2002 TOYOTA AVENSIS steering

A77521
Generator ASSY Cooler Refrigerant
Suction Hose No. 1
(RHD (w/ Air Conditioning)
Steering Position Type)
Radiator Hose Inlet
Radiator Hose Outlet
Cooler Refrigerant Suction Hose No. 1
(LHD (w/ Air Conditioning) Steering
Position Type)
Union to Connector
Tube Hose
Charcoal Canister Assy
Battery TrayBatteryRadiator ASSY
Compressor and
Magnetic Clutch
(w/ Air Conditioner)
Battery Clamp
Battery CarrierAir Cleaner Assembly with Hose
Radiator Relay Block
52 (530, 38)
9.8 (100, 7.2)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
13 (133, 10)
25 (250, 18)
5.0 (51, 44 in.
lbf)
21 (214, 16)
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
19 (194, 14)
19 (194, 14)
14±112
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A77313
Cooler Bracket
(LHD (w/ Air Conditioner) Steering Position Type)
Oil Reservoir
Bracket No. 1Heater Outlet Water Hose
Heater Inlet Water Hose
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silercer Sheet
Front Stabilizer Link Assy
Front Axle Assy
35 (360, 26)
7.0 (71, 62 in.
lbf)
74 (755, 55 )
216 (2,203,159 )
142 (1,448,105 )
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Front Axle Hub Nut
Tie Rod End Sub±assy
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)

Cotter Pin
49 (500, 36)
Front Suspension Arm
Sub±assy Lower No. 1
14±114
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

141BF±01
A77281
A77301
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.

A77308
A77303
A77307
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±123
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITION ER) STEER ING
POSITION TYPE)
(a)Remove 2 nuts and separate the suction hose.
28.REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a)Remove a bolt and the service cover bracket RH. 29.REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the cooler bracket.
30.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
31.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
32.DISCONNECT HEATER OUTLET WATER HOSE (W/ AIR CONDITIONING)
33.REMOVE CHARCOAL CANISTER ASSY
34.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±15)
35. DISCONNECT UNION TO CONNECTOR TUBE HOSE
36.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
38.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
39.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09330±00030

A77298
LHD Steering Position typeRHD Steering Position type
14±124
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE FRONT AXLE HUB RH NUT SST09330±00030
HINT:
Perform the same procedure as above on the opposite side.
41.SEPARATE TIE ROD END SUB±ASSY LH (See page 51±36)
42.SEPARATE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
43.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
44.SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
(See page 26±21)
46.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) (See page 26±16)
47.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
48.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
49.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
50.SEPARATE FRONT AXLE ASSY RH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side. 51.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
(a)Remove 7 bolts as shown in the illustration.
52.SEPARATE TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
53.SEPARATE TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
54. SEPARATE ACCELERATOR CONTROL CABLE ASSY

A77338
A77337
A77336
A57550
Engine Hanger No. 1 Engine Hanger No. 2
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
14±125
AVENSIS REPAIR MANUAL (RM1018E)
55. SEPARATE ENGINE ROOM RELAY BLOCK NO.2
(a) Remove the nut and disconnect the connector as shown
in the illustration.
56. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the grand terminal.
(b) Separate the grand terminal connector.
(c) Remove the glove compartment door panel.
(d) Separate the engine wire.
57.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9) 58. INSTALL ENGINE HANGERS
(a) Install the engine hanger No. 1 (12281±28010, 28020,28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Install the engine hanger No. 2 (12282±28010, 28020, 28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)

A77304
A77305
A77405
A
B
A
A
A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±132
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
120.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
121.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
122.INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
123.REMOVE ENGINE HANGERS
124.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
125.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (
See page 41±24)

126.INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25) 127. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
Torque:
Bolt A 12 N
m (122 kgf
cm, 89 ft
lbf)
Bolt B 9.0 N
m (92 kgf
cm, 79 in.
lbf)
Bolt C 5.0 N
m (51 kgf
cm, 44 in.
lbf)

±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±133
AVENSIS REPAIR MANUAL (RM1018E)
128.INSTALL FRONT AXLE ASSY LH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
129.INSTALL FRONT AXLE ASSY RH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
130.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
131.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE)
Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
132.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
133.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
134.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
135.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
136.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
137.INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
138.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
139.INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
140.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
141.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
142.INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
143.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
144.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
145.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
146.INSTALL COOLER REFRIGE RANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
147.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
148.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
149.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
150.INSTALL BATTERY CARRIER
151.INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
152.INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
Torque: 25 N
m (255 kgf
cm,18 in.
lbf)
153.INSTALL GENERATOR ASSY (See page 19±20)
154.INSTALL FAN AND GENERATOR V BELT (See page 14±105)