2002 TOYOTA AVENSIS check engine

A77396
HookPin
Turn
Disconnect
A77397
Push
Turn
Plunger
A77399
Seal Packing
A77400NutNut
A
BC A
AAAB
± ENGINE MECHANICALCAMSHAFT (1AZ±FE)
14±177
AVENSIS REPAIR MANUAL (RM1018E)
(c) Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d) Turn the crankshaft clockwise, and check the plunger is
extended.
18. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 5 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
Bolt A 11 N
m (112 kgf
cm, 8.0 ft
lbf)
Bolt B 14 N
m (143 kgf
cm, 10 ft
lbf)
Bolt C 21 N
m (214 kgf
cm, 15 ft
lbf)
Nut 11 N
m (112 kgf
cm, 8.0 ft
lbf)
19. INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
20. CHECK FOR ENGINE OIL LEAKS
21. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

A77345
Timing
Marks
Timing
Marks
A77286
Push
A77412
HoldLoosen
A77294
15973
481062
A52473
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
14±241
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that each timing mark of the camshaft timing gears
is aligned with each timing mark located on the No. 1 and
No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
13. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner and a gasket.
NOTICE:
Do not turn the crankshaft.
14. REMOVE NO.2 CAMSHAFT
(a) Hold the No. 2 camshaft with a wrench on the hexagonal
lobe, and loosen the camshaft timing gear set bolt.
NOTICE:
Be careful not to damage the cylinder head and valve lifter
with the wrench.
(b) Using several steps, loosen and remove the 10 camshaft
bearing cap bolts uniformly in the sequence shown in the
illustration.
(c) Remove the 5 camshaft bearing caps.
(d) Raising the No. 2 camshaft, remove the set bolt.
(e) Remove the camshaft timing gear from the No. 2 cam-
shaft with with the timing chain wrapped.
(f) Remove the camshaft timing gear from the timing chain.

A32639
A77414
Straight
Pin
Key
Groove
A77284
A77415Bearing Cap No. 1Bearing Cap No. 3 5
312 4
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
14±243
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove a fringe bolt of camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If reusing the camshaft timing gear, release the
straight pin lock first, and then install the gear.
17. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear and the camshaft together
with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) while lightly pushing it to-
ward the camshaft. Push further at the position where the
pin gets into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right direction).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
(e) Check that the camshaft timing gear can move to the re-
tard angle side (to the right direction), and is locked at the
most retarded position.
18. INSTALL CAMSHAFT
(a) Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
(b) Install the timing chain on the camshaft timing gear, with
the painted links aligned with the timing marks on the
camshaft timing gear.
(c) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
19. INSTALL NO.2 CAMSHAFT
(a) Put the No. 2 camshaft on the cylinder head with the
painted links of chain aligned with the timing mark on the
camshaft timing gear.

A52473
A77416
Bearing Cap No. 2 Bearing Cap No. 3
531 2 4
A77417
TightenHold
A77345
Timing
Marks
Timing
Marks
A77394
Raise
PinHook Push
14±244
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Raising the No. 2 camshaft, tighten the set bolt temporari-
ly.
(c) Examine the from marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(d) Hold the camshaft with a wrench on the hexagonal lobe,
and tighten the camshaft timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the cylinder head and valve lifter.
(e) Check that the match marks on the timing chain and the
camshaft timing gears are positioned as shown in the il-
lustration
20. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger is locked in posi-
tion.

A77395
Engine
Front
A77396
HookPinTurn
Disconnect
A77397
Push Turn
Plunger
±
ENGINE MECHANICAL CAMSHAFT(1AZ±FSE)
14±245
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket chain tensioner No. 1 with 2 nuts.
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
NOTICE:
If the hook is disengaged while installing, apply the hook
again, and then resume the installation.
(c)Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d)Turn the crankshaft clockwise, and check the plunger is extended.
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
22.INSTALL FUEL PUMP ASSY (See page 11±52)
23.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
24.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
25.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
26. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
27. CHECK FOR ENGINE OIL LEAKS
28. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

A79147
Fulcrum
Length
30 cm
SST
14±324
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c)Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d)Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e)Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
54.INSTALL INJECTION PIPE SUB±ASSY NO.2 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
55.INSTALL INJECTION PIPE SUB±ASSY NO.3 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56.INSTALL INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
57.INSTALL TIMING BELT(See page 14±307)
58.CHECK VALVE TIMING(See page 14±307)

±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±325
AVENSIS REPAIR MANUAL (RM1018E)
59.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
60.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
61.INSTALL TIMING BELT GUIDE(See page 14±307)
62.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
63.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
64.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
65.INSTALL CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021
66.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
67.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
68. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
69.INSTALL INJECTOR DRIVER (See page 14±286)
70.INSTALL AIR TUBE NO.1 (See page 14±270)
71. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
72.INSTALL AIR CLEANER ASSY (See page 14±286)
73. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
74. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
75.CHECK FOR FUEL LEAKS(See page 11±60)

A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Timing
Notch
A11858
A62186
Paint Mark
A62178
Push 14±66
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley to align the timing notch with
timing mark º0º of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock-
et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
13. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, then remove the V±ribbed belt
tensioner.
HINT:
Jack up and down to remove the bolt.
14. REMOVE CAMSHAFT
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the timing chain and the camshaft
timing sprockets.
(c) Remove the 2 nuts and the chain tensioner.