width 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 900 of 2234
A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
16±22
±
COOLINGWATER PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the con- tact surface.
(b)Apply seal packing to the water pump as shown in the il- lustration.
Seal packing: Part No. 08826 ± 00100 or equivalent
Install a nozzle that has been cut to a 2.2 to 2.5 mm
(0.09 to 0.10 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c)Install the water pump and wire clamp with 4 bolts and 2
nuts.
Torque: 9.0 N m (90 kgfcm, 80 in. lbf)
(d)Install the crankshaft position sensor wire harness clamp to the water pump.
(e)Install the crankshaft position sensor wire to the wire clamp on the water pump.
10.INSTALL WATER PUMP PULLEY
(a)Using SST, install the pump pulley with 4 bolts. SST09960±10010 (09962±01000, 09963±00700)
Torque: 26 N m (265 kgfcm, 19 ftlbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
13.ADD COOLANT (See page 16±19)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±17)
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Page 902 of 2234
A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
16±34
±
COOLINGWATER PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the contact surface.
(b)Apply seal packing to the water pump as shown in the il- lustration.
Seal packing: Part No. 08826 ± 00100 or equivalent
Install a nozzle that has been cut to a 2.2 to 2.5 mm
(0.09 to 0.10 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c)Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N m (90 kgfcm, 80 in. lbf)
(d)Install the crankshaft position sensor wire harness clamp to the water pump.
(e)Install the crankshaft position sensor wire to the wire clamp on the water pump.
10.INSTALL WATER PUMP PULLEY
(a)Using SST, install the pump pulley with 4 bolts. SST09960±10010 (09962±01000, 09963±00700)
Torque: 26 N m (265 kgfcm, 19 ftlbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
13.ADD COOLANT (See page 16±31)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS(See page 16±25)
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Page 934 of 2234
A56700
SST
B07987
New Gasket
Seal
Packing
Seal Width
2 to 4 mm
B08024
±
LUBRICATION OIL PUMP ASSY (1CD±FTV)
17±25
AVENSIS REPAIR MANUAL (RM1018E)
35. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316±60011 (09316±00011, 09316±00021)
36. INSTALL OIL PUMP ASSY
(a) Remove any old packing (FIPG) and be careful not to drop any oil on the contact surfaces of the oil pump and
the cylinder block.
(1) Using a razor blade and a gasket scraper, removeall the old packing from the gasket surfaces and the
sealing groove.
(2) Thoroughly clean all components to remove all the loose material.
(3) Using a non±residue solvent, clean both the sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
(1) Install a nozzle that has been cut to a 2 to 4 mm(0.08 to 0.16 in.) opening.
(2) Parts must be set within 3 minutes and assembled within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3) Immediately remove nozzle from the tube and rein- stall the cap.
(c) Install a new gasket to the oil pump.
(d) Pour in 0.5 cm
3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Apply engine oil to the cylinder block side where it con-
tacts with the oil pump driven rotor.
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Page 936 of 2234
A56703
Seal Width
4 to 7 mm
A
AB
B
A56697
AA
A
A AA
B
B
D
B
B
B
BC
C
C
CC
CC D
D
A56696
±
LUBRICATION OIL PUMP ASSY (1CD±FTV)
17±27
AVENSIS REPAIR MANUAL (RM1018E)
(b) Apply a seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 4 to 7 mm(0.16 to 0.28 in.) opening.
(2) Parts must be set within 3 minutes and assembled within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3) Immediately remove nozzle from the tube and rein- stall the cap.
(c) Install the oil pan with the 19 bolts and 3 nuts. Torque:
42 Nm (428 kgf cm, 31 ftlbf) for bolt A
21 N m (214 kgf cm, 15 ftlbf) for bolt B
11 N m (112 kgf cm, 8 ft lbf) for bolt C
12 N m (122 kgf cm, 9 ftlbf) for nut D
39. INSTALL OIL PAN INSULATOR
(a) Install the oil pan insulator with the bolt. Torque: 7.5 N m (76 kgf cm, 66 in. lbf)
40. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque:
21 Nm (209 kgf cm, 15 ftlbf) for bolt
13 N m (135 kgf cm, 10 ftlbf) for nut
41. INSTALL OIL PAN SUB±ASSY NO.2
(a) Remove any old packing and be careful not to drop any oil on the contact surfaces of the No. 1 and No. 2 oil pans.
(1) Using a razor blade and gasket scraper, remove allthe old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.
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Page 937 of 2234
A56704
Seal Width
4 to 7 mm
A
B B
A
A79173New O±ring
17±28
±
LUBRICATIONOIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(3)Using a non±residue solvent, clean both the sealing surfaces.
NOTICE:
Do not use a solvent, which will affect the painted surfaces.
(b)Apply a seal packing to the oil pan as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
(1)Install a nozzle that has been cut to a 4 to 7 mm
(0.16 to 0.28 in.) opening.
(2)Parts must be set within 3 minutes and assembled within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3)Immediately remove nozzle from the tube and rein- stall the cap.
(c)Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
Torque: 12 N m (119 kgfcm, 9ftlbf)
42.INSTALL ENGINE OIL LEVEL SENSOR Torque: 7.0 N m (71 kgfcm, 62 in. lbf)
43.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 kgfcm, 13 ftlbf)
(e)Apply engine oil to the O±ring on the oil level gage.
(f)Install the oil level gage.
44.INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 31 N m (320 kgfcm,23 ftlbf)
45.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
Torque: 35 N m (357 kgfcm,26 ftlbf)
46.INSTALL GENERATOR ASSY(See page 19±29)
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Page 1216 of 2234
C62956
D30058
1CD±FTV Engine Type:Others:
Transaxle Side
D25281
AB
C62958
±
CLUTCH CLUTCH UNIT (MTM)
42±27
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE CLUTCH DISC ASSY
NOTICE:
Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub±assy
away from oil and foreign attachment.
9. INSPECT CLUTCH DISC ASSY
(a) Using vernier calipers, measure the rivet head depth.Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assy as necessary.
(b) Install the clutch disc assy to the transaxle assy.
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
(c) Using a dial gage, check the clutch disc assy runout. Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assy as necessary.
10. INSPECT CLUTCH COVER ASSY
(a) Using vernier calipers, inspect the diaphragm spring for
the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assy as necessary.
11. INSPECT FLYWHEEL SUB±ASSY
(a) Using a dial gage, inspect the flywheel sub±assy runout. Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub±assy as necessary.
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Page 1404 of 2234
H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42761
Width
Inner
Diam.
H42792
SST(s)
60±44
±
SUPPLEMENTAL RESTRAINT SYSTEM CURTAIN SHIELD AIR BAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie down the curtain shield airbag assy LH to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the curtain shield airbag assy LH, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter of at least 1.25 mm
2 (0.0019 in.2).
HINT:
To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4
Position the curtain shield airbag assy LH inside the tire
as shown in the illustration.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the curtain shield airbag assy LH coming free
due to the shock from the airbag deployment.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(e) Install the SST(s).
Connect the connectors of the SST(s) to the curtain shield
airbag assy LH.
SST 09082±00802 (09082±10801, 09082±20801)
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Page 1410 of 2234
H41437
H41438
H40526
H42897
SST(s)
60±50
±
SUPPLEMENTAL RESTRAINT SYSTEM FRONT SEAT AIRBAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(1) Install the 2 nuts in the front seat airbag assy LH.
(2) Wind the wire harness around the stud bolts of the front seat airbag assy LH as shown in the illustra-
tion.
(3) Position the front seat airbag assy LH inside the tire with the airbag deployment direction facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Make sure the wire harness is tight. It is highly dan-
gerous when looseness in the wire harness results in
the front seat airbag assy LH coming free due to the
shock from the airbag deployment.
Always tie down the front seat airbag assy LH with the
airbag deployment direction facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(d) Install the SST(s). Connect the connector of SST(s) to the front seat airbag
assy LH connect.
SST 09082±00750
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Page 1421 of 2234
H4263210 m (33 ft) or moreBattery
SST(s)
H42633Weight
X
Y
Y
H40013
Inner Diam.
Tires
(3 or More) Width
60±24
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(2) Move the SST(s) to at least 10 m (33 ft) away from the horn button assy tied down to the disc wheel.
(e) Cover the horn button assy with a cardboard box or tires.
Covering method using a cardboard box:
Cover the horn button assy with the cardboard box
and weigh the cardboard box down in 4 places with
at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
X = 460 mm (18.11 in.)
Y = 650 mm (25.59 in.)
NOTICE:
When the dimension Y of the cardboard box exceeds
the diameter of the disc wheel with tire to which the
horn button assy is tied, X should be the following
size.
X = 460 mm (18.11 in.) + width of tire
If a cardboard box smaller than the specified size is
used, the cardboard box will be broken by the shock
from the airbag deployment.
Covering method using tires:
Place at least 3 tires with no disc wheels on top of
the tire with disc wheel to which the horn button assy
is tied.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:
The tires may be marked by the airbag deployment,
so use a redundant tires.
Do not place the SST(s) connector under the tire be-
cause the SST(s) connector could be damaged.
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Page 1428 of 2234
H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42664
Inner Diam. WidthTire
60±58
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie down the instrument panel airbag assy to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more)
CAUTION:
If the wire harness which is too thin or an alternative object
is used to tie down the instrument panel airbag assy, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter of at least 1.25 mm
2 (0.0019 in.2).
HINT:
To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4
Position the instrument panel airbag assy inside the tire
with the airbag deployment side facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the instrument panel airbag assy coming free
due to the shock from the airbag deployment.
Always tie down the instrument panel airbag assy
with the airbag deployment side facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
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