check oil TOYOTA AVENSIS 2003 Service Service Manual

A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
12.5 to 1.5 mm
A774101 2
3
4
10 9
85
67
A00976A77411
90
Engine
Front Paint Mark
14±260
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(a)Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Install the cylinder head within 3 minutes after apply-
ing seal packing.

After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.

Do not start the engine within 2 hours after installing.
(b)Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(c)Install bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d)Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e)Mark the front side of the cylinder head set bolts with paint.
(f)Retighten the cylinder head set bolts by 90 in the same sequence as a step (d).
(g)Check that each paint mark is now at a 90 angle to the front.
64.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm,79 in.
lbf)
65.INSTALL CAMSHAFT (See page 14±240)
66.INSTALL NO.2 CAMSHAFT (See page 14±240)
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14±262
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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A61189
10
11
12
13 14
15 16
17
18
2
1
4563
7 8
9
(A) (A)
(A)(A) (A)
(A)
(A)
(B) (B) (B) (B) (B) (B) (B)(B)
(B)(B)
(A)
A61190
90
 90

9090
 90

90
Front Paint Mark
90
A09683
TDC Mark
Dot Mark
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±337
AVENSIS REPAIR MANUAL (RM1018E)
70. INSTALL CYLINDER HEAD SUB±ASSY
HINT:

The cylinder head bolts are tightened in 4 successive
steps (steps (c), (e), (f) and (g)).

If the cylinder head bolt is broken or deformed, replace it
with a new bolt.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts and the plate washers.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 18 cylinder head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 45 N
m (459 kgf
cm, 33 ft
lbf)
HINT:
See the table below for the bolt length.
Bolt TypeBolt Length
(A)160mm (6.30 in.)
(B)104mm (4.09 in.)
If the cylinder head bolt does not meet the torque specification,
replace the cylinder head bolt with a new bolt.
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90  in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by additional 90  in the
same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional 90 in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man- ifold side.
71. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing pulley at the position
of 90  BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
72.INSTALL CAMSHAFT (See page 14±318)
73.INSTALL NO.2 CAMSHAFT (See page 14±318)
74.REMOVE CAMSHAFT OIL SEAL (See page 14±318)
75.INSTALL CAMSHAFT OIL SEAL (See page 14±318) SST 09223±46011
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A79148
SST
A79149
SST
14±340
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
88.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the cylinder head gasket replaced,
must replace fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the new fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com- mon rail side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the pump side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
89.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
90.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
91.INSTALL TURBOCHARGER STAY (See page 13±11)
92.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
93.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
94.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
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±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±341
AVENSIS REPAIR MANUAL (RM1018E)
95.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
96.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
97.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
98.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
99.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
100.INSTALL HEATER BRACKET (W/ COLD AREA)(See page 13±11)
101.INSTALL HEATER PUMP ASSY (W/ COLD AREA)(See page 13±11)
102.INSTALL FUEL FILTER ASSY(See page 11±82)
103.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
SST 09960±10010 (09962±01000, 09963±01000)
104.INSTALL TIMING BELT(See page 14±307)
105.CHECK VALVE TIMING(See page 14±307)
106.TIMING CHAIN COVER PLATE(See page 14±307)
107.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
108.INSTALL TIMING BELT GUIDE(See page 14±307)
109.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
110.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
111.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
112.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
113.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
114.INSTALL POWER STEERING IDLE PULLEY BRACKET(See page 14±307)
115. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
116.INSTALL INJECTOR DRIVER (See page 14±286)
117.INSTALL AIR TUBE NO.1(See page 14±270)
118.INSTALL AIR TUBE NO.2 (See page 14±286)
119.INSTALL AIR CLEANER ASSY (See page 14±286)
120.INSTALL VACUUM RESERVOIR SUB±ASSY (See page 13±11)
121. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
122. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
123. ADD ENGINE OIL
124.ADD ENGINE COOLANT(See page 16±44)
125.CHECK FOR FUEL LEAKS(See page 11±60)
126. CHECK FOR ENGINE OIL LEAKS
127.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
128. CHECK FOR EXHAUST GAS LEAKS
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A62816
84 2 59731610
A62823
Paint Mark
90

Front
A62150
Camshaft No. 2
Camshaft
A62825
62 4 8
51 3 7
11
10 9
A10079
14±88
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
52. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm hexagon
wrench uniformly in the sequence shown in the illustra-
tion.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90
in the same se-
quence as step (b).
(e) Check that the paint mark of each bolt is at 90
angle to
the front.
53. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head as shown in the illustration.
(c) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque:
23 N
m (235 kgf
cm, 17 ft
lbf) for Bearing cap No. 1
13 N
m (133 kgf
cm, 10 ft
lbf) for Bearing cap No. 3
54. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression. (1) Turn the camshafts using a wrench to align the tim-
ing marks of the 2 camshaft timing sprockets.
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A65677
AAA A
A
A
AAA
B
B
B
A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±91
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the timing chain cover with the 11 bolts and nut.
Torque:
13 N
m (133 kgf
cm, 10 ft
lbf) for A
19 N
m (194 kgf
cm, 14 ft
lbf) for B
(d) Using a torx wrench socket (E8), install the stud bolt. Torque: 9.5 N
m (97 kgf
cm, 84 in.
lbf)
60. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check that the O±ring is clean, and set the hook as shown in the illustration.
(b) Apply engine oil to the chain tensioner and install it with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
61. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of the engine oil to the O±ring on the crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
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A64023
A76713
A79324
A78459
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±95
AVENSIS REPAIR MANUAL (RM1018E)
75. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(b) Install the engine wire with the 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
76.INSTALL GENERATOR ASSY (See page 19±7)
77. INSTALL V±RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt. Torque: 39.2 N
m (400 kgf
cm, 29 ft
lbf)
78. INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
79. INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
80. INSTALL AIR CLEANER HOSE NO.1 Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
81. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
82. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
83.ADD ENGINE COOLANT(See page 16±7)
84.INSPECT COMPRESSION (See page 14±1)
SST 09992±00500
85.INSPECT CO/HC (See page 14±1)
86.INSPECT IGNITION TIMING (See page 14±1) SST 09843±18040
87.CHECK FOR ENGINE COOLANT LEAKS (See page 16±7)
88. CHECK FOR ENGINE OIL LEAKS
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140D1±02
CG
TCA51075
A52004
±
ENGINE MECHANICALENGINE(1AZ±FE)
14±101
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±13)
2.INSPECT ENGINE OIL (See page 17±6)
3. INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68F)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±9)
6. INSPECT V±RIBBED BELT
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using hand±held tester:(1) Connect the hand±held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF.
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.
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TA C
A52006
A13304
14±102
±
ENGINE MECHANICAL ENGINE (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 15  BTDC
(7) Confirm that ignition timing to go advanced angle side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
Idle speed: 650 to 750 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester.
(1) Using SST, connect the tachometer test prove toterminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 650 to 750 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.
(e) Inspect cylinder compression pressure. SST 09992±00500
(1) Insert a compression gauge into the spark plughole.
(2) Fully open the throttle.
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