radiator TOYOTA AVENSIS 2003 Service Owner's Guide

100FA±01
A79596
A78436
10

10
Upper
Engine
Front
10±52
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 18±16)
3.REMOVE ENGINE ROOM COVER SIDE (See page 18±17)
4.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±44)
5.DRAIN ENGINE COOLANT (See page 16±31)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±44)
7.REMOVE THROTTLE BODY ASSY (See page 10±44)
8.REMOVE CHARCOAL CANISTER ASSY
9.REMOVE ENGINE COVER BRACKET (See page 11±52)
10.REMOVE FUEL PUMP ASSY (See page 11±52)
11.REMOVE INTAKE MANIFOLD (See page 11±42)
12.REMOVE SURGE TANK STAY NO.1 (See page 11±42)
13.REMOVE INTAKE MANIFOLD INSULATOR NO.2 (See page 11±42) 14.REMOVE KNOCK SENSOR
(a)Remove the nut and the knock sensor.
15.INSTALL KNOCK SENSOR
(a)Install the knock sensor with the nut as shown in the il-lustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
16.INSTALL INTAKE MANIFOLD INSULATOR NO.2 (See page 11±42)
17.INSTALL SURGE TANK STAY NO.1 (See page 11±42)
18.INSTALL INTAKE MANIFOLD (See page 11±42)
19.INSTALL FUEL PUMP ASSY (See page 11±52)
20. INSTALL ENGINE COVER BRACKET
(a) Install the engine cover bracket and the bolt. Torque: 38 N
m (388 kgf
cm, 28 ft
lbf)
21. INSTALL CHARCOAL CANISTER ASSY
22.INSTALL THROTTLE BODY ASSY (See page 10±44)
23.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±44)
24.ADD ENGINE COOLANT (See page 16±31)
25.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
26. CHECK FOR FUEL LEAKS
27. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
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±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
10±53
AVENSIS REPAIR MANUAL (RM1018E)
28. INSTALL ENGINE ROOM COVER SIDE
29. INSTALL RADIATOR SUPPORT OPENING COVER
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100FG±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±24
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (1AZ±FE)
COMPONENTS
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100FH±01
A778975 Claws
A77902
A77872
10±26
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE ENGINE ROOM COVER SIDE
(a)Remove the retainer and 4 clips.
(b)Unfasten the 5 claws and remove the radiator support opening cover.
2.REMOVE RADIATOR SUPPORT OPENING COVER
(a)Remove the 2 clips, and then remove the engine room cover side.
3.DRAIN ENGINE COOLANT (See page 16±19)
4. REMOVE ENGINE COVER SUB±ASSY NO.1
(a) Remove the 2 nuts, and then remove the engine cover No. 1.
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A77879
45

A77880
83.8 mm
(3.299 in.)
Rotation
Center of
Throttle Link
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1AZ±FE)
10±29
AVENSIS REPAIR MANUAL (RM1018E)
11.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that throttle valve is fully closed.
(b)With the throttle position sensor rotated 45
counter-
clockwise 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.
12.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 3 screws.
13.INSTALL FUEL VAPOR FEED HOSE NO.2
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the fuel pipe support with the 3 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c)Install the fuel tube to the fuel pipe support.
(d)Connect the water by±pass hose.
(e)Connect the water by±pass hose No. 2.
(f)Connect the ISC valve connector.
(g)Connect the throttle position sensor connector.
15.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Instal 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
17.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±19)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER
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100FI±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)
10±42
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (1AZ±FSE)
COMPONENTS
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100FJ±01
A78509
A81620
(a)(c)
(c)
(b)
(d)
(f)
(g)
(d)
(h)
Air Cleaner Clamp
A78510
10±44
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
3.DRAIN ENGINE COOLANT (See page 16±31) 4. REMOVE ENGINE COVER SUB±ASSY NO.1
(a) Remove the 2 nuts, and then remove the engine coverNo. 1.
5. REMOVE AIR CLEANER CAP SUB±ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the VSV connector.
(c) Remove the 2 wire harness clamps.
(d) Disconnect the ventilation hose.
(e) Disconnect the fuel vapor feed hose No. 1.
(f) Disconnect the fuel vapor feed hose No. 2.
(g) Loosen the hose clamp bolt.
(h) Raise the air cleaner clamp up, slide it to the air cleaner cap.
(i) Remove the air cleaner cap together with the air cleaner hose No. 1.
6. REMOVE THROTTLE BODY ASSY
(a) Remove the bolt, and then remove the wire harness pro- tector.
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10±46
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
13. INSTALL RADIATOR SUPPORT OPENING COVER
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100FB±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 (1ZZ±FE)
10±7
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (1ZZ±FE)
COMPONENTS
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100FC±01
A784575 Claws
A78458
A78459
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1ZZ±FE)
10±9
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER
(a)Remove the retainer and 4 clips.
(b)Unfasten the 5 claws and remove the radiator support
opening cover.
2.REMOVE ENGINE ROOM COVER SIDE
(a)Remove the 2 clips, and then remove the engine room cover side.
3.DRAIN ENGINE COOLANT (See page 16±7)
4. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, and then remove the cylin- der head cover No. 2.
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