2002 TOYOTA AVENSIS Repair Manual

A62195
Painted Link
Timing Mark
A62196
4123
A62197
Painted Link
Timing Mark
A32124
A621983124 5 67 14±14
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(m) Install the timing chain on the camshaft timing gear with
the painted links aligned with the timing marks on the
camshaft timing sprocket as shown in the illustration.
(n) 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)
(o) 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 sprocket.
(p) Tighten the camshaft timing gear set bolt temporarily.
(q) 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)
(r) Install the bearing cap No. 1.
Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)

A62187
Hold
Tighten
A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Timing
Notch
A62177
Raise
Push
Hook
Pin
A62178
Push
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±15
AVENSIS REPAIR MANUAL (RM1018E)
(s) 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 damage the valve lifter.
(t) Check the match marks on the 2 camshaft sprockets are
aligned with each other and aligned with the painted links
of the timing chain as shown in the illustration. Also, check
the timing notch is aligned with the timing mark º0º of the
chain cover.
(u) Install chain tensioner.
(1) Check that the O±ring is clean, and set the hook as
shown in the illustration.
(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 fixit.

A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A11858
A64005
14±16
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(3) Turn the crankshaft counterclockwise, and take the
hook 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.
16. 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
17. 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
AAA
A
A A A
ABB
A64023
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±17
AVENSIS REPAIR MANUAL (RM1018E)
18. 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 cable bracket 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
19. 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
14±18
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
20. 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)
21. CHECK FOR ENGINE OIL LEAKS

1509U±01
A77864
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
Exhaust Pipe GasketExhaust Pipe Assy Front
Compression SpringExhaust Pipe Assy Center
Floor Panel Brace Front

Exhaust Pipe Gasket
43 (440, 32)
43 (440, 32)

Exhaust Pipe Gasket
30 (302, 22)
43 (440, 32)Compression Spring
Exhaust Pipe Assy Tail
Exhaust Pipe Assy Center
1AZ±FE (Leaded Gasoline)
1AZ±FSE: 15±6
± EXHAUSTEXHAUST PIPE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST PIPE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS

1509V±01
A77867
(a)
(a)
(b)
(b)
A77868
±
EXHAUST EXHAUST PIPE ASSY(1AZ±FE/1AZ±FSE)
15±7
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
2.REMOVE EXHAUST PIPE ASSY TAIL (See page 15±2)
3. REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts.
(b) Remove the exhaust pipe center and the gasket from the2 exhaust pipe supports.
4. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs, and then remove the exhaust pipe front.
(b) Remove the gasket from the exhaust manifold.

A77857
A78440
New Gasket
15±8
±
EXHAUST EXHAUST PIPE ASSY(1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
5.INSTALL EXHAUST PIPE ASSY FRONT
(a)Compression spring inspection (1)Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 41.5 mm (1.634 in.)
If the free length is less than minimum, replace the compression
spring.
(b)Install a new gasket to the exhaust manifold as shown in the illustration.
(c)Install the exhaust pipe front with the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
6.INSTALL EXHAUST PIPE ASSY CENTER
(a)Install a new gasket and the exhaust pipe center to the 2 exhaust pipe s\
upports.
(b)Tighten the 2 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
7.INSTALL EXHAUST PIPE ASSY TAIL (See page 15±2)
8. CHECK FOR EXHAUST GAS LEAKS
9.INSTALL FLOOR PANEL BRACE FRONT (See page 15±2)