2003 TOYOTA AVENSIS Insulator
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0313A±05
±
SERVICE SPECIFICATIONS FRONT SUSPENSION
03±35
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
Tie rod end lock nut7475555
Steering knuckle x Shock absorber2202,240162
Hub nut1031,05076
Suspension support x Piston rod4747935
Suspension support x Body3939829
Suspension crossmember sub±assy x Body1331,36098
Suspension crossmember sub±assy x Engine mounting insulator8081659
Suspension crossmember sub±assy x Center member9697971
Suspension member brace x Body Bolt A:
Bolt B:80
133816
1,36059
98
Speed sensor wire harness bracket set bolt1919214
Stabilizer bracket No.1 x Suspension crossmember (w/o HID)1919414
Stabilizer bracket No.1 x Suspension crossmember (w/ HID) Bolt A: Bolt B:5.41955
19448
14
Stabilizer bar link set nut7475555
Lower suspension arm x Lower ball joint8990866
Lower ball joint x Steering knuckle1031,05076
Lower suspension arm x Suspension crossmember1371,400101
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Page 198 of 2234
±
SERVICE SPECIFICATIONS FUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ftlbf
kgf cm
N m
Injection pipe clamp No. 2 x Intake manifold5.05144 in. lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in. lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.lbf
Engine cover No. 1 x Intake manifold8.08271 in.lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in. lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedNmkgf cmft lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in. lbf
Fuel tank protector No. 1 x Body5.45548 in.lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.lbf
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Page 205 of 2234
031FR±02
03±12
±
SERVICE SPECIFICATIONS INTAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1CD±FTV:
Part TightenedN mkgf cmft lbf
Turbo water pipe sub±assy No.1 x Turbocharger sub±assy131359.7
Turbocharger sub±assy x Exhaust manifold5354039
Turbo oil outlet pipe x Turbocharger sub±assy131359.7
Manifold converter sub±assy x Turbocharger sub±assy 1st
2nd8.0
2582
25571 in. lbf
18
Manifold stay x Manifold converter sub±assy 1st
2nd8.0
6182
62271 in. lbf
45
Manifold stay x Cylinder block sub±assy 1st
2nd8.0
6182
62271 in. lbf
45
Turbohcharger stay x Turbocharger sub±assy 1st
2nd8.0
5682
57171 in. lbf
41
Turbocharger stay x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in. lbf
41
Manifold stay No. 2 x Manifold converter sub±assy 1st
2nd8.0
5682
57171 in. lbf
41
Manifold stay No. 2 x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in. lbf
41
Exhaust manifold heat insulator No. 2 x Turbocharger sub±assy121228.9
Turbo insulator No. 1 x Manifold converter sub±assy2020415
Turbo insulator No. 1 x Turbocharger sub±assy2020415
Turbo insulator No. 2 x Manifold converter sub±assy2020415
Exhaust pipe assy x Heater bracket sub±assy w/ Cold area7.57666 in.lbf
Exhaust pipe assy x Body w/ Cold area7.57666 in.lbf
Heater bracket x Body w/ Cold area7.57666 in.lbf
Heater pump assy x Heater bracket w/ Cold area7.57666 in.lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Air cleaner case x Body7.07162 in.lbf
Intercooler assy x Body7.07162 in.lbf
Intercooler cooling air duct x Intercooler assy5.05144 in.lbf
Air cleaner case x Engine mounting insulator LH7.07162 in.lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.lbf
Engine cover No. 1 x Intake manifold8.08271 in.lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38573 in.lbf
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Page 208 of 2234
031H6±01
03±28
±
SERVICE SPECIFICATIONS LUBRICATION
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN mkgf cmft lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan3737727
Oil pump x Cylinder block9.09280 in. lbf
1AZ±FE:
Part TightenedNmkgf cmft lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in. lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.lbf
Oil pan sub±assy x Cylinder block9.09280 in.lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body w/o Air conditioning
RHD (w/ Air conditioning) steering position type9.0
9.092
9280 in. lbf
80 in. lbf
Cooler bracket RH x Body LHD (w/ Air conditioning) steering position type9.09280 in.lbf
Engine x wire7.07162 in.lbf
Oil reservoir bracket No. 1 x Body8.08271 in.lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD (w/ Air conditioning) steering position type9.09280 in.lbf
Return tube x Body8.08271 in.lbf
Ignition coil assy x Cylinder head cover9.09280 in.lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.lbf
Front wheel RH1031,05076
1AZ±FSE:
Part TightenedNmkgf cmft lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in. lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.lbf
Oil pan sub±assy x Cylinder block9.09280 in.lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body RHD steering position type9.09280 in.lbf
Cooler bracket RH x Body LHD steering position type9.09280 in.lbf
Engine x wire7.07162 in.lbf
Oil reservoir bracket No. 1 x Body8.08271 in.lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD steering position type9.09280 in.lbf
Return tube x Body8.08271 in.lbf
Ignition coil assy x Cylinder head cover9.09280 in.lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.lbf
Front wheel RH1031,05076
1CD±FTV:
Part TightenedNmkgf cmft lbf
Oil drain plug x Oil pan sub±assy No. 23435025
Oil pump x Cylinder block3132023
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Page 209 of 2234
±
SERVICE SPECIFICATIONS LUBRICATION
03±29
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ftlbf
kgf cm
N m
Crankshaft position sensor x Oil pump assy8.89078 in. lbf
Oil pan sub±assy x Cylinder block Bolt A
Bolt B
Bolt C
Bolt D42
21 11
12428
214 11 2
12231
15 8
9
Oil pan insulator x Oil pan sub±assy7.57666 in. lbf
Oil strainer sub±assy x Oil pan sub±assy Bolt
Nut21
13209
13515
10
Oil pan Sub±assy No.2 x Oil pan sub±assy1211 99
Engine oil level sensor x Oil pan sub±assy No.27.07162 in. lbf
Oil level gage guide x Cylinder block1818413
V±ribbed belt tensioner assy x Oil pump assy3132023
Timing belt idler sub±assy No. 1 x Cylinder head3535726
Timing belt idler sub±assy No. 2 x Oil pump assy4747935
Engine mounting insulator sub±assy RH x Transverse engine engine mount-
ing bracket5253038
Engine mounting insulator sub±assy RH x Body5253038
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.lbf
Engine cover No. 1 x Intake manifold8.08271 in.lbf
Front wheel RH1031,05076
Oil cooler assy x Cylinder block4545433
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Page 211 of 2234
030ND±02
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
03±53
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
Floor shift transmission control cable assy x Body5.05144 in. lbf
Front floor heat insulator No.1 x Body5.55649 in.lbf
FLOOR SHIFT SHIFT LEVER ASSY
Floor shift shift lever assy x Body121229
MANUAL TRANSAXLE ASSY (1ZZ±FE/ 3ZZ±FE)
Filler and drain plugs3940029
Engine hanger set bolt3838728
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
47
23650
480
23047
35
17
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Starter assy x Manual transaxle assy3738027
Starter wire set nut131309
Clutch release cylinder assy x TransaxleBolt A:
Bolt B:
Bolt C:25
14
5.0250
141 2119
10
44 in. lbf
Manual transaxle assy x Wire harness clmap Bolt A:
Bolt B:26
19260
19519
14
Manual transaxle assy x Ground cable Bolt A:
Bolt B:26
40260
41019
30
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in. lbf
31 in. lbf
Air cleaner assy x Body5.05144 in.lbf
Cylinder head cover No.2 x Engine7.07162 in.lbf
Hood set bolt1313310
MANUAL TRANSAXLE ASSY (1AZ±FE/ 1AZ±FSE)
Filler and drain plugs4950036
Engine hanger x Engine3838728
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Manual transaxle assy x Ground cableBolt A:
Bolt C:26
40260
41019
30
Manual transaxle assy x Wire harness clamp8.48574 in. lbf
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:9.0
1292
12080 in. lbf
9
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Page 212 of 2234
03±54
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in. lbf
31 in. lbf
Air cleaner assy x Body5.05144 in.lbf
Engine cover sub±assy No.1 x Engine9.09280 in.lbf
Hood set bolt1313210
MANUAL TRANSAXLE ASSY (1CD±FTV)
Filler and drain plugs4950036
Engine hanger x Engine3737727
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:
Bolt D:
Bolt E:64
46
40
20
8.0653
469
408
200 8247
34
30
14
71 in. lbf
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Accumulator to flexible hose tube x TransaxleBolt A:
Bolt B:
Bolt C:12
5.0
9.0120 51
929
44 in. lbf
80 in. lbf
Manual transaxle assy x Ground cable131319
Air tube No.2 x Transaxle2525518
Starter assy x Transaxle3738027
Starter wire set nut131309
Radiator reserve tank assy x Body6.06153 in.lbf
Air tube No.1 x Engine2525518
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in. lbf
31 in. lbf
Air cleaner assy x Body7.07162 in.lbf
Engine cover No.1 x Engine8.08271 in.lbf
Hood set bolt1313310
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Page 214 of 2234
031FW±01
03±44
±
SERVICE SPECIFICATIONS PARKING BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN mkgf cmft lbf
Wheel nut1031,05076
Parking brake lock nut5.05144 in. lbf
Parking brake lever sub±assy x Body131279
Front floor heat insulator No.2 x Body5.55649 in.lbf
Front floor heat insulator No.1 x Body5.55649 in.lbf
Exhaust pipe installation bolt4344032
Front floor panel brace x Body3030221
Fuel tank protector No.1 x Body5.55649 in.lbf
Parking brake cable assy No.3 x Fram5.05144 in.lbf
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