2002 TOYOTA AVENSIS Repair Manual

A09656
A79144
A09566
1
234 5
67 89
1011
12 13
1415
16
1718
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±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
57.REMOVE INJECTION PIPE SUB±ASSY NO.4 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
58.REMOVE VACUUM PUMP ASSY (See page 14±318)
59. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
60. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, the cylinder head cover and thegasket.
61.REMOVE NOZZLE LEAKAGE PIPE ASSY(See page 11±60)
62.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.
63.REMOVE CAMSHAFT OIL SEAL RETAINER (See page 14±318)
64.REMOVE NO.2 CAMSHAFT (See page 14±318)
65.REMOVE CAMSHAFT (See page 14±318) 66. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 18 cylinder head boltsuniformly in the sequence shown in the illustration. Re-
move the 18 cylinder head bolts and the plate washers.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.

A61194
Pry
A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring Tip
Protrusion Hight
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±335
AVENSIS REPAIR MANUAL (RM1018E)
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
67. REMOVE CYLINDER HEAD GASKET
68. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolts.
Standard outside diameter:
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
69. INSTALL CYLINDER HEAD GASKET
(a) Measure protrusion height of the piston heads.
(1) Clean the cylinder block with solvent.
(2) Set the piston to be measured to slightly before
TDC.
(3) Place a dial indicator on the cylinder block, and cali-
brate the dial indicator at 0 mm (0 in.).
HINT:

Place measuring tip of the dial indicator as shown in the
illustration.

Make sure that the measuring tip is square to the cylinder
block gasket and the piston head when measuring.
(4) Find the most overhung position of the piston head
by slowly turning the crankshaft clockwise and
counterclockwise.

A09571
Front
X Measuring Point
A80117
A
B
C
D
E
A56055
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± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Measure a protrusion height of the piston head for
each cylinder at 2 places as shown in the illustra-
tion. (Total of 8 measurements.)
(6) Record the highest protrusion height from the 2
measurements at each cylinder.
(b) Select new cylinder head gasket.
HINT:
There are 5 sizes of new cylinder head gaskets, marked ºAº,
ºBº, ºCº, ºDº, or ºEº.
New cylinder head gasket thickness:
A0.85 to 0.95 mm (0.0335 to 0.0374 in.)
B0.90 to 1.00 mm (0.0354 to 0.0394 in.)
C0.95 to 1.05 mm (0.0374 to 0.0413 in.)
D1.00 to 1.10 mm (0.0394 to 0.0433 in.)
E1.05 to 1.15 mm (0.0413 to 0.0453 in.)
(1) Find the highest protrusion height among the 4
measurement records. It is used to select a new cyl-
inder head gasket.
(2) Select the new gasket among A to E using the ma-
trix below.
New gasket matrix:
Piston protrusion mm (in.)Gasket size
0.165 to 0.220 (0.0065 to 0.0087)A
0.220 to 0.270 (0.0087 to 0.0106)B
0.270 to 0.320 (0.0106 to 0.0126)C
0.320 to 0.370 (0.0126 to 0.0146)D
0.370 to 0.425 (0.0146 to 0.0167)E
(c) Place new cylinder head gasket on the cylinder block.
NOTICE:
Pay attention to mounting orientation.

A61189
10
11
12
13 14
15 16
17
18
2
1
4
5 6
3
7 8
9
(A) (A)
(A)
(A) (A)
(A)
(A)
(B) (B) (B) (B) (B) (B) (B)
(B)
(B)
(B) (A)
A61190
90
 90

9090
 90

90
Front Paint Mark
90
A09683
TDC Mark
Dot Mark
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±337
AVENSIS REPAIR MANUAL (RM1018E)
70. INSTALL CYLINDER HEAD SUB±ASSY
HINT:

The cylinder head bolts are tightened in 4 successive
steps (steps (c), (e), (f) and (g)).

If the cylinder head bolt is broken or deformed, replace it
with a new bolt.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts and the plate washers.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 18 cylinder head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 45 N
m (459 kgf
cm, 33 ft
lbf)
HINT:
See the table below for the bolt length.
Bolt TypeBolt Length
(A)160mm (6.30 in.)
(B)104mm (4.09 in.)
If the cylinder head bolt does not meet the torque specification,
replace the cylinder head bolt with a new bolt.
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90  in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by additional 90  in the
same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional 90 in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man- ifold side.
71. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing pulley at the position
of 90  BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
72.INSTALL CAMSHAFT (See page 14±318)
73.INSTALL NO.2 CAMSHAFT (See page 14±318)
74.REMOVE CAMSHAFT OIL SEAL (See page 14±318)
75.INSTALL CAMSHAFT OIL SEAL (See page 14±318) SST 09223±46011

A09663
:Seal Packing
14±338
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
76.INSTALL CAMSHAFT OIL SEAL RETAINER (See page 14±318)
77.INSTALL CAMSHAFT TIMING PULLEY (See page 14±318) SST 09960±10010 (09962±01000, 09963±01000)
78.INSTALL CAMSHAFT POSITION SENSOR (See page 10±64)
79.INSTALL INJECTOR ASSY(See page 11±60)
80.INSTALL NOZZLE LEAKAGE PIPE ASSY(See page 11±60) SST 09992±00242
81. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head.Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
82. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
83.INSTALL VACUUM PUMP ASSY (See page 14±318) 84. INSTALL INJECTION PIPE SUB±ASSY NO.1(See page 11±60)
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.

A79147
Fulcrum
Length
30 cm
SST
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±339
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec-
tor side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
85. INSTALL INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
86. INSTALL INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
87. INSTALL INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.

A79148
SST
A79149
SST
14±340
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
88.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the cylinder head gasket replaced,
must replace fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the new fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com- mon rail side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the pump side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
89.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
90.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
91.INSTALL TURBOCHARGER STAY (See page 13±11)
92.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
93.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
94.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)

±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±341
AVENSIS REPAIR MANUAL (RM1018E)
95.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
96.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
97.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
98.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
99.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
100.INSTALL HEATER BRACKET (W/ COLD AREA)(See page 13±11)
101.INSTALL HEATER PUMP ASSY (W/ COLD AREA)(See page 13±11)
102.INSTALL FUEL FILTER ASSY(See page 11±82)
103.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
SST 09960±10010 (09962±01000, 09963±01000)
104.INSTALL TIMING BELT(See page 14±307)
105.CHECK VALVE TIMING(See page 14±307)
106.TIMING CHAIN COVER PLATE(See page 14±307)
107.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
108.INSTALL TIMING BELT GUIDE(See page 14±307)
109.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
110.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
111.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
112.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
113.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
114.INSTALL POWER STEERING IDLE PULLEY BRACKET(See page 14±307)
115. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
116.INSTALL INJECTOR DRIVER (See page 14±286)
117.INSTALL AIR TUBE NO.1(See page 14±270)
118.INSTALL AIR TUBE NO.2 (See page 14±286)
119.INSTALL AIR CLEANER ASSY (See page 14±286)
120.INSTALL VACUUM RESERVOIR SUB±ASSY (See page 13±11)
121. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
122. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
123. ADD ENGINE OIL
124.ADD ENGINE COOLANT(See page 16±44)
125.CHECK FOR FUEL LEAKS(See page 11±60)
126. CHECK FOR ENGINE OIL LEAKS
127.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
128. CHECK FOR EXHAUST GAS LEAKS