TOYOTA AVENSIS 2003 Service Repair Manual

141C5±01
A79425N´m (kgf´cm, ft´lbf): Specified torque
8.0 (82, 71 in.
lbf)
72 (734, 53)
V (Cooler
Compressor to
Crankshaft
Pulley) Belt No. 1
Engine Cover No. 1Engine Room Cover Side
Radiator Support
Opening Cover
Power Steering
Idle Pulley Bracket Engine Under Cover Sub±assy No. 1
Engine Under Cover RH
Injector Driver
52 (530, 38)
Engine Mounting Insulator Sub±assy RH
52 (530, 38)
52 (530, 38)
39 (398, 29)
Clip
Clip
Retainer
Clip
Clip
5.0 (51, 44 in.
lbf)
±
ENGINE MECHANICAL TIMING BELT (1CD±FTV)
14±305
AVENSIS REPAIR MANUAL (RM1018E)
TIMING BELT (1CD±FTV)
COMPONENTS
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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
14±306
±
ENGINE MECHANICAL TIMING BELT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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141C6±01
A61184
A79179
A61182
SST (B)
SSTSST (A)
±
ENGINE MECHANICALTIMING BELT(1CD±FTV)
14±307
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.REMOVE ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE INJECTOR DRIVER (See page 14±286)
8.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
9.REMOVE GENERATOR V BELT (See page 14±269)
10.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11. REMOVE ENGINE MOUNTING INSULATORSUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine.
(b) Remove the 3 bolts and 3 nuts, and then detach the en- gine mounting insulator sub assy RH.
12. REMOVE CRANKSHAFT PULLEY
(a) Using SSTs, remove the pulley bolt. SST 09213±54015 (90105±08076), 09330±00021
HINT:
When using SST (A) (90105±08076), a plate washer (5 mm or
0.20 in.) must be inserted between SST (A) and SST (B).
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A61183SST
A09605Turn
A61185
14±308
±
ENGINE MECHANICAL TIMING BELT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Using SST, remove the pulley. SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±05031)
13. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt and washer, and then remove the pulley.
14. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, and then remove the timing belt c\
over.
15. REMOVE TIMING BELT NO.1 COVER
(a) Remove the 5 bolts and 5 seal washers, and then remove the timing belt c\
over.
16. REMOVE TIMING BELT GUIDE
17. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 6 bolts and the engine mounting bracket. 18. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, align the dot mark of thecrankshaft timing pulley with the TDC mark of the oil pump
by turning the crankshaft.
(b) Check that the timing mark of the camshaft timing pulley is aligned with a joint of the cylinder head and the cylinder
head cover.
If not, revolve the crankshaft 1 revolution (360
) to align the
mark.
19. REMOVE TIMING CHAIN COVER PLATE
(a) Remove the bolt and the timing chain cover plate.
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A09609
A09680
SST
A09611
A09606
A09609
±
ENGINE MECHANICAL TIMING BELT (1CD±FTV)
14±309
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE TIMING BELT
HINT:
If re±use the timing belt, draw an arrow on the belt which indi-
cates the engine revolution direction and put match marks on
the pulleys and the belt before removing. This operation will be
very helpful when re±installing the timing belt.
(a) Alternately loosen the 2 bolts to remove the timing belt
tensioner.
(b) Remove the timing belt.
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, set the pulleys of the camshaft and the injec- tion pump so that each timing mark of the pulleys is
aligned with its timing mark on the cylinder head assem-
bly and the water pump assembly.
SST 09960±10010 (09962±01000, 09963±01000)
(b) Using the crankshaft pulley bolt, align the dot mark of the crankshaft timing pulley with the TDC mark of the oil pump
by turning the crankshaft.
NOTICE:
Take great care, when turning the camshaft and crank-
shaft. Since the valve head and the piston head are sensi-
tive, damage to them may result when the piston head con-
tacts with the valve heads.
22. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Remove any oil or water on each pulley and keep them
clean.
NOTICE:
Do not use any cleaning agent.
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A09612
1st2nd
5th
3rd
4th
6th
7th
A09589
Hexagon
Wrench
(1.27 mm)
(A)
A09623
A61179
Hexagon
Wrench
(1.27 mm)
A09605
Turn
Dot Mark
TDC Mark
14±310
±
ENGINE MECHANICAL TIMING BELT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the timing belt in the following order: 1. Camshaft timing pulley
2. Supply pump drive pulley
3. Water pump pulley
4. Crankshaft timing pulley
5. No. 2 idler pulley
6. Oil pump pulley
7. No. 1 idler pulley
(c) Install the timing belt tensioner. (1) Using a press, slowly press in the push rod with
pressure 981 to 9,807 N (100 to 1,000 kgf, 200 to
2,205 lbf).
(2) Align the holes of the push rod and the housing, in- sert hexagon wrench (1.27 mm) through the holes
to keep the setting position of the push rod.
(3) Release the press.
(4) Temporarily install the tensioner with bolt (A).
(5) Turn the tensioner clockwise and temporarily install the other bolt.
(6) Alternately tighten the 2 bolts.
Torque: 21 N´m (214 kgf´cm, 15 ft´lbf)
(7) Remove the hexagon wrench from the tensioner.
23. CHECK VALVE TIMING
(a) Slowly turn the crankshaft 2 complete revolutions (720
)
from TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.
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A09679
A09596
A09603
Seal PackingGasket
Groove
±
ENGINE MECHANICAL TIMING BELT (1CD±FTV)
14±311
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that each timing mark of the pulleys is aligning with
the timing marks of the engine assembly as shown in the
illustration.
If the timing marks are not aligned, remove the timing belt and
reinstall it.
(c) Remove the crankshaft pulley bolt.
24. INSTALL TIMING CHAIN COVER PLATE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
25. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Torque:
37 N´m (375 kgf´cm, 27 ft´lbf) for 14 mm head bolt
64 N´m (650 kgf´cm, 47 ft´lbf) for 17 mm head bolt
26. INSTALL TIMING BELT GUIDE
(a) Install the belt guide, facing the cap side outward.
27. INSTALL TIMING BELT NO.1 COVER
(a) Check the timing belt cover gasket for cracks or deteriora-tions etc.
If the gasket has cracks or has deteriorated, replace it by the
following steps: (1) Using a screwdriver and gasket scraper, remove allthe old gaskets.
(2) Thoroughly clean all components to remove all the loose material.
(3) Remove the backing paper from a new gasket and affix the gasket to the timing belt cover as shown in
the illustration.
NOTICE:

Affix the gasket at the center of the groove.

At the corners, try to keep the gasket thickness uni-
form.
(4) After installing the gasket, press it down so that the adhesive firmly sticks to the timing belt cover.
(5) If there is a gap where the end of the gasket meets, use seal packing to close the gap.
Seal packing: Part No. 08826±00080 or equivalent
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A09602
Seal
Packing
Gasket
Groove
A61186
SST
14±312
±
ENGINE MECHANICALTIMING BELT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the No. 1 timing belt cover and the gasket with the 5 bolts and 5 seal washers.
Torque: 7.4 N
m (75 kgf
cm,65 in.
lbf)
(c)After installing the belt cover, check that there is no peel- ings of the gasket.
28.INSTALL TIMING BELT NO.2 COVER
(a)Check the timing belt cover gasket for cracks or deteriora- tions etc.
If the gasket has cracks or has deteriorated, replace it by the
following steps: (1)Using a screwdriver and gasket scraper, remove allthe old gasket.
(2)Thoroughly clean all components to remove all the loose material.
(3)Remove the backing paper from a new gasket and affix the gasket to the timing belt cover as shown in
the illustration.
NOTICE:

Affix the gasket at the center of the groove.

At the corners, try to keep the gasket thickness uni-
form.
(4)After installing the gasket, press it down so that the adhesive firmly sticks to the timing belt cover.
(5)If there is a gap where the end of the gasket meets,
use a seal packing to close the gap.
Seal packing: Part No. 08826±00080 or equivalent
(b)Install the No. 2 timing belt cover and the gasket with the 7 bolts and 7 seal washers.
Torque: 7.4 N
m (75 kgf
cm,65 in.
lbf)
29.INSTALL IDLER PULLEY SUB±ASSY Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
30.INSTALL CRANKSHAFT PULLEY
(a)Align the keyway of the pulley with the key located on thecrankshaft, slide the pulley into place.
(b)Using SST, install the pulley bolt. SST09213±54015 (90105±08076), 09330±00021
Torque: 180 N´m (1,835 kgf´cm, 133 ft´lbf)
HINT:
When using a bolt (91651±60855), a plate washer (5 mm or
0.20 in.) must be inserted between the pulley bolt and SST.
31.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH Torque:52 N´m (530 kgf´cm, 38 ft´lbf)
32.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
33. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
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±
ENGINE MECHANICALTIMING BELT(1CD±FTV)
14±313
AVENSIS REPAIR MANUAL (RM1018E)
34.INSTALL INJECTOR DRIVER (See page 14±286)
35. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
36. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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141CN±01
A60622
A01045
A64005
A62837SST
14±96±
ENGINE MECHANICALTIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
TIMING GEAR COVER OIL SEAL(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE FRONT WHEEL RH (See page 14±27)
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
3.REMOVE ENGINE UNDER COVER RH (See page 14±27)
4.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±27) 6. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly andloosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
7. REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine. Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.
8. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the crankshaft pulley bolt. SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the crankshaft pulley from the crankshaft.
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