clock TOYOTA AVENSIS 2003 Service User Guide

A62191
Advanced
Side Path
Retard
Side Path
A62192
Hold Pressure
Decompress Advanced
Side Path
Retard
Side Path
A62193
Straight Pin
Fringe Bolt
A62194
Straight Pin
Key Groove
14±70
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1.5
kgf
cm}.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
(d) Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air
pressure of the timing retard path.
HINT:
When the lock pin is released, the camshaft timing gear re-
volves in the advance direction.
(e) When the camshaft timing gear comes to the most ad- vanced position, take out the air pressure of the timing re-
tard side path, next, take out that of timing advance side
path.
CAUTION:
Camshaft timing gear assembly occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released first. It often causes the breakage of
the lock pin.
(f) Remove the fringe bolt of camshaft timing gear assembly.
NOTICE:

Be sure not to remove the other 4 bolts.

In case of reusing the camshaft timing gear, release
the straight pin lock first, and then install the gear.
17. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly clockwise (as shown in the illustration) while pushing it lightly against
the camshaft. Push further at the position where the pin
gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
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A62178
Push
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
A11858
A64005
±
ENGINE MECHANICALCAMSHAFT(1ZZ±FE/3ZZ±FE)
14±73
AVENSIS REPAIR MANUAL (RM1018E)
(2)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.
(3)Turn the crankshaft counter clockwise, and take thehook off the knock pin to release the plunger.
(4)Turn the crankshaft clockwise, and check that the plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
19.ADJUST VALVE CLEARANCE(See page 14±6)
20. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
21. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
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A77382
Groove90


A77383
Groove
A66833
B11424
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±145
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90
, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
38. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Orient the flat portion of the drive shaft upward.
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A77384
Mark Link
Timing Mark
Timing Mark
Mark Link
A77385
Groove
A77386
Groove
A77387
90

14±146
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Align the mark links (yellow colored links) with the timing marks of each gear as shown in the illustration.
(d) Install the gears to the crankshaft and oil pump shaft with
the chain wrapped.
(e) Temporarily tighten the oil pump drive shaft gear with the nut.
(f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the bolt.
Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
(g) Align an adjusting hole of the sprocket with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the sprocket to lock in position, and tighten the nut.
Torque: 30 N
m (301 kgf
cm, 22 ft
lbf)
(i) Rotate the crankshaft clockwise 90
, and position the
crankshaft key upward.
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A77395
Engine
Front
A77396
Hook
PinTurn
Disconnect
A77397
Push Turn
Plunger
A77398
A
B
A
A
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±151
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install a new gasket chain tensioner with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is released wile inserting, apply the hook again,
and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise, and check that the
hook is disengaged from the plunger knock pin.
(d) Turn the crankshaft clockwise, and check that the plunger is extended.
52. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
53. 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)
54. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.
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A77382
Groove90


A77383
Groove
A66833
B11424
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±145
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90
, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
38. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Orient the flat portion of the drive shaft upward.
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A77384
Mark Link
Timing Mark
Timing Mark
Mark Link
A77385
Groove
A77386
Groove
A77387
90

14±146
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Align the mark links (yellow colored links) with the timing marks of each gear as shown in the illustration.
(d) Install the gears to the crankshaft and oil pump shaft with
the chain wrapped.
(e) Temporarily tighten the oil pump drive shaft gear with the nut.
(f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the bolt.
Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
(g) Align an adjusting hole of the sprocket with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the sprocket to lock in position, and tighten the nut.
Torque: 30 N
m (301 kgf
cm, 22 ft
lbf)
(i) Rotate the crankshaft clockwise 90
, and position the
crankshaft key upward.
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A77395
Engine
Front
A77396
Hook
PinTurn
Disconnect
A77397
Push Turn
Plunger
A77398
A
B
A
A
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±151
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install a new gasket chain tensioner with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is released wile inserting, apply the hook again,
and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise, and check that the
hook is disengaged from the plunger knock pin.
(d) Turn the crankshaft clockwise, and check that the plunger is extended.
52. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
53. 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)
54. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.
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A61194
Pry
A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring TipProtrusion Hight
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±335
AVENSIS REPAIR MANUAL (RM1018E)
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
67. REMOVE CYLINDER HEAD GASKET
68. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-eter of the bolts.
Standard outside diameter:
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
69. INSTALL CYLINDER HEAD GASKET
(a) Measure protrusion height of the piston heads. (1) Clean the cylinder block with solvent.
(2) Set the piston to be measured to slightly beforeTDC.
(3) Place a dial indicator on the cylinder block, and cali- brate the dial indicator at 0 mm (0 in.).
HINT:

Place measuring tip of the dial indicator as shown in the
illustration.

Make sure that the measuring tip is square to the cylinder
block gasket and the piston head when measuring.
(4) Find the most overhung position of the piston head by slowly turning the crankshaft clockwise and
counterclockwise.
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A60622
A79324
A76713
A64023
14±82
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±11) SST09268±21010
15.DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a)Disconnect the union to connector tube hose from the hose to hose tube.
16.DISCONNECT RADIATOR HOSE INLET
(a)Disconnect radiator hose inlet from the cylinder head.
17.DISCONNECT HEATER INLET WATER HOSE
(a)Disconnect the heater inlet water hose from the cylinder head.
18.REMOVE FAN AND GENERATOR V BELT
(a)Turn the V±ribbed belt tensioner clockwise slowly andloosen it. Remove the fan and generator V belt and put
back the V±ribbed belt tensioner carefully.
19.REMOVE V±RIBBED IDLER ASSY NO.1
(a)Remove the nut, bolt, tube and idler.
20.REMOVE GENERATOR ASSY (See page 19±7)
21. DISCONNECT IGNITION COIL ASSY
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.
(d) Remove the 4 bolts and the 4 ignition coils.
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