TOYOTA AVENSIS 2003 Service Repair Manual

A77317
Intake ManifoldIgnition Coil
Ventilation Hose No. 2 Ventilation Hose
Unleaded type:
Manifold Converter
Insulator No. 1
Intake Manifold Insulator
No. 1
V±ribbed Belt
Tensioner ASSY
Unleaded type:
Exhaust Manifold
Converter Sub±assy
Exhaust Manifold Stay Exhaust Manifold
Stay No. 2
Manifold Converter
Insulator No. 1
Exhaust Manifold
Converter Sub±assy
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
9.0 (92, 80 in.
lbf)

Gasket

Gasket
12 (122, 9.0)
12 (122, 9.0)
37 (378, 27)
44 (449, 32)
44 (449, 32)
44 (449, 32)

Gasket
Leaded type:
30 (306, 22)
30 (306, 22)
30 (306, 22)
12 (122, 9.0)
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
14±119
AVENSIS REPAIR MANUAL (RM1018E)
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A79295
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
5.0 (50, 43 in.
lbf)

O±ring

Gasket

Gasket

Gasket


Gasket

O±ring
15 (153, 11)
20 (204, 15)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
Fuel Delivery Pipe
w/ Injector
Oil Control Valve Knock Control Sensor Spacer
Water By±pass Pipe No. 1 Oil Level Gauge
Sub±assy
Oil Level Gauge Guide
Water Inlet
9.0 (92, 79 in.
lbf)Engine Oil Pressure Switch Assy
Water Temperature Sensor
Thermostat
9.0 (92, 80 in.
lbf)
19 (194, 14)
19 (194, 14)
20 (204, 15)
14±120
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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141BF±01
A77281
A77301
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
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.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
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A77302
A77300
A77299
14±122
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE BATTERY 21. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a) Disconnect 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 4 bolts and the air cleaner case.
22. REMOVE BATTERY CARRIER
(a) Remove 4 bolts and the battery carrier.
23. REMOVE RADIATOR RESERVE TANK SUB±ASSY
(a) Remove 2 bolts and the radiator reserve tank. 24. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove 3 bolts as shown in the illustration.
25. SEPARATE VANE PUMP OIL RESERVOIR ASSY
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A77308
A77303
A77307
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±123
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITION ER) STEER ING
POSITION TYPE)
(a)Remove 2 nuts and separate the suction hose.
28.REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a)Remove a bolt and the service cover bracket RH. 29.REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the cooler bracket.
30.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
31.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
32.DISCONNECT HEATER OUTLET WATER HOSE (W/ AIR CONDITIONING)
33.REMOVE CHARCOAL CANISTER ASSY
34.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±15)
35. DISCONNECT UNION TO CONNECTOR TUBE HOSE
36.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
38.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
39.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09330±00030
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A77298
LHD Steering Position typeRHD Steering Position type
14±124
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE FRONT AXLE HUB RH NUT SST09330±00030
HINT:
Perform the same procedure as above on the opposite side.
41.SEPARATE TIE ROD END SUB±ASSY LH (See page 51±36)
42.SEPARATE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
43.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
44.SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
(See page 26±21)
46.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) (See page 26±16)
47.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
48.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
49.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
50.SEPARATE FRONT AXLE ASSY RH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side. 51.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
(a)Remove 7 bolts as shown in the illustration.
52.SEPARATE TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
53.SEPARATE TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
54. SEPARATE ACCELERATOR CONTROL CABLE ASSY
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A77338
A77337
A77336
A57550
Engine Hanger No. 1 Engine Hanger No. 2
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
14±125
AVENSIS REPAIR MANUAL (RM1018E)
55. SEPARATE ENGINE ROOM RELAY BLOCK NO.2
(a) Remove the nut and disconnect the connector as shown
in the illustration.
56. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the grand terminal.
(b) Separate the grand terminal connector.
(c) Remove the glove compartment door panel.
(d) Separate the engine wire.
57.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9) 58. INSTALL ENGINE HANGERS
(a) Install the engine hanger No. 1 (12281±28010, 28020,28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Install the engine hanger No. 2 (12282±28010, 28020, 28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
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A77401
A77305
A77304
A59793
A63273
14±126
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
59. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
(a) Set the engine lifter.
(b) Remove 2 bolts and 2 nuts, and then remove the mount- ing bracket No. 2.
60. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Remove 3 bolts and the engine mounting insulator.
61. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Remove the through bolt and nut, and then detach the en- gine mounting insulator.
62. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Remove the8 bolts and the front suspension member braces.
(b) Remove the 2 bolts and 2 nuts shown in the illustration.
(c) Carefully remove the engine assembly with transaxle from the vehicle.
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A77402SST
A56446
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±127
AVENSIS REPAIR MANUAL (RM1018E)
63.SEPARATE VANE PUMP ASSY
(a)Disconnect the PS oil pressure switch connector.
(b)Remove the 2 bolts and separate the vane pump from the engine.
64.REMOVE STARTER ASSY (See page 19±12)
65.REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Remove the through bolt and nut from the engine mounting insulator FR.
(b)Remove the through bolt and nut from the engine mounting insulator RR.
66.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
67.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
68.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
69.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
70.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
71.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
72. REMOVE DRIVE PLATE AND RING GEAR ORFLYWHEEL
(a) Using SST, fix the crankshaft pulley and remove the drive plate and ring gear or flywheel.
SST 09213±54015 (91651±60855), 09330±00021
73. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Remove a bolt, O±ring and the camshaft timing oil control valve. 74. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts, and then remove the in-take manifold.
75. REMOVE VENTILATION HOSE
76. REMOVE VENTILATION HOSE NO.2
77. REMOVE ENGINE WIRE
78. REMOVE INTAKE MANIFOLD INSULATOR NO.1
79. REMOVE OIL LEVEL GAGE SUB±ASSY
80. REMOVE OIL LEVEL GAGE GUIDE
81. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a) Remove the 4 bolts and the manifold converter insulator No. 1.
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A60067
A52497
A32676
A78645
Oil Pressure Switch
14±128
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
82.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a)Remove the 3 bolts and 2 nuts, and then detach the No.
1 and No. 2 exhaust manifold stays.
(b)Remove the 5 nuts, and then remove the exhaust man- ifold converter and gasket.
83.REMOVE WATER INLET
(a)Remove the 2 nuts and the water inlet.
84.REMOVE THERMOSTAT
85.REMOVE IGNITION COIL ASSY
(a)Remove the 4 bolts and the 4 ignition coils. 86.REMOVE V±RIBBED BELT TENSIONER ASSY
(a)Remove the bolt and nut, and then remove the V±ribbedbelt tensioner.
87.REMOVE DRIVE SHAFT BEARING BRACKET
(a)Remove the 3 bolts and the drive shaft bearing bracket.
88.REMOVE FUEL DELIVERY PIPE W/INJECTOR (See page 11±26)
89. REMOVE WATER BY±PASS PIPE NO.1
(a) Remove the bolt and 2 nuts, and then detach the water by±pass pipe No\
. 1. 90. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a) Using SST, remove the engine oil pressure switch.SST 09268±46021
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