2002 TOYOTA AVENSIS Repair Manual

A76713
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90

A62838SST
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±41
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
113. INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts.
Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni-
formly in the sequence shown in the illustration.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(e) Mark each bolt head with paint.
(f) Retighten the bolts by an additional 90
in the same se-
quence as step (d).
(g) Check that the paint marks are at 90
angle about the
original position.
114. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)

A62204
1
5
3
82
6
4
7
A76719
A76718
A76717
14±42
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 88 N
m (897 kgf
cm, 65 ft
lbf)
115.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
116.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
117.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)(See page 41±15)
118.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
119.INSTALL STARTER ASSY(See page 19±3)
120. INS TALL FRO NT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen- sion crossmember and the engine mounting member.
(b) Install the bolt which is used to secure the rear engine
mounting bracket to the mounting insulator.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(c) Install the bolt which is used to secure the front engine mounting bracket to the mounting insulator.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
121. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670±00010
(a) Set the engine assembly with transaxle on the engine lift- er.
(b) Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N
m (816 kgf
cm, 59 ft
lbf)
(d) Install the engine mounting insulator RH. Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)

A76717
A
B
A
B
A76716
AA
BBBBBB
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±43
AVENSIS REPAIR MANUAL (RM1018E)
(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 N
m (459 kgf
cm, 33 ft
lbf) for Bolt A
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Nut B
(f) Install the front suspension member brace LH and RH with the 8 bolts.
Torque:
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Bolt A
80 N
m (816 kgf
cm, 59 ft
lbf) for Bolt B
NOTICE:
When installing the crossmember, check that the position-
ing holes on the crossmember and on the vehicle are
aligned with each other.
122.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
123. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
124.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
125. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
127. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
128.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
129. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
130.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±2)
131. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
132.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
133.INSTALL GENERATOR ASSY (See page 19±7)
134. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
135. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
136. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)

A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N
m (131 kgf
cm, 9 ft
lbf)
138. INSTALL BATTERY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. 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)
145. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL

141C5±01
A79425N´m (kgf´cm, ft´lbf)
: Specified torque
8.0 (82, 71 in.
lbf)
72 (734, 53)
V (Cooler
Compressor to
Crankshaft
Pulley) Belt No. 1
Engine Cover No. 1Engine Room Cover Side
Radiator Support
Opening Cover
Power Steering
Idle Pulley Bracket
Engine Under Cover Sub±assy No. 1
Engine Under Cover RH
Injector Driver
52 (530, 38)
Engine Mounting Insulator Sub±assy RH
52 (530, 38)
52 (530, 38)
39 (398, 29)
Clip
Clip
Retainer
Clip
Clip
5.0 (51, 44 in.
lbf)
± ENGINE MECHANICALTIMING BELT (1CD±FTV)
14±305
AVENSIS REPAIR MANUAL (RM1018E)
TIMING BELT (1CD±FTV)
COMPONENTS

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±306
± ENGINE MECHANICALTIMING BELT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

141C6±01
A61184
A79179
A61182
SST (B)
SSTSST (A)
±
ENGINE MECHANICAL TIMING BELT(1CD±FTV)
14±307
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.REMOVE 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 INJECTOR DRIVER (See page 14±286)
8.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
9.REMOVE GENERATOR V BELT (See page 14±269)
10.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11. REMOVE ENGINE MOUNTING INSULATORSUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine.
(b) Remove the 3 bolts and 3 nuts, and then detach the en- gine mounting insulator sub assy RH.
12. REMOVE CRANKSHAFT PULLEY
(a) Using SSTs, remove the pulley bolt. SST 09213±54015 (90105±08076), 09330±00021
HINT:
When using SST (A) (90105±08076), a plate washer (5 mm or
0.20 in.) must be inserted between SST (A) and SST (B).

A61183SST
A09605Turn
A61185
14±308
± ENGINE MECHANICALTIMING BELT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Using SST, remove the pulley.
SST 09950±50013 (09951±05010, 09952±05010,
09953±05020, 09954±05031)
13. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt and washer, and then remove the pulley.
14. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, and then remove the timing belt cover.
15. REMOVE TIMING BELT NO.1 COVER
(a) Remove the 5 bolts and 5 seal washers, and then remove the timing belt cover.
16. REMOVE TIMING BELT GUIDE
17. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 6 bolts and the engine mounting bracket.
18. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, align the dot mark of the
crankshaft timing pulley with the TDC mark of the oil pump
by turning the crankshaft.
(b) Check that the timing mark of the camshaft timing pulley
is aligned with a joint of the cylinder head and the cylinder
head cover.
If not, revolve the crankshaft 1 revolution (360
) to align the
mark.
19. REMOVE TIMING CHAIN COVER PLATE
(a) Remove the bolt and the timing chain cover plate.