wheel bolt torque TOYOTA AVENSIS 2003 Service User Guide
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.95 MB
Page 229 of 2234
031HM±01
±
SERVICE SPECIFICATIONS SUPPLEMENTAL RESTRAINT SYSTEM
03±63
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
Horn button assy x Steering wheel assy8.89078 in. lbf
Steering wheel assy x Steering column assy5051037
Instrument panel passenger airbag assy x Instrument panel reinforcement2020014
Curtain shield airbag assy x Body3.53631 in.lbfCurtain shield airbag assy x Body3.5
14
36
143
31 in. lbf
10
Instrument panel airbag assy x Instrument panel reinforcement1818413
Airbag sensor assy center x Body17.517813
Airbag front sensor set bolt7.57666 in.lbf
Side airbag sensor assy LH x Body17.517813
Airbag sensor rear LH x Body17.517813
Seat position airbag sensor x Front seat8.08271 in.lbf
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Page 498 of 2234
141B8±01
A77281
A77292
A77299
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
14±139
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE ENGINE UNDER COVER LH
6.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining the engine oil.
Torque: 25 N m (255 kgfcm,18 ftlbf)
7.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
8.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
9.REMOVE GENERATOR ASSY (See page 19±20)
10.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
11. SEPARATE VANE PUMP ASSY
(a) Remove the 2 through bolts and separate the vane pump.
12. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove 3 bolts and separate the return tube as shownin the illustration.
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Page 511 of 2234
A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply seal packing to the 2 locations as shown in the il- lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after
applying seal packing.
Do not expose the seal to engine oil 2 hours after
installing.
(c)install the cylinder head cover with the 8 bolts and 2 nuts. Torque:
Bolt A 11 Nm (112 kgfcm, 8 ftlbf)
Bolt B 14 Nm (143 kgfcm, 10 ftlbf)
Bolt C 21 Nm (214 kgfcm, 15 ftlbf)
Nut 11 N m (112 kgfcm, 8 ft lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N m (71 kgfcm,62 in. lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgfcm,71 in. lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N m (82 kgfcm,71 in. lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgfcm,80 in. lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgfcm,27 ftlbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 512 of 2234
141B8±01
A77281
A77292
A77299
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
14±139
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE ENGINE UNDER COVER LH
6.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining the engine oil.
Torque: 25 N m (255 kgfcm,18 ftlbf)
7.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
8.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
9.REMOVE GENERATOR ASSY (See page 19±20)
10.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
11. SEPARATE VANE PUMP ASSY
(a) Remove the 2 through bolts and separate the vane pump.
12. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove 3 bolts and separate the return tube as shownin the illustration.
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Page 525 of 2234
A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply seal packing to the 2 locations as shown in the il- lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after
applying seal packing.
Do not expose the seal to engine oil 2 hours after
installing.
(c)install the cylinder head cover with the 8 bolts and 2 nuts. Torque:
Bolt A 11 Nm (112 kgfcm, 8 ftlbf)
Bolt B 14 Nm (143 kgfcm, 10 ftlbf)
Bolt C 21 Nm (214 kgfcm, 15 ftlbf)
Nut 11 N m (112 kgfcm, 8 ft lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N m (71 kgfcm,62 in. lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgfcm,71 in. lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N m (82 kgfcm,71 in. lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgfcm,80 in. lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgfcm,27 ftlbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 534 of 2234
141CB±01
A61184
A79179
14±342
±
ENGINE MECHANICALCRANKSHAFT SEAL(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT SEAL(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 34 N m (350 kgfcm,25 ftlbf)
2.REMOVE FRONT WHEEL RH
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.REMOVE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11.REMOVE ENGINE MOUNTIN G INSULATOR
SUB±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.
12.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
13.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
14.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
15.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
16. REMOVE TIMING BELT GUIDE
17.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
18.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
19.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
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Page 544 of 2234
141BB±01
A77292
A77299
14±160
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2. REMOVE FRONT WHEEL RH
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgf cm, 18 ftlbf)
9.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 14±121)
10.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
11.REMOVE GENERATOR ASSY (See page 19±20)
12.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
13. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
14. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils. 15. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts and separate the return tube asshown in the illustration.
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Page 552 of 2234
141BO±01
A77339
A77292
14±254
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgfcm,18 ftlbf)
9.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
10.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
11.SEPARATE FUEL TUBE SUB±ASSY (See page 11±33)
12.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
13.REMOVE FUEL PUMP ASSY (See page 11±52)
14.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
15.REMOVE GENERATOR ASSY (See page 19±20)
16.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
17. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
18. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
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Page 596 of 2234
A64023
A76713
A79324
A78459
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±95
AVENSIS REPAIR MANUAL (RM1018E)
75. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
(b) Install the engine wire with the 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
76.INSTALL GENERATOR ASSY (See page 19±7)
77. INSTALL V±RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt. Torque: 39.2 N m (400 kgfcm, 29 ftlbf)
78. INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
79. INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
80. INSTALL AIR CLEANER HOSE NO.1 Torque: 1.5 N m (15 kgf cm, 13 in. lbf)
81. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N m (71 kgfcm, 62 in. lbf)
82. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
83.ADD ENGINE COOLANT(See page 16±7)
84.INSPECT COMPRESSION (See page 14±1)
SST 09992±00500
85.INSPECT CO/HC (See page 14±1)
86.INSPECT IGNITION TIMING (See page 14±1) SST 09843±18040
87.CHECK FOR ENGINE COOLANT LEAKS (See page 16±7)
88. CHECK FOR ENGINE OIL LEAKS
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Page 615 of 2234
141CC±01
A61182
SST
A09447
SST
A09448
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1CD±FTV)
14±345
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1CD±FTV)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (See page 41±33)
SST 09930±00010, 09628±62011, 09520±01010, 09520±24010 (09520±32040)
2.REMOVE CLUTCH COVER ASSY (See page 42±26)
3.REMOVE CLUTCH DISC ASSY (See page 42±26)
4. REMOVE FLYWHEEL SUB±ASSY
(a) Hold the crankshaft with SST.SST 09213±54015 (90105±08076), 09330±00021
(b) Using a torx socket wrench (T55), remove the 8 torx screws and the flywheel.
5. REMOVE REAR END PLATE
(a) Remove the 2 bolts and the rear end plate. 6. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpa-
per.
7. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the oil seal until its sur-face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
8. INSTALL REAR END PLATE Torque: 8.4 N m (86 kgf cm, 74 in. lbf)
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