TOYOTA AVENSIS 2003 Service Repair Manual

A79183
2
1
3
4
5
6
7
8
A79180
A62711
A59792
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±301
AVENSIS REPAIR MANUAL (RM1018E)
(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)
166.INSTALL CLUTCH DISC ASSY (See page 42±26) SST 09301±00210
167.INSTALL MANUAL TRANSAXLE (See page 41±33)
168.INSTALL STARTER ASSY (See page 19±24)
169. INS TALL FRO NT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Attach the engine and the transaxle assembly to the sus- pension crossmember and engine mounting member.
(b) Install the bolt which is used to secure the rear engine
mounting bracket to the mounting insulator.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(c) Install the bolt which is used to secure the front engine mounting bracket to the mounting insulator.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
170. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on the engine lift-
er.
(b) Temporarily, install the suspension crossmember with the 2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N
m (816 kgf
cm, 59 ft
lbf)
(d) Install the engine mounting insulator RH. Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
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A59792
BB
AA
A59793
AA
BBBBB
B
14±302
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(e)Install the front suspension crossmember with the 2 bolts and 2 nuts.
Torque:
45 N
m (459 kgf
cm, 33 ft
lbf) for bolt A
133 N
m (1,356 kgf
cm, 98 ft
lbf) for nut B
(f)Install the front suspension member brace LH and RH with the 8 bolts.
Torque:
133 N
m (1,356 kgf
cm, 98 ft
lbf) for bolt A
80 N
m (816 kgf
cm, 59 ft
lbf) for nut B
NOTICE:
After installing the crossmember, check that the position-
ing holes on the crossmember and the vehicle are aligned.
171.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
172.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 26±21)
HINT:
Perform the same procedure as above on the opposite side.
173.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
174.INSTALL FRONT STABILIZER LINK ASSY LH (See page 26±26)
HINT:
Perform the same procedure as above on the opposite side. SST 99999±70037
175.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
176.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
177. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
178.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±10)
179.INSTALL FLOOR PANEL BRACE FRONT (See page 15±10)
180. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See page 55±86)
181.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269 )
182.INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 42±17)
183.INSTALL CLUTCH ACCUMULATOR ASSY (See page 42±17) SST 09023±00100
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A64328
2 to 7 mm0 to 2 mm
A78274
Upward
90

Clamp
Bolt
A64328
2 to 7 mm 0 to 4 mm
A64007
Front
90

Clamp
Bolt
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±303
AVENSIS REPAIR MANUAL (RM1018E)
184.INSTALL AIR TUBE NO.1
(a)Install the new air hose No. 1 and new hose clamp as
shown in the illustration.
(b)Tighten the hose clamp as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
185.INSTALL INJECTOR DRIVER Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
186.CONNECT ENGINE WIRE Torque: 8.4 N
m (85 kgf
cm,74 in.
lbf)
187.INSTALL AIR TUBE NO.2
(a)Install the air hose and hose clamps as shown in the il- lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm,53 ft
lbf)
(c)Install the 2 bolts and the air tube No.2 assy.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
188.INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
189. INSTALL ENGINE ROOM RELAY BLOCK NO.3 Torque: 5.3 N
m (54 kgf
cm, 46 in.
lbf)
190. INSTALL FUEL FILTER ASSY Torque: 18 N
m (178 kgf
cm, 13 ft
lbf)
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14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)
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141CF±01
A76700
Cylinder Head
Cover No. 2
Radiator Support
Upper
Radiator Support Upper
Radiator
Hose Inlet
Radiator Hose Outlet
Radiator Assy Clip
7.0 (71, 62 in.

lbf)
19 (194, 14)
Engine Under Cover LH
Engine Under Cover RH
Clip
Clip
N´m (kgf´cm, ft´lbf): Specified torque
Clip
Engine Under Cover No.1
19 (194, 14)
Retainer
Clip
Clip
Engine Room Cover Side
Radiator Suport Opening Cover
5.0 (51, 44)
Relay Block
Oil Cooler Inlet Tube No.1
Oil Cooler
Outlet Tube No.1
x2
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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A76702
Accelerator Control Cable Assy
Heater Inlet Water Hose
Fuel Pipe Clamp
Fuel Tube Sub±assy
Heater Outlet Water HoseAir Cleaner Cap
W/ Hose
Air Cleaner Filter
Element Sub±assy
Air Cleaner Case Sub±assy
Battery Clamp
Sub±assy
Battery
Battery Tray
Battery Carrier
12.8 (131, 9)
N´m (kgf´cm, ft´lbf) : Specified torque
Union to Connector Tube Hose
Air Cleaner Clamp
Bracket
5.0 (51, 44 in.
lbf)
Fuel Vapor Feed Hose No.1
Fuel Vapor Feed Hose No.3
5.0 (51, 44 in.
lbf)
Oil Cooler
Inlet Hose
Oil Cooler
Outlet Hose
X4
VSV Connector
Mass Air Flow
Meter Connector
14±20
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A76703
Fan and Generator V BeltCooler Compressor Assy
N´m (kgf´cm, ft´lbf) : Specified torque
29 (296, 21)
A/T: Floor Shift Transmission
Control Cable Assy
Clip
Clutch Release Cylinder Assy
Floor Shift Cable Transmission
Control Shift
Floor Shift Cable Transmission
Control Select
Clip
Clip
25 (255, 18)
12 (122, 9)
25 (255, 18)
12 (122, 9)
54 (551, 40)
25 (255, 18)
Generator Assy
Terminal Cap
No. 19.8 (100, 7)
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±21
AVENSIS REPAIR MANUAL (RM1018E)
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A76704
Grove Compartment Door Assy
Cowl Side Trim Board RH
Front Door Scuff Plate RH
Clip
Clip
Column Hole Cover Silencer Sheet
Steering Intermediate Shaft

Cotter Pin
Tie Rod End Sub±assy LH
Front Suspension Arm
Sub±assy Lower No. 1 LH
Front Drive Shaft Assy LH
Front Stabilizer Link Assy LH
Exhaust Pipe Assy Front Floor Panel Brace FrontCompression
Spring
Compression Spring

Gasket

Gasket
89 (908, 66)
216 (2,203, 160)
49 (500, 36)
74 (755, 55)
35 (357, 26)
89 (908, 66)
Front Axle Hub LH Nut

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
43 (440, 32)
30 (306, 22)
43 (440, 32)
Front Floor Footrest (RHD)
Instrument Panel Under
Cover Sub±assy No. 2
14±22
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A76705N´m (kgf´cm, ft´lbf) : Specified torque
Engine Mounting
Insulator RH
Engine Assembly with Transaxle
Front Suspension
Crossmember
W/ Center Member
80 (816, 59)
133 (1,356, 98)45 (459, 33)
52 (530, 38)
52 (530, 38)
87 (887, 64)
52 (530, 38)
Front Suspension
Member Brace RH
133 (1,356, 98)
80 (816, 59)
Front Suspension
Member Brace RH
133 (1,356, 98)
80 (816, 59)
X3X3
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±23
AVENSIS REPAIR MANUAL (RM1018E)
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A79349N´m (kgf´cm, ft´lbf): Specified torqueAutomatic Transaxle Assy
Drive Plate Spacer
RR
Drive Plate & Ring Gear Sub±assy
Drive Plate Spacer
FR
A/T:
28 (286, 21)
88 (897, 65)
Clutch Disk Assy
Clutch Cover Assy
Manual Transaxle Assy
Starter Assy
Flywheel Sub±assy
See page 14±27
1st 49 (500, 36)
2nd Turn 90

37 (377, 27)
37 (377, 27)
64 (653, 47)
19 (194, 14)
64 (653, 47)
9.8 (100, 7)
47 (479, 35)
47 (479, 35)
14±24
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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