TOYOTA AVENSIS 2003 Service Repair Manual

141C9±01
A79429N´m (kgf´cm, ft´lbf): Specified torque
8.0 (82, 71 in.
lbf)
72 (734, 53)
39 (398, 29)
5.0 (51, 44 in.
lbf)
3.0 to 4.0 (31 to 41, 27 to 35 in.
lbf)
Engine Cover No. 1Engine Room Cover Side
Radiator Support Opening Cover
Power Steering
Idle Pulley Bracket
Battery Engine Under Cover Sub±assy No. 1Engine Under Cover LH
Battery Tray
Air Cleaner Cap w/ Hose
Air Cleaner Element
AIr Cleaner Case
7.0 (71, 62 in.

lbf)
Engine Under Cover RH
V (Cooler
Compressor to
Crankshaft Pulley)
Belt No. 1
Clip
Clip
Retainer
Clip
Clip
Clip
14±326
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CYLINDER HEAD GASKET (1CD±FTV)
COMPONENTS
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A79430
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
52 (530, 38)
52 (530, 38)
7.5 (76, 66 in.
lbf)
7.5 (76, 66 in.
lbf)
52 (530, 38)
25 (255, 18)
25 (255, 18)
43 (440, 32)
18 (178, 13)
30 (302, 22)
7.5 (76, 66 in.
lbf)
7.5 (76, 66 in.
lbf)
43 (440, 32)
Gasket

Gasket

Gasket
Injector Driver Engine Mounting Insulator
Sub±assy RH
Vacuum Reservoir Sub±assy
w/ Cold Area:
Heater Bracket
Radiator Hose Inlet
Radiator Hose Outlet
Fuel Filter Assy
Air Tube No. 1
Air Tube No. 2 Exhaust Pipe Assy Front
Floor Panel Brace Front
w/ Cold Area:
Exhaust PIpe Assy
Union To Connector Tube Hose
w/ Cold Area:
Heater Pump Assy
Compression Spring
Compression Spring
8.3 (85, 73 in.
lbf)
25 (255, 18)
5.0 (51, 44 in.
lbf)
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±327
AVENSIS REPAIR MANUAL (RM1018E)
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A79422
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

Gasket


Gasket
20 (204, 15)
20 (204, 15)
12 (122, 8.9)
53 (540, 39)
13 (135, 9.7)
36 (367, 27)61 (622, 45)
56 (571, 41)
25 (255, 18)
Turbo Insulator No. 1
Exhaust Manifold Heat Insulator No. 2
Turbocharger Stay Turbocharger Sub±assy
Turbo Oil Inlet Pipe
Sub±assy
Manifold Stay
Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy
Turbo Insulator No. 2


20 (204, 15)
12 (122, 8.9)
56 (571, 41)


Gasket
14±328
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A61211
: Specified torqueN´m (kgf´cm, ft´lbf)
* Replace only if damaged Timing Belt No. 2 Cover
Transverse Engine
Engine Mounting Bracket
Seal Washer
Timing Belt No.1 Cover
Crankshaft Pulley
Seal Washer
x 5
Generator V belt
Glow Plug
Screw Grommet
Timing Belt Guide Timing Belt
* Gasket
x 7
Glow Plug Assy
* Gasket
Timing Chain Cover Plate
Timing Belt
Tensioner
180 (1,837, 133)
21 (214, 15)
9.0 (92, 80 in.´lbf)
37 (375, 27)
64 (650, 47)
2.2 (22, 19 in.´lbf)
7.4 (76, 66 in.´lbf)
7.4 (76, 66 in.´lbf)
Idler Pulley
40 (408, 30)Glow Plug
No.1 Connector
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±329
AVENSIS REPAIR MANUAL (RM1018E)
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A79431
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
* Use SST
5.0 (51, 44 in.
lbf)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2
Injection Pipe Sub±assy
* 42 (428, 31)
46 (469, 34)
Fuel Inlet Pipe
Sub±assy

O±ring
43 (438, 32)
21 (214, 15)
Common Rail Assy
Fuel Hose No. 4
Camshaft Position Sensor
Set Key
Camshaft Timing Pulley
88 (899, 65)
Vacuum Pump Assy
8.8 (90, 78 in.

lbf)
* 42 (428, 31)
46 (469, 34)
14±330
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79432
N´m (kgf´cm, ft´lbf): Specified torque
 Non±reusable part  Gasket
18 (184, 13)
27 (270, 20)22 (224, 16)13 (135, 9.7)
 Gasket
 O±ring Fuel Injector
Back±up Ring No. 1

 Injection Nozzle Seat
20 (204, 15)
8.8 (90, 78 in.
lbf)
 Oil Seal
8.8 (90, 78 in.
lbf)
1st 45 (459, 33)
2nd Turn 90

3rd Turn 90

4th Turn 90

See page 14±332
20 (204, 15)
Washer
Nozzle Holder Clamp Nozzle Leakage
Pipe Assy
Injector Assy 
Nozzle Holder Seal
Cylinder Head Cover Sub±assy
Gasket
Camshaft Bearing Cap
No. 2 Camshaft Camshaft
Camshaft Carrier
 Cylinder Head Gasket
Camshaft Oil Seal Retainer
Cylilnder Head Sub±assy
Plate Washer
x 18
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±331
AVENSIS REPAIR MANUAL (RM1018E)
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141CA±01
14±332
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.DRAIN ENGINE COOLANT (See page 16±44)
6.DRAIN ENGINE OIL (See page 14±342)
7. REMOVE RADIATOR SUPPORT OPENING COVER
8. REMOVE ENGINE ROOM COVER SIDE
9. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
10.REMOVE VACUUM RESERVOIR SUB±ASSY (See page 13±11)
11.REMOVE AIR CLEANER ASSY (See page 14±286)
12. REMOVE BATTERY
13.REMOVE AIR TUBE NO.2 (See page 14±286)
14.REMOVE AIR TUBE NO.1(See page 14±270)
15.REMOVE INJECTOR DRIVER (See page 14±286)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
17.REMOVE GENERATOR V BELT (See page 14±269)
18.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
19.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
20.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
21.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
22.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
23.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
24. REMOVE TIMING BELT GUIDE
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
27.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
28.REMOVE TIMING BELT(See page 14±307)
HINT:
If re±using the timing belt, draw a direction arrow on the timing belt (\
in direction of engine revolution), and
place matchmarks on the pulleys and the timing belt.
29.REMOVE FUEL FILTER ASSY (See page 11±82)
30.REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13±11)
31.REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13±11)
32.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
34.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
35. DISCONNECT RADIATOR HOSE INLET
36. DISCONNECT HEATER INLET WATER HOSE
37. DISCONNECT HEATER OUTLET WATER HOSE
38. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
39. DISCONNECT OIL COOLER HOSE
40.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
41.REMOVE TURBO INSULATOR NO.1 (See page 13±11)
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A79148
SST
A79143
SST
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±333
AVENSIS REPAIR MANUAL (RM1018E)
42.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
43.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
44.REMOVE MANIFOLD STAY (See page 13±11)
45.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
46.REMOVE TURBOCHARGER STAY (See page 13±11)
47.REMOVE TURBO WATER HOSE NO.1 (See page 13±11)
48.REMOVE TURBO WATER HOSE NO.2 (See page 13±11)
49.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
50.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11)
51.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
52.REMOVE CAMSHAFT TIMING PULLEY (See page 14±318)
SST 09960±10010 (09962±01000, 09963±01000)
53. REMOVE FUEL INLET PIPE SUB±ASSY
(a) Using SST, remove the fuel inlet pipe from the commonrail side.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023±12700
NOTICE:
After removing the fuel pipe, cover the common rail and the
injector mounting holes with vinyl tape to prevent dust
from being introduced.
54. REMOVE INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
SST 09023±12700
(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.
55. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
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A09656
A79144
A09566
1
234 5
67 89
1011
12 13
1415
16
1718
14±334
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
57.REMOVE INJECTION PIPE SUB±ASSY NO.4 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
58.REMOVE VACUUM PUMP ASSY (See page 14±318)
59. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
60. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, the cylinder head cover and thegasket.
61.REMOVE NOZZLE LEAKAGE PIPE ASSY(See page 11±60)
62.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.
63.REMOVE CAMSHAFT OIL SEAL RETAINER (See page 14±318)
64.REMOVE NO.2 CAMSHAFT (See page 14±318)
65.REMOVE CAMSHAFT (See page 14±318) 66. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 18 cylinder head boltsuniformly in the sequence shown in the illustration. Re-
move the 18 cylinder head bolts and the plate washers.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
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A61194
Pry
A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring TipProtrusion Hight
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±335
AVENSIS REPAIR MANUAL (RM1018E)
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
67. REMOVE CYLINDER HEAD GASKET
68. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-eter of the bolts.
Standard outside diameter:
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
69. INSTALL CYLINDER HEAD GASKET
(a) Measure protrusion height of the piston heads. (1) Clean the cylinder block with solvent.
(2) Set the piston to be measured to slightly beforeTDC.
(3) Place a dial indicator on the cylinder block, and cali- brate the dial indicator at 0 mm (0 in.).
HINT:

Place measuring tip of the dial indicator as shown in the
illustration.

Make sure that the measuring tip is square to the cylinder
block gasket and the piston head when measuring.
(4) Find the most overhung position of the piston head by slowly turning the crankshaft clockwise and
counterclockwise.
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