2002 TOYOTA AVENSIS Repair Manual

A77395
Engine
Front
A77396
HookPinTurn
Disconnect
A77397
Push Turn
Plunger
±
ENGINE MECHANICAL CAMSHAFT(1AZ±FSE)
14±245
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket chain tensioner No. 1 with 2 nuts.
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
NOTICE:
If the hook is disengaged while installing, apply the hook
again, and then resume the installation.
(c)Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d)Turn the crankshaft clockwise, and check the plunger is extended.
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
22.INSTALL FUEL PUMP ASSY (See page 11±52)
23.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
24.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
25.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
26. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
27. CHECK FOR ENGINE OIL LEAKS
28. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

141C7±01
A79426N´m (kgf´cm, ft´lbf)
: Specified torque
8.0 (82, 71 in.
lbf)
7.0 (71, 62 in.
lbf)
39 (398, 29)
72 (734, 53)
Engine Cover No. 1Engine Room Cover Side
Radiator Support Opening Cover
Power Steering
Idle Pulley Bracket
Engine Under Cover Sub±assy No. 1
Air Cleaner Cap w/ Hose
Air Cleaner Element
AIr Cleaner Case
Engine Under Cover RH
V (Cooler
Compressor to
Crankshaft
Pulley) Belt No. 1Clip
Clip
Retainer
Clip
Clip
14±314
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1CD±FTV)
COMPONENTS

A79427N´m (kgf´cm, ft´lbf)
: Specified torque
52 (530, 38)52 (530, 38)
52 (530, 38)
Injector DriverEngine Mounting Insulator Sub±assy RH
Vacuum Reservoir Sub±assy
Union To Connector Tube Hose
Air Tube No. 1
25 (255, 18)
8.3 (85, 73 in.´lbf)
25 (255, 18)
5.0 (51, 44 in.´lbf)
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
14±315
AVENSIS REPAIR MANUAL (RM1018E)

A61211
: Specified torqueN´m (kgf´cm, ft´lbf)
* Replace only if damagedTiming Belt No. 2 Cover
Transverse Engine
Engine Mounting Bracket
Seal Washer Timing Belt No.1 Cover
Crankshaft Pulley Seal Washer
x 5 Generator V belt
Glow Plug
Screw Grommet Timing Belt GuideTiming Belt * Gasket
x 7
Glow Plug Assy * Gasket Timing Chain Cover Plate
Timing Belt
Tensioner
180 (1,837, 133)
21 (214, 15)
9.0 (92, 80 in.´lbf)
37 (375, 27)
64 (650, 47)
2.2 (22, 19 in.´lbf)
7.4 (76, 66 in.´lbf)
7.4 (76, 66 in.´lbf)
Idler Pulley
40 (408, 30)Glow Plug
No.1 Connector
14±316
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

A79428
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
18 (184, 13)
27 (270, 20)22 (224, 16)13 (135, 9.7)

Gasket

O±ring Fuel Injector
Back±up Ring No. 1


Injection Nozzle Seat
8.8 (90, 78 in.
lbf)

Oil Seal
8.8 (90, 78 in.
lbf)
20 (204, 15)
Washer
Nozzle Holder ClampNozzle Leakage
Pipe Assy
Injector AssyCylinder Head Cover Sub±assy
Gasket
Camshaft Bearing Cap
No. 2 CamshaftCamshaft
Camshaft Carrier
Camshaft Oil Seal
Retainer
88 (899, 65)
Camshaft Timing PulleySet Key
20 (204, 15)
* 42 (428, 31)
46 (469, 34)
Injection Pipe
Clamp No. 2
Injection Pipe
Sub±assy
O±ring
21 (214, 15)
Vacuum Pump Assy
5.0 (51, 44 in.
lbf)

Nozzle Holder Seal
* Use SST
* 42 (428, 31)
46 (469, 34)
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
14±317
AVENSIS REPAIR MANUAL (RM1018E)

141C8±01
SSTA61187
14±318
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
9.REMOVE AIR TUBE NO.1 (See page 14±270)
10.REMOVE INJECTOR DRIVER (See page 14±286)
11. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH (See page 14±307)
15.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)
16.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
17.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
19. REMOVE TIMING BELT GUIDE
20.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
23.REMOVE TIMING BELT (See page 14±307)
24.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
25. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the timing pulley.
HINT:
Using a plastic±faced hammer, tap out the pulley.
(c) Remove the set key.

A79143
SST
A09656
A79144
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
14±319
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE INJECTION PIPE SUB±ASSY NO.1
(See page 11±60)
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or a
plastic bag.
27.REMOVE INJECTION PIPE SUB±ASSY NO.2(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
28.REMOVE INJECTION PIPE SUB±ASSY NO.3(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
29.REMOVE INJECTION PIPE SUB±ASSY NO.4(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
30. REMOVE VACUUM PUMP ASSY
(a) Remove vacuum hose.
(b) Remove vacuum pump oil hose.
(c) Remove the 2 bolts and the vacuum pump assembly.
31. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
32. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, the cylinder head cover and thegasket.

A09668
A09650
5
6
4 2
1
12 3
1011
13
8
7
15
14
9
A09619
SST
A09620
14±320
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
33.REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11±60)
34.REMOVE INJECTOR ASSY (See page 11±60)
HINT:
Since each injector assembly has a characteristic fuel injecting behavior, store them in correct order so that
they can be returned to the original locations when re±assembling. 35. REMOVE CAMSHAFT OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by pryingbetween the oil seal retainer and the camshaft bearing
cap.
36. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 15 bearing cap bolts uniformly in the sequence shown in the illustra-
tion.
(b) Remove the 5 bearing caps and the camshaft sub±assy.
37. REMOVE NO.2 CAMSHAFT
(a) Remove the camshaft sub±assy and the camshaft carrier. 38. REMOVE CAMSHAFT OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
39. INSTALL CAMSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-face is flush with the camshaft oil seal retainer edge.
SST 09223±46011