30 (306, 22)

Gasket
30 (306, 22)
Intake Manifold Insulator No. 1
12 (122, 9.0)
Unleaded type:
Manifold Converter
Insulator No. 1

Gasket
Unleaded Gasoline type:
Exhaust Manifold Converter Sub±assy Exhaust Manifold
Stay No. 2
44 (449, 32)
Leaded Gasoline type:
Manifold Converter
Insulator No. 1
Exhaust Manifold
Converter Sub±assy
12 (122, 9.0)
12 (122, 9.0)
44 (449, 32)
37 (378, 27)
44 (449, 32)
44 (449, 32)
Exhaust Manifold Stay


Gasket
14±158
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A77328
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
30 (301, 22)

O±ring
Bearing Cap No. 1
Bearing Cap No. 2
9.0 (92, 80 in.
lbf)
Bearing Cap No. 3
Camshaft
No. 2 Camshaft
Camshaft Bearing No. 2
Camshaft Timing
Oil Control Valve Assy
Cylinder Head

Cylinder Head Gasket
9.0 (92, 80 in.
lbf)
Oil Level Gauge
Sub±assy
9.0 (92, 80 in.
lbf)

O±ring
Oil Level Gauge
Guide
1st: 79 (800, 58)
2nd: Turn 90

30 (301, 22)
9.0 (92, 79 in.
lbf)
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±159
AVENSIS REPAIR MANUAL (RM1018E)
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141BB±01
A77292
A77299
14±160
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2. REMOVE FRONT WHEEL RH
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
9.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 14±121)
10.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
11.REMOVE GENERATOR ASSY (See page 19±20)
12.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
13. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
14. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils. 15. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts and separate the return tube asshown in the illustration.
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A77303
A77308
A77306
A77307
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±161
AVENSIS REPAIR MANUAL (RM1018E)
16. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
17. SEPARATE VANE PUMP OIL RESERVOIR ASSY
NOTICE:
Do not disconnect the 2 hoses. 18. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil reservoir bracket No. 1.
19. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the clamp and the enginewire.
20. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove the bolt and the engine service cover bracket RH. 21. REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a) Remove the bolt and the cooler hose bracket.
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A77302
14±162
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
22.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the engine service cover bracket RH.
23.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
24.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
25.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
26.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)
27.REMOVE CRANKSHAFT PULLEY (See page 14±139)
SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
28.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
29.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17)
30.REMOVE OIL PAN SUB±ASSY (See page 14±139) SST09032±00100
31.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
32.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
33.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
34.REMOVE CHAIN TENSIONER SLIPPER
35.REMOVE CHAIN VIBRATION DAMPER NO.1
36.REMOVE TIMING CHAIN GUIDE (See page 14±139)
37.REMOVE CHAIN SUB±ASSY
38.REMOVE BATTERY 39.REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a)Disconnect the 2 connectors.
(b)Disconnect the air cleaner hose from the throttle body.
(c)Raise a clamp up, and slide it toward the air cleaner cap,then remove the air cleaner cap from its case.
(d)Remove the air cleaner element.
(e)Remove the 4 bolts and the air cleaner case.
40.DISCONNECT RADIATOR HOSE INLET
41.DISCONNECT UNION TO CONNECTOR TUBE HOSE
42.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
43.SEPARATE FUEL TUBE SUB±ASSY (See page 11±26)
44. SEPARATE ENGINE WIRE
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A56446
A52499
A52497
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
14±163
AVENSIS REPAIR MANUAL (RM1018E)
45.REMOVE THROTTLE BODY ASSY (See page 10±26)
46.REMOVE INTAKE MANIFOLD
(a)Remove the 5 bolts and 2 nuts, then remove the intakemanifold and gasket.
47.REMOVE INTAKE MANIFOLD INSULATOR NO.1
48.REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a)Disconnect the oxygen sensor connector.
(b)Remove the 2 bolts and nut, and then remove the manifold heat insulator. 49.REMOVE EXHAUST MANIFOLD CONVERTERSUB±ASSY
(a)Remove the 2 bolts and 2 nuts, then detach the No. 1 and No. 2 exhaust manifold stay.
(b)Disconnect the 3 oxygen sensor connectors.
(c)Remove the 5 nuts, the exhaust manifold and gasket.
50.REMOVE NO.2 CAMSHAFT (See page 14±171)
51.REMOVE CAMSHAFT (See page 14±171)
52. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Remove the bolt and the oil control valve.
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A32664
A56213
A7740612
3
4
10 9
8
5 6
7
A77407
Overall Length
14±164
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
53. REMOVE CAMSHAFT BEARING NO.2
54. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub±assy.
(b) Set the jack under the engine assembly w/ transaxle, and place a wooden block on the jack.
(c) Remove the chain block and sling devise.
55. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 10 cylinder head bolts, with 10 mm bi±hexagon wrench uniformly in the se-
quence shown in the illustration.
(b) Remove the 10 cylinder head bolts and plate washers.
NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cranking could result from remov-
ing bolts and installing in incorrect order.
56. REMOVE CYLINDER HEAD GASKET
57. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of the cylin-der head set bolts from the seat to the end.
Standard bolt length:
161.3 to 162.3 mm (6.350 to 6.390 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the cylinder head
set bolts.
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A77408
Lot No.
A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
12.5 to 1.5 mm
A7741012
3
4
10 9
85
67
A00976A77411
90
Engine
Front Paint Mark
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±165
AVENSIS REPAIR MANUAL (RM1018E)
58. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:

Remove any oil from contact surface.

Be careful of the installation direction.

Place the cylinder head gently in order not to damage
the gasket with the bottom part of the head.
59. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head set bolts are tightened in 2 successive steps.
(a) Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Install the cylinder head within 3 minutes after apply-
ing seal packing.

After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.

Do not start the engine within 2 hours after installing.
(b) Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(c) Install the bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d) Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e) Mark the front side of the cylinder head set bolts with paint.
(f) Retighten the cylinder head set bolts by 90 in the same
sequence as step (A).
(g) Check that each paint mark is now at a 90  angle to the
front.
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A77332
23
145
A52499
A56446
14±166
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
60.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm,79 in.
lbf)
61.INSTALL CAMSHAFT (See page 14±171)
62.INSTALL NO.2 CAMSHAFT (See page 14±171)
63.INSTALL EXHAUST MANIFOLD CONVERTERSUB±ASSY
(a)Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(b)Install the No. 1 and No. 2 exhaust manifold stay with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
64.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
65.INSTALL INTAKE MANIFOLD
(a)Install a new gasket and the intake manifold with the 5bolts and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
66.INSTALL THROTTLE BODY ASSY (See page 10±26)
67.INSTALL FUEL TUBE SUB±ASSY (See page 11±19)
68. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
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