2003 TOYOTA AVENSIS check engine

A61175
AA
B
A79147
Fulcrum
Length
30 cm
SST
14±296
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
123.INSTALL POWER STEERING IDLE PULLEY BRACKET
(a)Install the idle w/ bracket pulley with the 3 bolts.
Torque:
72 N
m (734 kgf
cm, 53 ft
lbf) for bolt A
39 N
m (398 kgf
cm, 29 ft
lbf) for bolt B
124.INSTALL COMMON RAIL ASSY (See page 11±78)
125. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
126. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:

In case of having the injectors replaced, must replace
the injection pipes, too.

When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection 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 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.
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±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±297
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using SST, tighten the nut of the injection pipe to the injec-
tor 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 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)
127. INSTALL INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
128. INSTALL INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
129. INSTALL INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1. 130. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
When assembling the pipe, perform the operation with the
engine cold under room temperature.
(a) Temporarily install the inlet pipe.
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A79149
Fulcrum
Length
30 cm
SST
A81587
14±298
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(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 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.
131. INSTALL NOZZLE LEAKAGE PIPE NO.2
(a) Install a new gasket and the leakage pipe with the check valve.
Torque:
21 N
m (214 kgf
cm, 15 ft
lbf) for check valve
8.8 N
m (90 kgf
cm, 78 in.
lbf) for bolt
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A61186
SST
A57108
Adhesive
14±300
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
147. INSTALL OIL FILTER BRACKET SUB±ASSY
(a) Install a new gasket and oil filter bracket with the bolt and 2 nuts. Torque: 34 N
m (347 kgf
cm, 25 ft
lbf)
148. INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 31 N
m (316 kgf
cm, 23 ft
lbf)
149. INSTALL GENERATOR BRACKET NO.1 Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
150.INSTALL GENERATOR ASSY (See page 19±29)
151.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
152.INSTALL TIMING BELT (See page 14±307)
153.CHECK VALVE TIMING (See page 14±307)
154.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
155.INSTALL TIMING BELT GUIDE (See page 14±307)
156.INSTALL TIMING BELT NO.1 COVER (See page 14±307)
157.INSTALL TIMING BELT NO.2 COVER (See page 14±307)
158. INSTALL IDLER PULLEY SUB±ASSY Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
159.INSTALL CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
160.INSTALL GLOW PLUG ASSY (See page 19±33)
161. INSTALL ENGINE MOUNTING BRACKET RR Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
162. INSTALL ENGINE MOUNTING BRACKET FR Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
163. INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
164. INSTALL REAR END PLATE Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
165. INSTALL FLYWHEEL SUB±ASSY
(a) Using SST, hold the crankshaft. SST 09213±54015 (90105±08076), 09330±00021
(b) Clean the bolts and its bolt holes.
(c) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent
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A59792
BB
AA
A59793
AA
BBBBB
B
14±302
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(e)Install the front suspension crossmember with the 2 bolts and 2 nuts.
Torque:
45 N
m (459 kgf
cm, 33 ft
lbf) for bolt A
133 N
m (1,356 kgf
cm, 98 ft
lbf) for nut B
(f)Install the front suspension member brace LH and RH with the 8 bolts.
Torque:
133 N
m (1,356 kgf
cm, 98 ft
lbf) for bolt A
80 N
m (816 kgf
cm, 59 ft
lbf) for nut B
NOTICE:
After installing the crossmember, check that the position-
ing holes on the crossmember and the vehicle are aligned.
171.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
172.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 26±21)
HINT:
Perform the same procedure as above on the opposite side.
173.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
174.INSTALL FRONT STABILIZER LINK ASSY LH (See page 26±26)
HINT:
Perform the same procedure as above on the opposite side. SST 99999±70037
175.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
176.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
177. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
178.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±10)
179.INSTALL FLOOR PANEL BRACE FRONT (See page 15±10)
180. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See page 55±86)
181.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269 )
182.INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 42±17)
183.INSTALL CLUTCH ACCUMULATOR ASSY (See page 42±17) SST 09023±00100
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14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)
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A76713
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90

A62838SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±41
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
113. INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold 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.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(e) Mark each bolt head with paint.
(f) Retighten the bolts by an additional 90
in the same se-
quence as step (d).
(g) Check that the paint marks are at 90
angle about the
original position.
114. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
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A76717
A
B
A
B
A76716
AA
BBBBBB
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±43
AVENSIS REPAIR MANUAL (RM1018E)
(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 N
m (459 kgf
cm, 33 ft
lbf) for Bolt A
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Nut B
(f) Install the front suspension member brace LH and RH with the 8 bolts.
Torque:
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Bolt A
80 N
m (816 kgf
cm, 59 ft
lbf) for Bolt B
NOTICE:
When installing the crossmember, check that the position-
ing holes on the crossmember and on the vehicle are
aligned with each other.
122.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
123. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
124.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
125. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
127. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
128.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
129. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
130.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±2)
131. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
132.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
133.INSTALL GENERATOR ASSY (See page 19±7)
134. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
135. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
136. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)
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