sensor TOYOTA AVENSIS 2003 Service Repair Manual

141C8±01
SSTA61187
14±318
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.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 AIR CLEANER ASSY (See page 11±60)
8.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
9.REMOVE AIR TUBE NO.1 (See page 14±270)
10.REMOVE INJECTOR DRIVER (See page 14±286)
11. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH (See page 14±307)
15.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)
16.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
17.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
19. REMOVE TIMING BELT GUIDE
20.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
23.REMOVE TIMING BELT (See page 14±307)
24.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
25. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the timing pulley.
HINT:
Using a plastic±faced hammer, tap out the pulley.
(c) Remove the set key.
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A62592
SST
A09663
:Seal Packing
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
14±323
AVENSIS REPAIR MANUAL (RM1018E)
(c)Install the oil seal retainer with the 4 bolts. Tighten the 4
bolts uniformly in several steps.
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
46.INSTALL CAMSHAFT TIMING PULLEY
(a)Install the pulley set key to the groove of the camshaft.
(b)Align the keyway of the timing pulley with the key located on the camshaft, slide the pulley into place.
(c)Using SST, install the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
47.INSTALL CAMSHAFT POSITION SENSOR (See page 10±63)
48.INSTALL INJECTOR ASSY (See page 11±60)
49.INSTALL NOZZLE LEAKAGE PIPE ASSY(See page 11±60) SST09992±00242
50.INSTALL CYLINDER HEAD COVER SUB±ASSY
(a)Remove any old packing (FIPG) material.
(b)Apply seal packing to the cylinder head.Seal packing: Part No. 08826±00080 or equivalent
(c)Install the gasket to the cylinder head cover.
(d)Install the cylinder head cover with the 10 bolts.
Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
51.INSTALL NOZZLE HOLDER SEAL
(a)Install 4 new nozzle holder seals.
52.INSTALL VACUUM PUMP ASSY Torque: 21 N
m (214 kgf
cm,15 ft
lbf)
53.INSTALL INJECTION PIPE SUB±ASSY NO.1(See page 11±60)
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
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A77321
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
43 (440, 32)

Gasket
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover
Sub±assy
Crankshaft Position
Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt
Tensioner Assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
43 (440, 32)
170 (1,735, 125)
Crank Shaft Pulley

Oil Seal
43 (440, 32)
Chain Sub±assy
Chain Tensioner
Slipper
Chain Vibration
Damber No. 1
Crankshaft
Timing Gear
or Sprocket
19 (195, 14)
Crankshaft Position
Sensor Plate No. 1
Timing Chain Guide
Oil Pump
Drive Gear
12 (122, 9.0)
Spring
Chain Tensioner
Oil Pump Drive Shaft Gear
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
30 (301, 22)
No. 2 Chain Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
14±138
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A77286
Push
A64641
A00019
A77288
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±143
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner No. 1 and gasket.
NOTICE:
Do not turn the crankshaft.
27. REMOVE CRANKSHAFT POSITION SENSOR 28. REMOVE OIL PAN SUB±ASSY
(a) Remove the 12 bolts and 2 nuts.
(b) Insert the blade of SST between the crank case, timingchain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, crank case and oil pan.
29. REMOVE V±RIBBED BELT TENSIONER ASSY
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A77289
Pry
A77243
14±144
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
30. REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Using a screwdriver, pry between the timing chain cover
and cylinder head or cylinder block.
(c) Remove the timing chain cover.
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, cylinder head and cylinder block.
31. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
32. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the 2 bolts and the chain tensioner slipper.
33. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the bolt and the chain vibration damper No. 1 34. REMOVE TIMING CHAIN GUIDE
(a) Remove the bolt and the timing chain guide.
35. REMOVE CHAIN SUB±ASSY
36. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
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A77389
Timing MarksMark Links
Timing Mark
A77290
Hold
Stopper
A32629
A77390Seal Packing
14±148
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Align the mark links (gold or yellow colored links) with each timing mark located on the camshaft timing gears,
and install the chain.
43. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
44. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
(b) Check that the chain tensioner slipper is hold on the cylin- der block stopper.
45. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
46. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the chain cover within 3 minutes after applying
seal packing.

Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing
chain cover.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent.
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A77392
Seal Packing6mm
A64641
A77393
SST
A77394
Raise
Pin Hook
Push
14±150
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
48. INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b) Apply a continuous bead (Diameter 3 mm to 4 mm (0.157 in.)) of seal packing as shown in the illustration, and install
the oil pan.
Seal packing: part No. 08826 ± 00080 or equivalent
(c) Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
49. INSTALL CRANKSHAFT POSITION SENSOR 50. INSTALL CRANKSHAFT PULLEY
(a) Using SST, tighten the set bolt.SST 09213±54015 (91651±60855), 09330±00021
Torque: 170 N
m (1,733 kgf
cm, 125 ft
lbf)
51. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap- ply the hook to the pin so that the plunger is located in
position.
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A77286
Push
A64641
A00019
A77288
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±143
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner No. 1 and gasket.
NOTICE:
Do not turn the crankshaft.
27. REMOVE CRANKSHAFT POSITION SENSOR 28. REMOVE OIL PAN SUB±ASSY
(a) Remove the 12 bolts and 2 nuts.
(b) Insert the blade of SST between the crank case, timingchain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, crank case and oil pan.
29. REMOVE V±RIBBED BELT TENSIONER ASSY
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A77289
Pry
A77243
14±144
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
30. REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Using a screwdriver, pry between the timing chain cover
and cylinder head or cylinder block.
(c) Remove the timing chain cover.
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, cylinder head and cylinder block.
31. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
32. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the 2 bolts and the chain tensioner slipper.
33. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the bolt and the chain vibration damper No. 1 34. REMOVE TIMING CHAIN GUIDE
(a) Remove the bolt and the timing chain guide.
35. REMOVE CHAIN SUB±ASSY
36. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
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A77389
Timing MarksMark Links
Timing Mark
A77290
Hold
Stopper
A32629
A77390Seal Packing
14±148
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Align the mark links (gold or yellow colored links) with each timing mark located on the camshaft timing gears,
and install the chain.
43. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
44. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
(b) Check that the chain tensioner slipper is hold on the cylin- der block stopper.
45. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
46. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the chain cover within 3 minutes after applying
seal packing.

Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing
chain cover.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent.
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