2002 TOYOTA AVENSIS engine coolant

±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
03±5
AVENSIS REPAIR MANUAL (RM1018E)
1CD±FTV:
Mass air flow meter
Resistance2 (THA) ± 1 (E2)
at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
12.5 to 16.9 k 
2.19 to 2.67 k 
0.50 to 0.68 k 
Intake shutter assy
Resistanceat 20
C (68
F)
2 ± 1, 3
5 ± 4, 6
18 to 22 
18 to 22 
Accelerator pedal assy (See page 10±56)
Resistance VPA1 ± EP1
VPA2 ± EP2
VCP1 ± EP1
VCP2 ± EP2
5.0 k or less
5.0 k or less
1.5 to 6.0 k 
1.5 to 6.0 k 
Diesel turbo inlet air temperature sensor
Resistance Approx. 20
C (68
F)
2.21 to 2.65 k 
Crankshaft position sensor
Resistance at cold
at hot
1630 to 2740 
2065 to 3225 
Camshaft position sensor
Resistance at cold
at hot
1630 to 2740 
2065 to 3225 
Diesel engine engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k 
0.310 to 0.326 k 
Injection or supply pump assy
Resistance THF ± E2
Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.21 to 2.69 k 
0.287 to 0.349 k 

031H2±01
± SERVICE SPECIFICATIONSENGINE MECHANICAL
03±15
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Camshaft bearing cap No. 3 x Cylinder head sub±assy1313310
Camshaft bearing cap No. 1 x Cylinder head sub±assy2323517
Camshaft timing gear or sprocket x Camshaft No. 25455140
Chain tensioner assy No. 1 x Timing chain or belt cover sub±assy9.09280 in.
lbf
V±ribbed belt tensioner assy x Cylinder block sub±assy6970451
V±ribbed belt tensioner assy x Cylinder head sub±assy2929621
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting bracket5253038
Cylinder head cover sub±assy x Cylinder head sub±assy A
B11
9.011 2
928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Ignition coil assy x Cylinder head cover sub±assy9.09280 in.
lbf
Engine wire x Cylinder head cover sub±assy9.09280 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Engine hanger x Cylinder head sub±assy3838728
Radio setting condenser x Cylinder head sub±assy101027
Engine coolant temperature sensor x Cylinder head sub±assy2020415
Exhaust manifold x Cylinder head sub±assy3737727
Exhaust manifold heat insulator No. 1 x Exhaust manifold Bolt
Nut18
12184
12213
9
Manifold stay No. 2 x Exhaust manifold4950036
Manifold stay No. 2 x Cylinder block sub±assy4950036
Manifold stay x Exhaust manifold A4950036
Manifold stay x Cylinder block sub±assy B3737727
Transverse engine engine mounting bracket x Timing chain or belt cover
sub±assy4747935
V±ribbed idler assy No.1 x Cylinder block sub±assy39.240029
Knock sensor x Cylinder block sub±assy2020415
Crankshaft position sensor x Timing chain or belt cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Water inlet x Cylinder block sub±assy1111 28
Water by±pass pipe No. 1 x Cylinder block sub±assy9.09280 in.
lbf
Water by±pass pipe No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Oil level gage guide x Water by±pass pipe No. 11313310
Intake manifold x Cylinder head sub±assy3030622
Flywheel sub±assy x Crankshaft 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Drive plate & ring gear sub±assy x Crankshaft8889765
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front5253038
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Transverse engine engine mounting bracket LH x Transverse engine engine
mounting insulator LH8081659
Transverse engine engine mounting bracket RH x Transverse engine engine
mounting insulator RH5253038
Front suspension crossmember sub±assy x Body A
B45
133459
1,35633
98
Front suspension member brace x Body Bolt A
Bolt B133
801,356
81698
59

03±16
± SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Floor panel brace front x Body3030622
Battery carrier x Body12.81319
Battery x Body5.05144 in.
lbf
Air cleaner case x Body5.05144 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket LH5.05144 in.
lbf
Radiator support upper x Body1919414
Front wheel RH & LH x Front axle hub sub±assy RH & LH1031,05076
Camshaft timing gear assy x Camshaft5455140
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
Crankshaft pulley x Crankshaft1381,407102
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
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
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Intake manifold x Cylinder head3030622
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133
801,356
81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356
81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038

±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B
52
113530
1,15238
83
Clutch release cylinder x manual transaxleBolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body
w/o Air conditioning
RHD (w/ Air conditioning) steering position type
9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket x BodyLHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder blockw/ Air conditioning2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±139)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815

±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±19
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±222)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Idle pulley set nut3839028
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head sub±assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020415
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6 and Nut
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5960043
Compressor mounting bracket x Cylinder block4242831
Injection pump x Water pump2121415
Oil level gage guide x Cylinder block1818413
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf
Intake manifold x Cylinder head2121415
Wiring harness clamp bracket x Intake manifold3.9 to 6.940 to 7035 to 61 in.
lbf
Power steering idle pulley bracket x Cylinder head Bolt A
Bolt B72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf

190JE±02
A82619
Light Lightning Time
Water Temperature ±20 0 28 0
±4 32 (
F) (
C)
82.4 (sec.)
10
3
1
A72562
Pre±heating Time (sec)Battery Voltage [V]
A80155
After Glow Time
Water Temperature68 104 (
F) 020 40(
C) (sec.)
1 19±30
± STARTING & CHARGINGPRE±HEATING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
PRE±HEATING SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
NOTICE:
Turn the ignition switch OFF for 60 seconds before performing the following inspections.
1. INSPECT LIGHTING DURATION OF GLOW INDICA-
TOR LIGHT
(a) Turn the ignition switch ON, and measure the lighting
duration.
Light lighting duration: Refer to the chart graph
2. INSPECT PRE±HEATING
(a) Turn the ignition switch ON, measure how long it takes to
the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
(b) Turn the ignition switch STA, check that the battery volt-
age applied to the glow plugs.
SST 09082±00030, 09083±00150
(c) While cranking the engine, measure how long it takes to
the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
3. INSPECT AFTER GLOW TIME
(a) After the engine starting, measure how long it takes to the
battery voltage is applied to the terminal SREL of the
ECM.
After glow time: Refer to the chart graph

190O0±01
19±24
±
STARTING & CHARGING STARTER ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
STARTER ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
4.REMOVE AIR CLEANER ASSY (See page 14±286)
5.REMOVE BATTERY
6.REMOVE STARTER ASSY
(a)Remove the nut and disconnect terminal 30.
(b)Disconnect the starter connector.
(c)Remove the 2 bolts and the starter.
7.INSTALL STARTER ASSY Torque:
37 N
m (377 kgf
cm, 27 ft
lbf) for bolt
9.8 N
m (100 kgf
cm, 7.2 ft
lbf) for terminal 30
8.INSTALL AIR CLEANER ASSY (See page 14±286)
9.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
10.ADD ENGINE COOLANT(See page 16±44)
11.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)