width TOYOTA AVENSIS 2003 Service User Guide

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PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM
02±53
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09042±00010Torx Socket T30HORN BUTTON ASSY
SPIRAL CABLE SUB±ASSY
09070±20010Moulding RemoverAIR BAG SENSOR ASSY CENTER
Equipment
Torque wrench
Bolt Length: 35.0 mm (1.378 in.) Pitch: 1.0 mm (0.039 in.)
Diam.: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)\
Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam.: 360 mm (14.17 in.)Airbag disposal
Plastic bagAirbag disposal
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030L1±03
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SERVICE SPECIFICATIONS CLUTCH
03±55
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH
SERVICE DATA
Pedal height from asphalt sheet
LHD steering position type
1CD±FTV engine type w/ intercooler
Others
154.0 ± 164.0 mm (6.063 ± 6.457 in.)
139.6 ± 149.6 mm (5.496 ± 5.890 in.)
Pedal height from asphalt sheet
RHD steering position type 1CD±FTV engine type w/ intercooler
Others
158.4 ± 168.4 mm (6.236 ± 6.630 in.)
148.4 ± 158.4 mm (5.843 ± 6.236 in.)
Clutch pedal free play5.0 ± 15.0 mm (0.197 ± 0591 in.)
Clutch pedal push rod play at pedal top1.0 ± 5.0 mm (0.039 ± 0.197 in.)
Slotted spring pin protrusion1.5 ± 3.5 mm (0.059 ± 0.138 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch disc rivet head depth Maximum0.3 mm (0.012 in.)
Clutch disc assy runout Minimum0.8 mm (0.031 in.)
Diaphragm spring finger wearMaximum depth:
Maximum width:0.5 mm (0.020 in.)
6.0 mm (0.236 in.)
Flywheel sub±assy runout Maximum0.1 mm (0.004 in.)
Diaphragm tip alignment Maximum0.5 mm (0.020 in.)
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A09601
Seal Packing
A09627
A09650
12
3
5
49
6
8
7
13
10
11
15
14 12
A09600
Seal Width
2 to 4 mm
Seal Packing
14±322
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ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(e)Install the camshaft bearing caps. (1)Remove any oil packing (FIPG) material from theNo. 5 camshaft bearing cap.
(2)Apply seal packing to the No. 5 camshaft bearing cap as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(3)Place the 5 bearing caps in their proper locations.
(4)Using several steps, install and tighten the 15 bear- ing cap bolts uniformly in the sequence shown in the
illustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
43.INSPECT VALVE CLEARANCE (See page 14±270)
44.ADJUST VALVE CLEARANCE (See page 14±270) 45. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the oil seal
retainer and the cylinder block.
(1) Thoroughly clean all components to remove all theloose material.
(2) Using non±residue solvent, clean both sealing sur- faces.
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 2 to 4 mm(0.08 to 0.16 in.) opening.
(2) Parts must be assembled within 15 minutes of ap- plication. Otherwise the material must be removed
and reapplied.
(3) Immediately remove nozzle from the tube and rein- stall the cap.
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A62174
SST
A62175
Seal Width
4 to 5 mm
Seal Packing
A65676
Timing Chain Cover side:
3 (0.118)3 (0.118)
A ABB
C
C
7 (0.276)
4.5 (0.177)
12 (0.472)6 (0.236)
3 (0.118)
Width 4 (0.157)
A ± AB ± B
C ± C
08826±00100 or equivalent
08826±00080 or equivalent
(mm (in.))
14±90
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ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
58. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to a new oil seal lip.
(b) Using SST, tap in the oil seal until its surface is flush with the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip free of foreign objects.
59. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material (FIPG) from the contact surface.
(b) Apply a continuous bead of seal packing (Diameter 3.5 mm to 4.5 mm (0.1379 to 0.177 in.)) as shown in the il-
lustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent.
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal to engine oil within 2 hours af-
ter installing.
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EM2534
A62785
Margin
Thickness
EM2534
A62785
Margin
Thickness
A62786
Width
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ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±31
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSPECT INTAKE VALVE
(a) Using a vernier calipers, check the valve overall length.
Standard overall length: 88.65 mm (3.4902 in.)
Minimum overall length: 88.35 mm (3.4784 in.)
(b) Using a vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
16. INSPECT EXHAUST VALVE
(a) Using a vernier calipers, check the valve overall length. Standard overall length: 88.69 mm (3.4917 in.)
Minimum overall length: 88.39 mm (3.4799 in.)
(b) Using a vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
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A62787
1.0 ± 1.4 mm30


45


A62788
1.0 ± 1.4 mm 60


45

P16860
A01080
14±32
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ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the valve face with the width between 1.0 ± 1.4 mm
(0.039 ± 0.055 in.).
18. REPAIR VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 30
and
45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 75
and 45

cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com- pound.
(d) Check the valve seating position.
19. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter. Lifter diameter:
30.966 ± 30.976 mm (1.2191 ±1.2195 in.)
20. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter:
31.000 ± 31.025 mm (1.2205 ± 1.2215 in.)
(b) Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance:
0.024 ± 0.059 mm (0.0009 ± 0.0023 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)
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A62821
Seal Width 4 ± 5 mm
6 mm Seal Packing
A62822
SST
A62817SST
14±14
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
42. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing material from the contact sur- face.
(b) Apply seal packing in the shape of bead (Diameter 3.5 mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not put into engine oil within 2 hours after instal-
ling.
(c) Install the oil pan with the 14 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
43. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install it. Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
44. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crank shaft.
45. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter union. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
46. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501
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A62173
Yellow Color MarkTiming Mark
A30867
A62174
SST
A62175
Seal Width
4 ± 5 mm
Seal Packing
14±18
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
56. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
57. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
58. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
59. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to the oil seal lip.
(b) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip off foreign materials.
60. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material from the contact sur- face.
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A62176
Chain Cover
Groove
Cylinder Head
Groove Seal Width
4 ± 5 mm
A B
7 mm 4.5 mm 3 mm
6 mm
12 mm
B
A
A ± A B ± B A
A
A62177
Raise
Push
Hook
Pin
A62178
Push
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Apply seal packing in the shape of bead (Diameter 3.5
mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent
(c) Install the timing chain cover, with the 12 bolts and nut.
Torque:
M6 13 N
m (133 kgf
cm, 10 ft
lbf)
M8 19 N
m (194 kgf
cm, 14 ft
lbf)
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not put into engine oil within 2 hours after instal-
ling.
61. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check the O±ring is clean, and set the hook as shown in the illustration.
(b) 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:
When installing the tensioner, set the hook again if the
hook releases the plunger.
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INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±9
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)Abbreviations Meaning
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/TManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
NO.Number
O2SOxygen Sensor
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
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