radiator TOYOTA AVENSIS 2003 Service Owner's Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.95 MB
Page 212 of 2234
03±54
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in. lbf
31 in. lbf
Air cleaner assy x Body5.05144 in.lbf
Engine cover sub±assy No.1 x Engine9.09280 in.lbf
Hood set bolt1313210
MANUAL TRANSAXLE ASSY (1CD±FTV)
Filler and drain plugs4950036
Engine hanger x Engine3737727
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:
Bolt D:
Bolt E:64
46
40
20
8.0653
469
408
200 8247
34
30
14
71 in. lbf
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Accumulator to flexible hose tube x TransaxleBolt A:
Bolt B:
Bolt C:12
5.0
9.0120 51
929
44 in. lbf
80 in. lbf
Manual transaxle assy x Ground cable131319
Air tube No.2 x Transaxle2525518
Starter assy x Transaxle3738027
Starter wire set nut131309
Radiator reserve tank assy x Body6.06153 in.lbf
Air tube No.1 x Engine2525518
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in. lbf
31 in. lbf
Air cleaner assy x Body7.07162 in.lbf
Engine cover No.1 x Engine8.08271 in.lbf
Hood set bolt1313310
http://vnx.su
Page 243 of 2234
100FN±01
A79433N´m (kgf´cm, ft´lbf): Specified torque Non±reusable part
Gasket
25 (255, 18)
25 (255,18 )
21 (214, 15)
30 to 40 (31 to 41 , 27 to 35 in. lbf)
5.0 (51, 44 in. lbf)
8.0 (82, 71 in. lbf)
Radiator Support Opening Cover
Engine Cover No. 1
Battery
Battery Tray Intake Shutter Assy
Air Hose No. 4
Clip
Retainer
Air Tube No. 2
10±60
±
ENGINE CONTROL SYSTEM INTAKE SHUTTER ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE SHUTTER ASSY (1CD±FTV)
COMPONENTS
http://vnx.su
Page 244 of 2234
100FO±01
A80092
B08171
A64328
2 to 7 mm0 to 4 mm
±
ENGINE CONTROL SYSTEM INTAKE SHUTTER ASSY (1CD±FTV)
10±61
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
3. REMOVE BATTERY
4. REMOVE AIR HOSE NO.4
(a) Loosen the 2 hose clamps.
(b) Remove the 2 bolts and separate the air tube No. 2.
(c) Remove the air hose No. 4.
5. REMOVE INTAKE SHUTTER ASSY
(a) Disconnect the 2 connectors.
(b) Remove the 3 nuts, then remove the intake shutter andthe gasket.
6. INSTALL INTAKE SHUTTER ASSY
(a) Install a new gasket and the intake shutter with the 3 nuts. Torque: 21 N m (214 kgf cm, 15 ftlbf)
7. INSTALL AIR HOSE NO.4
(a) Install the air hose No. 4 to the air tube No. 2.
(b) Install the air tube No. 2 with the 2 bolts.
Torque: 25 N m (255 kgf cm, 18 ftlbf)
(c) Install the air hose and hose clamp as shown in the il- lustration.
http://vnx.su
Page 246 of 2234
100FK±01
A77870
Mass Air Flow
Meter Connector
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Cover Sub±assy
No. 1
7.0 (71, 62 in.
lbf)
Fuel Vapor Feed Hose
No. 2
Air Cleaner Cap
Sub±assy VSV
Connector
Fuel Vapor Feed Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip Retainer
x2
x4
10±30
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
KNOCK SENSOR (1AZ±FE)
COMPONENTS
http://vnx.su
Page 250 of 2234
100FL±01
A77917
A77918
(a)
(b)
A77919
10±34
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4.ENGINE COOLANT (See page 16±19)
5.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
7.SEPARATE ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
8.REMOVE THROTTLE BODY ASSY (See page 10±26)
9.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26) SST 09268±21010
10.REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
11. REMOVE VARIABLE RESISTOR (LHD STEERINGPOSITION TYPE, LEADED GASOLINE)
(a) Disconnect the variable resistor connector.
(b) Remove the bolt, and then remove the variable resistor.
12. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the charcoal canister outlet hose No. 1.
(b) Disconnect the fuel hose.
(c) Pull up and remove the charcoal canister.
13. DISCONNECT HEATER INLET WATER HOSE
http://vnx.su
Page 252 of 2234
10±36
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
18.INSTALL INTAKE MANIFOLD INSULATOR NO.1
19.INSTALL INTAKE MANIFOLD
(a)Install a new gasket to the intake manifold.
(b)Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N m (306 kgfcm, 22 ftlbf)
(c)Install the wire harness clamp.
(d)Connect the union to connector tube hose.
20.CONNECT HEATER INLET WATER HOSE
21.INSTALL CHARCOAL CANISTER ASSY
22.INSTALL VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Torque: 5.0 N m (51 kgfcm, 44 in. lbf)
23.INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
24.CONNECT FUEL TUBE SUB±ASSY (See page 11±26)
25.INSTALL THROTTLE BODY ASSY (See page 10±26)
26.INSTALL ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
27. INSTALL AIR CLEANER CAP SUB±ASSY
28.ADD ENGINE COOLANT (See page 16±19)
29.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
30.CHECK FOR FUEL LEAKS (See page 11±19)
31.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
32. INSTALL ENGINE ROOM COVER SIDE
33. INSTALL RADIATOR SUPPORT OPENING COVER
http://vnx.su
Page 253 of 2234
100FK±01
A77870
Mass Air Flow
Meter Connector
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Cover Sub±assy
No. 1
7.0 (71, 62 in.
lbf)
Fuel Vapor Feed Hose
No. 2
Air Cleaner Cap
Sub±assy VSV
Connector
Fuel Vapor Feed Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip Retainer
x2
x4
10±30
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
KNOCK SENSOR (1AZ±FE)
COMPONENTS
http://vnx.su
Page 257 of 2234
100FL±01
A77917
A77918
(a)
(b)
A77919
10±34
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4.ENGINE COOLANT (See page 16±19)
5.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
7.SEPARATE ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
8.REMOVE THROTTLE BODY ASSY (See page 10±26)
9.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26) SST 09268±21010
10.REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
11. REMOVE VARIABLE RESISTOR (LHD STEERINGPOSITION TYPE, LEADED GASOLINE)
(a) Disconnect the variable resistor connector.
(b) Remove the bolt, and then remove the variable resistor.
12. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the charcoal canister outlet hose No. 1.
(b) Disconnect the fuel hose.
(c) Pull up and remove the charcoal canister.
13. DISCONNECT HEATER INLET WATER HOSE
http://vnx.su
Page 259 of 2234
10±36
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
18.INSTALL INTAKE MANIFOLD INSULATOR NO.1
19.INSTALL INTAKE MANIFOLD
(a)Install a new gasket to the intake manifold.
(b)Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N m (306 kgfcm, 22 ftlbf)
(c)Install the wire harness clamp.
(d)Connect the union to connector tube hose.
20.CONNECT HEATER INLET WATER HOSE
21.INSTALL CHARCOAL CANISTER ASSY
22.INSTALL VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Torque: 5.0 N m (51 kgfcm, 44 in. lbf)
23.INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
24.CONNECT FUEL TUBE SUB±ASSY (See page 11±26)
25.INSTALL THROTTLE BODY ASSY (See page 10±26)
26.INSTALL ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
27. INSTALL AIR CLEANER CAP SUB±ASSY
28.ADD ENGINE COOLANT (See page 16±19)
29.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
30.CHECK FOR FUEL LEAKS (See page 11±19)
31.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
32. INSTALL ENGINE ROOM COVER SIDE
33. INSTALL RADIATOR SUPPORT OPENING COVER
http://vnx.su
Page 260 of 2234
100F9±01
A78507
Mass Air Flow
Meter Connector
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Cover Sub±assy
No. 1
7.0 (71, 62 in.
lbf)
Air Cleaner Cap
Sub±assy VSV
Connector
Fuel Vapor Feed Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip Retainer
x2
x4
1.5 (15, 13 in.lbf)
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
10±47
AVENSIS REPAIR MANUAL (RM1018E)
KNOCK SENSOR (1AZ±FSE)
COMPONENTS
http://vnx.su