TOYOTA AVENSIS 2003 Service Repair Manual

A77285
Unleaded Gasoline
Leaded GasolineTiming
Marks
Timing
Marks
Timing
Marks
Timing
Marks
A77286
Push
A77412
HoldLoosen
A77294
15973
481062
14±172
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and
No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
8. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, then remove the chain tensioner and a gasket.
NOTICE:
Do not turn the crankshaft.
9. REMOVE NO.2 CAMSHAFT
(a) Hold the No. 2 camshaft with a wrench on the hexagonal lobe, and loosen the camshaft timing gear set bolt.
NOTICE:
Be careful not to damage the cylinder head and valve lifter
with the wrench.
(b) Using several steps, loosen and remove the 10 camshaft
bearing cap bolts uniformly in the sequence shown in the
illustration.
(c) Remove the 5 camshaft bearing caps.
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A52473
A77309
15973
481062
A56228
A77413
Advance
Side Port
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
14±173
AVENSIS REPAIR MANUAL (RM1018E)
(d) Raising the No. 2 camshaft, remove the set bolt.
(e) Remove the camshaft timing gear from the No. 2 cam-
shaft with the timing chain wrapped.
(f) Remove the camshaft timing gear from the timing chain.
10. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 10 camshaft bearing cap bolts uniformly in the sequence shown in the
illustration.
(b) Remove the 5 camshaft bearings.
(c) Remove the camshaft.
(d) Tie the timing chain as shown in the illustration.
NOTICE:

Be careful not to drop anything inside the timing
chain cover.

Do not expose the chain to water, and prevents dust.
11. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET (LEADED GASOLINE)
(a) Clamp the camshaft in a vise and remove the bolt and the camshaft timing\
gear. 12. REMOVE CAMSHAFT TIMING GEAR ASSY(UNLEADED GASOLINE)
(a) Fix the camshaft with a vise, and make sure the camshaft
timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except an advance side port shown in the illustration.
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A31032
A32639
A77414
Straight
Pin
Key
Groove
14±174
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Put air pressure into the oil port with 150 kpa (1.5 kgf/cm2
21 psi), and turn the camshaft timing gear to the advance
direction (counterclockwise) by hand.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
HINT:
Depending on the air pressure, the camshaft timing gear will
turn to the advance angle side without applying force by hand.
Also, under the condition that the pressure can be hardly ap-
plied because of the air leakage from the port, there may be the
case that the lock pin could be hardly released.
(d) Remove the fringe bolt of camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If reusing the camshaft timing gear, release the
straight pin lock first, and then install the gear.
13. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET (LEADED GASOLINE) Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
14. INSTALL CAMSHAFT TIMING GEAR ASSY (UNLEADED GASOLINE)
(a) Put the camshaft timing gear and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc- tion (as shown in the illustration) while lightly pushing it to-
ward the camshaft. Push further at the position where the
pin gets into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right direction).
(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
(e) Check that the camshaft timing gear can move to the re- tard angle side (to the right direction), and is locked at the
most retarded position.
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A77284
A77415Bearing Cap No. 1Bearing Cap No. 3
5
312 4
A52473
A77416
Bearing Cap No. 2 Bearing Cap No. 3
531 2 4
A77417
TightenHold
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
14±175
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL CAMSHAFT
(a) Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
(b) Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the
camshaft timing gear.
(c) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 1 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
16. INSTALL NO.2 CAMSHAFT
(a) Put the No. 2 camshaft on the cylinder head with the
painted links of the chain aligned with the timing mark on
the camshaft timing gear.
(b) Raising the No. 2 camshaft, tighten the set bolt temporari- ly.
(c) Examine the from marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(d) Hold the camshaft with a wrench on the hexagonal lobe, and tighten the camshaft timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the cylinder head and valve lifter.
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A77285
Unleaded Gasoline
Leaded GasolineTiming
Marks
Timing
Marks
Timing
Marks
Timing
Marks
A77394
Raise
Pin Hook
Push
A77395
Engine
Front
14±176
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(e) Check that the match marks on the timing chain and the camshaft timing gears are positioned as shown in the il-
lustration.
17. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap- ply the hook to the pin so that the plunger is locked in posi-
tion.
(b) Install a new gasket and the chain tensioner No. 1 with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is disengaged while installing, apply the hook
again, and then resume the installation.
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A77396
HookPinTurn
Disconnect
A77397
Push Turn
Plunger
A77399
Seal Packing
A77400NutNut
A
BC
A
AA AB
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
14±177
AVENSIS REPAIR MANUAL (RM1018E)
(c) Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d) Turn the crankshaft clockwise, and check the plunger is extended.
18. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il- lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 5 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover with the 8 bolts and 2 nuts. Torque:
Bolt A 11 N
m (112 kgf
cm, 8.0 ft
lbf)
Bolt B 14 N
m (143 kgf
cm, 10 ft
lbf)
Bolt C 21 N
m (214 kgf
cm, 15 ft
lbf)
Nut 11 N
m (112 kgf
cm, 8.0 ft
lbf)
19. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
20. CHECK FOR ENGINE OIL LEAKS
21. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
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141BP±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
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FSE)
14±237
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1AZ±FSE)
COMPONENTS
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A77374
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
Cylinder Head Cover Sub±assy
11 (115, 8.0)
Ventilation Hose No. 1

Gasket
Fuel Tube Sub±assy

Gasket
Fuel Pipe
Sub±assy No. 1
Fuel Pressure
Pulsation Damper
Assy
Fuel Pump Assy

Gasket14 (143, 10)
Ignition Control
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)

O±ring
Ventilation Hose No. 2
33 (331, 24)
25 (255, 18)
Fuel Pipe No. 1

Fuel Injector
Back±up Ring No. 1

Fuel Injector Back±up
Ring No. 3

Fuel Injector
Back±up Ring No. 2
30 (306, 22)
14±238
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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A79802
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
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
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FSE)
14±239
AVENSIS REPAIR MANUAL (RM1018E)
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141BQ±01
A77339
A77284
14±240
±
ENGINE MECHANICALCAMSHAFT(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH 5.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
6.REMOVE IGNITION COIL ASSY
(a)Remove the 4 bolts and the ignition coils.
7.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
8.REMOVE FUEL TUBE SUB±ASSY (See page 11±33)
9.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
10.REMOVE FUEL PUMP ASSY (See page 11±52)
11.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timingmark 0 of the timing chain cover.
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