2002 TOYOTA AVENSIS Repair Manual

A62195
Painted Link
Timing Mark
A62196
4123
A62197
Painted Link
Timing Mark
A32124
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
14±71
AVENSIS REPAIR MANUAL (RM1018E)
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
(e) Check that the camshaft timing gear assembly can move
to the retard angle side (the right angle) and is locked at
the most retarded position.
18. INSTALL CAMSHAFT
(a) Install the timing chain on the camshaft timing gear with
the painted links aligned with the timing marks on the
camshaft timing gear as shown in the illustration.
(b) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(c) Put the camshaft No.2 on the cylinder head with the
painted links of the chain aligned with the timing mark on
the camshaft timing gear.
(d) Tighten the camshaft timing gear set bolt temporarily.

A621983124 5 67
A62187
Hold
Tighten
A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Groove
A62177
Raise
Push
Hook
Pin
14±72
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(e) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(f) Install the bearing cap No. 1.
Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)
(g) Hold the camshaft with a wrench, tighten the camshaft
timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not to damage the valve lifter.
(h) Check that the match marks on the 2 camshaft sprockets
are aligned with each other and are aligned with the
painted links of the timing chain as shown in the illustra-
tion. Also, check the timing notch is aligned with the timing
mark º0º of the chain cover.
(i) Install chain tensioner.
(1) Check that the O±ring is clean, and set the hook as
shown in the illustration.

A62178
Push
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
A11858
A64005
±
ENGINE MECHANICAL CAMSHAFT(1ZZ±FE/3ZZ±FE)
14±73
AVENSIS REPAIR MANUAL (RM1018E)
(2)Apply engine oil to the chain tensioner and install it
with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
(3)Turn the crankshaft counter clockwise, and take thehook off the knock pin to release the plunger.
(4)Turn the crankshaft clockwise, and check that the plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
19.ADJUST VALVE CLEARANCE(See page 14±6)
20. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
21. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)

A62182
Seal Packing
A65687
A
A
A
A A A
A A
BB A
A64023
14±74
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
22. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover and 3 cable brackets with
the 9 bolts, 2 seal washers and 2 nuts. Tighten the bolts
and nuts uniformly in the several steps.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for A
9.0 N
m (92 kgf
cm, 80 in
lbf) for B
23. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

A76713
A78459
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
14±75
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
24. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
25. CHECK FOR ENGINE OIL LEAKS

141B7±01
A77310
Engine Cover Sub±assy No. 1
Radiator Support
Opening Cover
Engine Room
Cover Side
Fan and Generator V Belt
Engine Under Cover RH
Engine Under Cover LH
N´m (kgf´cm, ft´lbf)
: Specified torque
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±135
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1AZ±FE)
COMPONENTS

A77319
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Cooler Bracket
(LHD (w/ Air Conditioner)
Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant
Suction Hose No. 1
(LHD (w/ Air Conditioner)
Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator ASSY
Exhaust Pipe Assy Front
43 (440, 32)

Gasket
43 (440, 32)
7.0 (71, 62 in.
lbf)
52 (530, 38)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
Vane Pump Assy
37 (377, 27)
14±136
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A77320
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Ignition Coil Assy
9.0 (90, 80 in.
lbf)
14 (143, 10)
11 (115, 8.0)
Cylinder Head Cover Sub±assy

Gasket
11 (115, 8.0)
Ventilation Hose Ventilation Hose No. 2
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±137
AVENSIS REPAIR MANUAL (RM1018E)