2002 TOYOTA AVENSIS Repair Manual

160MJ±01
A62118
10
10

16±10
±
COOLING THERMOSTAT(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
THERMOSTAT(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.ENGINE ROOM COVER SIDE (See page 14±27)
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
4.DRAIN ENGINE COOLANT (See page 16±1)
5.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
6.REMOVE GENERATOR ASSY (See page 19±7)
7.REMOVE WATER INLET
(a)Remove the 2 nuts and the water inlet.
8.REMOVE THERMOSTAT 9.INSTALL THERMOSTAT
(a)Install a new gasket to the thermostat.
(b)Install the thermostat with the jiggle valve upward asshown in the illustration.
10.INSTALL WATER INLET
(a)Install the water inlet with the 2 nuts. Torque: 11 N
m (112 kgf
cm, 8 ft
lbf)
11.INSTALL GENERATOR ASSY (See page 19±7)
12.ADD ENGINE COOLANT (See page 16±7)
13.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)

160MT±01
A56451
A77424
10
10

±
COOLING THERMOSTAT(1AZ±FE)
16±23
AVENSIS REPAIR MANUAL (RM1018E)
THERMOSTAT(1AZ±FE)
REPLACEMENT
1.DRAIN COOLANT(See page 16±19)
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±105)
SST09249±63010
6.REMOVE GENERATOR ASSY (See page 19±20)
7.REMOVE WATER INLET
(a)Remove 2 nuts, and disconnect the water inlet from thecylinder block.
8.REMOVE THERMOSTAT 9.INSTALL THERMOSTAT
(a)Install a new gasket to the thermostat.
(b)Install the thermostat with the jiggle valve upward.
HINT:
The jiggle valve may be set within 10
on either side of the pre-
scribed position.
10.INSTALL WATER INLET
(a)Install the water inlet with 2 nuts. Torque: 9.0 N
m (92 kgf
cm,7 in.
lbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
13.ADD COOLANT (See page 16±19)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)

160MW±01
B12054
SST
B12052
B12053
Pry
PryPry
±
COOLING WATER PUMP ASSY(1AZ±FE)
16±21
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DRAIN COOLANT (See page 16±19)
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±105)
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±22
±
COOLING WATER PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the con- tact 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±105) SST 09249±63010
13.ADD COOLANT (See page 16±19)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±17)

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)