air filter TOYOTA AVENSIS 2003 Service Owner's Guide

14±4
±
ENGINE MECHANICAL ENGINE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E) CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:


Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

ISC valve

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke form exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:

Faulty pressure regulator

Defective water temperature sensor

Defective mass air flow meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor
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A79418N´m (kgf´cm, ft´lbf): Specified torque
25 (255, 18)
18 (178, 13)
Injector Driver
Air Tube No. 2 Union To Connector Tube Hose
Fuel Filter AssyHeater Inlet Water Hose
Heater Outlet Water Hose
Vacuum Reservoir Sub±assy
8.3 (85, 73 in.

lbf)
5.0 (51, 44 in.
lbf)
14±278
±
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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141C4±01
A80094
14±286
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEELS
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.DRAIN ENGINE COOLANT (See page 16±44)
8.DRAIN ENGINE OIL (See page 14±342)
9.DRAIN MANUAL TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
11.REMOVE BATTERY
12.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap together with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
13.DISCONNECT UNION TO CONNECTOR TUBE HOSE
14.REMOVE FUEL FILTER ASSY
(a)Disconnect the 2 fuel hose from the fuel filter (STD).
(b)Disconnect the 3 fuel hose from the fuel filter (COLD).
(c)Disconnect the connector (STD).
(d)Disconnect the 2 connectors (COLD).
(e)Remove the 2 bolts and the fuel filter.
15.REMOVE RADIATOR HOSE INLET
16.REMOVE RADIATOR HOSE OUTLET
17.DISCONNECT WATER BY±PASS HOSE NO.2
18.REMOVE ENGINE ROOM RELAY BLOCK NO.3
(a)Remove the 2 bolts and the engine room relay block.
19.REMOVE RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
20. DISCONNECT HEATER INLET WATER HOSE
21. DISCONNECT HEATER OUTLET WATER HOSE
22. DISCONNECT FUEL HOSE NO.2
23. REMOVE AIR TUBE NO.2
(a) Loosen the hose clamp and disconnect the air hose No.3.
(b) Remove the 2 bolts and the air tube No. 2.
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A15985
A78280
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±291
AVENSIS REPAIR MANUAL (RM1018E)
56.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
57.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
58.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
59.REMOVE TIMING BELT GUIDE
60.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
61.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
62.REMOVE TIMING BELT (See page 14±307)
HINT:
If re±use the timing belt, draw an arrow which indicates the engine rev\
olution direction on the belt and put
match marks on the pulleys and the belt before removing. This operation will \
be very helpful when re±instal-
ling the timing belt.
63.REMOVE GENERATOR ASSY
64.REMOVE GENERATOR BRACKET NO.1
(a)Remove the 2 bolts and the generator bracket.
65.REMOVE V±RIBBED BELT TENSIONER ASSY
66.REMOVE OIL FILTER BRACKET SUB±ASSY
(a)Remove the bolt and 2 nuts, and then remove the oil filter
bracket and the gasket.
67.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
68.REMOVE TURBO INSULATOR NO.1 (See page 13±11)
69.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
70.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
71.REMOVE MANIFOLD STAY (See page 13±11)
72.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
73.REMOVE TURBOCHARGER STAY (See page 13±11)
74.DISCONNECT TURBO WATER HOSE NO.1 (See page 13±11)
75.DISCONNECT TURBO WATER HOSE NO.2 (See page 13±11)
76.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
77.REMOVE TURBO OIL OUTLET PIPE NO.2 (See page 13±11)
78.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11) 79. DISCONNECT WATER BY±PASS HOSE NO.3
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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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A61186
SST
A57108
Adhesive
14±300
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
147. INSTALL OIL FILTER BRACKET SUB±ASSY
(a) Install a new gasket and oil filter bracket with the bolt and 2 nuts. Torque: 34 N
m (347 kgf
cm, 25 ft
lbf)
148. INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 31 N
m (316 kgf
cm, 23 ft
lbf)
149. INSTALL GENERATOR BRACKET NO.1 Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
150.INSTALL GENERATOR ASSY (See page 19±29)
151.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
152.INSTALL TIMING BELT (See page 14±307)
153.CHECK VALVE TIMING (See page 14±307)
154.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
155.INSTALL TIMING BELT GUIDE (See page 14±307)
156.INSTALL TIMING BELT NO.1 COVER (See page 14±307)
157.INSTALL TIMING BELT NO.2 COVER (See page 14±307)
158. INSTALL IDLER PULLEY SUB±ASSY Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
159.INSTALL CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
160.INSTALL GLOW PLUG ASSY (See page 19±33)
161. INSTALL ENGINE MOUNTING BRACKET RR Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
162. INSTALL ENGINE MOUNTING BRACKET FR Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
163. INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
164. INSTALL REAR END PLATE Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
165. INSTALL FLYWHEEL SUB±ASSY
(a) Using SST, hold the crankshaft. SST 09213±54015 (90105±08076), 09330±00021
(b) Clean the bolts and its bolt holes.
(c) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent
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A64328
2 to 7 mm0 to 2 mm
A78274
Upward
90

Clamp
Bolt
A64328
2 to 7 mm 0 to 4 mm
A64007
Front
90

Clamp
Bolt
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±303
AVENSIS REPAIR MANUAL (RM1018E)
184.INSTALL AIR TUBE NO.1
(a)Install the new air hose No. 1 and new hose clamp as
shown in the illustration.
(b)Tighten the hose clamp as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
185.INSTALL INJECTOR DRIVER Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
186.CONNECT ENGINE WIRE Torque: 8.4 N
m (85 kgf
cm,74 in.
lbf)
187.INSTALL AIR TUBE NO.2
(a)Install the air hose and hose clamps as shown in the il- lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm,53 ft
lbf)
(c)Install the 2 bolts and the air tube No.2 assy.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
188.INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
189. INSTALL ENGINE ROOM RELAY BLOCK NO.3 Torque: 5.3 N
m (54 kgf
cm, 46 in.
lbf)
190. INSTALL FUEL FILTER ASSY Torque: 18 N
m (178 kgf
cm, 13 ft
lbf)
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A76702
Accelerator Control Cable Assy
Heater Inlet Water Hose
Fuel Pipe Clamp
Fuel Tube Sub±assy
Heater Outlet Water HoseAir Cleaner Cap
W/ Hose
Air Cleaner Filter
Element Sub±assy
Air Cleaner Case Sub±assy
Battery Clamp
Sub±assy
Battery
Battery Tray
Battery Carrier
12.8 (131, 9)
N´m (kgf´cm, ft´lbf) : Specified torque
Union to Connector Tube Hose
Air Cleaner Clamp
Bracket
5.0 (51, 44 in.
lbf)
Fuel Vapor Feed Hose No.1
Fuel Vapor Feed Hose No.3
5.0 (51, 44 in.
lbf)
Oil Cooler
Inlet Hose
Oil Cooler
Outlet Hose
X4
VSV Connector
Mass Air Flow
Meter Connector
14±20
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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