2002 TOYOTA AVENSIS Repair Manual

A76718
A76719
A62838SST
A62838SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±33
AVENSIS REPAIR MANUAL (RM1018E)
60. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Remove the through bolt and nut, detach the engine
mounting insulator FR from the engine mounting bracket.
(b) Remove the through bolt, detach the engine mounting in- sulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the suspension crossmember and the engine mounting
member.
61.REMOVE STARTER ASSY(See page 19±3)
62.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
63.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
64.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
65.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) 66. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
67. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the
drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
68. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.

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A64023
A79363
A64026
14±34
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the 2 nuts which are used to secure the engine wire.
(c) Remove the 4 bolts and the 4 ignition coils.
69. REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±11)
70. REMOVE INTAKE MANIFOLD
(a) Disconnect the 2 water hoses from the throttle body.
(b) Disconnect the ventilation hose and the ventilation hose No. 2 from the cylinder head cover.
(c) Disconnect the vacuum hose from the water by±pass
pipe No. 1.
(d) Remove the 4 bolts, 2 nuts and 2 wire brackets,then re- move the intake manifold and the throttle body assembly.
(e) Remove the gasket from the intake manifold and the
throttle body assembly.
71. REMOVE OIL LEVEL GAGE SUB±ASSY
(a) Remove the oil level gage from the oil level gage guide.
72. REMOVE OIL LEVEL GAGE GUIDE
(a) Disconnect the crank shaft position sensor cramp.
(b) Remove the bolt and the oil level gage guide.

A64027
A64028
B00084
A76692
A64029
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±35
AVENSIS REPAIR MANUAL (RM1018E)
73. REMOVE WATER BY±PASS PIPE NO.1
(a) Disconnect the knock sensor cramp.
(b) Remove the 2 bolts and 2 nuts, then detach the water by±
pass pipe and the gasket.
74. REMOVE WATER INLET
(a) Remove the 2 nuts and the water inlet.
75. REMOVE THERMOSTAT
76. REMOVE ENGINE OIL PRESSURE SWITCH ASSY (See page 17±1)
77. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and the camshaft position sensor.
78. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and the crankshaft position sensor.
79. REMOVE KNOCK SENSOR
(a) Remove the nut and the knock sensor.

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A64059
A64060
A76720
A76721
14±36
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
80. REMOVE V±RIBBED IDLER ASSY NO.1
(a) Remove the nut, bolt, tube and the idler.
81. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolts, nut and the V±ribbed belt tensioner.
82. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and the transverse engine mounting
bracket.
83. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and the manifold stay.
84. REMOVE MANIFOLD STAY NO.2
(a) Remove the 3 bolts and the manifold stay.

A76722
A76723
A64033
A64034
A64034
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±37
AVENSIS REPAIR MANUAL (RM1018E)
85. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 3 bolts and the nut, and then remove the ex-
haust manifold heat insulator.
86. REMOVE EXHAUST MANIFOLD
(a) Remove the 5 nuts, then remove the exhaust manifold
and the gasket.
87. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the engine coolant temperature sen-
sor.
SST 09817±33190
88. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and the condenser.
89. REMOVE WATER BY±PASS HOSE NO.2
90. REMOVE RADIATOR HOSE INLET
91. REMOVE HEATER INLET WATER HOSE
92. REPLACE PARTIAL ENGINE ASSY
93. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)

A64033
A76723
A76722
A76721
A76720
ABB 14±38
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
94. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Install a new gasket to the engine coolant temperature
sensor.
(b) Using SST, install the engine coolant temperature sensor.
SST 09817±33190
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
95. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
96. INSTALL EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Install the exhaust manifold heat insulator,then install the
3 bolts and nut.
Torque:
18 N
m (184 kgf
cm, 13 ft
lbf) for Bolt
12 N
m (122 kgf
cm, 9 ft
lbf) for Nut
(b) Connect the heated oxygen sensor connector.
97. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay with the 3 bolts.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
98. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque:
49 N
m (500 kgf
cm, 36 ft
lbf) for A
37 N
m (377 kgf
cm, 27 ft
lbf) for B

A64060
A64059
A79324
A76692
B00084
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±39
AVENSIS REPAIR MANUAL (RM1018E)
99. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the transverse engine mounting bracket with the
bolts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
100. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the bolt and nut. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
101. INSTALL V±RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt. Torque: 39.2 N
m (400 kgf
cm, 29 ft
lbf)
102.INSTALL KNOCK SENSOR (See page 10±17)
103. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O±ring on the crank- shaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
104. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O±ring on the cam- shaft position sensor.
(b) Install the camshaft position sensor with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
105. INSTALL ENGINE OIL PR ESSURE SWITCH ASSY
(See page 17±1)
Adhesive: Part No.08833 ± 00080, THREE BOND 1344.
106.INSTALL THERMOSTAT(See page 16±9)

A64028
A64027
A64026
A79363
A64023
14±40
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
107. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts. Torque: 11 N
m (112 kgf
cm, 8 ft
lbf)
108. INSTALL WATER BY±PASS PIPE NO.1
(a) Install a new gasket and water by±pass pipe with the 2 nuts and 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
109. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil a new O±ring and install it to the oil level gage guide.
(b) Install the oil level gage guide with the bolt. Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
110. INSTALL INTAKE MANIFOLD
(a) Install a new gasket to the intake manifold.
(b) Install the intake manifold and 2 clamp brackets with the 2 nuts and 4 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
111. INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±11)
112. 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)