Insulator TOYOTA AVENSIS 2003 Service Repair Manual

A76705N´m (kgf´cm, ft´lbf) : Specified torque
Engine Mounting
Insulator RH
Engine Assembly with Transaxle
Front Suspension
Crossmember
W/ Center Member
80 (816, 59)
133 (1,356, 98)45 (459, 33)
52 (530, 38)
52 (530, 38)
87 (887, 64)
52 (530, 38)
Front Suspension
Member Brace RH
133 (1,356, 98)
80 (816, 59)
Front Suspension
Member Brace RH
133 (1,356, 98)
80 (816, 59)
X3X3
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±23
AVENSIS REPAIR MANUAL (RM1018E)
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A76707
Water By±pass Hose No. 2
Radiator Hose Inlet
Heater Inlet Water Hose
Gasket
Exhaust Manifold
Manifold Stay Exhaust Manifold
Heat Insulator No. 1


Gasket
Engine Coolant
Temperature Sensor

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
20 (204, 15)
9.0 (92, 80 in.
lbf)
37 (377, 27)
18 (184, 13)
49 (500, 36)
Clamp Bracket
10 (102, 7)
Radio Setting Condenser
V±Ribbed Idler Assy No. 1
Tube
18 (184, 13)
12 (122, 9)
Manifold Stay No. 2
49 (500, 36)
37 (377, 27)18 (184, 13)
39.2 (400, 29)
14±26
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A64005
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±31
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE GENERATOR ASSY (See page 19±7)
41. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

Secure the compressor and hoses off to the side instead of discharging the A/C system.

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
42. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and the column hole cover silencer sheet.
43.SEPARATE STEERING INTERMEDIATE SHAFT (See page 50±9)
44.REMOVE FRONT DOOR SCUFF PLATE RH (See page 71±11)
45.REMOVE COWL SIDE TRIM BOARD RH (See page 71±11)
46. REMOVE FRONT FLOOR FOOTREST
47. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and the floor panel brace front.
48.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±2)
49.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09930±00010
50. REMOVE FRONT AXLE HUB RH NUT SST 09930±00010
HINT:
Perform the same procedure as above on the opposite side.
51.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6)
SST 09628±62011
52. SEPARATE TIE ROD END SUB±ASSY RH SST 09628±62011
HINT:
Perform the same procedure as above on the opposite side.
53.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
54. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
55.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
56. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
57.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
58. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts and 2 nuts, and detach the enginemounting insulator.
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A76715
A76717
A76716
A62830Front SideRear Side
14±32
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Remove the through bolt and nut, detach the engine mounting insulator from the vehicle.
(d) Remove the 2 bolts and 2 nuts as shown in the illustration.
(e) Remove the 8 bolts and the front suspension member brace rear RH and LH.
(f) Carefully remove the engine with transaxle from the en- gine compartment.
(g) Install the engine hanger No. 1 (12281±15040) and the bolt (91512±B1016).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(h) Install the engine hanger (12281±22021) and the bolt
(91512±B1016).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
HINT:
Securely install the front engine hanger (12281±22021) and the
rear engine hanger No. 1 (12281±15040) to the engine assem-
bly.
(i) Attach the engine sling and hang the engine with the chain block.
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A76718
A76719
A62838SST
A62838SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±33
AVENSIS REPAIR MANUAL (RM1018E)
60. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(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 the transaxle assembly from the suspension crossmember and the engine mounting
member.
61.REMOVE STARTER ASSY(See page 19±3)
62.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
63.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
64.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
65.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) 66. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
67. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the
drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
68. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
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A76722
A76723
A64033
A64034
A64034
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±37
AVENSIS REPAIR MANUAL (RM1018E)
85. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 3 bolts and the nut, and then remove the ex-
haust manifold heat insulator.
86. REMOVE EXHAUST MANIFOLD
(a) Remove the 5 nuts, then remove the exhaust manifold and the gasket.
87. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Using SST, remove the engine coolant temperature sen- sor.
SST 09817±33190
88. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and the condenser.
89. REMOVE WATER BY±PASS HOSE NO.2
90. REMOVE RADIATOR HOSE INLET
91. REMOVE HEATER INLET WATER HOSE
92. REPLACE PARTIAL ENGINE ASSY
93. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt. Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)
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A64033
A76723
A76722
A76721
A76720
ABB
14±38
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
94. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the engine coolant temperature
sensor.
(b) Using SST, install the engine coolant temperature sensor. SST 09817±33190
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
95. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
96. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
(a) Install the exhaust manifold heat insulator,then install the 3 bolts and nut.
Torque:
18 N
m (184 kgf
cm, 13 ft
lbf) for Bolt
12 N
m (122 kgf
cm, 9 ft
lbf) for Nut
(b) Connect the heated oxygen sensor connector.
97. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay with the 3 bolts. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
98. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts. Torque:
49 N
m (500 kgf
cm, 36 ft
lbf) for A
37 N
m (377 kgf
cm, 27 ft
lbf) for B
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A62204
1
5
3
82
6
4
7
A76719
A76718
A76717
14±42
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 88 N
m (897 kgf
cm, 65 ft
lbf)
115.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
116.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
117.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)(See page 41±15)
118.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
119.INSTALL STARTER ASSY(See page 19±3)
120. INS TALL FRO NT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen- sion crossmember and the engine mounting member.
(b) Install the bolt which is used to secure the rear engine
mounting bracket to the mounting insulator.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(c) Install the bolt which is used to secure the front engine mounting bracket to the mounting insulator.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
121. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670±00010
(a) Set the engine assembly with transaxle on the engine lift- er.
(b) Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N
m (816 kgf
cm, 59 ft
lbf)
(d) Install the engine mounting insulator RH. Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
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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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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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