key TOYOTA AVENSIS 2003 Service User Guide

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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A77285
Unleaded Gasoline
Timing
Marks
Leaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
A52505
A77388
SST
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±147
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
40. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the camshafts with a wrench on the hexagonal lobe,and align the timing marks of the camshaft timing gear
with each timing mark located on the No. 1 and No. 2
bearing caps as shown in the illustration.
(b) Using the crankshaft pulley bolt, turn the crankshaft and position the key on the crankshaft upward.
41. INSTALL CHAIN VIBRATION DAMPER NO.1 42. INSTALL CHAIN SUB±ASSY
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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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A77285
Unleaded Gasoline
Timing
Marks
Leaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
A52505
A77388
SST
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±147
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
40. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the camshafts with a wrench on the hexagonal lobe,and align the timing marks of the camshaft timing gear
with each timing mark located on the No. 1 and No. 2
bearing caps as shown in the illustration.
(b) Using the crankshaft pulley bolt, turn the crankshaft and position the key on the crankshaft upward.
41. INSTALL CHAIN VIBRATION DAMPER NO.1 42. INSTALL CHAIN SUB±ASSY
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SST
A09582
B07973
Cut PositionPry
SST
A08528
SST
A09583
Angle
SensorInward
±
ENGINE MECHANICALCRANKSHAFT SEAL(1CD±FTV)
14±343
AVENSIS REPAIR MANUAL (RM1018E)
20.REMOVE TIMING BELT(See page 14±307)
21.REMOVE CRANKSHAFT TIMING PULLEY
(a)If the timing pulley cannot be removed by hand, use SSTto remove the pulley.
SST09950±50013 (09951±05010, 09952±05010, 09953±05010, 09953±05020, 09954±05021)
22.REMOVE CRANKSHAFT SEAL
(a)Using a knife, cut off the oil seal lip.
(b)Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Warp tip of the
screwdriver with tape.
23.INSTALL CRANKSHAFT SEAL
(a)Using SST and a hammer, tap in the oil seal until its sur- face is flush with the oil pump edge.
SST09316±60011 (09316±00011)
24.INSTALL CRANKSHAFT TIMING PULLEY
(a)Align the keyway of the timing pulley with the key located on the crankshaft, slide the pulley into place.
(b)Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
SST09223±46011
25.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
26.INSTALL TIMING BELT(See page 14±307)
27.CHECK VALVE TIMING(See page 14±307)
28.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
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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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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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A12816
A11858
A62837SST
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
14±92
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
62.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a)Install the transverse engine engine mounting bracket
with the 3 bolts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
63.INSTALL WATER PUMP ASSY (See page 16±9)
64. 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
65. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
(b) Using SST, install the crankshaft pulley bolt. SST 09960±10010 (09962±01000, 09963±01000)
Torque: 138 N
m (1,407 kgf
cm, 102 ft
lbf)
(c) Turn the crankshaft counterclockwise and take the hook off the knock pin to release the plunger.
(d) 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.
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A79196
New O±Ring
New O±Ring
A79182
Collar
Groove
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±299
AVENSIS REPAIR MANUAL (RM1018E)
132.INSTALL VACUUM PUMP ASSY
(a)Install 2 new O±rings to the vacuum pump.
(b)Align the key of the vacuum pump with the keyway of the
exhaust camshaft, insert the vacuum pump into place.
Secure the pump with the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
133.INSTALL EGR VALVE ASSY
(a)Install a new gasket and the EGR valve with the bolt and 2 nuts. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
134.INSTALL INTAKE AIR CONNECTOR SUB±ASSY
(a)Install a new gasket and the intake air connector with diesel throttle b\
ody with the bolt and 2 nuts. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
135.INSTALL WATER OUTLET SUB±ASSY
(a)Install a new gasket and the water outlet with the 2 bolts. Torque: 21 N
m (214 kgf
cm,15 ft
lbf)
136.INSTALL OIL COOLER ASSY (See page 17±32)
137.INSTALL EXHAUST MANIFOLD
(a)Install a new gasket, the exhaust manifold and the 8 col-lars with new 8 nuts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. Ring groove of the collar should be outside. Refer
to the illustration on the left.
138.INSTALL EGR PIPE SUB±ASSY NO.1
(a)Install 2 new gaskets and the EGR pipe with the bolt and 4 new nuts. Torque:
37 N
m (375 kgf
cm,27 ft
lbf) for bolt
25 N
m (250 kgf
cm,18 ft
lbf) for nut
139.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
140.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
141.INSTALL TURBOCHARGER STAY (See page 13±11)
142.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
143.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
144.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
145.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
146.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
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