2003 TOYOTA AVENSIS check engine light

A62813
Front Mark
A62797
Front
A01163
A62798
Paint Mark
90

Front
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±53
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
37. INSTALL CONNECTING ROD SUB±ASSY
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num- bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
(d) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.
NOTICE:

Clean the backside and the surface of the connecting
rod cap bearing and let not stick the oils and fats.

Match the numbered connecting rod cap with the
same numbered connecting rod.
(e) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(f) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(g) Using SST, tighten the bolts in several passes by the spe- cified torque.
SST 09205±16010
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(h) Mark the front of the connecting cap bolts with paint.
(i) Retighten the cap bolts by 90  as shown in the illustration.
(j) Check that the crankshaft turns smoothly.
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EM2534
A62785
Margin
Thickness
EM2534
A62785
Margin
Thickness
A62786
Width
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±31
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSPECT INTAKE VALVE
(a) Using a vernier calipers, check the valve overall length.
Standard overall length: 88.65 mm (3.4902 in.)
Minimum overall length: 88.35 mm (3.4784 in.)
(b) Using a vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
16. INSPECT EXHAUST VALVE
(a) Using a vernier calipers, check the valve overall length. Standard overall length: 88.69 mm (3.4917 in.)
Minimum overall length: 88.39 mm (3.4799 in.)
(b) Using a vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
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A62821
Seal Width 4 ± 5 mm
6 mm Seal Packing
A62822
SST
A62817SST
14±14
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
42. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing material from the contact sur- face.
(b) Apply seal packing in the shape of bead (Diameter 3.5 mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not put into engine oil within 2 hours after instal-
ling.
(c) Install the oil pan with the 14 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
43. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install it. Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
44. 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 oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crank shaft.
45. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter union. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
46. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501
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A30890
A62826
Lot No.
A62816
84 2 59731610
A62823
Paint Mark
90 
Front
A62815
Mesh
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±15
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
47. INSTALL OIL PUMP ASSY
(a) Engage the spline teeth of the oil pump drive rotor with the
large teeth of the crankshaft, and side the oil pump.
(b) Install the oil pump with the 5 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
48. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE:

Pay attention to the installation direction.

Place the cylinder head quietly in order not to damage
the gasket with the bottom part of the head.
49. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(b) Using a bi±hexagon wrench 10, install and uniformly tight- en the 10 cylinder head bolts with plate washers, in sever-
al passes, in the sequence shown.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90  in the numerical or-
der shown.
(e) Check that the point marked bolts are moved at 90 
angle.
50. INSTALL OIL CONTROL VALVE FILTER
(a) Confirm that the filter is clear.
(b) Install the oil control valve filter to the cylinder head.
(c) Place a new gasket on the bolt, and install it. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
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A62824
Straight Pin
Key Groove
A32167
A62150
14±16
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Install a new O±ring to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
52. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc- tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
(e) Check that the camshaft timing gear assembly can move to the retard angle side (the right angle), and is locked at
the most retarded position.
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and install the camshaft tim- ing gear.
Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
NOTICE:
Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT
(a) Apply light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.
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D01563
D25081
Flat Spring Clamp
Clamp Track
01±6
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(3) Never use any electric equipment like an electric motor or a working light as they may cause spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKEPARTS
(a) If any metal tip is mixed in the inlet pass, that may give a bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts, close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of inserting portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force to the arrow mark direction after the installation.
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170FQ±01
B14352
B14354
New O±RingNew O±Ring
B14355
17±32
±
LUBRICATIONOIL COOLER ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
OIL COOLER ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2.DRAIN ENGINE OIL(See page 17±30)
3.REMOVE ENGINE UNDER COVER LH 4.REMOVE OIL COOLER ASSY
(a)Disconnect the 2 cooler hoses from the oil cooler.
(b)Remove the union bolt and the oil cooler.
(c)Remove the O±ring from the oil cooler.
(d)Remove the O±ring from the union bolt.
5.INSTALL OIL COOLER ASSY
(a)Clean the oil cooler mounting surface.
(b)Install a new O±ring to the union bolt.
(c)Install a new O±ring to the oil cooler.
(d)Apply a light coat of engine oil on the threads of the unionbolt.
(e)Align the tab of the oil cooler with the tab located on the cylinder block.
(f)Install the oil cooler with the union bolt. Torque: 45 N
m (454 kgf
cm, 33 ft
lbf)
(g)Connect the 2 cooler hoses to the oil cooler.
6.ADD ENGINE OIL(See page 17±30)
7.ADD ENGINE COOLANT(See page 16±44)
8.CHECK FOR ENGINE OIL LEAKS(See page 16±44)
9. CHECK FOR ENGINE COOLANT LEAKS
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170FW±01
A56222
A56223
17±12
±
LUBRICATION OIL FILTER SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of nat\
ural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used \
engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or\
sol-
vents.

In order to preserve the environment, used oil and used oil filter must be\
disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil. Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter. SST 09228±06501
4. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn. SST 09228±06501
5. ADD ENGINE OIL
(a) Fill with fresh engine oil. Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. \
qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp.\
qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK
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