TOYOTA AVENSIS 2003 Service Repair Manual

160MR±01
B12054
SST
B12052
B12053
Pry
PryPry
±
COOLINGWATER PUMP ASSY(1AZ±FSE)
16±33
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DRAIN COOLANT (See page 16±31)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE ROOM COVER SIDE
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FAN AND GENERATOR V BELT (See page 14±185)
SST 09249±63010
6.REMOVE GENERATOR ASSY (See page 19±20)
7. REMOVE WATER PUMP PULLEY
(a) Using SST, remove 4 bolts and pump pulley.SST 09960±10010 (09962±01000, 09963±00700)
(b) Disconnect the crankshaft position sensor wire clamp from the water pump.
(c) Disconnect the crankshaft position sensor wire from the clamp on the water pump.
8. REMOVE WATER PUMP ASSY
(a) Remove 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry between the water pump and cyl- inder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.
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A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
16±34
±
COOLINGWATER PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the contact surface.
(b)Apply seal packing to the water pump as shown in the il- lustration.
Seal packing: Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 2.2 to 2.5 mm
(0.09 to 0.10 in.) opening.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c)Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d)Install the crankshaft position sensor wire harness clamp to the water pump.
(e)Install the crankshaft position sensor wire to the wire clamp on the water pump.
10.INSTALL WATER PUMP PULLEY
(a)Using SST, install the pump pulley with 4 bolts. SST09960±10010 (09962±01000, 09963±00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
13.ADD COOLANT (See page 16±31)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS(See page 16±25)
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160ME±01
A79148
SST
16±46
±
COOLINGWATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)
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A09580
8 mm
Hexagon
Wrench
A79170
A79170
A09581
8 mm
Hexagon
Wrench
Plate Washer
±
COOLINGWATER PUMP ASSY(1CD±FTV)
16±47
AVENSIS REPAIR MANUAL (RM1018E)
29.REMOVE INJECTION PUMP DRIVE PULLEY(See page 11±69)
SST09960±10010 (09962±01000, 09963±01000), 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
30.REMOVE INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
31.REMOVE TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, remove the idler pulleyshaft, the idler pulley and the plate washer.
32.REMOVE WATER PUMP ASSY
(a)Remove the 7 bolts, then remove the water pump and the gasket.
33.INSTALL WATER PUMP ASSY
(a)Install a new gasket and the water pump with the 7 bolts. Torque: 31 N
m (320 kgf
cm, 23 ft.
lbf)
34.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, install the plate washer and the idler pulley with the idler pulley shaft.
Torque: 35 N
m (357 kgf
cm, 26 ft
lbf)
(b)Check that the pulley bracket moves smoothly.
35.INSTALL INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
36.INSTALL INJECTION PUMP DRIVE PULLEY(See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
37.INSTALL WATER INLET(See page 16±50)
38.INSTALL OIL LEVEL GAGE GUIDE(See page 17±22)
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A79148
SST
A79149
SST
16±48
±
COOLINGWATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
39.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69) 40. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the water pump replaced, must re-
place fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a) Temporarily install the new fuel inlet pipe.
(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 injec- tion 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.
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±
COOLINGWATER PUMP ASSY(1CD±FTV)
16±49
AVENSIS REPAIR MANUAL (RM1018E)
41.SET NO. 1 CYLINDER TO TDC/COMPRESSION
SST09960±10010 (09962±01000, 09963±01000)
42.INSTALL TIMING BELT(See page 14±307)
43.CHECK VALVE TIMING(See page 14±307)
44.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
45.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
46.INSTALL TIMING BELT GUIDE(See page 14±307)
47.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
48.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
49.INSTALL IDLER PULLEY SUB±ASSY(See page 11±69)
50.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
51.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
52.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
53.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
54.INSTALL INJECTOR DRIVER(See page 11±69)
55. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
56. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
57.ADD ENGINE COOLANT(See page 16±44)
58.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
59.CHECK FOR FUEL LEAKS(See page 11±60)
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160MI±01
B00150
AB ABB
B
A32555
±
COOLINGWATER PUMP ASSY(1ZZ±FE/3ZZ±FE)
16±9
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
4.REMOVE ENGINE UNDER COVER RH (See page 14±27)
5.DRAIN ENGINE COOLANT (See page 16±1)
6.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
7.REMOVE GENERATOR ASSY (See page 19±7)
8.REMOVE WATER PUMP ASSY
(a)Remove the 6 bolts, the water pump and the O±ring.
9.INSTALL WATER PUMP ASSY
(a)Place a new O±ring on the timing chain cover.
(b)Install the water pump with the 6 bolts.Torque:
9.0 N
m (92 kgf
cm, 80 in
lbf) for Bolt A
11 N
m (113 kgf
cm, 8 ft
lbf) for Bolt B
10.INSTALL GENERATOR ASSY (See page 19±7)
11.ADD ENGINE COOLANT (See page 16±7)
12.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
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1700F±09
A56466
Recommended Viscosity (SAE)
BEFORE NEXT OIL CHANGE TEMPERATURE RANGE ANTICiPATED416 2738
0 20 40 60 80 100
±29
±20 ±18 ±7

C

F 20 W ± 50
15 W ± 40
10 W ± 30
5 W ± 30 PREFERRED
Oil Pressure Switch
B11410
Oil Pressure Switch
Oil Pressure Gauge
B11411
Oil Pressure Gauge
17±6
±
LUBRICATION LUBRICATION SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) After warm up the engine and then 5 minutes after the engine stop, oil l\
evel should be between the low level and full level marks of the dipstick.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, entry of water, discoloringor thinning.
If the quality is visibly poor, replace the oil. Oil grade:
API grade ºSJº Energy±Conserving, ºSLº Energy±
Conserving or ILSAC multi grade engine oil. Recom-
mended viscosity is as shown in the illustration.
3. REMOVE OIL PRESSURE SWITCH ASSY
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24mm, remove the oil pres- sure switch.
4. INSTALL OIL PRESSURE GAUGE
(a) Install the oil pressure gauge.
5. WARM UP ENGINE
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Adhesive
A50082
±
LUBRICATION LUBRICATION SYSTEM (1AZ±FE)
17±7
AVENSIS REPAIR MANUAL (RM1018E)
6. CHECK OIL PRESSURE
Oil pressure:
At idle29 kPa (0.3 kgf/cm2, 4.3 psi) or more
At 3,000 rpm245 to 539 kPa (2.5 to 5.5 kgf/cm2, 36 to 78 psi) or more
7. REMOVE OIL PRESSURE GAUGE
8. INSTALL OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.Adhesive:
Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a deep socket wrench 24mm, install the oil pres-
sure switch.
Torque: 15 N
m (153 kgf
cm, 11 ft
lbf)
NOTICE:
Do not start the engine within 1 hour after the installation.
(c) Connect the oil pressure switch connector.
9. START ENGINE AND CHECK FOR LEAKS
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1700E±07
A56466
Recommended Viscosity (SAE)
BEFORE NEXT OIL CHANGE TEMPERATURE RANGE ANTICiPATED416 2738
0 20 40 60 80 100
±29
±20 ±18 ±7

C

F 20 W ± 50
15 W ± 40
10 W ± 30
5 W ± 30 PREFERRED
B67536
B67537Oil Pressure Gauge
±
LUBRICATION LUBRICATION SYSTEM (1AZ±FSE)
17±13
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) After warm up the engine and then 5 minutes after the engine stop, oil l\
evel should be between the
low level and full level marks of the dipstick.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, entry of water, discoloringor thinning.
If the quality is visibly poor, replace the oil. Oil grade:
API grade ºSJº Energy±Conserving, ºSLº Energy±
Conserving or ILSAC multi grade engine oil. Recom-
mended viscosity is as shown in the illustration.
3. REMOVE OIL PRESSURE SWITCH ASSY
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24mm, remove the oil pres- sure switch.
4. INSTALL OIL PRESSURE GAUGE
(a) Install the oil pressure gauge.
5. WARM UP ENGINE
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