2003 TOYOTA AVENSIS Insulator

141CB±01
A61184
A79179
14±342
±
ENGINE MECHANICALCRANKSHAFT SEAL(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT SEAL(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 34 N
m (350 kgf
cm,25 ft
lbf)
2.REMOVE FRONT WHEEL RH
3.REMOVE 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 INJECTOR DRIVER (See page 14±286)
8.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
9.REMOVE GENERATOR V BELT (See page 14±269)
10.REMOVE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11.REMOVE ENGINE MOUNTIN G INSULATOR
SUB±ASSY RH
(a)Place a wooden block on a jack underneath the engine.
(b)Remove the 3 bolts and 3 nuts, and then detach the en- gine mounting insulator sub assy.
12.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)
13.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
14.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
15.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
16. REMOVE TIMING BELT GUIDE
17.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
18.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
19.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
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14±344
±
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
29.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
30.INSTALL TIMING BELT GUIDE(See page 14±307)
31.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
32.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
33.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
34.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
35.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
36.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
37. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
38.INSTALL INJECTOR DRIVER (See page 14±286)
39. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
40. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
41. ADD ENGINE OIL
42. CHECK FOR ENGINE OIL LEAKS
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A77319
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
Cooler Bracket
(LHD (w/ Air Conditioner)
Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant
Suction Hose No. 1
(LHD (w/ Air Conditioner)
Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator Assy
Exhaust Pipe Assy Front
43 (440, 32)
43 (440, 32)
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
52 (530, 38)
Vane Pump Assy

Gasket
8.0 (82, 44 in.
lbf)
37 (377, 27)
14±154
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A77326
Intake Manifold
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
30 (306, 22)

Gasket
30 (306, 22)
Intake Manifold Insulator No. 1
12 (122, 9.0)
Unleaded type:
Manifold Converter
Insulator No. 1

Gasket
Unleaded Gasoline type:
Exhaust Manifold Converter Sub±assy Exhaust Manifold
Stay No. 2
44 (449, 32)
Leaded Gasoline type:
Manifold Converter
Insulator No. 1
Exhaust Manifold
Converter Sub±assy
12 (122, 9.0)
12 (122, 9.0)
44 (449, 32)
37 (378, 27)
44 (449, 32)
44 (449, 32)
Exhaust Manifold Stay


Gasket
14±158
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A77302
14±162
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
22.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the engine service cover bracket RH.
23.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
24.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
25.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
26.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)
27.REMOVE CRANKSHAFT PULLEY (See page 14±139)
SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
28.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
29.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17)
30.REMOVE OIL PAN SUB±ASSY (See page 14±139) SST09032±00100
31.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
32.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
33.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
34.REMOVE CHAIN TENSIONER SLIPPER
35.REMOVE CHAIN VIBRATION DAMPER NO.1
36.REMOVE TIMING CHAIN GUIDE (See page 14±139)
37.REMOVE CHAIN SUB±ASSY
38.REMOVE BATTERY 39.REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a)Disconnect the 2 connectors.
(b)Disconnect the air cleaner hose from the throttle body.
(c)Raise a clamp up, and slide it toward the air cleaner cap,then remove the air cleaner cap from its case.
(d)Remove the air cleaner element.
(e)Remove the 4 bolts and the air cleaner case.
40.DISCONNECT RADIATOR HOSE INLET
41.DISCONNECT UNION TO CONNECTOR TUBE HOSE
42.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
43.SEPARATE FUEL TUBE SUB±ASSY (See page 11±26)
44. SEPARATE ENGINE WIRE
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A56446
A52499
A52497
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
14±163
AVENSIS REPAIR MANUAL (RM1018E)
45.REMOVE THROTTLE BODY ASSY (See page 10±26)
46.REMOVE INTAKE MANIFOLD
(a)Remove the 5 bolts and 2 nuts, then remove the intakemanifold and gasket.
47.REMOVE INTAKE MANIFOLD INSULATOR NO.1
48.REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a)Disconnect the oxygen sensor connector.
(b)Remove the 2 bolts and nut, and then remove the manifold heat insulator. 49.REMOVE EXHAUST MANIFOLD CONVERTERSUB±ASSY
(a)Remove the 2 bolts and 2 nuts, then detach the No. 1 and No. 2 exhaust manifold stay.
(b)Disconnect the 3 oxygen sensor connectors.
(c)Remove the 5 nuts, the exhaust manifold and gasket.
50.REMOVE NO.2 CAMSHAFT (See page 14±171)
51.REMOVE CAMSHAFT (See page 14±171)
52. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Remove the bolt and the oil control valve.
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A77332
23
145
A52499
A56446
14±166
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
60.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm,79 in.
lbf)
61.INSTALL CAMSHAFT (See page 14±171)
62.INSTALL NO.2 CAMSHAFT (See page 14±171)
63.INSTALL EXHAUST MANIFOLD CONVERTERSUB±ASSY
(a)Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(b)Install the No. 1 and No. 2 exhaust manifold stay with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
64.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
65.INSTALL INTAKE MANIFOLD
(a)Install a new gasket and the intake manifold with the 5bolts and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
66.INSTALL THROTTLE BODY ASSY (See page 10±26)
67.INSTALL FUEL TUBE SUB±ASSY (See page 11±19)
68. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
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±
ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
14±167
AVENSIS REPAIR MANUAL (RM1018E)
69.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
70.INSTALL CHAIN SUB±ASSY (See page 14±139)
71.INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
72.INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N
m (195 kgf
cm,15 ft
lbf)
73.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±171)
74.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
75.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
76.INSTALL OIL PAN SUB±ASSY (See page 14±139)
77.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
78.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST09213±54015 (91651±60855), 09330±00021
79.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
80.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm,38 ft
lbf)
81.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
82.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
83.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
84.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
85.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
86.INSTALL ENGINE WIRE
87.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
88.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
89.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
90.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
91.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
92.INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
93.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
94.INSTALL GENERATOR ASSY (See page 19±20)
95.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
96.ADD COOLANT (See page 16±19)
97. ADD ENGINE OIL
98.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
99. CHECK FOR ENGINE OIL LEAKS
100. CHECK FOR FUEL LEAKS
101. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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