2002 TOYOTA AVENSIS Repair Manual

031E1±02
03±8
± SERVICE SPECIFICATIONSFUEL
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy Bolt A
Bolt B19
9.0194
9214
80 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy2020415
Fuel pressure pulsation damper assy x Fuel delivery pipe sub±assy9.09280 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Cylinder head cover x Fuel pump assy2525518
Fuel pipe sub±assy No.1 x Fuel delivery pipe sub±assy9.09280 in.
lbf
Fuel pipe sub±assy No.1 x Fuel pump assy3030622
Fuel pressure pulsation damper assy x Fuel pump assy3333124
Engine cover bracket x Cylinder head3838828
Engine cover sub±assy No.1 x Cylinder head cover7.07162 in.
lbf
Nozzle holder clamp x Cylinder head131279
Fuel delivery pipe sub±assy x Cylinder head1919414
Surge tank stay No.1 x Cylinder block2121015
Intake manifold x Cylinder head Stud bolt
Bolt
Nut9.5
30
3097
306
30684 in.
lbf
22
22
GASOLINE:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy No. 1 LH x Body4040029
Fuel tank band sub±assy No. 1 RH x Body4040029
Parking brake cable assy No. 3 x Body5.05144 in.
lbf
Parking brake cable assy No. 2 x Body5.05144 in.
lbf
Fuel tank protector No. 1 x Body5.45447 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 1 RH5.45447 in.
lbf
Exhaust pipe assy front x Exhaust manifold (1ZZ±FE/3ZZ±FE)4344033
Exhaust pipe assy front x Exhaust pipe assy tail (1ZZ±FE/3ZZ±FE)4344033
Exhaust pipe assy center x Exhaust pipe assy front (1AZ±FE/1AZ±FSE)4344033
Exhaust pipe assy center x Exhaust pipe assy tail (1AZ±FE/1AZ±FSE)4344033
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Nozzle holder clamp x Cylinder head sub±assy2626519
Nozzle leakage pipe assy x Injector assy Hollow screw
Union bolt18
22184
22413
16
Nozzle leakage pipe No. 2 x Cylinder head sub±assy Hollow screw
Bolt21
8.8214
9016
79 in.
lbf
Injection pipe sub±assy No. 1 ± No. 4 x Injector assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe sub±assy No. 1 ± No. 4 x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25

± SERVICE SPECIFICATIONSFUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf

031HH±01
± SERVICE SPECIFICATIONSHEATER AND AIR CONDITIONING
03±61
AVENSIS REPAIR MANUAL (RM1018E)
HEATER AND AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume Standard:440
30 g (15.51
1.06 oz.)
Belt deflection New belt:
Used belt:11 ± 13 mm (0.43 ± 0.51 in.)
13.5 ± 16.5 mm (0.53 ± 0.64 in.)

031HI±01
03±62
± SERVICE SPECIFICATIONSHEATER AND AIR CONDITIONING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
Tighten2.52522 in.
lbf
Fully tighten3939029
AIR CONDITIONER RADIATOR ASSY
Air conditioning tube assy x Cooler evaporator sub±assy No. 13.53530 in.
lbf
Air conditioner unit assy x Body9.810087 in.
lbf
BLOWER ASSY
Blower assy x Body Bolt:9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (3ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1CD±FTV)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy RHD:9.810087 in.
lbf
Suction servic valve x W/pulley compressor assy LHD:9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x Suction servic valve9.810087 in.
lbf
W/RECEIVER CONDENSER ASSY
Cap x W/receiver condenser assy2.92925 in.
lbf
Magnet valve x W/receiver condenser assy3.43530 in.
lbf
Discharge tube x Magnet valve3.43530 in.
lbf
Discharge tube x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy B x W/receiver condenser assy5.45547 in.
lbf
Discharge hose sub±assy x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy A x W/receiver condenser assy5.45547 in.
lbf
HEAER ASSY
Heater assy x Body7.57666 in.
lbf

031E4±01
03±30
± SERVICE SPECIFICATIONSIGNITION
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Spark plug
Recommended spark plug DENSO made
NGK made
Electrode gap K16R±U11, BKR5EYA11
K16R±U11
BKR5EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold
Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance Cold
Hot
1,630 to 2,740

2,065 to 3,225

1AZ±FE:
Spark plug
Recommended spark plug DENSO made
NGK made
Electrode gap K20R±U11, BKR6EYA11
K20R±U11
BKR6EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold
Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance Cold
Hot
985 to 1,600

1,265 to 1,890

1AZ±FSE:
Spark plug
Recommended spark plug DENSO made
Electrode gap SK20BR11
SK20BR11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold
Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance Cold
Hot
985 to 1,600

1,265 to 1,890

031E5±01
± SERVICE SPECIFICATIONSIGNITION
03±31
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1818413
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf
Cord clamp x Timing chain cover sub±assy9.09280 in.
lbf
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1919414
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf

031I3±01
03±70
± SERVICE SPECIFICATIONSINSTRUMENT PANEL/METER
AVENSIS REPAIR MANUAL (RM1018E)
INSTRUMENT PANEL/METER
TORQUE SPECIFICATION
Part TightenedNmkgfcmftlbf
Instrument Panel Reinforcement Passenger Airbag2020415

031FQ±01
± SERVICE SPECIFICATIONSINTAKE
03±11
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE
SERVICE DATA
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
33 to 39

1CD±FTV:
Turbocharging pressure
Standard pressure
15 to 45 kPa (0.15 to 0.46 kgf/cm2, 2.2 to 6.5 psi)
Turbo pressure sensor
Voltage 3 (VC) ± 1 (E2)
Voltage drop apply vacuum 13.3 kPa (100 mmHg, 3.94 in.Hg)
apply vacuum 26.7 kPa (200 mmHg, 7.87 in.Hg)
apply vacuum 40.0 kPa (300 mmHg, 11.81 in.Hg)
apply vacuum 57.3 kPa (400 mmHg, 15.75 in.Hg)
apply vacuum 66.7 kPa (500 mmHg, 19.96 in.Hg)
Voltage up applied vacuum 19.6 kPa (0.20 kgf/cm2, 2.84 psi)
applied vacuum 39.2 kPa (0.40 kgf/cm2, 5.69psi)
applied vacuum 58.8 kPa (0.60 kgf/cm2, 8.53psi)
applied vacuum 78.5 kPa (0.80 kgf/cm2, 11.4psi)
applied vacuum 98.0 kPa (1.00 kgf/cm2, 14.2psi)
4.5 to 5.5 V
0.1 to 0.3 V
0.3 to 0.5 V
0.5 to 0.7 V
0. 7 to 0.9 V
0. 9 to 1.0 V
0.1 to 0.4 V
0.4 to 0.7 V
0.7 to 1.0 V
1.0 to 1.3 V
1.3 to 1.6 V