2002 TOYOTA AVENSIS belt

160MR±01
B12054
SST
B12052
B12053
Pry
PryPry
±
COOLING WATER PUMP ASSY(1AZ±FSE)
16±33
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DRAIN COOLANT (See page 16±31)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE ROOM COVER SIDE
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FAN AND GENERATOR V BELT (See page 14±185)
SST 09249±63010
6.REMOVE GENERATOR ASSY (See page 19±20)
7. REMOVE WATER PUMP PULLEY
(a) Using SST, remove 4 bolts and pump pulley.SST 09960±10010 (09962±01000, 09963±00700)
(b) Disconnect the crankshaft position sensor wire clamp from the water pump.
(c) Disconnect the crankshaft position sensor wire from the clamp on the water pump.
8. REMOVE WATER PUMP ASSY
(a) Remove 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry between the water pump and cyl- inder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
16±34
±
COOLING WATER PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the contact surface.
(b)Apply seal packing to the water pump as shown in the il- lustration.
Seal packing: Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 2.2 to 2.5 mm
(0.09 to 0.10 in.) opening.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c)Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d)Install the crankshaft position sensor wire harness clamp to the water pump.
(e)Install the crankshaft position sensor wire to the wire clamp on the water pump.
10.INSTALL WATER PUMP PULLEY
(a)Using SST, install the pump pulley with 4 bolts. SST09960±10010 (09962±01000, 09963±00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
13.ADD COOLANT (See page 16±31)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS(See page 16±25)

160ME±01
A79148
SST
16±46
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)

A09580
8 mm
Hexagon
Wrench
A79170
A79170
A09581
8 mm
Hexagon
Wrench
Plate Washer
±
COOLING WATER PUMP ASSY(1CD±FTV)
16±47
AVENSIS REPAIR MANUAL (RM1018E)
29.REMOVE INJECTION PUMP DRIVE PULLEY(See page 11±69)
SST09960±10010 (09962±01000, 09963±01000), 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
30.REMOVE INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
31.REMOVE TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, remove the idler pulleyshaft, the idler pulley and the plate washer.
32.REMOVE WATER PUMP ASSY
(a)Remove the 7 bolts, then remove the water pump and the gasket.
33.INSTALL WATER PUMP ASSY
(a)Install a new gasket and the water pump with the 7 bolts. Torque: 31 N
m (320 kgf
cm, 23 ft.
lbf)
34.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, install the plate washer and the idler pulley with the idler pulley shaft.
Torque: 35 N
m (357 kgf
cm, 26 ft
lbf)
(b)Check that the pulley bracket moves smoothly.
35.INSTALL INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
36.INSTALL INJECTION PUMP DRIVE PULLEY(See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
37.INSTALL WATER INLET(See page 16±50)
38.INSTALL OIL LEVEL GAGE GUIDE(See page 17±22)

±
COOLING WATER PUMP ASSY(1CD±FTV)
16±49
AVENSIS REPAIR MANUAL (RM1018E)
41.SET NO. 1 CYLINDER TO TDC/COMPRESSION
SST09960±10010 (09962±01000, 09963±01000)
42.INSTALL TIMING BELT(See page 14±307)
43.CHECK VALVE TIMING(See page 14±307)
44.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
45.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
46.INSTALL TIMING BELT GUIDE(See page 14±307)
47.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
48.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
49.INSTALL IDLER PULLEY SUB±ASSY(See page 11±69)
50.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
51.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
52.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
53.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
54.INSTALL INJECTOR DRIVER(See page 11±69)
55. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
56. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
57.ADD ENGINE COOLANT(See page 16±44)
58.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
59.CHECK FOR FUEL LEAKS(See page 11±60)

160MI±01
B00150
AB ABB
B
A32555
±
COOLING WATER PUMP ASSY(1ZZ±FE/3ZZ±FE)
16±9
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
4.REMOVE ENGINE UNDER COVER RH (See page 14±27)
5.DRAIN ENGINE COOLANT (See page 16±1)
6.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
7.REMOVE GENERATOR ASSY (See page 19±7)
8.REMOVE WATER PUMP ASSY
(a)Remove the 6 bolts, the water pump and the O±ring.
9.INSTALL WATER PUMP ASSY
(a)Place a new O±ring on the timing chain cover.
(b)Install the water pump with the 6 bolts.Torque:
9.0 N
m (92 kgf
cm, 80 in
lbf) for Bolt A
11 N
m (113 kgf
cm, 8 ft
lbf) for Bolt B
10.INSTALL GENERATOR ASSY (See page 19±7)
11.ADD ENGINE COOLANT (See page 16±7)
12.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)

B67989
Front Door Outside Handle Frame Sub±assy LHw/ Key:
Front Door Outside Handle Cover LH
Front Door Handle
Assy Outside LH
Front Door Outside Handle Pad Rear Front Door Outside
Handle Pad Front
Hole Plug
Front Door Lock Open Rod
Front Door w/ Motor Lock Assy LH
Door Lock Wire Harness Packing 5.0 (51, 44 in.´lbf)
Front Door Belt Moulding LH
Front Door Hinge
Assy Upper LH
Front Door Check Assy
30 (306, 22)

5.5 (56, 49 in.´lbf)
Front Door Hinge
Assy Lower LH26 (265, 19)
Front Door Weatherstrip LH
Cushion RubberFront Door Lower Frame
Bracket Garnish LH Outer Rear View Mirror Assy LH
Front Door Speaker No. 2
Front Door Service Hole Cover 
: Specified torqueN´m (kgf´cm, ft´lbf)


Precoated Part Non±reusable part Clip
26 (265, 19)
Front Door Lower
Frame Seal


Butyl Tape

10 (102, 7)
Front Door Stiffener
Cushion No. 1
Side Trim
Spacer LH
Key Cylinder
w/o Key:
Front Door Outside
Handle Cover LHw/ Speaker
Front Door Lower Frame
Bracket Garnish LH
± ENGINE HOOD/DOORFRONT DOOR
75±5
AVENSIS REPAIR MANUAL (RM1018E)

B69067
Butyl Tape
B66981
B68929
B61431
75±10
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE FRONT DOOR SERVICE HOLE COVER
(a)Remove the service hole cover.
NOTICE:
Remove the tape remaining on the door side.
(b)Remove the lower frame seal.
9.REMOVE OUTER REAR VIEW MIRROR ASSY LH
(a)Disconnect the mirror connector.
(b)Remove the 3 screws and mirror.
NOTICE:
When the screws are removed, the mirror may fall and be-
come deformed.
10.REMOVE FRONT NO.1 SPEAKER ASSY (W/ SPEAKER)
(a)Using a drill of less than ù 4 mm (0.16 in.), drill out the 3 rivets heads and remove the speaker.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Be careful with the cut rivet, because it is hot.
(b)Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
(c)Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.
11.REMOVE FRONT DOOR BELT MOULDING ASSY LH (See page 76±23)
12. REMOVE FRONT DOOR STIFFENER CUSHION NO.1
(a) Using a screwdriver, disengage the 2 claws and remove the cushion.
13. REMOVE FRONT DOOR SPACER LH
(a) Using a screwdriver, disengage the 2 claws and remove the spacer.