TOYOTA AVENSIS 2003 Service Repair Manual

A15985
A78280
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±291
AVENSIS REPAIR MANUAL (RM1018E)
56.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
57.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
58.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
59.REMOVE TIMING BELT GUIDE
60.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
61.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
62.REMOVE TIMING BELT (See page 14±307)
HINT:
If re±use the timing belt, draw an arrow which indicates the engine rev\
olution direction on the belt and put
match marks on the pulleys and the belt before removing. This operation will \
be very helpful when re±instal-
ling the timing belt.
63.REMOVE GENERATOR ASSY
64.REMOVE GENERATOR BRACKET NO.1
(a)Remove the 2 bolts and the generator bracket.
65.REMOVE V±RIBBED BELT TENSIONER ASSY
66.REMOVE OIL FILTER BRACKET SUB±ASSY
(a)Remove the bolt and 2 nuts, and then remove the oil filter
bracket and the gasket.
67.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
68.REMOVE TURBO INSULATOR NO.1 (See page 13±11)
69.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
70.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
71.REMOVE MANIFOLD STAY (See page 13±11)
72.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
73.REMOVE TURBOCHARGER STAY (See page 13±11)
74.DISCONNECT TURBO WATER HOSE NO.1 (See page 13±11)
75.DISCONNECT TURBO WATER HOSE NO.2 (See page 13±11)
76.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
77.REMOVE TURBO OIL OUTLET PIPE NO.2 (See page 13±11)
78.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11) 79. DISCONNECT WATER BY±PASS HOSE NO.3
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A80118
A80115
A80116
A09660
14±292
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
80.REMOVE EGR PIPE SUB±ASSY NO.1
(a)Remove the bolt and 4 nut, and then detach the EGR pipe and the 2 gasket\
s. 81.REMOVE EXHAUST MANIFOLD
(a)Remove the 8 nuts, the exhaust manifold and the gasket.
82.REMOVE OIL COOLER ASSY (See page 17±32)
83. REMOVE WATER OUTLET SUB±ASSY 84. REMOVE INTAKE AIR CONNECTOR SUB±ASSY
(a) Remove the bolt and 2 nuts, and then remove the intakeair connector and the gasket.
85. REMOVE EGR VALVE ASSY
(a) Remove the bolt and 2 nuts, and then remove the EGR valve and the gasket.
86. REMOVE VACUUM PUMP ASSY
(a) Remove the 2 bolts, the vacuum pump and the 2 O±rings.
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A79194
A79148
SST
A79143
SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±293
AVENSIS REPAIR MANUAL (RM1018E)
87. REMOVE NOZZLE LEAKAGE PIPE NO.2
(a) Remove the check valve and bolt, and then detach the
leakage pipe and the gasket.
88. REMOVE FUEL INLET PIPE SUB±ASSY
(a) Using SST, remove the fuel inlet pipe from the common rail side.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the pump side. SST 09023±12700
89. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects being introduces, cover the common rail with vinyl
tape and protect the injector inlet with a vinyl or a plastic
bag.
(e) Remove the 2 lower injection pipe clamps from the intake
manifold.
90. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
91. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
92. REMOVE INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
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A79150
A61175
A09671
14±294
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
93.REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a)Remove the 2 bolts and the intake manifold insulator.
94.REMOVE COMMON RAIL ASSY (See page 11±78) 95.REMOVE POWER STEERING IDLE PULLEY
BRACKET
(a)Remove the 3 bolts and the idle pulley bracket.
96.REMOVE INTAKE MANIFOLD
(a)Remove the 2 bolts and the wiring harness clamp bracket.
(b)Remove the 8 bolts and 2 nuts, and then remove the in- take manifold and the gasket.
97.REMOVE INJECTION PUMP DRIVE PULLEY (See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
98. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, and then remove the timing belt c\
over.
99.REMOVE OIL LEVEL GAGE GUIDE (See page 17±22)
100.REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11±69)
101. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
(a) Remove the 4 bolts and the compressor mounting bracket.
102. REMOVE WATER INLET
(a) Remove the 2 bolts and the water inlet.
103. REMOVE THERMOSTAT
104. REMOVE OIL COOLER PIPE
(a) Remove the union bolt, the oil cooler pipe and the gasket.
105. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and nut, and then detach the fuel pipe.
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A79173New O±Ring
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±295
AVENSIS REPAIR MANUAL (RM1018E)
106.REMOVE CRANKSHAFT POSITION SENSOR
(a)Remove the bolt and the crankshaft position sensor.
107.REMOVE CAMSHAFT POSITION SENSOR
(a)Remove the bolt and the camshaft position sensor.
108.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
109.REPLACE PARTIAL ENGINE ASSY
110.INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Torque: 20 N
m (204 kgf
cm,15 ft
lbf)
111.INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
112.INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
113.INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE Torque:
8.8 N
m (90 kgf
cm,78 ft
lbf) for M6 and Nut
21 N
m (209 kgf
cm,15 ft
lbf) for M8
114.INSTALL OIL COOLER PIPE
(a)Install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 59 N
m (600 kgf
cm,43 ft
lbf)
115.INSTALL THERMOSTAT (See page 16±50)
116.INSTALL WATER INLET (See page 16±50)
117. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
118. INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
119. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O±ring to the oil level gage guide.
(b) Apply engine oil to the O±ring.
(c) Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d) Install the oil level gage guide with the bolt. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
(e) Apply engine oil to the O±ring on the oil level gage.
(f) Install the oil level gage.
120. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
121.INSTALL INJECTION PUMP DRIVE PULLEY (See page 11±69)
SST 09960±10010 (09962±01000, 09963±01000)
122. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts\
. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(b) Install the wiring harness clamp bracket with the 2 bolts.
Torque: 3.9 to 6.9 N
m (40 to 70 kgf
cm, 35 to 61 in.
lbf)
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A61175
AA
B
A79147
Fulcrum
Length
30 cm
SST
14±296
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
123.INSTALL POWER STEERING IDLE PULLEY BRACKET
(a)Install the idle w/ bracket pulley with the 3 bolts.
Torque:
72 N
m (734 kgf
cm, 53 ft
lbf) for bolt A
39 N
m (398 kgf
cm, 29 ft
lbf) for bolt B
124.INSTALL COMMON RAIL ASSY (See page 11±78)
125. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
126. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:

In case of having the injectors replaced, must replace
the injection pipes, too.

When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST 09023±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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
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±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±297
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using SST, tighten the nut of the injection pipe to the injec-
tor side.
SST 09023±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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
127. INSTALL INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
128. INSTALL INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
129. INSTALL INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1. 130. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
When assembling the pipe, perform the operation with the
engine cold under room temperature.
(a) Temporarily install the inlet pipe.
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A79149
Fulcrum
Length
30 cm
SST
A81587
14±298
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Using SST, tighten the nut of the fuel inlet pipe to the com- mon rail side.
SST 09023±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.
SST 09023±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.
131. INSTALL NOZZLE LEAKAGE PIPE NO.2
(a) Install a new gasket and the leakage pipe with the check valve.
Torque:
21 N
m (214 kgf
cm, 15 ft
lbf) for check valve
8.8 N
m (90 kgf
cm, 78 in.
lbf) for bolt
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A79196
New O±Ring
New O±Ring
A79182
Collar
Groove
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±299
AVENSIS REPAIR MANUAL (RM1018E)
132.INSTALL VACUUM PUMP ASSY
(a)Install 2 new O±rings to the vacuum pump.
(b)Align the key of the vacuum pump with the keyway of the
exhaust camshaft, insert the vacuum pump into place.
Secure the pump with the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
133.INSTALL EGR VALVE ASSY
(a)Install a new gasket and the EGR valve with the bolt and 2 nuts. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
134.INSTALL INTAKE AIR CONNECTOR SUB±ASSY
(a)Install a new gasket and the intake air connector with diesel throttle b\
ody with the bolt and 2 nuts. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
135.INSTALL WATER OUTLET SUB±ASSY
(a)Install a new gasket and the water outlet with the 2 bolts. Torque: 21 N
m (214 kgf
cm,15 ft
lbf)
136.INSTALL OIL COOLER ASSY (See page 17±32)
137.INSTALL EXHAUST MANIFOLD
(a)Install a new gasket, the exhaust manifold and the 8 col-lars with new 8 nuts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. Ring groove of the collar should be outside. Refer
to the illustration on the left.
138.INSTALL EGR PIPE SUB±ASSY NO.1
(a)Install 2 new gaskets and the EGR pipe with the bolt and 4 new nuts. Torque:
37 N
m (375 kgf
cm,27 ft
lbf) for bolt
25 N
m (250 kgf
cm,18 ft
lbf) for nut
139.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
140.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
141.INSTALL TURBOCHARGER STAY (See page 13±11)
142.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
143.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
144.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
145.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
146.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
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A61186
SST
A57108
Adhesive
14±300
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
147. INSTALL OIL FILTER BRACKET SUB±ASSY
(a) Install a new gasket and oil filter bracket with the bolt and 2 nuts. Torque: 34 N
m (347 kgf
cm, 25 ft
lbf)
148. INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 31 N
m (316 kgf
cm, 23 ft
lbf)
149. INSTALL GENERATOR BRACKET NO.1 Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
150.INSTALL GENERATOR ASSY (See page 19±29)
151.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
152.INSTALL TIMING BELT (See page 14±307)
153.CHECK VALVE TIMING (See page 14±307)
154.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
155.INSTALL TIMING BELT GUIDE (See page 14±307)
156.INSTALL TIMING BELT NO.1 COVER (See page 14±307)
157.INSTALL TIMING BELT NO.2 COVER (See page 14±307)
158. INSTALL IDLER PULLEY SUB±ASSY Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
159.INSTALL CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
160.INSTALL GLOW PLUG ASSY (See page 19±33)
161. INSTALL ENGINE MOUNTING BRACKET RR Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
162. INSTALL ENGINE MOUNTING BRACKET FR Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
163. INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
164. INSTALL REAR END PLATE Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
165. INSTALL FLYWHEEL SUB±ASSY
(a) Using SST, hold the crankshaft. SST 09213±54015 (90105±08076), 09330±00021
(b) Clean the bolts and its bolt holes.
(c) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent
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