TOYOTA AVENSIS 2003 Service Repair Manual

±
ENGINE MECHANICAL ENGINE (1ZZ±FE/3ZZ±FE)
14±3
AVENSIS REPAIR MANUAL (RM1018E)
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure


1,300 kPa (13.3 kgf
cm
2, 189 psi)
Minimum pressure: 1,000 kPa (10.2 kgf
cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf
cm
2, 14 psi)
NOTICE:

Always use a fully charged battery to obtain engine
speed of 250 rpm or more.

Check other cylinder's compression pressure in the
same way.

This measurement must be done in as short a time as
possible.
(4) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cyl-
inder through the spark plug hole and repeat steps
(1) through (3) for the cylinders that have low com-
pression.
HINT:

If adding oil helps increase the compression, the piston
rings and/or cylinder bore may be worn or damaged.

If pressure stays low, a valve may be sticking or seating
improperly, or there may be leakage past the gasket.
10. INSPECT CO/HC
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tail\
pipe during idling.
(d) Check CO/HC concentration at idle.
Idle CO concentration: 0 to 0.5 %
Idle HC concentration: Applicable local regulation
If the CO/HC concentration does not conform to specifications, perform tro\
ubleshooting in the order given
below.

Check heated oxygen sensor operation.

See the table below for possible causes, and then inspect and repair the applicable causes if
necessary.
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14±4
±
ENGINE MECHANICAL ENGINE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E) CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:


Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

ISC valve

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke form exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:

Faulty pressure regulator

Defective water temperature sensor

Defective mass air flow meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor
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141BI±01
A77421
Cut Position
A77422SST
14±180
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1AZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
5.REMOVE ENGINE REAR OIL SEAL
(a)Using a knife, cut off the engine rear oil seal lip.
(b)Using a screwdriver with the tip wrapped in tape, pry outthe engine rear oil seal.
HINT:
After the removal, check if the crankshaft is not damaged.
If is damaged, smooth the surface with 400±grit sandpaper.
6.INSTALL ENGINE REAR OIL SEAL
(a)Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
7.INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
8.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
9.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
10.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
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141BS±01
A77421
Cut Position
A77422SST
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1AZ±FSE)
14±265
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1AZ±FSE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±204)
SST09213±54015 (91651±60855), 09330±00021
5.REMOVE ENGINE REAR OIL SEAL
(a)Using a knife, cut off the engine rear oil seal lip.
(b)Using a screwdriver with the tip wrapped in tape, pry outthe engine rear oil seal.
HINT:
After the removal, check if the crankshaft is not damaged.
If is damaged, smooth the surface with 400±grit sandpaper.
6.INSTALL ENGINE REAR OIL SEAL
(a)Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
7.INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±204) SST 09213±54015 (91651±60855), 09330±00021
8.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
9.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
10.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
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141CC±01
A61182
SST
A09447
SST
A09448
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1CD±FTV)
14±345
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1CD±FTV)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (See page 41±33)
SST 09930±00010, 09628±62011, 09520±01010, 09520±24010 (09520±32040)
2.REMOVE CLUTCH COVER ASSY (See page 42±26)
3.REMOVE CLUTCH DISC ASSY (See page 42±26)
4. REMOVE FLYWHEEL SUB±ASSY
(a) Hold the crankshaft with SST.SST 09213±54015 (90105±08076), 09330±00021
(b) Using a torx socket wrench (T55), remove the 8 torx screws and the flywheel.
5. REMOVE REAR END PLATE
(a) Remove the 2 bolts and the rear end plate. 6. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpa-
per.
7. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the oil seal until its sur-face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
8. INSTALL REAR END PLATE Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
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A61186
SST
A79183
1
7
5
8
4
3
26
14±346
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ENGINE MECHANICALENGINE REAR OIL SEAL(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL FLYWHEEL SUB±ASSY
(a)Hold the crankshaft with SST. SST09213±54015 (90105±08076), 09330±00021
(b)Clean the bolt and the bolt hole.
(c)Apply Adhesive to the bolts. Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
(d)Using several steps, install and tighten the 8 screws with a torx socket wrench (T55) uniformly in the sequence
shown in the illustration.
Torque: 71 N
m (720 kgf
cm, 52 ft
lbf)
10.INSTALL CLUTCH DISC ASSY (See page 42±26) SST 09301±00220
11.INSTALL CLUTCH COVER ASSY (See page 42±26)
12.INSTALL MANUAL TRANSAXLE ASSY (See page 41±33) SST 09670±00010
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141CO±01
A62838SST
A62838SST
A62202
Cut Position
A62203
SST
14±98
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 5. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
6. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
7. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grid sandpa-
per.
8. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223±15020, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
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A62838SST
A62205
1
5
3
82
6
4
7
A62206
90

A62838SST
A62204
1
5
3
82
6
4
7
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ENGINE MECHANICALENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
14±99
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a)Fix the crankshaft with SST.
SST09960±10010 (09962±01000, 09963±01000)
(b)Clean the bolt and bolt hole.
(c)Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d)Using several steps, Install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(e)Mark the bolts with paint as shown in the illustration.
(f)Retighten the bolts by an additional 90
in the same se- quence as step (d).
(g)Check that the paint marks of each bolt are at 90
angle from the original position.
10.IN STALL CLUTCH DISC ASSY (M/T TRANSAXLE)
(See page 42±26)
11. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
12. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Fix the crankshaft with SST. SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
(e) Fix the crankshaft with SST.
Torque: 88 N
m (897 kgf
cm, 65 ft
lbf)
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14±100
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ENGINE MECHANICALENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
13.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
14.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
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141B5±01
A77293
SST
±
ENGINE MECHANICAL FAN AND GENERATOR V BELT (1AZ±FE)
14±105
AVENSIS REPAIR MANUAL (RM1018E)
FAN AND GENERATOR V BELT (1AZ±FE)
REPLACEMENT
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE ROOM COVER SIDE
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FAN AND GENERATOR V BELT
(a) Using SST, loosen the V±ribbed belt tensioner arm clock-wise, and remove the fan and generator V belt.
SST 09249±63010
5. INSTALL FAN AND GENERATOR V BELT
(a) Using SST, loosen the V±ribbed belt tensioner arm clockwise, and install the f\
an and generator V belt. SST 09249±63010
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