oil level TOYOTA AVENSIS 2003 Service User Guide

90

A09683
TDC Mark
Dot Mark
A09624
A09625
A09626
Alignment Mark
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±321
AVENSIS REPAIR MANUAL (RM1018E)
40. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set
the dot mark of the crankshaft timing pulley at the position
of 90
BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
41. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, damage to the cylinder head or
the camshaft may result. To avoid this, the following proce-
dures should be carried out.
(a) Place the camshaft carrier on the cylinder head.
(b) Install the camshaft sub±assy No. 1.
(c) Apply engine oil to the cam and gear of the camshaft, and the journal of the camshaft carrier.
(d) Place the intake camshaft on the camshaft carrier as
shown in the illustration so that the No. 3 and No. 4 of cyl-
inder cam lobes face downward.
42. INSTALL NO.2 CAMSHAFT
(a) Install the camshaft sub±assy No. 2.
(b) Apply engine oil to the cam and gear of the camshaft, and the journal of the camshaft carrier.
(c) Engage the exhaust camshaft gear and the intake cam- shaft gear by aligning the alignment marks on each gear.
(d) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.
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A77328
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
30 (301, 22)

O±ring
Bearing Cap No. 1
Bearing Cap No. 2
9.0 (92, 80 in.
lbf)
Bearing Cap No. 3
Camshaft
No. 2 Camshaft
Camshaft Bearing No. 2
Camshaft Timing
Oil Control Valve Assy
Cylinder Head

Cylinder Head Gasket
9.0 (92, 80 in.
lbf)
Oil Level Gauge
Sub±assy
9.0 (92, 80 in.
lbf)

O±ring
Oil Level Gauge
Guide
1st: 79 (800, 58)
2nd: Turn 90

30 (301, 22)
9.0 (92, 79 in.
lbf)
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±159
AVENSIS REPAIR MANUAL (RM1018E)
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A76712
Camshaft
Camshaft No. 2
Plate Washer Camshaft Bearing Cap No. 1
Camshaft Bearing Cap No. 3
Cylinder Head Sub±assy Camshaft Timing
Oil Control Valve Assy
 Cylinder Head Gasket
Manifold Stay No. 1 Intake Manifold
Clamp Bracket
Oil Level Gage Guide
 O±ring Oil Level Gage
Sub±assy
 Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
13 (133, 10)
23 (235, 17)
30 (306, 22)
9.0 (92, 80 in.
lbf)
1st 49 (500, 36)
2nd Turn 90
See page 14±81
49 (500, 36)

Gasket
Manifold Stay No. 2
37 (377, 27)
 O±ring
9.0 (92, 80 in.
lbf)
13 (133, 10)
49 (500, 36)
14±80
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
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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A76720
AAB
A76721
B06777
A64026
A79363
14±94
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
68.INSTALL MANIFOLD STAY
(a)Install the manifold stay with the 3 bolts. Torque:
37 N
m (377 kgf
cm, 27 ft
lbf) for Bolt A
49 N
m (500 kgf
cm, 36 ft
lbf) for Bolt B
69.INSTALL MANIFOLD STAY NO.2
(a)Install the manifold stay with the 3 bolts. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
70.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±2)
71. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Apply a light coat of engine oil on a new O±ring, and install it to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
72. INSTALL WATER BY±PASS PIPE NO.1
(a) Install a new gasket and water by±pass pipe with the 2 nuts and 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
73. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil on a new O±ring, and install it to the oil level gage guide.
(b) Install the oil level gage guide with the bolt.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
74. INSTALL INTAKE MANIFOLD
(a) Install a new gasket to the intake manifold.
(b) Install the intake manifold and the throttle body assembly with the 2 brackets, 4 bolts and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c) Connect the 2 vacuum hoses to the intake manifold.
(d) Connect the 2 water hoses to the throttle body.
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A79295
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
5.0 (50, 43 in.
lbf)

O±ring

Gasket

Gasket

Gasket


Gasket

O±ring
15 (153, 11)
20 (204, 15)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
Fuel Delivery Pipe
w/ Injector
Oil Control Valve Knock Control Sensor Spacer
Water By±pass Pipe No. 1 Oil Level Gauge
Sub±assy
Oil Level Gauge Guide
Water Inlet
9.0 (92, 79 in.
lbf)Engine Oil Pressure Switch Assy
Water Temperature Sensor
Thermostat
9.0 (92, 80 in.
lbf)
19 (194, 14)
19 (194, 14)
20 (204, 15)
14±120
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A77402SST
A56446
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±127
AVENSIS REPAIR MANUAL (RM1018E)
63.SEPARATE VANE PUMP ASSY
(a)Disconnect the PS oil pressure switch connector.
(b)Remove the 2 bolts and separate the vane pump from the engine.
64.REMOVE STARTER ASSY (See page 19±12)
65.REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Remove the through bolt and nut from the engine mounting insulator FR.
(b)Remove the through bolt and nut from the engine mounting insulator RR.
66.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
67.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
68.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
69.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
70.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
71.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
72. REMOVE DRIVE PLATE AND RING GEAR ORFLYWHEEL
(a) Using SST, fix the crankshaft pulley and remove the drive plate and ring gear or flywheel.
SST 09213±54015 (91651±60855), 09330±00021
73. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Remove a bolt, O±ring and the camshaft timing oil control valve. 74. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts, and then remove the in-take manifold.
75. REMOVE VENTILATION HOSE
76. REMOVE VENTILATION HOSE NO.2
77. REMOVE ENGINE WIRE
78. REMOVE INTAKE MANIFOLD INSULATOR NO.1
79. REMOVE OIL LEVEL GAGE SUB±ASSY
80. REMOVE OIL LEVEL GAGE GUIDE
81. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a) Remove the 4 bolts and the manifold converter insulator No. 1.
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A52499
A56446
A77333SST
14±130
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(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)
105. INSTALL MANIFOLD CONVERTER INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
106. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil\
level gauge guide.
(b) Install the oil level gauge and guide with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
107. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
108. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Apply light coat of engine oil to the new O±ring and install it to th\
e camshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)
109. I N S TA L L D R I V E P L AT E A N D R I N G G E A R O R FLYWHEEL
(a) Hold the crankshaft with SST.
SST 09213±54015 (91651±60855), 09330±00021
Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
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A79424
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
8.8 (90, 65 in.
lbf)
8.8 (90, 6.5 in.
lbf)
8.4 (86, 74 in.
lbf)
21 (209, 15)
8.8 (90, 78 in.
lbf)
34 (347, 25)
18 (184, 13)21 (210, 15)
21 (210, 15)
42 (428, 31)
37 (377, 27)
59 (600, 43)
21 (214, 15)
45 (454, 33)

O±ring

O±ring

Gasket

O±ring

O±ring
Vacuum Pump Oil Pipe
Union Bolt
Oil Cooler Assy Fuel Filter To Injection Pump
Fuel Pipe
Rear End Plate
Crankshaft Position
Sensor
Thermostat Water Inlet
Oil Level Gage Guide
Oil Filter Bracket Sub±assy
Injection or Supply Pump Assy
Compressor Mounting
Bracket No. 1
Generator Bracket No. 1
V±ribbed Belt
Tensioner
Assy Generator Assy
Oil Cooler Pipe

Gasket
Turbo Oil Outlet Pipe No. 2
31 (320, 23)

Gasket
33 (331, 24)
8.8 (90, 78 in.
lbf)
47 (475, 34)
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±285
AVENSIS REPAIR MANUAL (RM1018E)
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A79150
A61175
A09671
14±294
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
93.REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a)Remove the 2 bolts and the intake manifold insulator.
94.REMOVE COMMON RAIL ASSY (See page 11±78) 95.REMOVE POWER STEERING IDLE PULLEY
BRACKET
(a)Remove the 3 bolts and the idle pulley bracket.
96.REMOVE INTAKE MANIFOLD
(a)Remove the 2 bolts and the wiring harness clamp bracket.
(b)Remove the 8 bolts and 2 nuts, and then remove the in- take manifold and the gasket.
97.REMOVE INJECTION PUMP DRIVE PULLEY (See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
98. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, and then remove the timing belt c\
over.
99.REMOVE OIL LEVEL GAGE GUIDE (See page 17±22)
100.REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11±69)
101. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
(a) Remove the 4 bolts and the compressor mounting bracket.
102. REMOVE WATER INLET
(a) Remove the 2 bolts and the water inlet.
103. REMOVE THERMOSTAT
104. REMOVE OIL COOLER PIPE
(a) Remove the union bolt, the oil cooler pipe and the gasket.
105. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and nut, and then detach the fuel pipe.
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