2003 TOYOTA AVENSIS Insulator

A52499
A56446
A77333SST
14±130
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
105. INSTALL MANIFOLD CONVERTER INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
106. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil\
level gauge guide.
(b) Install the oil level gauge and guide with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
107. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
108. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Apply light coat of engine oil to the new O±ring and install it to th\
e camshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)
109. I N S TA L L D R I V E P L AT E A N D R I N G G E A R O R FLYWHEEL
(a) Hold the crankshaft with SST.
SST 09213±54015 (91651±60855), 09330±00021
Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
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A77403
15
3
7
2
6
4 8
A63273
A77404
B
A
BBBB
A
B
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±131
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the drive plate. (A/T)
(1)Clean the bolt and bolt hole.
(2)Apply adhesive to the bolts.
(3)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 98 N
m (1,000 kgf
cm, 72 ft
lbf)
(c)Install the flywheel. (M/T)
(1)Clean the bolt hole.
(2)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 130 N
m (1,327 kgf
cm, 96 ft
lbf)
NOTICE:
Do not reuse the flywheel bolt.
110.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
111.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
112.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
113.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
114.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
115.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
116.INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Install the engine mounting insulator FR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
(b)Install the engine mounting insulator RR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
117.INSTALL STARTER ASSY (See page 19±12)
118. INSTALL VANE PUMP ASSY
Torque: 37 N
m (370 kgf
cm, 27 ft
lbf)
119. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the 2 bolts and 2 nuts as shown in the illustration. Torque:
Bolt 45 N
m (459 kgf
cm, 33 ft
lbf)
Nut 133 N
m (1,356 kgf
cm, 98 ft
lbf)
(b) Install the front suspension member braces with the 8 bolts.
Torque:
Bolt A 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B 80 N
m (816 kgf
cm, 59 ft
lbf)
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A77304
A77305
A77405
A
B
A
A
A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±132
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
120.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
121.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
122.INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
123.REMOVE ENGINE HANGERS
124.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
125.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24 )
126 .INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
127. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
Torque:
Bolt A 12 N
m (122 kgf
cm, 89 ft
lbf)
Bolt B 9.0 N
m (92 kgf
cm, 79 in.
lbf)
Bolt C 5.0 N
m (51 kgf
cm, 44 in.
lbf)
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A79420N´m (kgf´cm, ft´lbf): Specified torque
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)
87 (887, 64)
80 (816, 59)
133 (1,356, 98)52 (530, 38)
72 (734, 53)
39 (398, 29)
Engine Mounting Insulator
Sub±assy RH Air Tube No. 1
Front Suspension Crossmember
Sub±assy25 (255, 18)
25 (255, 18)
14±280
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79422
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

Gasket


Gasket
20 (204, 15)
20 (204, 15)
53 (540, 39)
13 (135, 9.7)
36 (367, 27)61 (622, 45)
56 (571, 41)
25 (255, 18)
Turbo Insulator No. 1
Exhaust Manifold Heat Insulator No. 2
Turbocharger Stay Turbocharger Sub±assy
Turbo Oil Inlet Pipe
Sub±assy
Manifold Stay
Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy
Turbo Insulator
No. 2


20 (204, 15)
12 (122, 8.9)
56 (571, 41)


Gasket
12 (122, 8.9)
14±282
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79179
A61177
A59793
A59792
A79193
Engine Hanger No.1 UPR
Engine Hanger No.2
Engine Hanger No.1
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±289
AVENSIS REPAIR MANUAL (RM1018E)
(b) Set the engine lifter.
(c) Remove the 3 bolts, 3 nuts and the engine mounting insu-
lator sub±assy RH.
(d) Remove the through bolt and nut, detach the engine mounting insulator LH from the vehicle.
(e) Remove the 8 bolts and the front suspension member brace rear RH and LH.
(f) Remove the 2 bolts and 2 nuts.
(g) Carefully remove the engine with transaxle from the ve- hicle.
(h) Install the 2 engine hangers with the 2 bolts. Part No.:
No. 1 engine hanger UPR (yellow) 12284±27020
No. 1 engine hanger UPR (black) 12284±27030
No. 1 engine hanger 12281±27050
No. 2 engine hanger (yellow) 12282±27060
No. 2 engine hanger (black) 12282±27070
Bolt 91642±81025
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
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A62711
A79180
A61186
SST
14±290
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(i)Attach the engine sling and hang the engine with the chain block.
44.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY
(a)Remove the through bolt and nut, detach the engine mounting insulator FR from the engine mounting bracket.
(b)Remove the through bolt, detach the engine mounting in- sulator RR from the suspension crossmember.
(c)Separate the engine and transaxle assembly from the suspension crossmember and engine mounting member.
45.REMOVE STARTER ASSY (See page 19±24)
46.REMOVE MANUAL TRANSAXLE (See page 41±33)
47.REMOVE CLUTCH DISC ASSY (See page 42±26) 48. REMOVE FLYWHEEL SUB±ASSY
(a) Hold the crank shaft with SST.SST 09213±54015 (90105±08076), 09330±00021
(b) Using a torx socket wrench (T55), remove the 8 torx
screws and the flywheel.
49. REMOVE REAR END PLATE
(a) Remove the 2 bolts and the rear end plate.
50. REMOVE DRIVE SHAFT BEARING BRACKET
51. REMOVE ENGINE MOUNTING BRACKET FR
52. REMOVE ENGINE MOUNTING BRACKET RR
53.REMOVE GLOW PLUG ASSY (See page 19±33)
54.REMOVE GENERATOR V BELT (See page 14±269)
55.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)
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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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