2002 TOYOTA AVENSIS Repair Manual

100FD±01
A78454
N´m (kgf´cm, ft´lbf) : Specified torqueClip
Cylinder Head Cover No.2
Fuel
Vapor Feed Hose No.1
VSV
Connector
Mass Air Flow
Meter Connector Accelerator Control
Cable Assy
Fuel Vapor Feed Hose
No.3 Engine Room Cover Side
Radiator Support Opening Cover
Clip
Retainer
7.0 (71, 62 in.´lbf)
Clip
1.5 (15, 13 in.´lbf)
13 (129, 9)
Air Cleaner Cap
Sub±assy
x2
x4
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3ZZ±FE)
10±13
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (3ZZ±FE)
COMPONENTS

A78504

Throttle Body Gasket

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueISC Valve
Throttle Body Cover
GasketThrottle Position
SensorWater By±pass
Hose Water By±pass
Hose No.2
ISC Valve ConnectorThrottle Body Assy Ventilation Hose
Throttle Position
Sensor Connector
30 (306, 22)
30 (306, 22)
Accelerator
Control Cable Bracket
3.7 (38, 33 in.´lbf)
2.0 (20, 18 in.´lbf)
x2
x2
x4 10±14
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

100FE±01
A78497
A78498
(a)
(b)
(c)
A78499
(d)
(e)
A78500
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(3ZZ±FE)
10±15
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
3.DRAIN ENGINE COOLANT (See page 16±7)
4.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
5.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±9)
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator controlcable.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the ventilation hose.
(b) Disconnect the water by±pass hose.
(c) Disconnect the water by±pass hose No. 2.
(d) Disconnect the throttle position sensor.
(e) Disconnect the ISC valve connector.
(f) Remove the bolt and 2 nuts, and then remove the acceler- ator control bracket and the throttle body.
(g) Remove the gasket from the intake manifold.
8. REMOVE ISC VALVE
(a) Remove the 4 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.

A78501
A78503
30
to 45

A78469
66.3 mm
(2.610 in.)
Rotation
Center of
Throttle Link
11

10±16
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE THROTTLE POSITION SENSOR
(a)Remove the 2 screws, and then remove the throttle posi- tion sensor.
10.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that the throttle valve is fully closed.
(b)With the throttle position sensor rotated 30
to 45
coun-
terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
11.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 4 screws.
Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
12.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the accelerator control brack- et with the bolt and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
13.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
14.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±9)
15.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
16.ADD ENGINE COOLANT (See page 16±7)
17.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
18. INSTALL ENGINE ROOM COVER SIDE
19. INSTALL RADIATOR SUPPORT OPENING COVER

750N4±01
B66986
Back Door Trim
Panel Assy Upper
Back Door Trim Board Assy Back Door Side
Garnish LHBack Door Garnish Sub±assy
Outside RH
Floor Finish Plate Center Stop Lamp Assy
Back Door Lock Striker Hook
Back Door Side
Garnish RHBack Door Stay Assy RH
Back Door Lock Assy Rear Wiper Motor Assy
Back Door
Stay Assy LH
Back Door Service
Hole Cover
: Specified torqueN´m (kgf´cm, ft´lbf)
19.5 (200, 14)
5.5 (56, 49 in.´lbf)
Hook Rear Wiper Arm and Blade Assy
Rear Wiper
w/ Packing Washer
Wiper Arm Head Cap
Nut5.5 (56, 49 in.´lbf)
5.5 (56, 49 in.´lbf)
Cushion Rubber
Cushion Rubber
Rope Hook Assy
11.5 (120, 8)
22 (264, 19)
7.0 (71, 62 in.´lbf)
5.5 (56, 49 in.´lbf)
8.0 (82, 71 in.´lbf)
7.0 (71, 62 in.´lbf)22 (264, 19)
Female
Stopper RH
Female
Stopper LH
4.9 (49, 43 in.´lbf)Back Door Damper Assy
5.5 (56, 49 in.´lbf)
± ENGINE HOOD/DOORBACK DOOR (LIFTBACK MODELS)
75±37
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (LIFTBACK MODELS)
COMPONENTS

750N5±01
B57104
Centering BoltStandard Bolt
B67535
A
BC
D
B66993
75±38
± ENGINE HOOD/DOORBACK DOOR (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a door hinge mounting bolt
on the body side and door side, the door can not be adjusted
with them on. Substitute a bolt with a washer for the centering
bolt.
1. INSPECT BACK DOOR PANEL SUB±ASSY
(a) Check that the clearance is within the standard range.
Standard range:
A6.3
1.5 mm (0.248
0.059 in.)
B4.9
1.5 mm (0.193
0.059 in.)
C5.0
1.5 mm (0.197
0.059 in.)
D8.0
1.5 mm (0.315
0.059 in.)
2. ADJUST BACK DOOR PANEL SUB±ASSY
(a) Adjust the door vertically and forward/rearward by loos-
ening the body side hinge bolts.
(b) Tighten the body side hinge bolts after the adjustment.
Torque: 19.5 N
m (200 kgf
cm, 14 ft
lbf)

B66992
B66994
B66995
±
ENGINE HOOD/DOOR BACK DOOR(LIFTBACK MODELS)
75±39
AVENSIS REPAIR MANUAL (RM1018E)
(c)Horizontally and vertically adjust the door by loosening
the 8 door side hinge bolts.
(d)Tighten the door side hinge bolts after the adjustment.
Torque: 19.5 N
m (200 kgf
cm, 14 ft
lbf)
(e)Remove the floor finish plate (See page 76±45)
(f) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic±
faced hammer.
(g) Tighten the striker mounting screws after the adjustment. Torque: 11.5 N
m (120 kgf
cm, 8 ft
lbf)
(h) Adjust the side female stopper so that the door can be opened/closed smoothly, as shown in the illustration.
(i) Tighten the side female stopper after the adjustment. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)

750N6±01
B66988: Clip
B66989: Clip
Hook
B66990: Clip
B66991
75±40
±
ENGINE HOOD/DOOR BACK DOOR(LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated. 1.REMOVE BACK DOOR TRIM PANEL ASSY UPPER
(a)Using a screwdriver, disengage the 4 clips and removethe trim.
HINT:
Tape the screwdriver tip before use.
2.REMOVE BACK DOOR SIDE GARNISH LH
(a)Using a clip remover, remove the hook.
(b)Using a screwdriver, disengage the 2 clips and remove the side garnish.
HINT:
Tape the screwdriver tip before use.
3.REMOVE BACK DOOR SIDE GARNISH RH
HINT:
Use the same procedures described for the LH side.
4.REMOVE BACK DOOR TRIM BOARD ASSY
(a)Remove the 2 screws.
(b)Using a screwdriver, disengage the 12 clips and remove the trim board.
HINT:
Tape the screwdriver tip before use.
(c)Remove the 4 service hole covers.
5.REMOVE BACK DOOR DAMPER ASSY
(a)Remove the 4 bolts and damper.
6.REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE RH (See page 76±27)
7.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
8.REMOVE CENTER STOP LAMP ASSY (See page 65±26)