TOYOTA AVENSIS 2003 Service Repair Manual

A76708
Fan and Generator V BeltV±Ribbed Idler Assy No. 1
Generator Assy
Terminal Cap
No. 1
Cylinder Head Cover No. 2
Clip
Engine Mounting
Insulator RH
N´m (kgf´cm, ft´lbf) : Specified torque
54 (551, 40)
25 (255, 18)
39.2 (400, 29)
7.0 (71, 62 in.
lbf)52 (530, 38)
52 (530, 38)
9.8 (100, 7)
Tube
14±46
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A76709
Ventilation Hose No. 2Clamp Bracket
Ventilation Hose
Ignition Coil Assy
Engine Wire
Clamp Bracket
Clamp Bracket
Gasket
Cylinder Head Cover
Sub±assy
Seal Washer
N´m (kgf´cm, ft´lbf) : Specified torque
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
11 (112, 8)
11 (112, 8)11 (112, 8)
11 (112, 8)
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±47
AVENSIS REPAIR MANUAL (RM1018E)
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A60625
Crankshaft Pulley
V±ribbed Belt
Tensioner Assy
Water Pump AssyTransverse Engine
Engine Mounting Bracket
Crankshaft Position Sensor
Chain Tensioner Assy No. 1
Timing Chain or
Belt Cover Sub±assy

Oil Seal
Crankshaft Position Sensor
Plate No. 1 Chain Sub±assy
Chain Tensioner Slipper
Crankshaft timing Sprocket

O±ring

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
47 (479, 35)
29 (296, 21)
69 (704, 51)
138 (1,047, 102)
13 (133, 10)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
19 (194, 14)
9.0 (92, 80 in.
lbf) (L=20)
11 (112, 8) (L=35)
9.5 (97, 84 in.
lbf)
13 (133, 10) (M6)
19 (194, 14) (M8)
14±48
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

141CB±01
A61184
A79179
14±342
±
ENGINE MECHANICALCRANKSHAFT SEAL(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT SEAL(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 34 N
m (350 kgf
cm,25 ft
lbf)
2.REMOVE FRONT WHEEL RH
3.REMOVE ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE INJECTOR DRIVER (See page 14±286)
8.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
9.REMOVE GENERATOR V BELT (See page 14±269)
10.REMOVE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11.REMOVE ENGINE MOUNTIN G INSULATOR
SUB±ASSY RH
(a)Place a wooden block on a jack underneath the engine.
(b)Remove the 3 bolts and 3 nuts, and then detach the en- gine mounting insulator sub assy.
12.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
13.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
14.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
15.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
16. REMOVE TIMING BELT GUIDE
17.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
18.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
19.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
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SST
A09582
B07973
Cut PositionPry
SST
A08528
SST
A09583
Angle
SensorInward
±
ENGINE MECHANICALCRANKSHAFT SEAL(1CD±FTV)
14±343
AVENSIS REPAIR MANUAL (RM1018E)
20.REMOVE TIMING BELT(See page 14±307)
21.REMOVE CRANKSHAFT TIMING PULLEY
(a)If the timing pulley cannot be removed by hand, use SSTto remove the pulley.
SST09950±50013 (09951±05010, 09952±05010, 09953±05010, 09953±05020, 09954±05021)
22.REMOVE CRANKSHAFT SEAL
(a)Using a knife, cut off the oil seal lip.
(b)Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Warp tip of the
screwdriver with tape.
23.INSTALL CRANKSHAFT SEAL
(a)Using SST and a hammer, tap in the oil seal until its sur- face is flush with the oil pump edge.
SST09316±60011 (09316±00011)
24.INSTALL CRANKSHAFT TIMING PULLEY
(a)Align the keyway of the timing pulley with the key located on the crankshaft, slide the pulley into place.
(b)Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
SST09223±46011
25.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
26.INSTALL TIMING BELT(See page 14±307)
27.CHECK VALVE TIMING(See page 14±307)
28.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
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14±344
±
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
29.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
30.INSTALL TIMING BELT GUIDE(See page 14±307)
31.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
32.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
33.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
34.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
35.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
36.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
37. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
38.INSTALL INJECTOR DRIVER (See page 14±286)
39. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
40. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
41. ADD ENGINE OIL
42. CHECK FOR ENGINE OIL LEAKS
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141BA±01
A77310
Engine Room
Cover SideRadiator Support
Opening Cover Engine Cover Sub±assy No. 1
Fan and Generator V Belt Engine Under Cover RH Engine Under Cover LH
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
N´m (kgf´cm, ft´lbf)
: Specified torque
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±153
AVENSIS REPAIR MANUAL (RM1018E)
CYLINDER HEAD GASKET (1AZ±FE)
COMPONENTS
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A77319
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
Cooler Bracket
(LHD (w/ Air Conditioner)
Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant
Suction Hose No. 1
(LHD (w/ Air Conditioner)
Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator Assy
Exhaust Pipe Assy Front
43 (440, 32)
43 (440, 32)
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
52 (530, 38)
Vane Pump Assy

Gasket
8.0 (82, 44 in.
lbf)
37 (377, 27)
14±154
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

A77325
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
Accelerator Control
Cable Sub±assy
30 (305, 22)
30 (305, 22)
Throttle Body Assy
Heater Inlet Water Hose
Union To Connector
Tube Hose
Fuel Tube Sub±assy
Fuel Pipe ClampRadiator Hose Inlet
Battery Clamp
Battery
Battery Tray
Air Cleaner Assembly
w/ Hose
30 (305, 22)
5.0 (51, 44 in.
lbf)5.0 (51, 44 in.
lbf)
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±155
AVENSIS REPAIR MANUAL (RM1018E)
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
Ventilation Hose No. 2
14±156
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su