2003 TOYOTA AVENSIS air filter

0214A±01
±
PREPARATION ENGINE MECHANICAL
02±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
ENGINE MECHANICAL
PREPARATION
SST
09011±3812112 mm Socket Wrench for 12
Pointed HeadCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09032±00100Oil Pan Seal CutterPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09201±01055Valve Guide Bushing Remover &
Replacer 5.5CYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09201±10000Valve Guide Bushing Remover &
Replacer SetCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09201±41020Valve Stem Oil Seal ReplacerCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09202±70020Valve Spring CompressorCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
(09202±00010)AttachmentCYLINDER HEAD ASSY
(1ZZ±FE/3ZZ±FE)
09205±16010Cylinder Head Bolt WrenchCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09222±30010Connecting Rod Bushing Remover
& ReplacerCYLINDER BLOCK
(1ZZ±FE/3ZZ±FE)
09223±15030Oil Seal & Bearing ReplacerPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09223±22010Crankshaft Front Oil Seal
ReplacerPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
09228±06501Oil Filter WrenchPARTIAL ENGINE ASSY
(1ZZ±FE/3ZZ±FE)
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0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Cylinder block water drain cock sub±assy x Cylinder block sub±assy\
2020415
Oil strainer sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan drain plug x Oil pan sub±assy3737727
Oil filter union x Cylinder block sub±assy3030622
Oil pump assy x Cylinder block sub±assy9.09280 in.
lbf
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Oil control valve filter x Cylinder head sub±assy3030622
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing gear or sprocket x Camshaft No. 25455140
Camshaft, Camshaft No. 2 x Cylinder head sub±assy Bearing cap No. 1
Bearing cap No. 323
13235
13317
10
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
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
Chain tensioner assy No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft pulley x Crankshaft1381,407102
Water pump assy x Cylinder block sub±assy1111 28
Water pump assy x Timing chain or belt cover sub±assy9.09280 in.
lbf
Cylinder head cover sub±assy x Cylinder head sub±assy w/o washer
w/ washer11
9.011 2 928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Spark plug x Cylinder head sub±assy2525518
Stud bolt
Timing chain or belt cover sub±assy x Cylinder head sub±assy
length 89 mm (3.50 in.)
length 53.5 mm (2.11 in.)
Cylinder head cover sub±assy x Cylinder head sub±assy
Intake manifold x Cylinder head sub±assy
Exhaust manifold x Cylinder head sub±assy
9.5
5.0
5.0
9.5
9.597
51
51
97
9784 in.
lbf
44 in.
lbf
44 in.
lbf
84 in.
lbf
84 in.
lbf
W/ Head taper screw plug No. 2 x Cylinder head sub±assy4444933
Crankshaft bearing cap sub±assy x Cylinder block sub±assy M10 1st
2nd3rd
M822
44
Turn 90
19224
449
Turn 90
19416
33
Turn 90
14
Connecting rod x Connecting rod cap 1st
2nd20
Turn 90
204
Turn 90
15
Turn 90

Stud bolt
Water by±pass pipe No. 1 x Cylinder block sub±assy
Water inlet x Cylinder block sub±assy
Oil strainer sub±assy x Cylinder block sub±assy
Oil pan sub±assy x Cylinder block sub±assy
Knock control sensor x Cylinder block sub±assy
5.0
5.0
5.0
5.0 1151
51
51
51
11 244 in.
lbf
44 in.
lbf
44 in.
lbf
44 in.
lbf
8
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0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Cylinder block water drain cock sub±assy x Cylinder block sub±assy\
2020415
Oil strainer sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan drain plug x Oil pan sub±assy3737727
Oil filter union x Cylinder block sub±assy3030622
Oil pump assy x Cylinder block sub±assy9.09280 in.
lbf
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Oil control valve filter x Cylinder head sub±assy3030622
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing gear or sprocket x Camshaft No. 25455140
Camshaft, Camshaft No. 2 x Cylinder head sub±assy Bearing cap No. 1
Bearing cap No. 323
13235
13317
10
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
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
Chain tensioner assy No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft pulley x Crankshaft1381,407102
Water pump assy x Cylinder block sub±assy1111 28
Water pump assy x Timing chain or belt cover sub±assy9.09280 in.
lbf
Cylinder head cover sub±assy x Cylinder head sub±assy w/o washer
w/ washer11
9.011 2 928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Spark plug x Cylinder head sub±assy2525518
Stud bolt
Timing chain or belt cover sub±assy x Cylinder head sub±assy
length 89 mm (3.50 in.)
length 53.5 mm (2.11 in.)
Cylinder head cover sub±assy x Cylinder head sub±assy
Intake manifold x Cylinder head sub±assy
Exhaust manifold x Cylinder head sub±assy
9.5
5.0
5.0
9.5
9.597
51
51
97
9784 in.
lbf
44 in.
lbf
44 in.
lbf
84 in.
lbf
84 in.
lbf
W/ Head taper screw plug No. 2 x Cylinder head sub±assy4444933
Crankshaft bearing cap sub±assy x Cylinder block sub±assy M10 1st
2nd3rd
M822
44
Turn 90
19224
449
Turn 90
19416
33
Turn 90
14
Connecting rod x Connecting rod cap 1st
2nd20
Turn 90
204
Turn 90
15
Turn 90

Stud bolt
Water by±pass pipe No. 1 x Cylinder block sub±assy
Water inlet x Cylinder block sub±assy
Oil strainer sub±assy x Cylinder block sub±assy
Oil pan sub±assy x Cylinder block sub±assy
Knock control sensor x Cylinder block sub±assy
5.0
5.0
5.0
5.0 1151
51
51
51
11 244 in.
lbf
44 in.
lbf
44 in.
lbf
44 in.
lbf
8
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160ME±01
A79148
SST
16±46
±
COOLINGWATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.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)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)
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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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170FV±01
A56222
A56223
±
LUBRICATION OIL FILTER SUB±ASSY (1AZ±FSE)
17±19
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FSE)
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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170FO±01
A79191
A79192
17±30
±
LUBRICATION OIL FILTER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1CD±FTV)
REPLACEMENT
NOTICE:

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

Precautions should be taken when replacing engine oil to minimize the risk of your \
skin making
contact with used engine 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 no\
t use
gasoline, thinners, or solvents.

In order to preserve the environment, used oil and oil filter must be dispo\
sed of at designated
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug and drain the oil into a container.
2. REMOVE OIL FILTER SUB±ASSY
(a) Remove the clip and open the engine under cover.
(b) Using SST, remove the oil filter.SST 09228±10002
3. 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±10002
4. ADD ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket. Torque: 34 N
m (350 kgf
cm, 25 ft
lbf)
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±
LUBRICATION OIL FILTER SUB±ASSY (1CD±FTV)
17±31
AVENSIS REPAIR MANUAL (RM1018E)
(b) Fill with fresh engine oil.
Capacity:
With the oil filter replacement: 5.9 liters (6.2 US qts, 5.2 lmp. qts)\
Without the oil filter replacement: 5.3 liters (5.6 US qts, 4.7 lmp. qt\
s)
Dry fill: 6.7 liters (7.1 US qts, 5.9 lmp. qts)
(c) Install the oil filler cap.
5. CHECK FOR ENGINE OIL LEAKS
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