2002 TOYOTA AVENSIS Repair Manual

± LUBRICATIONOIL FILTER SUB±ASSY (1ZZ±FE/3ZZ±FE)
17±5
AVENSIS REPAIR MANUAL (RM1018E)
4. INSTALL OIL PAN DRAIN PLUG
(a) Clean and install the oil pan drain plug with a new gasket.
Torque: 37 N
m (377 kgf
cm, 27 in.
lbf)
5. ADD ENGINE OIL
Capacity:
With oil filler replacement: 3.7 liters (3.9 US qts, 3.3 lmp. qts)
Without oil filler replacement: 3.5 liters (3.7 US qts, 3.1 lmp. qts)
Dry fill: 4.2 liters (4.4 US qts, 3.7 lmp. qts)
6. CHECK FOR ENGINE OIL LEAKS

170FU±01
A77281
17±8
±
LUBRICATION OIL PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.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)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
10.REMOVE GENERATOR ASSY (See page 19±20)
11.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
12.SEPARATE VANE PUMP ASSY (See page 14±139)
13.SEPARATE RETURN TUBE SUB±ASSY (See page 14±139)
14. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) (See page 14±139)
15. SEPARATE VANE PUMP OIL RESERVOIR ASSY
16.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±139)
17. SEPARATE ENGINE WIRE
18. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove a bolt and the engine service cover bracket RH.
19.REMOVE COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE\
) (See
page 14±139)
20. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
21. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
22.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
23.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
24.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)

A64641
A00019
B11673
±
LUBRICATION OIL PUMP ASSY(1AZ±FE)
17±9
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE CRANKSHAFT PULLEY (See page 14±139)
SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
27.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
28.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±16) 29.REMOVE OIL PAN SUB±ASSY
(a)Remove 12 bolts and 2 nuts.
(b)Insert the blade of SST between the crank case, timingchain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST09032±00100
NOTICE:
Be careful not to damage the contact surface of timing
chain cover, crank case and oil pan.
30.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
31.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
32. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
33. REMOVE CHAIN TENSIONER SLIPPER
34. REMOVE CHAIN VIBRATION DAMPER NO.1
35.REMOVE TIMING CHAIN GUIDE (See page 14±139)
36. REMOVE CHAIN SUB±ASSY
37. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
38.REMOVE NO.2 CHAIN SUB±ASSY (See page 14±139) 39. REMOVE OIL PUMP ASSY
(a) Remove 3 bolts, the oil pump and gasket.
40. INSTALL OIL PUMP ASSY
(a) Install a new gasket and oil pump with 3 bolts. Torque: 19 N
m (195 kgf
cm, 15 ft
lbf)
41.INSTALL NO.2 CHAIN SUB±ASSY (See page 14±139)
42. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

A77392Seal Packing6mm
A64641
17±10
±
LUBRICATION OIL PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
43.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
44. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
45.INSTALL CHAIN SUB±ASSY (See page 14±139)
46. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
47.INSTALL CHAIN TENSIONER SLIPPER (See page 14±139)
48.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±139)
49.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
50.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
51. INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b) Apply seal packing in the shape of bead (Diameter 3 to 4
mm (0.157 in.)) as shown in the illustration, and install the
oil pan.
Seal Packing: Part No. 08826 ± 00080 or equivalent
(c) Insert the oil pan with 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
52.INSTALL CRANKSHAFT POSITION SENSOR (See page 14±139)
53.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST 09213±54015 (91651±60855), 09330±00021
54.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
55. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
56.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
57.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
58. INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
59. INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
60. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

±
LUBRICATION OIL PUMP ASSY (1AZ±FE)
17±11
AVENSIS REPAIR MANUAL (RM1018E)
61. INSTALL ENGINE WIRE
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
62. INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
63. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
64. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
65. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
66. INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
67.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
68.INSTALL GENERATOR ASSY (
See page 19±20)

69.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
70. ADD ENGINE OIL
71. CHECK FOR ENGINE OIL LEAKS
72. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
73. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

170FX±01
A77339
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±15
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.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)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16.SEPARATE VANE PUMP ASSY (See page 14±222)
17.SEPARATE RETURN TUBE SUB±ASSY (See page 14±222)
18. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14±222)
19. SEPARATE VANE PUMP OIL RESERVOIR ASSY
20.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±222)
21. SEPARATE ENGINE WIRE
22.REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14±222)
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
25.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
27.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
28.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±222)

A64641
A00019
B11673
17±16
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
29.REMOVE CRANKSHAFT PULLEY (See page 14±222) SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
30.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
31.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17) 32.REMOVE OIL PAN SUB±ASSY
(a)Remove 12 bolts and 2 nuts.
(b)Insert the blade of SST between the crank case, timingchain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST09032±00100
NOTICE:
Be careful not to damage the contact surface of timing
chain cover, crank case and oil pan.
33.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
34.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
35.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
36.REMOVE CHAIN TENSIONER SLIPPER
37.REMOVE CHAIN VIBRATION DAMPER NO.1
38.REMOVE TIMING CHAIN GUIDE (See page 14±139)
39.REMOVE CHAIN SUB±ASSY
40.REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
41.REMOVE NO.2 CHAIN SUB±ASSY (See page 14±139) 42.REMOVE OIL PUMP ASSY
(a)Remove 3 bolts, the oil pump and gasket.
43.INSTALL OIL PUMP ASSY
(a)Install a new gasket and oil pump with 3 bolts. Torque: 19 N
m (195 kgf
cm,15 ft
lbf)
44.INSTALL NO.2 CHAIN SUB±ASSY (See page 14±139)
45. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

A77392Seal Packing6mm
A64641
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±17
AVENSIS REPAIR MANUAL (RM1018E)
46.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
47.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
48.INSTALL CHAIN SUB±ASSY (See page 14±139)
49.INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
50.INSTALL CHAIN TENSIONER SLIPPER (See page 14±139)
51.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±139)
52.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
53.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
54.INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a)Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b)Apply seal packing in the shape of bead (Diameter 3 to 4
mm (0.157 in.)) as shown in the illustration, and install the
oil pan.
Seal Packing: Part No. 08826 ± 00080 or equivalent
(c)Insert the oil pan with 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
55.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
56.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST 09213±54015 (91651±60855), 09330±00021
57. INSTALL CHAIN TENSIONER ASSY NO.1
58. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
60.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
61. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
62. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
63. INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)