2002 TOYOTA AVENSIS Repair Manual

A79419
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
29 (296, 21)
80 (816, 59)
133 (1,348, 97)
43 (440, 32)
30 (302, 22)
43 (440, 32)

Gasket
74 (755, 55)
49 (500, 36)

Gasket
Cotter Pin V (Cooler Compressor
to Crankshaft pulley)
Belt No. 1Glove Compartment Door Assy
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silencer Sheet
Front Stabilizer Link Assy LHClip
Tie Rod End Sub±assy LH
Front Axle Hub LH Nut
Front Suspension Member
Brace Rear LH
Compression
Spring
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring w/ A/C:
Compressor And Magnetic ClutchFront Drive Shaft Assy LHClip Transmission Control
Cable Assy
Clip
Clutch Accumulator Assy
Clutch Release Cylinder Assy
Transmission Control Cable Assy
35 (357, 26)
142 (1,448, 105)
Clip
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±279
AVENSIS REPAIR MANUAL (RM1018E)

A79420N´m (kgf´cm, ft´lbf)
: Specified torque
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)
87 (887, 64)
80 (816, 59)
133 (1,356, 98)52 (530, 38)
72 (734, 53)
39 (398, 29)
Engine Mounting Insulator
Sub±assy RHAir Tube No. 1
Front Suspension Crossmember
Sub±assy25 (255, 18)
25 (255, 18)
14±280
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

A79421N´m (kgf´cm, ft´lbf)
: Specified torque
88 (897, 65)
19 (195, 14)
64 (653, 47)
37 (377, 27)
Drive Shaft Bearing Bracket
Flywheel Sub±assy
Clutch Cover Assy
Starter Assy
Manual Transaxle
Clutch Disc Assy
64 (653, 47)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±281
AVENSIS REPAIR MANUAL (RM1018E)

A79422
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket

Gasket
Gasket
20 (204, 15)
20 (204, 15)
53 (540, 39)
13 (135, 9.7)
36 (367, 27)61 (622, 45)
56 (571, 41)
25 (255, 18)
Turbo Insulator No. 1
Exhaust Manifold Heat Insulator No. 2
Turbocharger Stay
Turbocharger Sub±assy
Turbo Oil Inlet Pipe
Sub±assy
Manifold Stay Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy Turbo Insulator
No. 2


20 (204, 15)
12 (122, 8.9)
56 (571, 41)

Gasket
12 (122, 8.9)
14±282
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
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)
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
21 (214, 15)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±283
AVENSIS REPAIR MANUAL (RM1018E)

A79423
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket

O±ring
* Use SST
Gasket
Gasket

Gasket

Gasket

Gasket3.6 to 6.9 (40 to 70, 35 to 61 in.
lbf)
5.0 (51, 44 in.
lbf)
7.4 (76, 66 in.
lbf)
* 31 (316, 23)
34 (347, 25)
43 (438, 32)
21 (214, 15)
18 (184, 13)
21 (214, 15)
21 (214, 15)
21 (214, 15)
64 (650, 47)
21 (214, 15)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
Common Rail Assy
Fuel Hose No. 4
Vacuum Pump Assy
Nozzle Leakage Pipe No. 2Fuel Inlet Pipe Sub±assy
EGR Valve Assy
Water Outlet Sub±assy
Engine Coolant
Temperature Sensor
Intake Air Connector Sub±assy
Intake Manifold
Wiring Harness Clamp Bracket Injection Pump
Drive Pulley Timing Belt
No. 3 CoverSeal Washer Camshaft Position Sensor
Check Valve
8.8 (90, 78 in.
lbf)
8.8 (90, 78 in.
lbf)
21 (214, 15)
21 (214, 15)
14±284
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

A79424
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
8.8 (90, 65 in.
lbf)
8.8 (90, 6.5 in.
lbf)
8.4 (86, 74 in.
lbf)
21 (209, 15)
8.8 (90, 78 in.
lbf)
34 (347, 25)
18 (184, 13)21 (210, 15)
21 (210, 15)
42 (428, 31)
37 (377, 27)
59 (600, 43)
21 (214, 15)
45 (454, 33)

O±ring

O±ring

Gasket

O±ring

O±ring
Vacuum Pump Oil Pipe
Union Bolt
Oil Cooler AssyFuel Filter To Injection Pump
Fuel Pipe
Rear End Plate
Crankshaft Position
Sensor
Thermostat
Water Inlet
Oil Level Gage Guide Oil Filter Bracket Sub±assy
Injection or Supply Pump Assy Compressor Mounting
Bracket No. 1Generator Bracket No. 1 V±ribbed Belt
Tensioner
AssyGenerator Assy
Oil Cooler Pipe

Gasket
Turbo Oil Outlet Pipe No. 2
31 (320, 23)

Gasket
33 (331, 24)
8.8 (90, 78 in.
lbf)
47 (475, 34)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±285
AVENSIS REPAIR MANUAL (RM1018E)

141C4±01
A80094
14±286
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEELS
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.DRAIN ENGINE COOLANT (See page 16±44)
8.DRAIN ENGINE OIL (See page 14±342)
9.DRAIN MANUAL TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
11.REMOVE BATTERY
12.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap together with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
13.DISCONNECT UNION TO CONNECTOR TUBE HOSE
14.REMOVE FUEL FILTER ASSY
(a)Disconnect the 2 fuel hose from the fuel filter (STD).
(b)Disconnect the 3 fuel hose from the fuel filter (COLD).
(c)Disconnect the connector (STD).
(d)Disconnect the 2 connectors (COLD).
(e)Remove the 2 bolts and the fuel filter.
15.REMOVE RADIATOR HOSE INLET
16.REMOVE RADIATOR HOSE OUTLET
17.DISCONNECT WATER BY±PASS HOSE NO.2
18.REMOVE ENGINE ROOM RELAY BLOCK NO.3
(a)Remove the 2 bolts and the engine room relay block.
19.REMOVE RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
20. DISCONNECT HEATER INLET WATER HOSE
21. DISCONNECT HEATER OUTLET WATER HOSE
22. DISCONNECT FUEL HOSE NO.2
23. REMOVE AIR TUBE NO.2
(a) Loosen the hose clamp and disconnect the air hose No.3.
(b) Remove the 2 bolts and the air tube No. 2.