2002 TOYOTA AVENSIS engine coolant

141C4±01
A80094
14±286
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEELS
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.DRAIN ENGINE COOLANT (See page 16±44)
8.DRAIN ENGINE OIL (See page 14±342)
9.DRAIN MANUAL TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
11.REMOVE BATTERY
12.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap together with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
13.DISCONNECT UNION TO CONNECTOR TUBE HOSE
14.REMOVE FUEL FILTER ASSY
(a)Disconnect the 2 fuel hose from the fuel filter (STD).
(b)Disconnect the 3 fuel hose from the fuel filter (COLD).
(c)Disconnect the connector (STD).
(d)Disconnect the 2 connectors (COLD).
(e)Remove the 2 bolts and the fuel filter.
15.REMOVE RADIATOR HOSE INLET
16.REMOVE RADIATOR HOSE OUTLET
17.DISCONNECT WATER BY±PASS HOSE NO.2
18.REMOVE ENGINE ROOM RELAY BLOCK NO.3
(a)Remove the 2 bolts and the engine room relay block.
19.REMOVE RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
20. DISCONNECT HEATER INLET WATER HOSE
21. DISCONNECT HEATER OUTLET WATER HOSE
22. DISCONNECT FUEL HOSE NO.2
23. REMOVE AIR TUBE NO.2
(a) Loosen the hose clamp and disconnect the air hose No.3.
(b) Remove the 2 bolts and the air tube No. 2.

A79173New O±Ring
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±295
AVENSIS REPAIR MANUAL (RM1018E)
106.REMOVE CRANKSHAFT POSITION SENSOR
(a)Remove the bolt and the crankshaft position sensor.
107.REMOVE CAMSHAFT POSITION SENSOR
(a)Remove the bolt and the camshaft position sensor.
108.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
109.REPLACE PARTIAL ENGINE ASSY
110.INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Torque: 20 N
m (204 kgf
cm,15 ft
lbf)
111.INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
112.INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
113.INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE Torque:
8.8 N
m (90 kgf
cm,78 ft
lbf) for M6 and Nut
21 N
m (209 kgf
cm,15 ft
lbf) for M8
114.INSTALL OIL COOLER PIPE
(a)Install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 59 N
m (600 kgf
cm,43 ft
lbf)
115.INSTALL THERMOSTAT (See page 16±50)
116.INSTALL WATER INLET (See page 16±50)
117. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
118. INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
119. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O±ring to the oil level gage guide.
(b) Apply engine oil to the O±ring.
(c) Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d) Install the oil level gage guide with the bolt. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
(e) Apply engine oil to the O±ring on the oil level gage.
(f) Install the oil level gage.
120. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
121.INSTALL INJECTION PUMP DRIVE PULLEY (See page 11±69)
SST 09960±10010 (09962±01000, 09963±01000)
122. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts\
. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(b) Install the wiring harness clamp bracket with the 2 bolts.
Torque: 3.9 to 6.9 N
m (40 to 70 kgf
cm, 35 to 61 in.
lbf)

14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)

A76707
Water By±pass Hose No. 2
Radiator Hose Inlet
Heater Inlet Water Hose

Gasket
Exhaust Manifold
Manifold StayExhaust Manifold
Heat Insulator No. 1

Gasket
Engine Coolant
Temperature Sensor

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
20 (204, 15)
9.0 (92, 80 in.
lbf)
37 (377, 27)
18 (184, 13)
49 (500, 36)
Clamp Bracket
10 (102, 7)
Radio Setting Condenser
V±Ribbed Idler Assy No. 1
Tube
18 (184, 13)
12 (122, 9)
Manifold Stay No. 2
49 (500, 36)
37 (377, 27)18 (184, 13)
39.2 (400, 29)
14±26
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A78516
A78459
14±28
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
7.REMOVE ENGINE UNDER COVER RH
(a)Remove the 6 screws and 3 clips, then detach the engine under cover.
8.DRAIN ENGINE COOLANT(See page 16±7)
9. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil. Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
10.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (See page 41±15)
11.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±42)
12. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, then detach cylinder headcover No.2.
13.REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
14. REMOVE AIR CLEANER FILTER ELEMENT SUB±ASSY
15. REMOVE AIR CLEANER CASE SUB±ASSY
(a) Remove the 3 bolts and the air cleaner case.
16. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the radiator.
17. DISCONNECT RADIATOR HOSE OUTLET
(a) Disconnect the radiator hose outlet from the radiator.
18. DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
19. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.

A76722
A76723
A64033
A64034
A64034
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±37
AVENSIS REPAIR MANUAL (RM1018E)
85. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 3 bolts and the nut, and then remove the ex-
haust manifold heat insulator.
86. REMOVE EXHAUST MANIFOLD
(a) Remove the 5 nuts, then remove the exhaust manifold
and the gasket.
87. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the engine coolant temperature sen-
sor.
SST 09817±33190
88. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and the condenser.
89. REMOVE WATER BY±PASS HOSE NO.2
90. REMOVE RADIATOR HOSE INLET
91. REMOVE HEATER INLET WATER HOSE
92. REPLACE PARTIAL ENGINE ASSY
93. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)

A64033
A76723
A76722
A76721
A76720
ABB 14±38
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
94. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Install a new gasket to the engine coolant temperature
sensor.
(b) Using SST, install the engine coolant temperature sensor.
SST 09817±33190
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
95. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
96. INSTALL EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Install the exhaust manifold heat insulator,then install the
3 bolts and nut.
Torque:
18 N
m (184 kgf
cm, 13 ft
lbf) for Bolt
12 N
m (122 kgf
cm, 9 ft
lbf) for Nut
(b) Connect the heated oxygen sensor connector.
97. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay with the 3 bolts.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
98. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque:
49 N
m (500 kgf
cm, 36 ft
lbf) for A
37 N
m (377 kgf
cm, 27 ft
lbf) for B

A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N
m (131 kgf
cm, 9 ft
lbf)
138. INSTALL BATTERY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
145. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL