2003 TOYOTA AVENSIS Service Repair Manual

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Page 177 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 031DY±01
03±4
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE CONTROL SYSTEM
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Power steering oil pressure switch
Voltage EMPS ±

Page 178 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual ±
SERVICE SPECIFICATIONSENGINE CONTROL SYSTEM
03±5
AVENSIS REPAIR MANUAL (RM1018E)
1CD±FTV:
Mass air flow meter
Resistance2 (THA) ± 1 (E2)
at ±20C (±4F)
at 20C (68F)
at 60C (140F)
12.5 t

Page 179 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 031DZ±02
03±6
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN mkgf cmft lbf
Throttle position sensor x Thro

031DZ±02
03±6
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN mkgf cmft lbf
Throttle position sensor x Throttle body assy2.02018 in. lbf
ISC valve x Throttle body assy3.73833 in.lbf
Accelerator control cable bracket x Throttle body assy1313310
Throttle body assy x Intake manifold3030622
Throttle body bracket x Cylinder block sub±assy (1ZZ±FE)3030622
Manifold stay No. 2 x Throttle body assy (M/T)1313310
Accelerator control cable assy x Accelerator control cable bracket131299
Air cleaner hose No. 1 x Throttle body assy1.51513 in.lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.lbf
Knock sensor x Cylinder block sub±assy2020415
1AZ±FE:
Part TightenedNmkgf cmft lbf
Throttle body assy x Intake manifold3030622
Accelerator control cable assy x Throttle body assy131299
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in. lbf
Knock sensor x Cylinder block sub±assy2020415
Intake manifold x Cylinder head sub±assy3030622
Variable resister x Body (Leaded gasoline (Steering position LHD))5.05144 in.lbf
1AZ±FSE:
Part TightenedNmkgf cmft lbf
Throttle body assy x Intake manifold9.09280 in. lbf
Throttle body bracket x Throttle body assy2121015
Throttle body bracket x Cylinder head sub±assy2121015
Ground terminal x Throttle body bracket8.48674 in.lbf
Wire harness protector x Throttle body bracket8.48674 in.lbf
Air cleaner hose No. 1 x Throttle body assy1.51513 in.lbf
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.lbf
Accelerator pedal x Body5.45548 in.lbf
Knock control sensor x Cylinder block2020415
Engine cover bracket x Cylinder head3838828
1CD±FTV:
Part TightenedNmkgf cmft lbf
Intake shutter assy x Intake air connector2121415
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in. lbf
Engine cover No. 1 x Intake manifold8.08271 in.lbf
Air tube No. 2 x Transmission2525518
Air tube No. 1 x Air tube No. 22525518
Camshaft position sensor x Camshaft oil seal retainer8.89079 in.lbf
Return tube sub±assy x Engine hanger No. 19.09280 in.lbf
Crankshaft position sensor x Oil pump assy8.89079 in.lbf
ECM x Body5.55649 in.lbf
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Page 180 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 031GG±01
±
SERVICE SPECIFICATIONS ENGINE HOOD/DOOR
03±73
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE HOOD/DOOR
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
HOOD
Hood hinge x Hood1313310
Hood h

031GG±01
±
SERVICE SPECIFICATIONS ENGINE HOOD/DOOR
03±73
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE HOOD/DOOR
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
HOOD
Hood hinge x Hood1313310
Hood hinge x Body5.55649 in. lbf
Hood lock x Hood8.08271 in.lbf
FRONT DOOR
Door check x Body3030622
Door check x Door panel5.55646 in.lbf
Door frame sub±assy rear lower x Door panel8.08271 in.lbf
Door glass x Front door window regulator5.55649 in.lbf
Door hinge x Body2626519
Door hinge x Door panel2626519
Door lock x Door panel5.05144 in.lbf
Door lock striker x Body2323517
Door outside handle cover x Door panel7.07162 in.lbf
Door outside handle frame x Door panel4.04135 in.lbf
Outer view mirror x Door panel101027
Window regulator x Door panel8.08271 in.lbf
REAR DOOR
Door check x Body3030622
Door check x Door panel5.55649 in.lbf
Door hinge x Body2626519
Door hinge x Door panel2626519
Door lock x Door panel5.05144 in.lbf
Door lock striker x Body2323517
Door outside handle cover x Door panel4.04135 in.lbf
Door outside handle frame x Door panel7.07162 in.lbf
Window division bar sub±assy x Door panel5.55649 in.lbf
LAGGAGE COMPERTMENT DOOR
Back door striker assy x Body11.51208.0
Luggage compertment door x Hinge7.07062 in.lbf
Luggage lock assy x Luggage compertment door5.05144 in.lbf
Luggage compertment outside garnish x Luggage compertment door4.94943 in.lbf
BACK DOOR (LIFTBACK MODEL)
Back door femaie stopper x Door panel5.55649 in.lbf
Back door hinge assy x Body19.520014
Back door hinge assy x Door panel19.520014
Back door lock assy x Door panel8.08271 in.lbf
Back door lock Striker x Body11.51208.0
Back door stay sub±assy x Body7.07162 in.lbf
Back door stay sub±assy x Door panel2222416
Center stop lamp assy x Door panel5.55649 in.lbf
BACK DOOR (WAGON MODEL)
Back door femaie stopper x Door panel5.55649 in.lbf
Back door hinge assy x Body19.520014
Back door hinge assy x Door panel19.520014
Back door lock assy x Door panel8.08271 in.lbf
Back door lock Striker x Body11.51208.0
Back door stay sub±assy x Body7.07162 in.lbf
http://vnx.su

Page 181 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 03±74
±
SERVICE SPECIFICATIONS ENGINE HOOD/DOOR
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Back door stay sub±assy x Door panel2222416
Center stop lamp assy x Door panel5.

Page 182 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 031H1±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±13
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE MECHANICAL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Ignition timingw/ Terminal TC and CG of DLC3 connected
W/

031H1±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±13
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE MECHANICAL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Ignition timingw/ Terminal TC and CG of DLC3 connected
W/ Terminal TC and CG of DLC3 disconnected8 to 12 BTDC
10 to 18 BTDC (1ZZ±FE)
3.5 to 11.5 BTDC (3ZZ±FE)
Idle speed600 to 700 rpm
Compression
Compression pressure
Minimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf cm2, 189 psi)
1,000 kPa (10.2 kgf cm2, 145 psi)
100 kPa (1.0 kgf cm2, 14 psi)
Cylinder head set bolt Length Standard
Maximum146.8 to 148.2 mm (5.780 to 5.835 in.)
148.5 mm (5.846 in.)
Valve clearance (Cold)
No. 1 Cylinder TDC/Compression Intake Exhaust
No. 4 Cylinder TDC/Compression Intake Exhaust
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
1AZ±FE:
Battery specific gravityat 20C (68 F)1.25 to 1.29
Ignition timing w/ Terminals TC and CG of DLC3 connected
w/ Terminals TC and CG of DLC3 disconnected8 to 12 BTDC
5 to 15 BTDC
Idle speed650 to 750 rpm
Compression
Compression pressureMinimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf/cm2, 189 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 14 psi)
Cylinder head set bolt
Bolt length Standard Maximum
161.3 to 162.3 mm (6.350 to 6.390 in.)
164.2 mm (6.465 in.)
Valve clearance
Intake (Cold)
Exhaust
0.19 to 0.29 mm (0.0075 to 0.0114 in.)
0.30 to 0.40 mm (0.0118 to 0.0157 in.)
1AZ±FSE:
Battery specific gravityat 20C (68 F)1.25 to 1.29
Ignition timing w/ Terminals TC and CG of DLC3 connected
w/ Terminals TC and CG of DLC3 disconnected8 to 12 BTDC
5 to 23 BTDC
Idle speed625 to 725 rpm
Compression
Compression pressureMinimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf/cm2, 189 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 14 psi)
Cylinder head set bolt
Bolt length Standard Maximum
161.3 to 162.3 mm (6.350 to 6.390 in.)
164.2 mm (6.465 in.)
Valve clearance
Intake (Cold)
Exhaust
0.19 to 0.29 mm (0.0075 to 0.0114 in.)
0.30 to 0.40 mm (0.0118 to 0.0157 in.)
http://vnx.su

Page 183 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 03±14
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
1CD±FTV:
New drive belt deflection Pressing force: 98 N (10 kgf, 22 lbf)
For vane pump V belt (A/C equipped)
For v

03±14
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
1CD±FTV:
New drive belt deflection Pressing force: 98 N (10 kgf, 22 lbf)
For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
Used drive belt deflection Pressing force: 98 N (10 kgf, 22 lbf)
For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
9.5 to 11.5 mm (0.37 to 0.45 in.)
10 to 12 mm (0.39 to 0.47 in.)
12.5 to 15.5 mm (0.49 to 0.61 in.)
14 to 17 mm (0.55 to 0.67 in.)
New drive belt tension For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
Used drive belt tension For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
519 to 755 N (53 to 77 kgf, 117 to 170 lbf)
686 to 784 N (70 to 80 kgf, 154 to 176 lbf)
196 to 392 N (20 to 40 kgf, 44 to 88 lbf)
294 to 441 N (30 to 45 kgf, 66 to 99 lbf)
Idle speed750 to 850 rpm.
Maximum speed5,100 to 5,250 rpm.
Compression pressure at 250 rpm.
Minimum
Difference between each cylinder
2,628 kPa (26.8 kgf/cm2, 381 psi) or more
2,157 kPa (22.0 kgf/cm2, 312 psi) or more
490 kPa (5.0 kgf/cm2, 71 psi) or less
Cylinder head set bolt
Outside diameter Standard Minimum
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
10.40 mm (0.4904 in.)
Valve clearance
Intake (cold)
Exhaust
Adjusting shim thickness Mark 2.500
Mark 2.550
Mark 2.600
Mark 2.650
Mark 2.700
Mark 2.750
Mark 2.800
Mark 2.850
Mark 2.900
Mark 2.950
Mark 3.000
Mark 3.050
Mark 3.100
Mark 3.150
Mark 3.200
Mark 3.250
Mark 3.300
0.20 to 0.30 mm (0.008 to 0.012 in.)
0.35 to 0.45 mm (0.014 to 0.018 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Cylinder head set bolt
Outside diameter Standard Minimum
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
10.40 mm (0.4904 in.)
http://vnx.su

Page 184 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 031H2±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±15
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedNmkgf cmft lbf
Camshaft bearing cap No. 3 x Cylind

031H2±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±15
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedNmkgf cmft lbf
Camshaft bearing cap No. 3 x Cylinder head sub±assy1313310
Camshaft bearing cap No. 1 x Cylinder head sub±assy2323517
Camshaft timing gear or sprocket x Camshaft No. 25455140
Chain tensioner assy No. 1 x Timing chain or belt cover sub±assy9.09280 in. lbf
V±ribbed belt tensioner assy x Cylinder block sub±assy6970451
V±ribbed belt tensioner assy x Cylinder head sub±assy2929621
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting bracket5253038
Cylinder head cover sub±assy x Cylinder head sub±assy A
B11
9.011 2 928
80 in. lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Ignition coil assy x Cylinder head cover sub±assy9.09280 in.lbf
Engine wire x Cylinder head cover sub±assy9.09280 in.lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.lbf
Engine hanger x Cylinder head sub±assy3838728
Radio setting condenser x Cylinder head sub±assy101027
Engine coolant temperature sensor x Cylinder head sub±assy2020415
Exhaust manifold x Cylinder head sub±assy3737727
Exhaust manifold heat insulator No. 1 x Exhaust manifold Bolt
Nut18
12184
12213 9
Manifold stay No. 2 x Exhaust manifold4950036
Manifold stay No. 2 x Cylinder block sub±assy4950036
Manifold stay x Exhaust manifold A4950036
Manifold stay x Cylinder block sub±assyB3737727
Transverse engine engine mounting bracket x Timing chain or belt cover
sub±assy4747935
V±ribbed idler assy No.1 x Cylinder block sub±assy39.240029
Knock sensor x Cylinder block sub±assy2020415
Crankshaft position sensor x Timing chain or belt cover9.09280 in.lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.lbf
Water inlet x Cylinder block sub±assy1111 28
Water by±pass pipe No. 1 x Cylinder block sub±assy9.09280 in.lbf
Water by±pass pipe No. 1 x Cylinder head sub±assy9.09280 in.lbf
Oil level gage guide x Water by±pass pipe No. 11313310
Intake manifold x Cylinder head sub±assy3030622
Flywheel sub±assy x Crankshaft 1st
2nd49
Turn 90500
Turn 9036
Turn 90
Drive plate & ring gear sub±assy x Crankshaft8889765
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front5253038
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Transverse engine engine mounting bracket LH x Transverse engine engine
mounting insulator LH8081659
Transverse engine engine mounting bracket RH x Transverse engine engine
mounting insulator RH5253038
Front suspension crossmember sub±assy x Body A
B45
133459
1,35633
98
Front suspension member brace x Body Bolt A
Bolt B133 801,356 81698
59
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