TOYOTA AVENSIS 2003 Service Repair Manual

A77332
23
145
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±129
AVENSIS REPAIR MANUAL (RM1018E)
91.REMOVE KNOCK SENSOR
(a)Remove the nut and the knock sensor.
92.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a)Using SST, remove the engine coolant temperature sensor.
SST09817±33190
93.REPLACE PARTIAL ENGINE ASSY
94.INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a)Install a new gasket to the engine coolant temperature sensor.
(b)Install the engine coolant temperature sensor. Torque: 20 N
m (208 kgf
cm,15 ft
lbf)
SST09817±33190
95.INSTALL KNOCK SENSOR
Torque: 20 N
m (208 kgf
cm,15 ft
lbf)
96.INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a)Clean the threads of the oil pressure switch, apply adhesive there. Adhesive: Part No. 08833±00080 THREE BOND 1344 or equivalent
(b)Install the oil pressure switch. Torque: 15 N
m (153 kgf
cm,11 ft
lbf)
97.INSTALL WATER BY±PASS PIPE NO.1
(a)Install a new gasket and the water by±pass pipe No. 1 with the bolt a\
nd 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
98.INSTALL FUEL DELIVERY PIPE W/INJECTOR (See page 11±26)
99.INSTALL DRIVE SHAFT BEARING BRACKET Torque: 54 N
m (551 kgf
cm,40 ft
lbf)
100.INSTALL V±RIBBED BELT TENSIONER ASSY
Torque: 60 N
m (607 kgf
cm,44 ft
lbf)
101.INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
102.INSTALL THERMOSTAT (See page 16±23)
103. INSTALL WATER INLET
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
104. I N S TA L L E X HAUST MANIFOLD CONVERTER
SUB±ASSY
(a) Install a new gasket and the exhaust manifold converter
with the 5 nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
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A52499
A56446
A77333SST
14±130
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
105. INSTALL MANIFOLD CONVERTER INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
106. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil\
level gauge guide.
(b) Install the oil level gauge and guide with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
107. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
108. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Apply light coat of engine oil to the new O±ring and install it to th\
e camshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)
109. I N S TA L L D R I V E P L AT E A N D R I N G G E A R O R FLYWHEEL
(a) Hold the crankshaft with SST.
SST 09213±54015 (91651±60855), 09330±00021
Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
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A77403
15
3
7
2
6
4 8
A63273
A77404
B
A
BBBB
A
B
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±131
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the drive plate. (A/T)
(1)Clean the bolt and bolt hole.
(2)Apply adhesive to the bolts.
(3)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 98 N
m (1,000 kgf
cm, 72 ft
lbf)
(c)Install the flywheel. (M/T)
(1)Clean the bolt hole.
(2)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 130 N
m (1,327 kgf
cm, 96 ft
lbf)
NOTICE:
Do not reuse the flywheel bolt.
110.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
111.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
112.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
113.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
114.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
115.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
116.INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Install the engine mounting insulator FR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
(b)Install the engine mounting insulator RR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
117.INSTALL STARTER ASSY (See page 19±12)
118. INSTALL VANE PUMP ASSY
Torque: 37 N
m (370 kgf
cm, 27 ft
lbf)
119. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the 2 bolts and 2 nuts as shown in the illustration. Torque:
Bolt 45 N
m (459 kgf
cm, 33 ft
lbf)
Nut 133 N
m (1,356 kgf
cm, 98 ft
lbf)
(b) Install the front suspension member braces with the 8 bolts.
Torque:
Bolt A 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B 80 N
m (816 kgf
cm, 59 ft
lbf)
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A77304
A77305
A77405
A
B
A
A
A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±132
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
120.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
121.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
122.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)
123.REMOVE ENGINE HANGERS
124.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
125.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24 )
126 .INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
127. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
Torque:
Bolt A 12 N
m (122 kgf
cm, 89 ft
lbf)
Bolt B 9.0 N
m (92 kgf
cm, 79 in.
lbf)
Bolt C 5.0 N
m (51 kgf
cm, 44 in.
lbf)
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±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±133
AVENSIS REPAIR MANUAL (RM1018E)
128.INSTALL FRONT AXLE ASSY LH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
129.INSTALL FRONT AXLE ASSY RH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
130.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
131.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE)
Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
132.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
133.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
134.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
135.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
136.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
137.INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
138.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
139.INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
140.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
141.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
142.INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
143.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
144.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
145.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
146.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
147.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
148.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
149.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
150.INSTALL BATTERY CARRIER
151.INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
152.INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
Torque: 25 N
m (255 kgf
cm,18 in.
lbf)
153.INSTALL GENERATOR ASSY (See page 19±20)
154.INSTALL FAN AND GENERATOR V BELT (See page 14±105)
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14±134
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
155.INSTALL RADIATOR ASSY (See page 16±24)
156.INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
157.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
158.ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
159.ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
160.ADD ENGINE OIL
161.ADD COOLANT (See page 16±19)
162. ADD POWER STEERING FLUID
163. BLEED POWER STEERING FLUID
164. CHECK FOR ENGINE OIL LEAKS
165.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
166.CHECK FOR FUEL LEAKS (See page 11±15)
167. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
168.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
169.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±101)
170.INSPECT CO/HC (See page 14±101)
171. CHECK ABS SPEED SENSOR SIGNAL
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141C3±01
A79198N´m (kgf´cm, ft´lbf): Specified torque
5.0 (51, 44 in.
lbf)
19 (194, 14)
3.0 to 4.0 (31 to 41, 27 to 35 in.
lbf)
7.0 (71, 62 in.
lbf)
5.3 (54, 47in.
lbf)
Engine Room Relay Block No. 3
8.0 (82, 71 in.
lbf)
Engine Room Cover Side
Radiator Support Opening Cover
Radiator Support Upper Radiator Hose Inlet
Engine Cover No. 1
Radiator Hose Outlet w/ A/C:
Radiator Assy
Battery Battery Tray Engine Under Cover RH Engine Under Cover Sub±assy No. 1
Engine Under Cover LH
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Clip
Clip
Clip
Retainer
Clip
Clip
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±277
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1CD±FTV)
COMPONENTS
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A79418N´m (kgf´cm, ft´lbf): Specified torque
25 (255, 18)
18 (178, 13)
Injector Driver
Air Tube No. 2 Union To Connector Tube Hose
Fuel Filter AssyHeater Inlet Water Hose
Heater Outlet Water Hose
Vacuum Reservoir Sub±assy
8.3 (85, 73 in.

lbf)
5.0 (51, 44 in.
lbf)
14±278
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79419
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
29 (296, 21)
80 (816, 59)
133 (1,348, 97)
43 (440, 32)
30 (302, 22)
43 (440, 32)

Gasket
74 (755, 55)
49 (500, 36)

Gasket


Cotter Pin
V (Cooler Compressor
to Crankshaft pulley)
Belt No. 1
Glove Compartment Door Assy
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silencer Sheet
Front Stabilizer Link Assy LHClip
Tie Rod End Sub±assy LH
Front Axle Hub LH Nut
Front Suspension Member
Brace Rear LH
Compression
Spring
Floor Panel Brace Front
Exhaust Pipe Assy Front
Compression Spring
w/ A/C:
Compressor And Magnetic Clutch
Front Drive Shaft Assy LH Clip
Transmission Control
Cable Assy
Clip
Clutch Accumulator Assy
Clutch Release Cylinder Assy
Transmission Control Cable Assy
35 (357, 26)
142 (1,448, 105)
Clip
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±279
AVENSIS REPAIR MANUAL (RM1018E)
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A79420N´m (kgf´cm, ft´lbf): Specified torque
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)
87 (887, 64)
80 (816, 59)
133 (1,356, 98)52 (530, 38)
72 (734, 53)
39 (398, 29)
Engine Mounting Insulator
Sub±assy RH Air Tube No. 1
Front Suspension Crossmember
Sub±assy25 (255, 18)
25 (255, 18)
14±280
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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