2003 TOYOTA AVENSIS check engine

141BI±01
A77421
Cut Position
A77422SST
14±180
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1AZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
5.REMOVE ENGINE REAR OIL SEAL
(a)Using a knife, cut off the engine rear oil seal lip.
(b)Using a screwdriver with the tip wrapped in tape, pry outthe engine rear oil seal.
HINT:
After the removal, check if the crankshaft is not damaged.
If is damaged, smooth the surface with 400±grit sandpaper.
6.INSTALL ENGINE REAR OIL SEAL
(a)Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
7.INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
8.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
9.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
10.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
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141BS±01
A77421
Cut Position
A77422SST
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1AZ±FSE)
14±265
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1AZ±FSE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±204)
SST09213±54015 (91651±60855), 09330±00021
5.REMOVE ENGINE REAR OIL SEAL
(a)Using a knife, cut off the engine rear oil seal lip.
(b)Using a screwdriver with the tip wrapped in tape, pry outthe engine rear oil seal.
HINT:
After the removal, check if the crankshaft is not damaged.
If is damaged, smooth the surface with 400±grit sandpaper.
6.INSTALL ENGINE REAR OIL SEAL
(a)Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
7.INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±204) SST 09213±54015 (91651±60855), 09330±00021
8.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
9.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
10.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
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141CC±01
A61182
SST
A09447
SST
A09448
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1CD±FTV)
14±345
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1CD±FTV)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (See page 41±33)
SST 09930±00010, 09628±62011, 09520±01010, 09520±24010 (09520±32040)
2.REMOVE CLUTCH COVER ASSY (See page 42±26)
3.REMOVE CLUTCH DISC ASSY (See page 42±26)
4. REMOVE FLYWHEEL SUB±ASSY
(a) Hold the crankshaft with SST.SST 09213±54015 (90105±08076), 09330±00021
(b) Using a torx socket wrench (T55), remove the 8 torx screws and the flywheel.
5. REMOVE REAR END PLATE
(a) Remove the 2 bolts and the rear end plate. 6. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpa-
per.
7. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the oil seal until its sur-face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
8. INSTALL REAR END PLATE Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
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141CO±01
A62838SST
A62838SST
A62202
Cut Position
A62203
SST
14±98
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 5. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
6. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
7. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grid sandpa-
per.
8. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223±15020, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
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A62838SST
A62205
1
5
3
82
6
4
7
A62206
90

A62838SST
A62204
1
5
3
82
6
4
7
±
ENGINE MECHANICALENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
14±99
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a)Fix the crankshaft with SST.
SST09960±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 the bolts with paint as shown in the illustration.
(f)Retighten the bolts by an additional 90
in the same se- quence as step (d).
(g)Check that the paint marks of each bolt are at 90
angle from the original position.
10.IN STALL CLUTCH DISC ASSY (M/T TRANSAXLE)
(See page 42±26)
11. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
12. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Fix 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.
(e) Fix the crankshaft with SST.
Torque: 88 N
m (897 kgf
cm, 65 ft
lbf)
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14±134
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
155.INSTALL RADIATOR ASSY (See page 16±24)
156.INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
157.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
158.ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
159.ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
160.ADD ENGINE OIL
161.ADD COOLANT (See page 16±19)
162. ADD POWER STEERING FLUID
163. BLEED POWER STEERING FLUID
164. CHECK FOR ENGINE OIL LEAKS
165.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
166.CHECK FOR FUEL LEAKS (See page 11±15)
167. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
168.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
169.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±101)
170.INSPECT CO/HC (See page 14±101)
171. CHECK ABS SPEED SENSOR SIGNAL
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A79423
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

O±ring
* Use SST

Gasket


Gasket

Gasket

Gasket

Gasket3.6 to 6.9 (40 to 70, 35 to 61 in.
lbf)
5.0 (51, 44 in.
lbf)
7.4 (76, 66 in.
lbf)
* 31 (316, 23)
34 (347, 25)
43 (438, 32)
21 (214, 15)
18 (184, 13)
21 (214, 15)
21 (214, 15)
21 (214, 15)
64 (650, 47)
21 (214, 15)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
Common Rail Assy
Fuel Hose No. 4
Vacuum Pump Assy
Nozzle Leakage Pipe No. 2 Fuel Inlet Pipe Sub±assy
EGR Valve AssyWater Outlet Sub±assy
Engine Coolant
Temperature Sensor
Intake Air Connector Sub±assy Intake Manifold
Wiring Harness Clamp Bracket
Injection Pump
Drive Pulley
Timing Belt
No. 3 Cover
Seal Washer
Camshaft Position Sensor
Check Valve
8.8 (90, 78 in.

lbf)
8.8 (90, 78 in.
lbf)
21 (214, 15)
21 (214, 15)
14±284
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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A79194
A79148
SST
A79143
SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±293
AVENSIS REPAIR MANUAL (RM1018E)
87. REMOVE NOZZLE LEAKAGE PIPE NO.2
(a) Remove the check valve and bolt, and then detach the
leakage pipe and the gasket.
88. REMOVE FUEL INLET PIPE SUB±ASSY
(a) Using SST, remove the fuel inlet pipe from the common rail side.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the pump side. SST 09023±12700
89. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects being introduces, cover the common rail with vinyl
tape and protect the injector inlet with a vinyl or a plastic
bag.
(e) Remove the 2 lower injection pipe clamps from the intake
manifold.
90. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
91. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
92. REMOVE INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
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