sensor TOYOTA AVENSIS 2003 Service Repair Manual

A77350
A52497
A32664
A56213
14±258
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
53.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a)Remove the 2 bolts and 2 nuts, and then detach the No.
1 and No. 2 exhaust manifold stay.
(b)Disconnect the 3 oxygen sensor connectors.
(c)Remove the 5 nuts, the exhaust manifold and gasket.
54.REMOVE NO.2 CAMSHAFT (See page 14±240)
55.REMOVE CAMSHAFT (See page 14±240)
56. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt and the oil control valve. 57. REMOVE CAMSHAFT BEARING NO.2
58. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub±assy.
(b) Set the jack under the engine assembly w/ transaxle, andplace a wooden block on the jack.
(c) Remove the chain block and sling devise.
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A77332
23
145
A77350
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FSE)
14±261
AVENSIS REPAIR MANUAL (RM1018E)
67.IN STALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a)Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(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)
68.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
69.INSTALL INTAKE AIR CONTROL VALVE ASSY
(a)Install a new gasket and the intake air control valve.
70.INSTALL INTAKE MANIFOLD
(a)Install the 2 stud bolts. Torque: 10 N
m (97 kgf
cm,84 in.
lbf)
(b)Install the intake manifold and insulator with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
71.INSTALL THROTTLE BODY ASSY (See page 10±44)
72. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
73. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
74.INSTALL CHAIN SUB±ASSY (See page 14±222)
75. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
76. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 N
m (195 kgf
cm, 15 ft
lbf)
77.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±240)
78.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±222)
79.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±222)
80.INSTALL OIL PAN SUB±ASSY (See page 14±222)
81.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
82.INSTALL CRANKSHAFT PULLEY (See page 14±222) SST 09213±54015 (91651±60855), 09330±00021
83.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±222)
84. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
85.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
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A79431
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
* Use SST
5.0 (51, 44 in.
lbf)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2
Injection Pipe Sub±assy
* 42 (428, 31)
46 (469, 34)
Fuel Inlet Pipe
Sub±assy

O±ring
43 (438, 32)
21 (214, 15)
Common Rail Assy
Fuel Hose No. 4
Camshaft Position Sensor
Set Key
Camshaft Timing Pulley
88 (899, 65)
Vacuum Pump Assy
8.8 (90, 78 in.

lbf)
* 42 (428, 31)
46 (469, 34)
14±330
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79148
SST
A79143
SST
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±333
AVENSIS REPAIR MANUAL (RM1018E)
42.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
43.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
44.REMOVE MANIFOLD STAY (See page 13±11)
45.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
46.REMOVE TURBOCHARGER STAY (See page 13±11)
47.REMOVE TURBO WATER HOSE NO.1 (See page 13±11)
48.REMOVE TURBO WATER HOSE NO.2 (See page 13±11)
49.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
50.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11)
51.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
52.REMOVE CAMSHAFT TIMING PULLEY (See page 14±318)
SST 09960±10010 (09962±01000, 09963±01000)
53. REMOVE FUEL INLET PIPE SUB±ASSY
(a) Using SST, remove the fuel inlet pipe from the commonrail side.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023±12700
NOTICE:
After removing the fuel pipe, cover the common rail and the
injector mounting holes with vinyl tape to prevent dust
from being introduced.
54. REMOVE INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
SST 09023±12700
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector
side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or a
plastic bag.
55. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
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A09663
:Seal Packing
14±338
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
76.INSTALL CAMSHAFT OIL SEAL RETAINER (See page 14±318)
77.INSTALL CAMSHAFT TIMING PULLEY (See page 14±318) SST 09960±10010 (09962±01000, 09963±01000)
78.INSTALL CAMSHAFT POSITION SENSOR (See page 10±64)
79.INSTALL INJECTOR ASSY(See page 11±60)
80.INSTALL NOZZLE LEAKAGE PIPE ASSY(See page 11±60) SST 09992±00242
81. 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 head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
82. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
83.INSTALL VACUUM PUMP ASSY (See page 14±318) 84. 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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A60625
Crankshaft Pulley
V±ribbed Belt
Tensioner Assy
Water Pump AssyTransverse Engine
Engine Mounting Bracket
Crankshaft Position Sensor
Chain Tensioner Assy No. 1
Timing Chain or
Belt Cover Sub±assy

Oil Seal
Crankshaft Position Sensor
Plate No. 1 Chain Sub±assy
Chain Tensioner Slipper
Crankshaft timing Sprocket

O±ring

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
47 (479, 35)
29 (296, 21)
69 (704, 51)
138 (1,047, 102)
13 (133, 10)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
19 (194, 14)
9.0 (92, 80 in.
lbf) (L=20)
11 (112, 8) (L=35)
9.5 (97, 84 in.
lbf)
13 (133, 10) (M6)
19 (194, 14) (M8)
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±79
AVENSIS REPAIR MANUAL (RM1018E)
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A65078
A64058
A79363
A64026
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±83
AVENSIS REPAIR MANUAL (RM1018E)
22. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head
cover.
23. DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head cover.
24. REMOVE INTAKE MANIFOLD
(a) Disconnect the 2 water hoses from the throttle body.
(b) Disconnect the ventilation hose and ventilation hose No. 2 from the cylinder head cover.
(c) Disconnect the vacuum hose from the water by±pass
pipe No. 1.
(d) Remove the 4 bolts, 2 nuts and 2 wire brackets.
(e) Remove the intake manifold and the throttle body assem- bly.
(f) Remove the gasket from the intake manifold and the throttle body assembly.
25. REMOVE OIL LEVEL GAGE SUB±ASSY
(a) Remove the oil level gage from the oil level gage guide.
26. REMOVE OIL LEVEL GAGE GUIDE
(a) Disconnect the crankshaft position sensor cramp.
(b) Remove the bolt and the oil level gage guide.
27. SEPARATE WATER BY±PASS PIPE NO.1
(a) Remove the 2 bolts which are used to secure the water by±pass pipe.
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A12816
A76692
A62178
Push
A10076
A30848
14±86
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and the transverse engine engine
mounting bracket.
39. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts which are used to secure the crank- shaft position sensor.
40. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and the chain tensioner.
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
41. REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove the 11 bolts and nuts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying between the cyl- inder head and the cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the timing chain cover, the cylin-
der head and the cylinder block.
42. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.
43. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
44. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and the chain tensioner slipper.
45. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolt and the chain vibration damper.
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A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
A62172
SST
A62173
Yellow Color MarkTiming Mark
A30867
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±89
AVENSIS REPAIR MANUAL (RM1018E)
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain on the crankshaft timing sprocket with the yellow color link and the timing mark on the crank-
shaft timing sprocket aligned.
HINT:
Three yellow color links are on the chain.
(c) Using SST, install the crankshaft timing sprocket. SST 09223±22010
(d) Install the timing chain to the camshaft timing sprockets with the yellow color links and the timing marks on the
camshaft timing sprockets aligned.
55. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install chain vibration damper with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
56. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
57. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
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A65677
AAA A
A
A
AAA
B
B
B
A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±91
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the timing chain cover with the 11 bolts and nut.
Torque:
13 N
m (133 kgf
cm, 10 ft
lbf) for A
19 N
m (194 kgf
cm, 14 ft
lbf) for B
(d) Using a torx wrench socket (E8), install the stud bolt. Torque: 9.5 N
m (97 kgf
cm, 84 in.
lbf)
60. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check that the O±ring is clean, and set the hook as shown in the illustration.
(b) Apply engine oil to the chain tensioner and install it with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
61. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of the engine oil to the O±ring on the crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
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