TOYOTA AVENSIS 2003 Service Repair Manual

A79421N´m (kgf´cm, ft´lbf): Specified torque
88 (897, 65)
19 (195, 14)
64 (653, 47)
37 (377, 27)
Drive Shaft Bearing Bracket
Flywheel Sub±assy Clutch Cover Assy
Starter Assy Manual Transaxle
Clutch Disc Assy
64 (653, 47)
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±281
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)
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
12 (122, 8.9)
14±282
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (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)
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
21 (214, 15)
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±283
AVENSIS REPAIR MANUAL (RM1018E)
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A79423
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

O±ring
* Use SST

Gasket


Gasket

Gasket

Gasket

Gasket3.6 to 6.9 (40 to 70, 35 to 61 in.
lbf)
5.0 (51, 44 in.
lbf)
7.4 (76, 66 in.
lbf)
* 31 (316, 23)
34 (347, 25)
43 (438, 32)
21 (214, 15)
18 (184, 13)
21 (214, 15)
21 (214, 15)
21 (214, 15)
64 (650, 47)
21 (214, 15)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
Common Rail Assy
Fuel Hose No. 4
Vacuum Pump Assy
Nozzle Leakage Pipe No. 2 Fuel Inlet Pipe Sub±assy
EGR Valve AssyWater Outlet Sub±assy
Engine Coolant
Temperature Sensor
Intake Air Connector Sub±assy Intake Manifold
Wiring Harness Clamp Bracket
Injection Pump
Drive Pulley
Timing Belt
No. 3 Cover
Seal Washer
Camshaft Position Sensor
Check Valve
8.8 (90, 78 in.

lbf)
8.8 (90, 78 in.
lbf)
21 (214, 15)
21 (214, 15)
14±284
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79424
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
8.8 (90, 65 in.
lbf)
8.8 (90, 6.5 in.
lbf)
8.4 (86, 74 in.
lbf)
21 (209, 15)
8.8 (90, 78 in.
lbf)
34 (347, 25)
18 (184, 13)21 (210, 15)
21 (210, 15)
42 (428, 31)
37 (377, 27)
59 (600, 43)
21 (214, 15)
45 (454, 33)

O±ring

O±ring

Gasket

O±ring

O±ring
Vacuum Pump Oil Pipe
Union Bolt
Oil Cooler Assy Fuel Filter To Injection Pump
Fuel Pipe
Rear End Plate
Crankshaft Position
Sensor
Thermostat Water Inlet
Oil Level Gage Guide
Oil Filter Bracket Sub±assy
Injection or Supply Pump Assy
Compressor Mounting
Bracket No. 1
Generator Bracket No. 1
V±ribbed Belt
Tensioner
Assy Generator Assy
Oil Cooler Pipe

Gasket
Turbo Oil Outlet Pipe No. 2
31 (320, 23)

Gasket
33 (331, 24)
8.8 (90, 78 in.
lbf)
47 (475, 34)
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±285
AVENSIS REPAIR MANUAL (RM1018E)
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141C4±01
A80094
14±286
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEELS
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.DRAIN ENGINE COOLANT (See page 16±44)
8.DRAIN ENGINE OIL (See page 14±342)
9.DRAIN MANUAL TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
11.REMOVE BATTERY
12.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap together with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
13.DISCONNECT UNION TO CONNECTOR TUBE HOSE
14.REMOVE FUEL FILTER ASSY
(a)Disconnect the 2 fuel hose from the fuel filter (STD).
(b)Disconnect the 3 fuel hose from the fuel filter (COLD).
(c)Disconnect the connector (STD).
(d)Disconnect the 2 connectors (COLD).
(e)Remove the 2 bolts and the fuel filter.
15.REMOVE RADIATOR HOSE INLET
16.REMOVE RADIATOR HOSE OUTLET
17.DISCONNECT WATER BY±PASS HOSE NO.2
18.REMOVE ENGINE ROOM RELAY BLOCK NO.3
(a)Remove the 2 bolts and the engine room relay block.
19.REMOVE RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
20. DISCONNECT HEATER INLET WATER HOSE
21. DISCONNECT HEATER OUTLET WATER HOSE
22. DISCONNECT FUEL HOSE NO.2
23. REMOVE AIR TUBE NO.2
(a) Loosen the hose clamp and disconnect the air hose No.3.
(b) Remove the 2 bolts and the air tube No. 2.
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A79178
A78277
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±287
AVENSIS REPAIR MANUAL (RM1018E)
24.SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a)Remove the 2 clips and 2 washers, separate the control cable assy.
25.REMOVE INJECTOR DRIVER
(a)Remove the 2 nuts which is used to secure the injector driver.
(b)Disconnect the injector driver connector and the harness clamp.
(c)Remove the injector driver.
26.DISCONNECT ENGINE WIRE
(a)Remove the glove compartment door.
(b)Disconnect the engine wire from the ECM and the junc-
tion block.
(c)Pull out the engine wire.
(d)Disconnect the engine wire from engine room junction block.
(e)Remove the bolt and disconnect the wire harness from the body.
27.REMOVE AIR TUBE NO.1
(a)Loosen the hose clamps.
(b)Remove the 2 bolts and nut, and then detach the air tube No. 1.
28.REMOVE CLUTCH ACCUMULATOR ASSY (See page 42±17) SST 09023±00100
29.REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 42±17)
30. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
31. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See page 55±86)
HINT:
Secure the hoses off to the side instead of detaching.
32.REMOVE FLOOR PANEL BRACE FRONT (See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±10)
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A79140
A79184
14±288
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
34.SEPARATE RETURN TUBE SUB±ASSY
(a)Remove the 2 clamp bolts and separate the return tube sub±assy.
35.SEPARATE VANE PUMP OIL RESERVOIR ASSY
36.REMOVE FRONT AXLE HUB LH NUT (See page 30±6) SST09930±00010
HINT:
Perform the same procedure as above on the opposite side.
37.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
HINT:
Perform the same procedure as above on the opposite side.
38.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
HINT:
Perform the same procedure as above on the opposite side.
39. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and the column hole cover silencer sheet.
40.REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
41.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 26±21)
HINT:
Perform the same procedure as above on the opposite side.
42.SEPARATE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
43. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Disconnect the height control sensor connector (w/ Dis-charge head lamp).
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A79179
A61177
A59793
A59792
A79193
Engine Hanger No.1 UPR
Engine Hanger No.2
Engine Hanger No.1
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±289
AVENSIS REPAIR MANUAL (RM1018E)
(b) Set the engine lifter.
(c) Remove the 3 bolts, 3 nuts and the engine mounting insu-
lator sub±assy RH.
(d) Remove the through bolt and nut, detach the engine mounting insulator LH from the vehicle.
(e) Remove the 8 bolts and the front suspension member brace rear RH and LH.
(f) Remove the 2 bolts and 2 nuts.
(g) Carefully remove the engine with transaxle from the ve- hicle.
(h) Install the 2 engine hangers with the 2 bolts. Part No.:
No. 1 engine hanger UPR (yellow) 12284±27020
No. 1 engine hanger UPR (black) 12284±27030
No. 1 engine hanger 12281±27050
No. 2 engine hanger (yellow) 12282±27060
No. 2 engine hanger (black) 12282±27070
Bolt 91642±81025
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
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A62711
A79180
A61186
SST
14±290
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(i)Attach the engine sling and hang the engine with the chain block.
44.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY
(a)Remove the through bolt and nut, detach the engine mounting insulator FR from the engine mounting bracket.
(b)Remove the through bolt, detach the engine mounting in- sulator RR from the suspension crossmember.
(c)Separate the engine and transaxle assembly from the suspension crossmember and engine mounting member.
45.REMOVE STARTER ASSY (See page 19±24)
46.REMOVE MANUAL TRANSAXLE (See page 41±33)
47.REMOVE CLUTCH DISC ASSY (See page 42±26) 48. REMOVE FLYWHEEL SUB±ASSY
(a) Hold the crank shaft with SST.SST 09213±54015 (90105±08076), 09330±00021
(b) Using a torx socket wrench (T55), remove the 8 torx
screws and the flywheel.
49. REMOVE REAR END PLATE
(a) Remove the 2 bolts and the rear end plate.
50. REMOVE DRIVE SHAFT BEARING BRACKET
51. REMOVE ENGINE MOUNTING BRACKET FR
52. REMOVE ENGINE MOUNTING BRACKET RR
53.REMOVE GLOW PLUG ASSY (See page 19±33)
54.REMOVE GENERATOR V BELT (See page 14±269)
55.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)
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