fuel TOYOTA AVENSIS 2003 Service Owner's Manual

02±10
±
PREPARATION ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
09249±63010Torque Wrench AdaptorFAN AND GENERATOR V
BELT(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
FAN AND GENERATOR V
BELT(1AZ±FSE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
09268±21010Fuel Hose PullerCYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
09268±46021Nozzle Holder Retaining Nut
WrenchPARTIAL ENGINE ASSY(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
09301±00210Clutch Guide ToolPARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09301±00220Clutch Guide ToolENGINE REAR OIL SEAL(1CD±FTV)
09316±60011Transmission & Transfer Bearing
ReplacerCRANKSHAFT SEAL(1CD±FTV)
(09316±00011)Replacer PipeCRANKSHAFT SEAL(1CD±FTV)
09330±00021Companion Flange Holding ToolPARTIAL ENGINE ASSY(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
ENGINE REAR OIL SEAL(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
ENGINE REAR OIL SEAL(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
ENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
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022J6±01
02±4
±
PREPARATION FUEL
AVENSIS REPAIR MANUAL (RM1018E)
FUEL
PREPARATION
SST
09023±12700Union Nut Wrench 17mmINJECTOR ASSY(1CD±FTV)
INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
COMMON RAIL ASSY(1CD±FTV)
09213±54015Crankshaft Pulley Holding ToolINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(90105±08076)BoltINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09228±64030Fuel Filter WrenchFUEL FILTER ASSY(1CD±FTV)
09268±21010Fuel Hose PullerFUEL INJECTOR ASSY(1AZ±FE)
FUEL PRESSURE PULSATION
DAMPER ASSY(1AZ±FE)
FUEL INJECTOR ASSY
(1ZZ±FE/3ZZ±FE)
09268±41047Injection Measuring Tool SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09268±41110)AdaptorFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09268±41300)ClampFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(95336±08070)HoseFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09280±00010Union Bolt,inspectionINJECTOR ASSY(1CD±FTV)
09330±00021Companion Flange Holding ToolINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09617±24011)Steering Rack WrenchFUEL PUMP ASSY(1AZ±FSE)
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±
PREPARATION FUEL
02±5
AVENSIS REPAIR MANUAL (RM1018E)
09808±14010Fuel Sender Gauge Tool AssyFUEL TANK ASSY(DIESEL)
FUEL PUMP ASSY(GASOLINE)
FUEL TANK ASSY(GASOLINE)
09842±30080Wire ºHº EFI InspectionFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09950±50013Puller C SetINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09951±05010)Hanger 150INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09952±05010)Slide ArmINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09953±05020)Center Bolt 150INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09954±05021)Claw No.2INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09954±05031)Claw No.3INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09962±01000)Variable Pin Wrench Arm AssyINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09963±01000)Pin 10INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09992±00242Turbocharger Pressure GaugeINJECTOR ASSY(1CD±FTV)
Recomended Tools
09042±00020Torx Socket T40FUEL INJECTOR ASSY(1AZ±FSE)
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02±6
±
PREPARATION FUEL
AVENSIS REPAIR MANUAL (RM1018E)
09082±00040TOYOTA Electrical TesterFUEL SYSTEM(1CD±FTV)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1AZ±FSE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09130±00150Water Pump PliersFUEL FILTER ASSY(1CD±FTV)
09216±00021Belt Tension GaugeINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
Equipment
Clip
Hexagon wrench (6 mm)
Measuring Flask
Ohmmeter
Radiator cap tester
Service Wire Harness
Stopwatch
Torque wrench
Vernier calipers
Wooden block
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)INJECTOR ASSY(1CD±FTV)
08850±00065Butyl Tape SetFUEL TANK ASSY(DIESEL)
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031H4±01
03±26
±
SERVICE SPECIFICATIONS COOLING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Radiator drain plug131309
Water pump x Cylinder block Bolt A
Bolt B9.0 1192
11 38.0 in.lbf 8
Water inlet x Cylinder block sub±assy1111 28
Radiator x Radiator support upper1919414
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Drain plug1313310
Water pump x Cylinder block3132023
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 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
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Timing belt idler Sub±assy No.1 x Cylinder block3535726
Water inlet x Cylinder block8.89078 in.
lbf
Radiator reserve tank assy x Radiator assy6.06153 in.
lbf
Fan assy w/ motor x Fan shroud assy7.57666 in.
lbf
Upper support x Body1919414
Relay box x Radiator assy5.35447 in.
lbf
Front wheel1031,05076
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031FP±01
03±10
±
SERVICE SPECIFICATIONS EMISSION CONTROL
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Heated oxygen sensor
Resistance Bank 1 sensor 1 1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10  at 20
C (68
F)
No continuity
Heated oxygen sensor
Resistance Bank 1 sensor 2 1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10  at 20
C (68
F)
No continuity
Vacuum switching valve
Resistance at 20
C (68
F)
26 to 30 
1AZ±FE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
26 to 30 
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16  at 20
C (68
F)
No continuity
Air fuel ratio sensor
Resistance 1 (HT) ± 2 (+B) 1 (HT) ± 2 (+B)
1 (HT) ± 4 (E1)
1.8 to 3.4 at 20
C (68
F)
5.0 to 7.5 at 500
C (932
F)
No continuity
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
26 to 30 
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16  at 20
C (68
F)
No continuity
1CD±FTV:
EGR valve assy
Resistance +B1 ± EGR1 +B1 ± EGR2
+B1 ± EGR3
+B1 ± EGR4
19.6
1.4  at 20
C (68
F)
19.6
1.4  at 20
C (68
F)
19.6
1.4  at 20
C (68
F)
19.6
1.4  at 20
C (68
F)
Vacuum switching valve assy
Resistance at 20
C (68
F)
10 to 14 
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±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±19
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedft
lbf
kgf
cm
N
m
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±222)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Idle pulley set nut3839028
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head sub±assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020415
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6 and Nut
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5960043
Compressor mounting bracket x Cylinder block4242831
Injection pump x Water pump2121415
Oil level gage guide x Cylinder block1818413
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf
Intake manifold x Cylinder head2121415
Wiring harness clamp bracket x Intake manifold3.9 to 6.940 to 7035 to 61 in.
lbf
Power steering idle pulley bracket x Cylinder head Bolt A
Bolt B72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
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03±20
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Injection pipe, Fuel inlet pipe x Common rail
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 x Injector 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 clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
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 x injection pump 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
Nozzle leakage pipe No.2 x Cylinder head Check valve
Bolt21
8.8214 9015
78 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2121415
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub±assy x Cylinder head2121415
Exhaust manifold x Cylinder head4747935
EGR pipe sub±assy x Cylinder head Bolt
Nut37
25375
25027
18
Oil filter bracket x Oil pan sub±assy3434725
V±ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub±assy x V±ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub±assy center x Body4545933
Front suspension crossmember sub±assy x Rear engine mounting bracket8788764
Front suspension crossmember sub±assy x Front engine mounting bracket\
5253038
Front suspension crossmember sub±assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub±assy\
1331,35698
Front suspension member brace x Body8081659
Return tube sub±assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Injector driver x Engine mounting insulator RH5.05144 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay box x Radiator assy5.35446 in.
lbf
Fuel filter assy x Fuel filter support1817813
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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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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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