2003 TOYOTA AVENSIS Insulator

A79159
A79156
A79157
A79160
13±12
±
INTAKETURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
10.REMOVE HEATER BRACKET (W/ COLD AREA)
(a)Remove the bolt and the heater bracket.
11.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
12.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10) 13. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA)
(a) Remove the 2 nuts.
(b) Remove the 2 nuts and the exhaust pipe sub±assy.
14. REMOVE TURBO INSULATOR NO.2
(a) Remove the 4 bolts and the turbo insulator.
http://vnx.su

A79161
A79162
A79163
A79164
A79444
±
INTAKE TURBOCHARGER SUB±ASSY (1CD±FTV)
13±13
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE TURBO INSULATOR NO.1
(a) Remove the 2 bolts and nut, and then remove the turbo
insulator.
16. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
(a) Remove the 2 bolts and the exhaust manifold heat insula- tor.
17. REMOVE MANIFOLD STAY NO.2
(a) Remove the bolt and nut and then remove the manifold stay.
18. REMOVE MANIFOLD STAY
(a) Remove the 4 bolts and the manifold stay.
19. REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a) Remove the 3 nuts, the manifold converter and the gas-
ket.
http://vnx.su


A80106
A
A
B
B
A79163
13±16
±
INTAKETURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket and the manifold converter, and tem- porarily tighten bolts A and bolts B while pushing the up-
per portion of the converter toward the turbocharger.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c)Tighten the 3 nuts. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(d)Tighten bolts A.
Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
(e)Tighten bolts B. Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
31.INSTALL MANIFOLD STAY NO.2
(a)Install the manifold stay No. 2, and temporarily tighten the bolt.
(b)Temporarily tighten the nut while pushing the manifold stay No. 2 toward the cylinder head.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
HINT:
No clearance between the stay and the cylinder head should be
confirmed.
(c)Tighten the bolt. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d)Tighten the nut. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
32.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)
33.INSTALL TURBO INSULATOR NO.1 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
34.INSTALL TURBO INSULATOR NO.2
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
35.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
36.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
37.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
38. INSTALL HEATER BRACKET (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
39. INSTALL HEATER PUMP ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
40.INSTALL FUEL FILTER ASSY(See page 11±82)
http://vnx.su

A79427N´m (kgf´cm, ft´lbf): Specified torque
52 (530, 38)52 (530, 38)
52 (530, 38)
Injector DriverEngine Mounting Insulator Sub±assy RH
Vacuum Reservoir Sub±assy
Union To Connector Tube Hose
Air Tube No. 1
25 (255, 18)
8.3 (85, 73 in.´lbf)
25 (255, 18)
5.0 (51, 44 in.´lbf)
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±315
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

141C8±01
SSTA61187
14±318
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
9.REMOVE AIR TUBE NO.1 (See page 14±270)
10.REMOVE INJECTOR DRIVER (See page 14±286)
11. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH (See page 14±307)
15.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
16.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
17.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
19. REMOVE TIMING BELT GUIDE
20.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
23.REMOVE TIMING BELT (See page 14±307)
24.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
25. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the timing pulley.
HINT:
Using a plastic±faced hammer, tap out the pulley.
(c) Remove the set key.
http://vnx.su

±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±325
AVENSIS REPAIR MANUAL (RM1018E)
59.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
60.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
61.INSTALL TIMING BELT GUIDE(See page 14±307)
62.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
63.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
64.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
65.INSTALL CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021
66.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
67.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
68. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
69.INSTALL INJECTOR DRIVER (See page 14±286)
70.INSTALL AIR TUBE NO.1 (See page 14±270)
71. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
72.INSTALL AIR CLEANER ASSY (See page 14±286)
73. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
74. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
75.CHECK FOR FUEL LEAKS(See page 11±60)
http://vnx.su

A76710
Fan and Generator V BeltCylinder Head Cover No. 2
Clip
Engine Mounting
Insulator RH
N´m (kgf´cm, ft´lbf) : Specified torque
7.0 (71, 62 in.
lbf)
52 (530, 38)
52 (530, 38)
±
ENGINE MECHANICAL CAMSHAFT (1ZZ±FE/3ZZ±FE)
14±61
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

A64058
A64856
A60622
A01045
A64005
±
ENGINE MECHANICALCAMSHAFT(1ZZ±FE/3ZZ±FE)
14±65
AVENSIS REPAIR MANUAL (RM1018E)
6.DISCONNECT VENTILATION HOSE NO.2
(a)Disconnect the ventilation hose from the cylinder head
cover.
7.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts, and 3 clamp brackets.
(b)Remove the cylinder head cover.
8.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
9. REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
10. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly and loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
11. REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine. Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.
http://vnx.su