2003 TOYOTA AVENSIS Service Repair Manual

air suspension display engine oil bolt pattern fold seats coolant level

Page 185 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 03±16
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Floor panel brace front x Body3030622
Battery carrier x Body12.81319
Battery x B

03±16
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Floor panel brace front x Body3030622
Battery carrier x Body12.81319
Battery x Body5.05144 in. lbf
Air cleaner case x Body5.05144 in.lbf
Air cleaner case x Transverse engine engine mounting bracket LH5.05144 in.lbf
Radiator support upper x Body1919414
Front wheel RH & LH x Front axle hub sub±assy RH & LH1031,05076
Camshaft timing gear assy x Camshaft5455140
Chain tensioner slipper x Cylinder block sub±assy1919414
Timing chain or belt cover sub±assy x Cylinder head sub±assy1313310
Timing chain or belt cover sub±assy x Cylinder block sub±assy M6
M813
19133
19410
14
Crankshaft pulley x Crankshaft1381,407102
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90500
Turn 9036
Turn 90
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in. lbf
Chain vibration damper No. 1 x Cylinder head sub±assy9.09280 in.lbf
Chain vibration damper No. 1 x Cylinder block sub±assy9.09280 in.lbf
1AZ±FE:
Part TightenedNmkgf cmft lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in. lbf
Drive shaft bearing bracket x Cylinder block5455140
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.lbf
Water inlet x Cylinder block9.09280 in.lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Intake manifold x Cylinder head3030622
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133 801,356 81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356 81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
http://vnx.su

Page 186 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual ±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedftlbf
kgfcm
Nm
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B

±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedftlbf
kgfcm
Nm
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B
52
113530
1,15238
83
Clutch release cylinder x manual transaxleBolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.lbf
44 in.lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body w/o Air conditioning
RHD (w/ Air conditioning) steering position type
9.0
9.092
9280 in.lbf
80 in.lbf
Cooler bracket x BodyLHD (w/ Air conditioning) steering position type9.09280 in.lbf
Oil reservoir bracket No. 1 x Body8.08271 in.lbf
Return tube sub±assy x Frame8.08271 in.lbf
Radiator reserve tank x sub±assy x body5.05144 in.lbf
Compressor and magnetic clutch x Cylinder blockw/ Air conditioning2525518
Radiator relay block x Frame5.05144 in.lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.lbf
Air cleaner assy x Body5.05144 in.lbf
Cylinder head x Cylinder block1st
2nd79
Turn 90806
Turn 9058
Turn 90
Camshaft timing control valve assy x Cylinder head9.09280 in.lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.lbf
Timing chain guide x Cylinder block9.09280 in.lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±139)Bolt A Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in. lbf
15
32
80 in. lbf
Oil pan x Stiffening crankcase assy9.09280 in.lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1AZ±FSE:
Part TightenedN mkgf cmft lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
http://vnx.su

Page 187 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 03±18
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder

03±18
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in. lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.lbf
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.lbf
Water inlet x Cylinder block9.09280 in.lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133 801,356 81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356 81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulator A B
52
11 3530
1,15238
83
Clutch release cylinder x manual transaxle Bolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in. lbf
44 in. lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.lbf
Cooler bracket x Body LHD steering position type9.09280 in.lbf
Oil reservoir bracket No. 1 x Body8.08271 in.lbf
Return tube sub±assy x Frame8.08271 in.lbf
Radiator reserve tank x sub±assy x body5.05144 in.lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.lbf
Air cleaner assy x Body5.05144 in.lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90806
Turn 9058
Turn 90
Camshaft timing control valve assy x Cylinder head9.09280 in. lbf
Camshaft timing gear assy x Camshaft5455140
http://vnx.su

Page 188 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual ±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±19
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedftlbf
kgfcm
Nm
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder hea

±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±19
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedftlbf
kgfcm
Nm
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.lbf
Timing chain guide x Cylinder block9.09280 in.lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±222)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in. lbf
15
32
80 in. lbf
Oil pan x Stiffening crankcase assy9.09280 in.lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1CD±FTV:
Part TightenedN mkgf cmft lbf
Idle pulley set nut3839028
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head sub±assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in. lbf
Engine cover No. 1 x Intake manifold8.08271 in.lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020415
Crankshaft position sensor x Oil pump assy8.89078 in.lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6 and Nut
M88.82190
20978 in. lbf
15
Oil cooler pipe x Cylinder block5960043
Compressor mounting bracket x Cylinder block4242831
Injection pump x Water pump2121415
Oil level gage guide x Cylinder block1818413
Timing belt No.3 cover x Cylinder head7.47565 in. lbf
Intake manifold x Cylinder head2121415
Wiring harness clamp bracket x Intake manifold3.9 to 6.940 to 7035 to 61 in. lbf
Power steering idle pulley bracket x Cylinder head Bolt A
Bolt B72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.lbf
http://vnx.su

Page 189 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 03±20
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Injection pipe, Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not

03±20
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Injection pipe, Fuel inlet pipe x Common rail
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
Injection pipe x Injector 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
Injection pipe clamp x Intake manifold5.05144 in. lbf
Fuel inlet pipe x Common rail
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 x injection pump 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
Nozzle leakage pipe No.2 x Cylinder head Check valve
Bolt21
8.8214 9015
78 in. lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2121415
Water inlet x Cylinder block8.89078 in.lbf
Water outlet sub±assy x Cylinder head2121415
Exhaust manifold x Cylinder head4747935
EGR pipe sub±assy x Cylinder head Bolt
Nut37
25375
25027
18
Oil filter bracket x Oil pan sub±assy3434725
V±ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub±assy x V±ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in. lbf
Flywheel x Crankshaft7172052
Engine mounting member sub±assy center x Body4545933
Front suspension crossmember sub±assy x Rear engine mounting bracket8788764
Front suspension crossmember sub±assy x Front engine mounting bracket\
5253038
Front suspension crossmember sub±assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub±assy\
1331,35698
Front suspension member brace x Body8081659
Return tube sub±assy x Body8.08271 in.lbf
Engine mounting insulator RH x Body5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Injector driver x Engine mounting insulator RH5.05144 in.lbf
Engine wire x Body8.48574 in.lbf
Air tube No.2 x Manual transaxle2525518
Relay box x Radiator assy5.35446 in.lbf
Fuel filter assy x Fuel filter support1817813
http://vnx.su

Page 190 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual ±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±21
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ftlbf
kgf cm
N m
Air cleaner assy x Body x Engine mounting bracket LH7.07162 in. lbf
Engine cover

Page 191 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 031E2±02
03±22
±
SERVICE SPECIFICATIONS EXHAUST
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Compression spring
Free length Minimum Front x Manifold Front x Tail
41.5 mm

Page 192 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual 031E3±02
±
SERVICE SPECIFICATIONS EXHAUST
03±23
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedNmkgf cmft lbf
Exhaust pipe assy front x Exhaust manifold434

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