TOYOTA AVENSIS 2003 Service Repair Manual

031E4±01
03±30
±
SERVICE SPECIFICATIONS IGNITION
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Spark plug
Recommended spark plug DENSO made NGK made
Electrode gap K16R±U11, BKR5EYA11
K16R±U11
BKR5EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance ColdHot
1,630 to 2,740

2,065 to 3,225

1AZ±FE:
Spark plug
Recommended spark plug DENSO madeNGK made
Electrode gap K20R±U11, BKR6EYA11
K20R±U11
BKR6EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance ColdHot
985 to 1,600

1,265 to 1,890

1AZ±FSE:
Spark plug
Recommended spark plug DENSO made
Electrode gap SK20BR11
SK20BR11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance ColdHot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance ColdHot
985 to 1,600

1,265 to 1,890

http://vnx.su

031E5±01
±
SERVICE SPECIFICATIONS IGNITION
03±31
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1818413
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf
Cord clamp x Timing chain cover sub±assy9.09280 in.
lbf
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1919414
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf
http://vnx.su

031I3±01
03±70
±
SERVICE SPECIFICATIONS INSTRUMENT PANEL/METER
AVENSIS REPAIR MANUAL (RM1018E)
INSTRUMENT PANEL/METER
TORQUE SPECIFICATION
Part TightenedN mkgf cmft lbf
Instrument Panel Reinforcement Passenger Airbag2020415
http://vnx.su

031FQ±01
±
SERVICE SPECIFICATIONS INTAKE
03±11
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE
SERVICE DATA
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
33 to 39

1CD±FTV:
Turbocharging pressure
Standard pressure
15 to 45 kPa (0.15 to 0.46 kgf/cm2, 2.2 to 6.5 psi)
Turbo pressure sensor
Voltage 3 (VC) ± 1 (E2)
Voltage drop apply vacuum 13.3 kPa (100 mmHg, 3.94 in.Hg)
apply vacuum 26.7 kPa (200 mmHg, 7.87 in.Hg)
apply vacuum 40.0 kPa (300 mmHg, 11.81 in.Hg)
apply vacuum 57.3 kPa (400 mmHg, 15.75 in.Hg)
apply vacuum 66.7 kPa (500 mmHg, 19.96 in.Hg)
Voltage up applied vacuum 19.6 kPa (0.20 kgf/cm2, 2.84 psi) applied vacuum 39.2 kPa (0.40 kgf/cm2, 5.69psi)
applied vacuum 58.8 kPa (0.60 kgf/cm2, 8.53psi)
applied vacuum 78.5 kPa (0.80 kgf/cm2, 11.4psi)
applied vacuum 98.0 kPa (1.00 kgf/cm2, 14.2psi)
4.5 to 5.5 V
0.1 to 0.3 V
0.3 to 0.5 V
0.5 to 0.7 V
0. 7 to 0.9 V
0. 9 to 1.0 V
0.1 to 0.4 V
0.4 to 0.7 V
0.7 to 1.0 V
1.0 to 1.3 V
1.3 to 1.6 V
http://vnx.su

031FR±02
03±12
±
SERVICE SPECIFICATIONS INTAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Turbo water pipe sub±assy No.1 x Turbocharger sub±assy131359.7
Turbocharger sub±assy x Exhaust manifold5354039
Turbo oil outlet pipe x Turbocharger sub±assy131359.7
Manifold converter sub±assy x Turbocharger sub±assy 1st
2nd8.0
2582
25571 in.
lbf
18
Manifold stay x Manifold converter sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Manifold stay x Cylinder block sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Turbohcharger stay x Turbocharger sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Turbocharger stay x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Manifold converter sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Exhaust manifold heat insulator No. 2 x Turbocharger sub±assy121228.9
Turbo insulator No. 1 x Manifold converter sub±assy2020415
Turbo insulator No. 1 x Turbocharger sub±assy2020415
Turbo insulator No. 2 x Manifold converter sub±assy2020415
Exhaust pipe assy x Heater bracket sub±assy w/ Cold area7.57666 in.
lbf
Exhaust pipe assy x Body w/ Cold area7.57666 in.
lbf
Heater bracket x Body w/ Cold area7.57666 in.
lbf
Heater pump assy x Heater bracket w/ Cold area7.57666 in.
lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Air cleaner case x Body7.07162 in.
lbf
Intercooler assy x Body7.07162 in.
lbf
Intercooler cooling air duct x Intercooler assy5.05144 in.
lbf
Air cleaner case x Engine mounting insulator LH7.07162 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 outer8.38573 in.
lbf
http://vnx.su

031HC±01
±
SERVICE SPECIFICATIONS LIGHTING
03±65
AVENSIS REPAIR MANUAL (RM1018E)
LIGHTING
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Height control sensor sub±assy Fr RH x Body7.98170 in.
lbf
Height control sensor sub±assy Fr RH x Stabilizer bar rear5.85951 in.
lbf
Height control sensor sub±assy Rr RH x Suspension menber7.98170 in.
lbf
Height control sensor sub±assy Rr RH x Upper control arm assy5.85951 in.
lbf
http://vnx.su

031H5±01
±
SERVICE SPECIFICATIONS LUBRICATION
03±27
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Oil pressure at idle speed
at 3,000 r/min29 kPa (0.3 kgf
cm2, 4.2 psi) or more
294 to 539 kPa (3.0 to 5.5 kgf
cm2, 43 to 78 psi) or more
AdhesivePart No. 08833 ± 00080, THREE BOND 1344, LOCTITE 242, or
equivalent
1AZ±FE:
Oil pressure at idle speed
at 3,000 rpm29 kPa (0.3 kgf
cm2, 4.3 psi) or more
245 to 539 kPa (2.5 to 5.5 kgf
cm2, 36 to 78 psi) or more
AdhesivePart No. 08833 ± 00080, THREE BOND 1344, LOCTITE 242, or
equivalent
1AZ±FSE:
Oil pressure at idle speed
at 3,000 rpm29 kPa (0.3 kgf
cm2, 4.3 psi) or more
245 to 539 kPa (2.5 to 5.5 kgf
cm2, 36 to 78 psi) or more
AdhesivePart No. 08833 ± 00080, THREE BOND 1344, LOCTITE 242, or
equivalent
1CD±FTV:
Oil pressure at idle speed
at 4,500 rpm29 kPa (0.3 kgf
cm2, 4.3 psi) or more
245 ± 588 kPa (2.5 ± 6.0 kgf
cm2, 36 ± 85 psi)
AdhesivePart No. 08833 ± 00080, THREE BOND 1344, LOCTITE 242, or
equivalent
http://vnx.su

031H6±01
03±28
±
SERVICE SPECIFICATIONS LUBRICATION
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan3737727
Oil pump x Cylinder block9.09280 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.
lbf
Oil pan sub±assy x Cylinder block9.09280 in.
lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body w/o Air conditioning
RHD (w/ Air conditioning) steering position type9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket RH x Body LHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Engine x wire7.07162 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Return tube x Body8.08271 in.
lbf
Ignition coil assy x Cylinder head cover9.09280 in.
lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.
lbf
Front wheel RH1031,05076
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.
lbf
Oil pan sub±assy x Cylinder block9.09280 in.
lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket RH x Body LHD steering position type9.09280 in.
lbf
Engine x wire7.07162 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD steering position type9.09280 in.
lbf
Return tube x Body8.08271 in.
lbf
Ignition coil assy x Cylinder head cover9.09280 in.
lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.
lbf
Front wheel RH1031,05076
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Oil drain plug x Oil pan sub±assy No. 23435025
Oil pump x Cylinder block3132023
http://vnx.su

±
SERVICE SPECIFICATIONS LUBRICATION
03±29
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Oil pan sub±assy x Cylinder block Bolt A
Bolt B
Bolt C
Bolt D42
21 11
12428
214 11 2
12231
15 8
9
Oil pan insulator x Oil pan sub±assy7.57666 in.
lbf
Oil strainer sub±assy x Oil pan sub±assy Bolt
Nut21
13209
13515
10
Oil pan Sub±assy No.2 x Oil pan sub±assy1211 99
Engine oil level sensor x Oil pan sub±assy No.27.07162 in.
lbf
Oil level gage guide x Cylinder block1818413
V±ribbed belt tensioner assy x Oil pump assy3132023
Timing belt idler sub±assy No. 1 x Cylinder head3535726
Timing belt idler sub±assy No. 2 x Oil pump assy4747935
Engine mounting insulator sub±assy RH x Transverse engine engine mount-
ing bracket5253038
Engine mounting insulator sub±assy RH x Body5253038
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel RH1031,05076
Oil cooler assy x Cylinder block4545433
http://vnx.su

030NC±02
03±52
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSMISSION / TRANSAXLE
SERVICE DATA
C50, C250
Transmission case oil seal drive in depth9.9
0.3 mm (0.390
0.012 in.)
Transaxle case oil seal drive in depth1.9
0.3 mm (0.075
0.012 in.)
E354, E357
Transmission case oil seal drive in depth3.5
0.5 mm (0.138
0.020 in.)
Transaxle case cover oil seal drive in depth0
0.5 mm (0
0.020 in.)
http://vnx.su