water pump TOYOTA AVENSIS 2003 Service Owner's Manual

A64856
A62185
MarkMark
Mark Timing Chain
Cover Surface
Timing
Notch
A62837SST
A11858
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
14±85
AVENSIS REPAIR MANUAL (RM1018E)
33.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts and 3 clamp
brackets.
(b)Remove the cylinder head cover.
34.SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a)Turn the crankshaft pulley to align the timing notch with the timing mark º0º of the timing chain cover.
(b)Check that the point marks of the camshaft timing sprock- et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
35.REMOVE CRANKSHAFT PULLEY
(a)Using SST, remove the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
(b)Remove the crankshaft pulley from the crankshaft.
36.REMOVE V±RIBBED BELT TENSIONER ASSY
(a)Remove the bolt and nut and detach the V±ribbed belt tensioner.
HINT:
Jack up and down to remove the bolt.
37.REMOVE WATER PUMP ASSY(See page 16±9)
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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
±
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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A12816
A11858
A62837SST
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
14±92
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
62.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a)Install the transverse engine engine mounting bracket
with the 3 bolts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
63.INSTALL WATER PUMP ASSY (See page 16±9)
64. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
65. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
(b) Using SST, install the crankshaft pulley bolt. SST 09960±10010 (09962±01000, 09963±01000)
Torque: 138 N
m (1,407 kgf
cm, 102 ft
lbf)
(c) Turn the crankshaft counterclockwise and take the hook off the knock pin to release the plunger.
(d) Turn the crankshaft clockwise, and check that the plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
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A79423
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

O±ring
* Use SST

Gasket


Gasket

Gasket

Gasket

Gasket3.6 to 6.9 (40 to 70, 35 to 61 in.
lbf)
5.0 (51, 44 in.
lbf)
7.4 (76, 66 in.
lbf)
* 31 (316, 23)
34 (347, 25)
43 (438, 32)
21 (214, 15)
18 (184, 13)
21 (214, 15)
21 (214, 15)
21 (214, 15)
64 (650, 47)
21 (214, 15)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
Common Rail Assy
Fuel Hose No. 4
Vacuum Pump Assy
Nozzle Leakage Pipe No. 2 Fuel Inlet Pipe Sub±assy
EGR Valve AssyWater Outlet Sub±assy
Engine Coolant
Temperature Sensor
Intake Air Connector Sub±assy Intake Manifold
Wiring Harness Clamp Bracket
Injection Pump
Drive Pulley
Timing Belt
No. 3 Cover
Seal Washer
Camshaft Position Sensor
Check Valve
8.8 (90, 78 in.

lbf)
8.8 (90, 78 in.
lbf)
21 (214, 15)
21 (214, 15)
14±284
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79424
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
8.8 (90, 65 in.
lbf)
8.8 (90, 6.5 in.
lbf)
8.4 (86, 74 in.
lbf)
21 (209, 15)
8.8 (90, 78 in.
lbf)
34 (347, 25)
18 (184, 13)21 (210, 15)
21 (210, 15)
42 (428, 31)
37 (377, 27)
59 (600, 43)
21 (214, 15)
45 (454, 33)

O±ring

O±ring

Gasket

O±ring

O±ring
Vacuum Pump Oil Pipe
Union Bolt
Oil Cooler Assy Fuel Filter To Injection Pump
Fuel Pipe
Rear End Plate
Crankshaft Position
Sensor
Thermostat Water Inlet
Oil Level Gage Guide
Oil Filter Bracket Sub±assy
Injection or Supply Pump Assy
Compressor Mounting
Bracket No. 1
Generator Bracket No. 1
V±ribbed Belt
Tensioner
Assy Generator Assy
Oil Cooler Pipe

Gasket
Turbo Oil Outlet Pipe No. 2
31 (320, 23)

Gasket
33 (331, 24)
8.8 (90, 78 in.
lbf)
47 (475, 34)
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±285
AVENSIS REPAIR MANUAL (RM1018E)
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A80118
A80115
A80116
A09660
14±292
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
80.REMOVE EGR PIPE SUB±ASSY NO.1
(a)Remove the bolt and 4 nut, and then detach the EGR pipe and the 2 gasket\
s. 81.REMOVE EXHAUST MANIFOLD
(a)Remove the 8 nuts, the exhaust manifold and the gasket.
82.REMOVE OIL COOLER ASSY (See page 17±32)
83. REMOVE WATER OUTLET SUB±ASSY 84. REMOVE INTAKE AIR CONNECTOR SUB±ASSY
(a) Remove the bolt and 2 nuts, and then remove the intakeair connector and the gasket.
85. REMOVE EGR VALVE ASSY
(a) Remove the bolt and 2 nuts, and then remove the EGR valve and the gasket.
86. REMOVE VACUUM PUMP ASSY
(a) Remove the 2 bolts, the vacuum pump and the 2 O±rings.
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A79150
A61175
A09671
14±294
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
93.REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a)Remove the 2 bolts and the intake manifold insulator.
94.REMOVE COMMON RAIL ASSY (See page 11±78) 95.REMOVE POWER STEERING IDLE PULLEY
BRACKET
(a)Remove the 3 bolts and the idle pulley bracket.
96.REMOVE INTAKE MANIFOLD
(a)Remove the 2 bolts and the wiring harness clamp bracket.
(b)Remove the 8 bolts and 2 nuts, and then remove the in- take manifold and the gasket.
97.REMOVE INJECTION PUMP DRIVE PULLEY (See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
98. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, and then remove the timing belt c\
over.
99.REMOVE OIL LEVEL GAGE GUIDE (See page 17±22)
100.REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11±69)
101. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
(a) Remove the 4 bolts and the compressor mounting bracket.
102. REMOVE WATER INLET
(a) Remove the 2 bolts and the water inlet.
103. REMOVE THERMOSTAT
104. REMOVE OIL COOLER PIPE
(a) Remove the union bolt, the oil cooler pipe and the gasket.
105. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and nut, and then detach the fuel pipe.
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A79173New O±Ring
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±295
AVENSIS REPAIR MANUAL (RM1018E)
106.REMOVE CRANKSHAFT POSITION SENSOR
(a)Remove the bolt and the crankshaft position sensor.
107.REMOVE CAMSHAFT POSITION SENSOR
(a)Remove the bolt and the camshaft position sensor.
108.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
109.REPLACE PARTIAL ENGINE ASSY
110.INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Torque: 20 N
m (204 kgf
cm,15 ft
lbf)
111.INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
112.INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
113.INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE Torque:
8.8 N
m (90 kgf
cm,78 ft
lbf) for M6 and Nut
21 N
m (209 kgf
cm,15 ft
lbf) for M8
114.INSTALL OIL COOLER PIPE
(a)Install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 59 N
m (600 kgf
cm,43 ft
lbf)
115.INSTALL THERMOSTAT (See page 16±50)
116.INSTALL WATER INLET (See page 16±50)
117. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
118. INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
119. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O±ring to the oil level gage guide.
(b) Apply engine oil to the O±ring.
(c) Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d) Install the oil level gage guide with the bolt. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
(e) Apply engine oil to the O±ring on the oil level gage.
(f) Install the oil level gage.
120. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
121.INSTALL INJECTION PUMP DRIVE PULLEY (See page 11±69)
SST 09960±10010 (09962±01000, 09963±01000)
122. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts\
. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(b) Install the wiring harness clamp bracket with the 2 bolts.
Torque: 3.9 to 6.9 N
m (40 to 70 kgf
cm, 35 to 61 in.
lbf)
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A79196
New O±Ring
New O±Ring
A79182
Collar
Groove
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±299
AVENSIS REPAIR MANUAL (RM1018E)
132.INSTALL VACUUM PUMP ASSY
(a)Install 2 new O±rings to the vacuum pump.
(b)Align the key of the vacuum pump with the keyway of the
exhaust camshaft, insert the vacuum pump into place.
Secure the pump with the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
133.INSTALL EGR VALVE ASSY
(a)Install a new gasket and the EGR valve with the bolt and 2 nuts. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
134.INSTALL INTAKE AIR CONNECTOR SUB±ASSY
(a)Install a new gasket and the intake air connector with diesel throttle b\
ody with the bolt and 2 nuts. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
135.INSTALL WATER OUTLET SUB±ASSY
(a)Install a new gasket and the water outlet with the 2 bolts. Torque: 21 N
m (214 kgf
cm,15 ft
lbf)
136.INSTALL OIL COOLER ASSY (See page 17±32)
137.INSTALL EXHAUST MANIFOLD
(a)Install a new gasket, the exhaust manifold and the 8 col-lars with new 8 nuts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. Ring groove of the collar should be outside. Refer
to the illustration on the left.
138.INSTALL EGR PIPE SUB±ASSY NO.1
(a)Install 2 new gaskets and the EGR pipe with the bolt and 4 new nuts. Torque:
37 N
m (375 kgf
cm,27 ft
lbf) for bolt
25 N
m (250 kgf
cm,18 ft
lbf) for nut
139.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
140.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
141.INSTALL TURBOCHARGER STAY (See page 13±11)
142.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
143.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
144.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
145.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
146.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
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A09609
A09680
SST
A09611
A09606
A09609
±
ENGINE MECHANICAL TIMING BELT (1CD±FTV)
14±309
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE TIMING BELT
HINT:
If re±use the timing belt, draw an arrow on the belt which indi-
cates the engine revolution direction and put match marks on
the pulleys and the belt before removing. This operation will be
very helpful when re±installing the timing belt.
(a) Alternately loosen the 2 bolts to remove the timing belt
tensioner.
(b) Remove the timing belt.
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, set the pulleys of the camshaft and the injec- tion pump so that each timing mark of the pulleys is
aligned with its timing mark on the cylinder head assem-
bly and the water pump assembly.
SST 09960±10010 (09962±01000, 09963±01000)
(b) Using the crankshaft pulley bolt, align the dot mark of the crankshaft timing pulley with the TDC mark of the oil pump
by turning the crankshaft.
NOTICE:
Take great care, when turning the camshaft and crank-
shaft. Since the valve head and the piston head are sensi-
tive, damage to them may result when the piston head con-
tacts with the valve heads.
22. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Remove any oil or water on each pulley and keep them
clean.
NOTICE:
Do not use any cleaning agent.
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