TOYOTA AVENSIS 2003 Service Repair Manual

A64027
A64028
B00084
A76692
A64029
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±35
AVENSIS REPAIR MANUAL (RM1018E)
73. REMOVE WATER BY±PASS PIPE NO.1
(a) Disconnect the knock sensor cramp.
(b) Remove the 2 bolts and 2 nuts, then detach the water by±
pass pipe and the gasket.
74. REMOVE WATER INLET
(a) Remove the 2 nuts and the water inlet.
75. REMOVE THERMOSTAT
76. REMOVE ENGINE OIL PRESSURE SWITCH ASSY (See page 17±1)
77. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and the camshaft position sensor.
78. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and the crankshaft position sensor.
79. REMOVE KNOCK SENSOR
(a) Remove the nut and the knock sensor.
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A79324
A64059
A64060
A76720
A76721
14±36
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
80. REMOVE V±RIBBED IDLER ASSY NO.1
(a) Remove the nut, bolt, tube and the idler.
81. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolts, nut and the V±ribbed belt tensioner.
82. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and the transverse engine mounting bracket.
83. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and the manifold stay.
84. REMOVE MANIFOLD STAY NO.2
(a) Remove the 3 bolts and the manifold stay.
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A76722
A76723
A64033
A64034
A64034
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±37
AVENSIS REPAIR MANUAL (RM1018E)
85. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 3 bolts and the nut, and then remove the ex-
haust manifold heat insulator.
86. REMOVE EXHAUST MANIFOLD
(a) Remove the 5 nuts, then remove the exhaust manifold and the gasket.
87. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Using SST, remove the engine coolant temperature sen- sor.
SST 09817±33190
88. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and the condenser.
89. REMOVE WATER BY±PASS HOSE NO.2
90. REMOVE RADIATOR HOSE INLET
91. REMOVE HEATER INLET WATER HOSE
92. REPLACE PARTIAL ENGINE ASSY
93. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt. Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)
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A64033
A76723
A76722
A76721
A76720
ABB
14±38
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
94. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the engine coolant temperature
sensor.
(b) Using SST, install the engine coolant temperature sensor. SST 09817±33190
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
95. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
96. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
(a) Install the exhaust manifold heat insulator,then install the 3 bolts and nut.
Torque:
18 N
m (184 kgf
cm, 13 ft
lbf) for Bolt
12 N
m (122 kgf
cm, 9 ft
lbf) for Nut
(b) Connect the heated oxygen sensor connector.
97. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay with the 3 bolts. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
98. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts. Torque:
49 N
m (500 kgf
cm, 36 ft
lbf) for A
37 N
m (377 kgf
cm, 27 ft
lbf) for B
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A64060
A64059
A79324
A76692
B00084
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±39
AVENSIS REPAIR MANUAL (RM1018E)
99. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the transverse engine mounting bracket with the
bolts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
100. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the bolt and nut. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
101. INSTALL V±RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt. Torque: 39.2 N
m (400 kgf
cm, 29 ft
lbf)
102.INSTALL KNOCK SENSOR (See page 10±17)
103. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O±ring on the crank- shaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
104. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O±ring on the cam- shaft position sensor.
(b) Install the camshaft position sensor with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
105. INSTALL ENGINE OIL PR ESSURE SWITCH ASSY
(See page 17±1)
Adhesive: Part No.08833 ± 00080, THREE BOND 1344.
106.INSTALL THERMOSTAT(See page 16±9)
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A64028
A64027
A64026
A79363
A64023
14±40
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
107. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts. Torque: 11 N
m (112 kgf
cm, 8 ft
lbf)
108. INSTALL WATER BY±PASS PIPE NO.1
(a) Install a new gasket and water by±pass pipe with the 2 nuts and 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
109. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil a new O±ring and install it to the oil level gage guide.
(b) Install the oil level gage guide with the bolt. Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
110. INSTALL INTAKE MANIFOLD
(a) Install a new gasket to the intake manifold.
(b) Install the intake manifold and 2 clamp brackets with the 2 nuts and 4 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
111. INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±11)
112. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
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A76713
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90

A62838SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±41
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
113. INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold 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.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(e) Mark each bolt head with paint.
(f) Retighten the bolts by an additional 90
in the same se-
quence as step (d).
(g) Check that the paint marks are at 90
angle about the
original position.
114. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
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A62204
1
5
3
82
6
4
7
A76719
A76718
A76717
14±42
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(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: 88 N
m (897 kgf
cm, 65 ft
lbf)
115.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
116.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
117.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)(See page 41±15)
118.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
119.INSTALL STARTER ASSY(See page 19±3)
120. INS TALL FRO NT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen- sion crossmember and the 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)
121. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670±00010
(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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A76717
A
B
A
B
A76716
AA
BBBBBB
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±43
AVENSIS REPAIR MANUAL (RM1018E)
(e) Tighten 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 Bolt B
NOTICE:
When installing the crossmember, check that the position-
ing holes on the crossmember and on the vehicle are
aligned with each other.
122.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
123. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
124.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
125. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
127. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
128.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
129. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
130.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±2)
131. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
132.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
133.INSTALL GENERATOR ASSY (See page 19±7)
134. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
135. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
136. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)
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A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N
m (131 kgf
cm, 9 ft
lbf)
138. INSTALL BATTERY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
145. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL
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