sst TOYOTA AVENSIS 2003 Service Owner's Guide

022JS±01
02±44
±
PREPARATION STEERING COLUMN
AVENSIS REPAIR MANUAL (RM1018E)
STEERING COLUMN
PREPARATION
SST
09616±00011Steering Worm Bearing Adjusting
SocketSTEERING COLUMN ASSY
09950±50013Puller C SetSTEERING COLUMN ASSY
(09951±05010)Hanger 150STEERING COLUMN ASSY
(09952±05010)Slide ArmSTEERING COLUMN ASSY
(09953±05020)Center Bolt 150STEERING COLUMN ASSY
(09954±05021)Claw No.2STEERING COLUMN ASSY
Recomended Tools
09025±00010Torque Wrench (30 kgf±cm)STEERING COLUMN ASSY
09042±00010Torx Socket T30STEERING COLUMN ASSY
09070±20010Moulding RemoverSTEERING COLUMN ASSY
POWER STEERING ECU ASSY
EQUIPMENT
Torque wrench
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022L5±01
02±52
±
PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
PREPARATION
SST
09082±00700SRS Airbag Deployment ToolHORN BUTTON ASSY
CURTAIN SHIELD AIR BAG ASSY LH
FRONT SEAT AIRBAG ASSY LH
INSTRUMENT PANEL PASSENGER
AIR BAG ASSY
INSTRUMENT PANEL AIR BAG
ASSY
09082±00750Airbag Deployment Wire
Sub±harness No.3FRONT SEAT AIRBAG ASSY LH
09082±00780Airbag Deployment Wire
Sub±harness No.6HORN BUTTON ASSY
INSTRUMENT PANEL PASSENGER
AIR BAG ASSY
09082±00802Airbag Deployment Wire
Sub±Harness No. 8HORN BUTTON ASSY
CURTAIN SHIELD AIR BAG ASSY LH
INSTRUMENT PANEL AIR BAG
ASSY
(09082±10801)Wire AHORN BUTTON ASSY
CURTAIN SHIELD AIR BAG ASSY LH
INSTRUMENT PANEL AIR BAG
ASSY
(09082±20801)Wire BCURTAIN SHIELD AIR BAG ASSY LH
INSTRUMENT PANEL AIR BAG
ASSY
(09082±30801)Wire CHORN BUTTON ASSY
09950±50013Puller C SetSPIRAL CABLE SUB±ASSY
(09951±05010)Hanger 150SPIRAL CABLE SUB±ASSY
(09952±05010)Slide ArmSPIRAL CABLE SUB±ASSY
(09953±05020)Center Bolt 150SPIRAL CABLE SUB±ASSY
(09954±05021)Claw No.2SPIRAL CABLE SUB±ASSY
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022KW±01
02±54
±
PREPARATION WIPER & WASHER
AVENSIS REPAIR MANUAL (RM1018E)
WIPER & WASHER
PREPARATION
SST
09843±18040Diagnosis Check Wire No.2WIPER AND WASHER SYSTEM
Recomended Tools
09042±00010Torx Socket T30WINDSHIELD WIPER MOTOR ASSY
09082±00040TOYOTA Electrical TesterWIPER AND WASHER SYSTEM
(09083±00150)Test Lead SetWIPER AND WASHER SYSTEM
Equipment
Torque wrench
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030MU±02
±
SERVICE SPECIFICATIONS BRAKE
03±41
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) RHD:
LHD: M/T
A/T142.5 ± 152.5 mm (5.610 ± 6.004 in.)
148.1 ± 158.1 mm (5.831 ± 6.224 in.)
149.9 ± 159.9 mm (5.902 ± 6.295 in.)
Brake Pedal free play1 ± 6 mm (0.04 ± 0.24 in.)
Stop light switch clearance0.5 ± 2.6 mm (0.020 ± 0.102 in.)
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf)More than 60 mm (2.36 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front disc brake pad thickness Standard
Minimum12.5 mm (0.492 in.)
2.0 mm (0.079 in.)
Front brake disc thickness Standard
Minimum26.0 mm (1.024 in.)
24.0 mm (0.945 in.)
Front disc runout Maximum0.05 mm (0.0020 in.)
Rear disc brake pad thickness Standard
Minimum10.0 mm (0.394 in.)
2.0 mm (0.079 in.)
Rear disc thickness Standard
Minimum10.0 mm (0.394 in.)
8.0 mm (0.315 in.)
Rear disc runout Maximum0.05 mm (0.0020 in.)
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031H4±01
03±26
±
SERVICE SPECIFICATIONS COOLING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Radiator drain plug131309
Water pump x Cylinder block Bolt A
Bolt B9.0 1192
11 38.0 in.lbf 8
Water inlet x Cylinder block sub±assy1111 28
Radiator x Radiator support upper1919414
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Drain plug1313310
Water pump x Cylinder block3132023
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Timing belt idler Sub±assy No.1 x Cylinder block3535726
Water inlet x Cylinder block8.89078 in.
lbf
Radiator reserve tank assy x Radiator assy6.06153 in.
lbf
Fan assy w/ motor x Fan shroud assy7.57666 in.
lbf
Upper support x Body1919414
Relay box x Radiator assy5.35447 in.
lbf
Front wheel1031,05076
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03±20
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Injection pipe, Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe x Injector Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe x injection pump Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Nozzle leakage pipe No.2 x Cylinder head Check valve
Bolt21
8.8214 9015
78 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2121415
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub±assy x Cylinder head2121415
Exhaust manifold x Cylinder head4747935
EGR pipe sub±assy x Cylinder head Bolt
Nut37
25375
25027
18
Oil filter bracket x Oil pan sub±assy3434725
V±ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub±assy x V±ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub±assy center x Body4545933
Front suspension crossmember sub±assy x Rear engine mounting bracket8788764
Front suspension crossmember sub±assy x Front engine mounting bracket\
5253038
Front suspension crossmember sub±assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub±assy\
1331,35698
Front suspension member brace x Body8081659
Return tube sub±assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Injector driver x Engine mounting insulator RH5.05144 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay box x Radiator assy5.35446 in.
lbf
Fuel filter assy x Fuel filter support1817813
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031E1±02
03±8
±
SERVICE SPECIFICATIONS FUEL
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy Bolt A
Bolt B19
9.0194 9214
80 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy2020415
Fuel pressure pulsation damper assy x Fuel delivery pipe sub±assy9.09280 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Cylinder head cover x Fuel pump assy2525518
Fuel pipe sub±assy No.1 x Fuel delivery pipe sub±assy9.09280 in.
lbf
Fuel pipe sub±assy No.1 x Fuel pump assy3030622
Fuel pressure pulsation damper assy x Fuel pump assy3333124
Engine cover bracket x Cylinder head3838828
Engine cover sub±assy No.1 x Cylinder head cover7.07162 in.
lbf
Nozzle holder clamp x Cylinder head131279
Fuel delivery pipe sub±assy x Cylinder head1919414
Surge tank stay No.1 x Cylinder block2121015
Intake manifold x Cylinder head Stud bolt
BoltNut9.5
30
3097
306
30684 in.
lbf
22
22
GASOLINE:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy No. 1 LH x Body4040029
Fuel tank band sub±assy No. 1 RH x Body4040029
Parking brake cable assy No. 3 x Body5.05144 in.
lbf
Parking brake cable assy No. 2 x Body5.05144 in.
lbf
Fuel tank protector No. 1 x Body5.45447 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 1 RH5.45447 in.
lbf
Exhaust pipe assy front x Exhaust manifold (1ZZ±FE/3ZZ±FE)4344033
Exhaust pipe assy front x Exhaust pipe assy tail (1ZZ±FE/3ZZ±FE)\
4344033
Exhaust pipe assy center x Exhaust pipe assy front (1AZ±FE/1AZ±FS\
E)4344033
Exhaust pipe assy center x Exhaust pipe assy tail (1AZ±FE/1AZ±FSE\
)4344033
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Nozzle holder clamp x Cylinder head sub±assy2626519
Nozzle leakage pipe assy x Injector assy Hollow screw
Union bolt18
22184
22413
16
Nozzle leakage pipe No. 2 x Cylinder head sub±assy Hollow screw Bolt21
8.8214 9016
79 in.
lbf
Injection pipe sub±assy No. 1 ± No. 4 x Injector assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe sub±assy No. 1 ± No. 4 x Common rail assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
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±
SERVICE SPECIFICATIONS FUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf
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030G7±04
03±60
±
SERVICE SPECIFICATIONS POWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedN
mkgf
cmft
lbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356 81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in.
lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)
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100FL±01
A77917
A77918
(a)
(b)
A77919
10±34
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4.ENGINE COOLANT (See page 16±19)
5.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
7.SEPARATE ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
8.REMOVE THROTTLE BODY ASSY (See page 10±26)
9.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26) SST 09268±21010
10.REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
11. REMOVE VARIABLE RESISTOR (LHD STEERINGPOSITION TYPE, LEADED GASOLINE)
(a) Disconnect the variable resistor connector.
(b) Remove the bolt, and then remove the variable resistor.
12. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the charcoal canister outlet hose No. 1.
(b) Disconnect the fuel hose.
(c) Pull up and remove the charcoal canister.
13. DISCONNECT HEATER INLET WATER HOSE
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