TOYOTA AVENSIS 2003 Service Repair Manual

A62180
DisconnectHook
Pin Turn
A62181
Plunger
Turn
Push
A11858
A64005
14±16
±
ENGINE MECHANICAL VALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(3) Turn the crankshaft counterclockwise, and take the hook off the knock pin to release the plunger.
(4) Turn the crankshaft clockwise, and check that the plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
16. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
17. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and 2 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
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A62182
Seal Packing
A65687
A
A A
A
A
A
A
A
A BB
A64023
±
ENGINE MECHANICAL VALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±17
AVENSIS REPAIR MANUAL (RM1018E)
18. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(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 3 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts. Tighten the bolts and
nuts uniformly in the several steps.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for A
9.0 N
m (92 kgf
cm, 80 in
lbf) for B
19. 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
A78459
14±18
±
ENGINE MECHANICAL VALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
20. 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)
21. CHECK FOR ENGINE OIL LEAKS
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1509U±01
A77864
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque


Exhaust Pipe Gasket Exhaust Pipe Assy Front
Compression Spring Exhaust Pipe Assy Center
Floor Panel Brace Front

Exhaust Pipe Gasket
43 (440, 32)
43 (440, 32)

Exhaust Pipe Gasket
30 (302, 22)
43 (440, 32)Compression Spring
Exhaust Pipe Assy Tail
Exhaust Pipe Assy Center
1AZ±FE (Leaded Gasoline)
1AZ±FSE:
15±6
±
EXHAUST EXHAUST PIPE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST PIPE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS
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1509V±01
A77867
(a)
(a)
(b)
(b)
A77868
±
EXHAUSTEXHAUST PIPE ASSY(1AZ±FE/1AZ±FSE)
15±7
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
2.REMOVE EXHAUST PIPE ASSY TAIL (See page 15±2)
3. REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts.
(b) Remove the exhaust pipe center and the gasket from the2 exhaust pipe supports.
4. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs, and then remove the exhaust pipe front.
(b) Remove the gasket from the exhaust manifold.
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A77857
A78440
New Gasket
15±8
±
EXHAUSTEXHAUST PIPE ASSY(1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
5.INSTALL EXHAUST PIPE ASSY FRONT
(a)Compression spring inspection (1)Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 41.5 mm (1.634 in.)
If the free length is less than minimum, replace the compression
spring.
(b)Install a new gasket to the exhaust manifold as shown in the illustration.
(c)Install the exhaust pipe front with the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
6.INSTALL EXHAUST PIPE ASSY CENTER
(a)Install a new gasket and the exhaust pipe center to the 2 exhaust pipe s\
upports.
(b)Tighten the 2 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
7.INSTALL EXHAUST PIPE ASSY TAIL (See page 15±2)
8. CHECK FOR EXHAUST GAS LEAKS
9.INSTALL FLOOR PANEL BRACE FRONT (See page 15±2)
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1509W±01
A79443
30 (302, 22)43 (440, 32)
Gasket

Gasket
Floor Panel Brace Front
Exhaust Pipe Assy Front
Compression Spring
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable part
43 (440, 32)
Compression Spring
Exhaust Pipe Assy Tail
±
EXHAUST EXHAUST PIPE ASSY (1CD±FTV)
15±9
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST PIPE ASSY (1CD±FTV)
COMPONENTS
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1509X±01
A80114
(a)(a) (b)
(b)
(b)
15±10
±
EXHAUST EXHAUST PIPE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and the floor panel brace front. 2. REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 bolts and 2 compression springs.
(b) Disconnect the 3 exhaust pipe supports and remove theexhaust pipe tail.
(c) Remove the gasket from the exhaust pipe tail.
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A78272
(a)(b)
(b)
(a)
A77857
A76194
Wooden
Block
Gasket
±
EXHAUST EXHAUST PIPE ASSY (1CD±FTV)
15±11
AVENSIS REPAIR MANUAL (RM1018E)
3. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs.
(b) Disconnect the 2 exhaust pipe supports and remove the
exhaust pipe front.
(c) Remove the gasket from the manifold converter.
4. INSTALL EXHAUST PIPE ASSY FRONT
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum Length: 41.5 mm (1.634 in.)
If the minimum length is less than minimum, replace the com-
pression spring.
(b) Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.
NOTICE:

Tap in the gasket in the correct direction.

Do not reuse the removed gasket.

Be sure not to push in the gasket when installing the
exhaust pipe.
(c) Connect the 2 exhaust pipe supports and install the ex-
haust pipe front with the 2 compression springs and 2
bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
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A77857
A78440
New Gasket
15±12
±
EXHAUST EXHAUST PIPE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL EXHAUST PIPE ASSY TAIL
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum Length: 38.5 mm (1.515 in.)
If the minimum length is less than minimum, replace the com-
pression spring.
(b) Install a new gasket to the pipe front converter as shown in the illustration.
(c) Connect the 3 exhaust pipe supports and install the ex- haust pipe tail with the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
6. CHECK FOR EXHAUST GAS LEAKS
7. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (302 kgf
cm, 22 ft
lbf)
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