TOYOTA AVENSIS 2003 Service Repair Manual

A79159
A79156
A79157
A79160
13±12
±
INTAKETURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
10.REMOVE HEATER BRACKET (W/ COLD AREA)
(a)Remove the bolt and the heater bracket.
11.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
12.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10) 13. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA)
(a) Remove the 2 nuts.
(b) Remove the 2 nuts and the exhaust pipe sub±assy.
14. REMOVE TURBO INSULATOR NO.2
(a) Remove the 4 bolts and the turbo insulator.
http://vnx.su

A79161
A79162
A79163
A79164
A79444
±
INTAKE TURBOCHARGER SUB±ASSY (1CD±FTV)
13±13
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE TURBO INSULATOR NO.1
(a) Remove the 2 bolts and nut, and then remove the turbo
insulator.
16. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
(a) Remove the 2 bolts and the exhaust manifold heat insula- tor.
17. REMOVE MANIFOLD STAY NO.2
(a) Remove the bolt and nut and then remove the manifold stay.
18. REMOVE MANIFOLD STAY
(a) Remove the 4 bolts and the manifold stay.
19. REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a) Remove the 3 nuts, the manifold converter and the gas-
ket.
http://vnx.su

A79165
A79166
A79167
B13094
B13095
13±14
±
INTAKE TURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE TURBOCHARGER STAY
(a) Remove the 2 bolts and 2 nuts, and then remove the turbocharger stay.
21. DISCONNECT TURBO WATER HOSE NO.1
22. DISCONNECT TURBO WATER HOSE NO.2
23. SEPARATE TURBO OIL INLET PIPE SUB±ASSY
(a) Remove the 2 nuts, the turbo oil pipe and the gasket.
24. REMOVE TURBOCHARGER SUB±ASSY
(a) Remove the 3 nuts, the turbocharger and the gasket.
http://vnx.su

B13096
A79165
B
BAA
±
INTAKE TURBOCHARGER SUB±ASSY (1CD±FTV)
13±15
AVENSIS REPAIR MANUAL (RM1018E)
25. REMOVE TURBO WATER PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts, the turbo water pipe and the gasket.
26. INSTALL TURBO WATER PIPE SUB±ASSY NO.1
(a) Install a new gasket and the turbo water pipe with the 2 nuts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
27. INSTALL TURBOCHARGER SUB±ASSY
(a) Install a new gasket and the turbocharger with the 3 nuts. Torque: 53 N
m (540 kgf
cm, 39 ft
lbf)
28. INSTALL TURBO OIL INLET PIPE SUB±ASSY
(a) Install a new gasket and the oil pipe with the 2 nuts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
29. INSTALL TURBOCHARGER STAY
(a) Install the turbocharger stay, and temporarily tighten bolt A.
(b) Temporarily tighten nut B while pushing the cylinder head toward the turbocharger stay.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c) Tighten bolt A. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d) Tighten nut B.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
30. INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a) Install the manifold stay, and temporarily tighten the cylin- der block side of the manifold stay.
http://vnx.su


A80106
A
A
B
B
A79163
13±16
±
INTAKETURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket and the manifold converter, and tem- porarily tighten bolts A and bolts B while pushing the up-
per portion of the converter toward the turbocharger.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c)Tighten the 3 nuts. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(d)Tighten bolts A.
Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
(e)Tighten bolts B. Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
31.INSTALL MANIFOLD STAY NO.2
(a)Install the manifold stay No. 2, and temporarily tighten the bolt.
(b)Temporarily tighten the nut while pushing the manifold stay No. 2 toward the cylinder head.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
HINT:
No clearance between the stay and the cylinder head should be
confirmed.
(c)Tighten the bolt. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d)Tighten the nut. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
32.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)
33.INSTALL TURBO INSULATOR NO.1 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
34.INSTALL TURBO INSULATOR NO.2
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
35.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
36.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
37.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
38. INSTALL HEATER BRACKET (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
39. INSTALL HEATER PUMP ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
40.INSTALL FUEL FILTER ASSY(See page 11±82)
http://vnx.su

A64328
2 to 7 mm0 to 2 mm
A78274
Upward90

Clamp
Bolt
±
INTAKETURBOCHARGER SUB±ASSY(1CD±FTV)
13±17
AVENSIS REPAIR MANUAL (RM1018E)
41.INSTALL INTERCOOLER AIR HOSE
(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 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)
42.INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
43.INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
44.INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
45.ADD ENGINE COOLANT(See page 16±44)
46. CHECK ENGINE OIL LEVEL
47.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
48. CHECK FOR ENGINE OIL LEAKS
49.CHECK FOR FUEL LEAKS(See page 11±60)
50. CHECK FOR EXHAUST GAS LEAKS
http://vnx.su

141BG±01
A77322
7.0 (71.62, in.
lbf)
7.0 (71.62, in.
lbf)
Engine Room
Cover Side
Radiator Support
Opening Cover Engine Cover Sub±assy No. 1
Engine Under Cover RH
N´m (kgf´cm, ft´lbf) : Specified torque
14±168
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1AZ±FE)
COMPONENTS
http://vnx.su

A77320
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
Ignition Coil Assy
9.0 (90, 80 in.
lbf)
14 (143, 10)
11 (115, 8.0)
Cylinder Head Cover Sub±assy

Gasket
11 (115, 8.0)
Ventilation Hose No. 2
Ventilation Hose No. 2
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
14±169
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

A77323
Leaded Gasoline type:
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
54 (551, 40)

Gasket
Crankshaft Timing Geaer or
Sprocket
Bearing Cap No. 3
Bearing Cap No. 2
Camshaft
No. 2 Camshaft
Camshaft Timing Gear
Unleaded Gasoline type:
Camshaft Timing Gear Assy
54 (551, 40)
Chain Tensioner Assy No. 1
30 (301, 22)
Bearing Cap No. 1
30 (301, 22)
9.0 (92, 80 in.
lbf)
54 (551, 40)
9.0 (92, 80 in.
lbf)
Chain Sub±assy
14±170
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

141BK±01
A77281
A77283
A77284
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
14±171
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE ROOM COVER SIDE
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE COVER SUB±ASSY NO.1
(a) Remove the 2 nuts and the engine cover No. 1.
5. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils. 6. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Disconnect the 2 PCV hoses from the cylinder head cov-er.
(b) Remove the 8 bolts and 2 nuts, and then remove the cylin- der head cover and gasket.
7. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its timing notch with timing mark 0 of the timing chain cover.
http://vnx.su