2003 TOYOTA AVENSIS check engine
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ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
14±167
AVENSIS REPAIR MANUAL (RM1018E)
69.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
70.INSTALL CHAIN SUB±ASSY (See page 14±139)
71.INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
72.INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N m (195 kgfcm,15 ftlbf)
73.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±171)
74.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
75.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
76.INSTALL OIL PAN SUB±ASSY (See page 14±139)
77.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
78.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST09213±54015 (91651±60855), 09330±00021
79.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
80.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N m (530 kgfcm,38 ftlbf)
81.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
82.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
83.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
84.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
85.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
86.INSTALL ENGINE WIRE
87.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgfcm,71 in. lbf)
88.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
89.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgfcm,71 in. lbf)
90.INSTALL IGNITION COIL ASSY
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
91.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgfcm,62 in. lbf)
92.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgfcm,27 ftlbf)
93.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
94.INSTALL GENERATOR ASSY (See page 19±20)
95.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
96.ADD COOLANT (See page 16±19)
97. ADD ENGINE OIL
98.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
99. CHECK FOR ENGINE OIL LEAKS
100. CHECK FOR FUEL LEAKS
101. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 558 of 2234
A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket 2.5 to 3 mm
12.5 to 1.5 mm
A774101 2
3
4
10 9
85
67
A00976A77411
90
Engine
Front Paint Mark
14±260
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ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(a)Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Remove any oil from contact surface.
Install the cylinder head within 3 minutes after apply-
ing seal packing.
After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.
Do not start the engine within 2 hours after installing.
(b)Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(c)Install bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d)Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N m (806 kgfcm, 58 ftlbf)
(e)Mark the front side of the cylinder head set bolts with paint.
(f)Retighten the cylinder head set bolts by 90 in the same sequence as a step (d).
(g)Check that each paint mark is now at a 90 angle to the front.
64.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N m (92 kgfcm,79 in. lbf)
65.INSTALL CAMSHAFT (See page 14±240)
66.INSTALL NO.2 CAMSHAFT (See page 14±240)
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Page 560 of 2234
14±262
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ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgf cm, 27 ftlbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 572 of 2234
A61189
10
11
12
13 14
15 16
17
18
2
1
4563
7 8
9
(A) (A)
(A)(A) (A)
(A)
(A)
(B) (B) (B) (B) (B) (B) (B)(B)
(B)(B)
(A)
A61190
90
90
9090
90
90
Front Paint Mark
90
A09683
TDC Mark
Dot Mark
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ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±337
AVENSIS REPAIR MANUAL (RM1018E)
70. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 4 successive
steps (steps (c), (e), (f) and (g)).
If the cylinder head bolt is broken or deformed, replace it
with a new bolt.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts and the plate washers.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 18 cylinder head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 45 N m (459 kgfcm, 33 ftlbf)
HINT:
See the table below for the bolt length.
Bolt TypeBolt Length
(A)160mm (6.30 in.)
(B)104mm (4.09 in.)
If the cylinder head bolt does not meet the torque specification,
replace the cylinder head bolt with a new bolt.
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by additional 90 in the
same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional 90 in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man- ifold side.
71. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing pulley at the position
of 90 BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
72.INSTALL CAMSHAFT (See page 14±318)
73.INSTALL NO.2 CAMSHAFT (See page 14±318)
74.REMOVE CAMSHAFT OIL SEAL (See page 14±318)
75.INSTALL CAMSHAFT OIL SEAL (See page 14±318) SST 09223±46011
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Page 574 of 2234
A79147
Fulcrum
Length
30 cm
SST
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ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±339
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 Nm (428 kgf cm, 31 ftlbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ftlbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ftlbf) 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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST 09023±12700
Torque:
42 Nm (428 kgf cm, 31 ftlbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ftlbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ftlbf) 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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
85. INSTALL INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
86. INSTALL INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
87. INSTALL INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
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Page 575 of 2234
A79148
SST
A79149
SST
14±340
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ENGINE MECHANICALCYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
88.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
In case of having the cylinder head gasket replaced,
must replace 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.
SST09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 N m (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgf cm, 25 ftlbf) 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 pump side.
SST09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 N m (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgf cm, 25 ftlbf) 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.
89.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
90.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
91.INSTALL TURBOCHARGER STAY (See page 13±11)
92.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
93.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
94.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
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Page 576 of 2234
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ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±341
AVENSIS REPAIR MANUAL (RM1018E)
95.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
96.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
97.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
98.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
99.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
100.INSTALL HEATER BRACKET (W/ COLD AREA)(See page 13±11)
101.INSTALL HEATER PUMP ASSY (W/ COLD AREA)(See page 13±11)
102.INSTALL FUEL FILTER ASSY(See page 11±82)
103.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
SST 09960±10010 (09962±01000, 09963±01000)
104.INSTALL TIMING BELT(See page 14±307)
105.CHECK VALVE TIMING(See page 14±307)
106.TIMING CHAIN COVER PLATE(See page 14±307)
107.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
108.INSTALL TIMING BELT GUIDE(See page 14±307)
109.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
110.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
111.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
112.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
113.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
114.INSTALL POWER STEERING IDLE PULLEY BRACKET(See page 14±307)
115. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
116.INSTALL INJECTOR DRIVER (See page 14±286)
117.INSTALL AIR TUBE NO.1(See page 14±270)
118.INSTALL AIR TUBE NO.2 (See page 14±286)
119.INSTALL AIR CLEANER ASSY (See page 14±286)
120.INSTALL VACUUM RESERVOIR SUB±ASSY (See page 13±11)
121. INSTALL ENGINE COVER NO.1
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
122. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
123. ADD ENGINE OIL
124.ADD ENGINE COOLANT(See page 16±44)
125.CHECK FOR FUEL LEAKS(See page 11±60)
126. CHECK FOR ENGINE OIL LEAKS
127.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
128. CHECK FOR EXHAUST GAS LEAKS
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Page 586 of 2234
A64856
A62185
MarkMark
Mark Timing Chain
Cover Surface
Timing
Notch
A62837SST
A11858
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ENGINE MECHANICALCYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
14±85
AVENSIS REPAIR MANUAL (RM1018E)
33.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts and 3 clamp
brackets.
(b)Remove the cylinder head cover.
34.SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a)Turn the crankshaft pulley to align the timing notch with the timing mark º0º of the timing chain cover.
(b)Check that the point marks of the camshaft timing sprock- et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360) and align the
marks as above.
35.REMOVE CRANKSHAFT PULLEY
(a)Using SST, remove the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
(b)Remove the crankshaft pulley from the crankshaft.
36.REMOVE V±RIBBED BELT TENSIONER ASSY
(a)Remove the bolt and nut and detach the V±ribbed belt tensioner.
HINT:
Jack up and down to remove the bolt.
37.REMOVE WATER PUMP ASSY(See page 16±9)
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