TOYOTA AVENSIS 2003 Service Repair Manual

031E2±02
03±22
±
SERVICE SPECIFICATIONS EXHAUST
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Compression spring
Free length Minimum Front x Manifold Front x Tail
41.5 mm (1.634 in.)
38.5 mm (1.516 in.)
1AZ±FE/1AZ±FSE:
Compression spring
Free length Minimum Front x ManifoldCenter x Tail
41.5 mm (1.634 in.)
38.5 mm (1.516 in.)
1CD±FTV:
Compression spring
Minimum length Exhaust pipe assy front x Exhaust manifold
41.5mm (1.634 in)
Compression spring
Minimum length Exhaust pipe assy front x Tail pipe assy
38.5mm (1.515 in)
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031E3±02
±
SERVICE SPECIFICATIONS EXHAUST
03±23
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy front x Exhaust pipe assy tail4344032
Heated oxygen sensor x Exhaust pipe assy front4444933
Floor panel brace front x Body3030222
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy center x Exhaust pipe assy front4344032
Exhaust pipe assy tail x Exhaust pipe assy center4344032
Floor panel brace front x Body3030222
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy front x Tail pipe assy4344032
Floor panel brace front x Body3030222
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031GY±01
±
SERVICE SPECIFICATIONS EXTERIOR/INTERIOR TRIM
03±75
AVENSIS REPAIR MANUAL (RM1018E)
EXTERIOR/INTERIOR TRIM
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FUEL LID CONTROL ASSY
Fuel lid control assy x Body8.08271 in.
lbf
REAR BUMPER COVER
Rear bumper cover x Body5.55649 in.
lbf
Rear bumper reinforcement No. 1 x Body11.511 516
BACK DOOR GARNISH OUTSIDE
Back door garnish  Body4.95043 in.
lbf
REAR SPOILER (WAGON MODELS)
Rear spoiler  Body9.89987 in.
lbf
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0313B±05
03±34
±
SERVICE SPECIFICATIONS FRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
SERVICE DATA
Vehicle height
(Normal package) Front: A *1 ± B *2
Rear: D *4 ± C *3
(Rough road package) Front: A *1
± B *2
Rear: D *4 ± C *3
92 mm (3.62 in.)
61 mm (2.40 in.)
72 mm (2.83 in.)
41 mm (1.61 in.)
Toe±in (total)
Rack end length difference0
06'
12' (0.1

0.2
), 1
2 mm (0.04
0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
[Electric motor power steering]
(Normal package) Inside wheel Outside wheel: Reference
(Rough road package) Inside wheel Outside wheel: Reference
\b\f
17'  2
\b\f\f
 

32
52' \b\f

\b\f
42'  2
\b\f
 

33
16' \b\b

Front wheel align-
ment
Wheel angle
[Oil pressure power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel Outside wheel: Reference
\b
47'  2
\b \f
 

31
15' \b

\b
09'  2
\b

 

31
38' \b
\b

Camber
Normal package
Rough road package
Right±left error
±0
34'  45' (±0.57
 0.75
)
±0
19'  45' (±0.32
 0.75
)
45' (0.75
) or less
Caster
Normal package
Rough road package
Right±left error

54'  45' (2.90
 0.75
)

40'  45' (2.67
 0.75
)
45' (0.75
) or less
Steering axis inclination
Normal package
Rough road package
Right±left error
12
27'  45' (12.45
 0.75
)
11
56'  45' (11.93
 0.75
)
45' (0.75
) or less
Front suspensionLower ball joint turning torque0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
*1: Ground clearance of front wheel center
*2: Ground clearance of lower suspension arm front bolt center
*3: Ground clearance of toe control arm inner bolt center
*4: Ground clearance of rear wheel center
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0313A±05
±
SERVICE SPECIFICATIONS FRONT SUSPENSION
03±35
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Tie rod end lock nut7475555
Steering knuckle x Shock absorber2202,240162
Hub nut1031,05076
Suspension support x Piston rod4747935
Suspension support x Body3939829
Suspension crossmember sub±assy x Body1331,36098
Suspension crossmember sub±assy x Engine mounting insulator8081659
Suspension crossmember sub±assy x Center member9697971
Suspension member brace x Body Bolt A:
Bolt B:80
133816
1,36059
98
Speed sensor wire harness bracket set bolt1919214
Stabilizer bracket No.1 x Suspension crossmember (w/o HID)1919414
Stabilizer bracket No.1 x Suspension crossmember (w/ HID) Bolt A: Bolt B:5.41955
19448
14
Stabilizer bar link set nut7475555
Lower suspension arm x Lower ball joint8990866
Lower ball joint x Steering knuckle1031,05076
Lower suspension arm x Suspension crossmember1371,400101
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031E0±01
±
SERVICE SPECIFICATIONS FUEL
03±7
AVENSIS REPAIR MANUAL (RM1018E)
FUEL
SERVICE DATA
GASOLINE:
Compression spring
Free length Minimum Front x Manifold (1ZZ±FE/3ZZ±FE)
Front x Tail (1ZZ±FE/3ZZ±FE)
Center x Tail (1AZ±FE/1AZ±FSE)
41.5 mm (1.634 in.)
38.5 mm (1.516 in.)
38.5 mm (1.516 in.)
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031E1±02
03±8
±
SERVICE SPECIFICATIONS FUEL
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy Bolt A
Bolt B19
9.0194 9214
80 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy2020415
Fuel pressure pulsation damper assy x Fuel delivery pipe sub±assy9.09280 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Cylinder head cover x Fuel pump assy2525518
Fuel pipe sub±assy No.1 x Fuel delivery pipe sub±assy9.09280 in.
lbf
Fuel pipe sub±assy No.1 x Fuel pump assy3030622
Fuel pressure pulsation damper assy x Fuel pump assy3333124
Engine cover bracket x Cylinder head3838828
Engine cover sub±assy No.1 x Cylinder head cover7.07162 in.
lbf
Nozzle holder clamp x Cylinder head131279
Fuel delivery pipe sub±assy x Cylinder head1919414
Surge tank stay No.1 x Cylinder block2121015
Intake manifold x Cylinder head Stud bolt
BoltNut9.5
30
3097
306
30684 in.
lbf
22
22
GASOLINE:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy No. 1 LH x Body4040029
Fuel tank band sub±assy No. 1 RH x Body4040029
Parking brake cable assy No. 3 x Body5.05144 in.
lbf
Parking brake cable assy No. 2 x Body5.05144 in.
lbf
Fuel tank protector No. 1 x Body5.45447 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 1 RH5.45447 in.
lbf
Exhaust pipe assy front x Exhaust manifold (1ZZ±FE/3ZZ±FE)4344033
Exhaust pipe assy front x Exhaust pipe assy tail (1ZZ±FE/3ZZ±FE)\
4344033
Exhaust pipe assy center x Exhaust pipe assy front (1AZ±FE/1AZ±FS\
E)4344033
Exhaust pipe assy center x Exhaust pipe assy tail (1AZ±FE/1AZ±FSE\
)4344033
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Nozzle holder clamp x Cylinder head sub±assy2626519
Nozzle leakage pipe assy x Injector assy Hollow screw
Union bolt18
22184
22413
16
Nozzle leakage pipe No. 2 x Cylinder head sub±assy Hollow screw Bolt21
8.8214 9016
79 in.
lbf
Injection pipe sub±assy No. 1 ± No. 4 x Injector assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe sub±assy No. 1 ± No. 4 x Common rail assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
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±
SERVICE SPECIFICATIONS FUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf
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031HH±01
±
SERVICE SPECIFICATIONS HEATER AND AIR CONDITIONING
03±61
AVENSIS REPAIR MANUAL (RM1018E)
HEATER AND AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume Standard:440
30 g (15.51
1.06 oz.)
Belt deflection New belt:
Used belt:11 ± 13 mm (0.43 ± 0.51 in.)
13.5 ± 16.5 mm (0.53 ± 0.64 in.)
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031HI±01
03±62
±
SERVICE SPECIFICATIONS HEATER AND AIR CONDITIONING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
Tighten2.52522 in.
lbf
Fully tighten3939029
AIR CONDITIONER RADIATOR ASSY
Air conditioning tube assy x Cooler evaporator sub±assy No. 13.53530 in.
lbf
Air conditioner unit assy x Body9.810087 in.
lbf
BLOWER ASSY
Blower assy x Body Bolt:9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (3ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1CD±FTV)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy RHD:9.810087 in.
lbf
Suction servic valve x W/pulley compressor assy LHD:9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x Suction servic valve9.810087 in.
lbf
W/RECEIVER CONDENSER ASSY
Cap x W/receiver condenser assy2.92925 in.
lbf
Magnet valve x W/receiver condenser assy3.43530 in.
lbf
Discharge tube x Magnet valve3.43530 in.
lbf
Discharge tube x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy B x W/receiver condenser assy5.45547 in.
lbf
Discharge hose sub±assy x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy A x W/receiver condenser assy5.45547 in.
lbf
HEAER ASSY
Heater assy x Body7.57666 in.
lbf
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