TOYOTA AVENSIS 2003 Service Repair Manual

A78463
A
A
A
A
BB
A
(d)
(c)
A78468
65.1 mm
(2.563 in.)
Rotation
Center of
Throttle Link
18

10±12
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the throttle body bracket with the 3 bolts and 2 nuts. (A/T)
Torque:
30 N
m (306 kgf
cm, 22 ft
lbf) for bolt and nut A
(c)Install the throttle body and the throttle body bracket with
the 5 bolts and 2 nuts. (M/T)
Torque:
30 N
m (306 kgf
cm, 22 ft
lbf) for bolt and nut A
13 N
m (133 kgf
cm, 10 ft
lbf) for bolt B
(d)Connect the ISC valve connector.
(e)Connect the throttle position sensor connector.
(f)Connect the ventilation hose.
(g)Connect the water by±pass hose No. 2.
(h)Connect the water by±pass hose.
15.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il-
lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
16.INSTALL AIR CLEANER CAP SUB±ASSY Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
17.INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±7)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER
http://vnx.su

100FD±01
A78454
N´m (kgf´cm, ft´lbf) : Specified torqueClip
Cylinder Head Cover No.2Fuel
Vapor Feed Hose No.1VSV
Connector
Mass Air Flow
Meter Connector
Accelerator Control
Cable Assy
Fuel Vapor Feed Hose
No.3
Engine Room Cover Side
Radiator Support Opening Cover
Clip Retainer
7.0 (71, 62 in.´lbf)
Clip
1.5 (15, 13 in.´lbf)
13 (129, 9)
Air Cleaner Cap
Sub±assy
x2
x4
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (3ZZ±FE)
10±13
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (3ZZ±FE)
COMPONENTS
http://vnx.su

A78504

Throttle Body Gasket

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque ISC Valve


Throttle Body Cover
Gasket Throttle Position
SensorWater By±pass
Hose
Water By±pass
Hose No.2
ISC Valve Connector Throttle Body Assy
Ventilation Hose
Throttle Position
Sensor Connector
30 (306, 22)
30 (306, 22)
Accelerator
Control Cable Bracket
3.7 (38, 33 in.´lbf)
2.0 (20, 18 in.´lbf)
x2
x2
x4
10±14
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

100FE±01
A78497
A78498
(a)
(b)
(c)
A78499
(d)
(e)
A78500
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(3ZZ±FE)
10±15
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
3.DRAIN ENGINE COOLANT (See page 16±7)
4.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
5.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±9)
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator controlcable.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the ventilation hose.
(b) Disconnect the water by±pass hose.
(c) Disconnect the water by±pass hose No. 2.
(d) Disconnect the throttle position sensor.
(e) Disconnect the ISC valve connector.
(f) Remove the bolt and 2 nuts, and then remove the acceler- ator control bracket and the throttle body.
(g) Remove the gasket from the intake manifold.
8. REMOVE ISC VALVE
(a) Remove the 4 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.
http://vnx.su

A78501
A78503
30
to 45

A78469
66.3 mm
(2.610 in.)
Rotation
Center of
Throttle Link
11

10±16
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE THROTTLE POSITION SENSOR
(a)Remove the 2 screws, and then remove the throttle posi- tion sensor.
10.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that the throttle valve is fully closed.
(b)With the throttle position sensor rotated 30
to 45
coun- terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
11.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 4 screws.
Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
12.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the accelerator control brack- et with the bolt and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
13.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
14.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±9)
15.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
16.ADD ENGINE COOLANT (See page 16±7)
17.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
18. INSTALL ENGINE ROOM COVER SIDE
19. INSTALL RADIATOR SUPPORT OPENING COVER
http://vnx.su

110UB±01
A79437
8.0 (82, 71 in.
lbf)
Engine Cover No. 1 Radiator Support Opening Cover
N´m (kgf´cm, ft´lbf)
: Specified torque
6.0 (61, 53 in.
lbf)
Radiator Reserve
Tank Assy
Clip
Ratainer
11±76
±
FUEL COMMON RAIL ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
COMMON RAIL ASSY (1CD±FTV)
COMPONENTS
http://vnx.su

A79438
5.0 (51, 44 in.
lbf)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
* Use SST
Common Rail Assy
Intake Manifold
Insulator No. 1
Fuel Hose No. 4

Fuel Inlet Pipe Sub±assy
5.0 (51, 44 in.
lbf)
43 (438, 32)
* 31 (316, 23)
34 (347, 25)
±
FUEL COMMON RAIL ASSY (1CD±FTV)
11±77
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

110UC±01
A79148
SST
A79143
SST
11±78
±
FUELCOMMON RAIL ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50) 5. REMOVE FUEL INLET PIPE SUB±ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and the injection pump with vinyl tape to prevent dust from
being introduced.
(a) Using SST, remove the fuel inlet pipe from the commonrail.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and the 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
http://vnx.su

A79154
A79147
30 cm
(11.81 in.)
SST
±
FUELCOMMON RAIL ASSY(1CD±FTV)
11±79
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10.DISCONNECT FUEL HOSE NO.4
(a)Disconnect the fuel hose from the common rail.
11.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
12.REMOVE COMMON RAIL ASSY
(a)Disconnect the engine wire connector from the bracket.
(b)Remove the 2 bolts and the common rail.
13.INSTALL COMMON RAIL ASSY Torque: 43 N
m (438 kgf
cm, 32 ft
lbf)
14.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
15. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:

In case of having the common rail replaced, must re-
place the injection pipes, too.

When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
http://vnx.su

11±80
±
FUEL COMMON RAIL ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
16. INSTALL INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
17. INSTALL INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
18. INSTALL INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
http://vnx.su