ignition TOYOTA AVENSIS 2003 Service Workshop Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.95 MB
Page 525 of 2234
A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(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 Nm (112 kgfcm, 8 ftlbf)
Bolt B 14 Nm (143 kgfcm, 10 ftlbf)
Bolt C 21 Nm (214 kgfcm, 15 ftlbf)
Nut 11 N m (112 kgfcm, 8 ft lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N m (71 kgfcm,62 in. lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgfcm,71 in. lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N m (82 kgfcm,71 in. lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgfcm,80 in. lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgfcm,27 ftlbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 528 of 2234
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±220
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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Page 532 of 2234
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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Page 540 of 2234
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)
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Page 544 of 2234
141BB±01
A77292
A77299
14±160
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2. REMOVE FRONT WHEEL RH
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgf cm, 18 ftlbf)
9.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 14±121)
10.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
11.REMOVE GENERATOR ASSY (See page 19±20)
12.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
13. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
14. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils. 15. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts and separate the return tube asshown in the illustration.
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Page 551 of 2234
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
14±167
AVENSIS REPAIR MANUAL (RM1018E)
69.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
70.INSTALL CHAIN SUB±ASSY (See page 14±139)
71.INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
72.INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N m (195 kgfcm,15 ftlbf)
73.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±171)
74.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
75.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
76.INSTALL OIL PAN SUB±ASSY (See page 14±139)
77.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
78.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST09213±54015 (91651±60855), 09330±00021
79.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
80.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N m (530 kgfcm,38 ftlbf)
81.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
82.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
83.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
84.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
85.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
86.INSTALL ENGINE WIRE
87.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgfcm,71 in. lbf)
88.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
89.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgfcm,71 in. lbf)
90.INSTALL IGNITION COIL ASSY
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
91.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgfcm,62 in. lbf)
92.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgfcm,27 ftlbf)
93.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
94.INSTALL GENERATOR ASSY (See page 19±20)
95.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
96.ADD COOLANT (See page 16±19)
97. ADD ENGINE OIL
98.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
99. CHECK FOR ENGINE OIL LEAKS
100. CHECK FOR FUEL LEAKS
101. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 552 of 2234
141BO±01
A77339
A77292
14±254
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgfcm,18 ftlbf)
9.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
10.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
11.SEPARATE FUEL TUBE SUB±ASSY (See page 11±33)
12.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
13.REMOVE FUEL PUMP ASSY (See page 11±52)
14.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
15.REMOVE GENERATOR ASSY (See page 19±20)
16.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
17. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
18. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
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Page 560 of 2234
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 ftlbf)
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 kgfcm, 76 ft lbf)
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Page 579 of 2234
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)
14±78
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su
Page 583 of 2234
A60622
A79324
A76713
A64023
14±82
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±11) SST09268±21010
15.DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a)Disconnect the union to connector tube hose from the hose to hose tube.
16.DISCONNECT RADIATOR HOSE INLET
(a)Disconnect radiator hose inlet from the cylinder head.
17.DISCONNECT HEATER INLET WATER HOSE
(a)Disconnect the heater inlet water hose from the cylinder head.
18.REMOVE FAN AND GENERATOR V BELT
(a)Turn the V±ribbed belt tensioner clockwise slowly andloosen it. Remove the fan and generator V belt and put
back the V±ribbed belt tensioner carefully.
19.REMOVE V±RIBBED IDLER ASSY NO.1
(a)Remove the nut, bolt, tube and idler.
20.REMOVE GENERATOR ASSY (See page 19±7)
21. DISCONNECT IGNITION COIL ASSY
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.
(d) Remove the 4 bolts and the 4 ignition coils.
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