2002 TOYOTA AVENSIS width

A56703
Seal Width
4 to 7 mm
A
AB
B
A56697
AA
A
A
AA B B DBBB
BC C
C CC
CCDD
A56696
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±27
AVENSIS REPAIR MANUAL (RM1018E)
(b) Apply a seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 4 to 7 mm
(0.16 to 0.28 in.) opening.
(2) Parts must be set within 3 minutes and assembled
within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3) Immediately remove nozzle from the tube and rein-
stall the cap.
(c) Install the oil pan with the 19 bolts and 3 nuts.
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for bolt A
21 N
m (214 kgf
cm, 15 ft
lbf) for bolt B
11 N
m (112 kgf
cm, 8 ft
lbf) for bolt C
12 N
m (122 kgf
cm, 9 ft
lbf) for nut D
39. INSTALL OIL PAN INSULATOR
(a) Install the oil pan insulator with the bolt.
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
40. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (209 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
41. INSTALL OIL PAN SUB±ASSY NO.2
(a) Remove any old packing and be careful not to drop any
oil on the contact surfaces of the No. 1 and No. 2 oil pans.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.

A56704
Seal Width
4 to 7 mm
A
B B
A
A79173New O±ring
17±28
±
LUBRICATION OIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(3)Using a non±residue solvent, clean both the sealing surfaces.
NOTICE:
Do not use a solvent, which will affect the painted surfaces.
(b)Apply a seal packing to the oil pan as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
(1)Install a nozzle that has been cut to a 4 to 7 mm
(0.16 to 0.28 in.) opening.
(2)Parts must be set within 3 minutes and assembled within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3)Immediately remove nozzle from the tube and rein- stall the cap.
(c)Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
Torque: 12 N m (119 kgf cm, 9ft lbf)
42.INSTALL ENGINE OIL LEVEL SENSOR Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
43.INSTALL OIL LEVEL GAGE GUIDE
(a)Install a new O±ring to the oil level gage guide.
(b)Apply engine oil to the O±ring.
(c)Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d)Install the oil level gage guide with the bolt. Torque: 18 N m (184 kgf cm, 13 ft lbf)
(e)Apply engine oil to the O±ring on the oil level gage.
(f)Install the oil level gage.
44.INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 31 N m (320 kgf cm,23 ft lbf)
45.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
Torque: 35 N m (357 kgf cm,26 ft lbf)
46.INSTALL GENERATOR ASSY(See page 19±29)

± PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
02±53
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09042±00010Torx Socket T30HORN BUTTON ASSY
SPIRAL CABLE SUB±ASSY
09070±20010Moulding RemoverAIR BAG SENSOR ASSY CENTER
Equipment
Torque wrench
Bolt Length: 35.0 mm (1.378 in.) Pitch: 1.0 mm (0.039 in.)
Diam.: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam.: 360 mm (14.17 in.)Airbag disposal
Plastic bagAirbag disposal

030L1±03
± SERVICE SPECIFICATIONSCLUTCH
03±55
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH
SERVICE DATA
Pedal height from asphalt sheet
LHD steering position type
1CD±FTV engine type w/ intercooler
Others
154.0 ± 164.0 mm (6.063 ± 6.457 in.)
139.6 ± 149.6 mm (5.496 ± 5.890 in.)
Pedal height from asphalt sheet
RHD steering position type
1CD±FTV engine type w/ intercooler
Others
158.4 ± 168.4 mm (6.236 ± 6.630 in.)
148.4 ± 158.4 mm (5.843 ± 6.236 in.)
Clutch pedal free play5.0 ± 15.0 mm (0.197 ± 0591 in.)
Clutch pedal push rod play at pedal top1.0 ± 5.0 mm (0.039 ± 0.197 in.)
Slotted spring pin protrusion1.5 ± 3.5 mm (0.059 ± 0.138 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch disc rivet head depth Maximum0.3 mm (0.012 in.)
Clutch disc assy runout Minimum0.8 mm (0.031 in.)
Diaphragm spring finger wear Maximum depth:
Maximum width:0.5 mm (0.020 in.)
6.0 mm (0.236 in.)
Flywheel sub±assy runout Maximum0.1 mm (0.004 in.)
Diaphragm tip alignment Maximum0.5 mm (0.020 in.)

H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42761
Width
Inner
Diam.
H42792
SST(s) 60±44
± SUPPLEMENTAL RESTRAINT SYSTEMCURTAIN SHIELD AIR BAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie
down the curtain shield airbag assy LH to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2
or more (0.0019 in.2 or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the curtain shield airbag assy LH, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter of at least 1.25 mm
2 (0.0019 in.2).
HINT:

To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4

Position the curtain shield airbag assy LH inside the tire
as shown in the illustration.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the curtain shield airbag assy LH coming free
due to the shock from the airbag deployment.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(e) Install the SST(s).
Connect the connectors of the SST(s) to the curtain shield
airbag assy LH.
SST 09082±00802 (09082±10801, 09082±20801)

H41437
H41438
H40526
H42897
SST(s)
60±50
± SUPPLEMENTAL RESTRAINT SYSTEMFRONT SEAT AIRBAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(1) Install the 2 nuts in the front seat airbag assy LH.
(2) Wind the wire harness around the stud bolts of the
front seat airbag assy LH as shown in the illustra-
tion.
(3) Position the front seat airbag assy LH inside the tire
with the airbag deployment direction facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure the wire harness is tight. It is highly dan-
gerous when looseness in the wire harness results in
the front seat airbag assy LH coming free due to the
shock from the airbag deployment.

Always tie down the front seat airbag assy LH with the
airbag deployment direction facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(d) Install the SST(s).
Connect the connector of SST(s) to the front seat airbag
assy LH connect.
SST 09082±00750

H4263210 m (33 ft) or moreBattery
SST(s)
H42633Weight
X Y
Y
H40013
Inner Diam.
Tires
(3 or More)Width 60±24
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(2) Move the SST(s) to at least 10 m (33 ft) away from
the horn button assy tied down to the disc wheel.
(e) Cover the horn button assy with a cardboard box or tires.

Covering method using a cardboard box:
Cover the horn button assy with the cardboard box
and weigh the cardboard box down in 4 places with
at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
X = 460 mm (18.11 in.)
Y = 650 mm (25.59 in.)
NOTICE:

When the dimension Y of the cardboard box exceeds
the diameter of the disc wheel with tire to which the
horn button assy is tied, X should be the following
size.
X = 460 mm (18.11 in.) + width of tire

If a cardboard box smaller than the specified size is
used, the cardboard box will be broken by the shock
from the airbag deployment.

Covering method using tires:
Place at least 3 tires with no disc wheels on top of
the tire with disc wheel to which the horn button assy
is tied.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:

The tires may be marked by the airbag deployment,
so use a redundant tires.

Do not place the SST(s) connector under the tire be-
cause the SST(s) connector could be damaged.

H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42664
Inner Diam.
WidthTire
60±58
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie
down the instrument panel airbag assy to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2
or more (0.0019 in.2 or more)
CAUTION:
If the wire harness which is too thin or an alternative object
is used to tie down the instrument panel airbag assy, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter of at least 1.25 mm
2 (0.0019 in.2).
HINT:

To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4

Position the instrument panel airbag assy inside the tire
with the airbag deployment side facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the instrument panel airbag assy coming free
due to the shock from the airbag deployment.

Always tie down the instrument panel airbag assy
with the airbag deployment side facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.