2002 TOYOTA AVENSIS key

A79301
Upper Hook
Fan
Shroud
Radiator
16±12
±
COOLING RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
10.INSTALL RADIATOR ASSY
(a)Align the 2 keyways of the fan shroud with the 2 keys lo- cated on the lower bottom of the radiator and fit them.
(b)Install the fan should to the radiator with the 2 upper hooks. You can hear ºclickº sounds when the hooks are
securely fitted.
(c)Install the 2 support radiator LWRs to the radiator.
(d)Install the radiator with the 2 bolts and 2 radiator support
uppers.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(e)Install the relay block with the 2 bolts.
(f)Connect the fan connector and 2 harness clamps.
11.ADD ENGINE COOLANT (See page 16±7)
12.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)

A79301
Upper Hook
Fan
Shroud
Radiator
16±12
±
COOLING RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
10.INSTALL RADIATOR ASSY
(a)Align the 2 keyways of the fan shroud with the 2 keys lo- cated on the lower bottom of the radiator and fit them.
(b)Install the fan should to the radiator with the 2 upper hooks. You can hear ºclickº sounds when the hooks are
securely fitted.
(c)Install the 2 support radiator LWRs to the radiator.
(d)Install the radiator with the 2 bolts and 2 radiator support
uppers.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(e)Install the relay block with the 2 bolts.
(f)Connect the fan connector and 2 harness clamps.
11.ADD ENGINE COOLANT (See page 16±7)
12.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)

B67989
Front Door Outside Handle Frame Sub±assy LHw/ Key:
Front Door Outside Handle Cover LH
Front Door Handle
Assy Outside LH
Front Door Outside Handle Pad Rear Front Door Outside
Handle Pad Front
Hole Plug
Front Door Lock Open Rod
Front Door w/ Motor Lock Assy LH
Door Lock Wire Harness Packing 5.0 (51, 44 in.´lbf)
Front Door Belt Moulding LH
Front Door Hinge
Assy Upper LH
Front Door Check Assy
30 (306, 22)

5.5 (56, 49 in.´lbf)
Front Door Hinge
Assy Lower LH26 (265, 19)
Front Door Weatherstrip LH
Cushion RubberFront Door Lower Frame
Bracket Garnish LH Outer Rear View Mirror Assy LH
Front Door Speaker No. 2
Front Door Service Hole Cover 
: Specified torqueN´m (kgf´cm, ft´lbf)


Precoated Part Non±reusable part Clip
26 (265, 19)
Front Door Lower
Frame Seal


Butyl Tape

10 (102, 7)
Front Door Stiffener
Cushion No. 1
Side Trim
Spacer LH
Key Cylinder
w/o Key:
Front Door Outside
Handle Cover LHw/ Speaker
Front Door Lower Frame
Bracket Garnish LH
± ENGINE HOOD/DOORFRONT DOOR
75±5
AVENSIS REPAIR MANUAL (RM1018E)

B62422
B62423
12
B66968
B61434

B68932Hole Plug
± ENGINE HOOD/DOORFRONT DOOR
75±11
AVENSIS REPAIR MANUAL (RM1018E)
14. REMOVE FRONT DOOR GLASS SUB±ASSY LH
HINT:
Insert a shop rag inside the door panel to prevent the glass from
being scratched.
(a) Move the door glass until the bolts appear in the service
holes.
(b) Remove the 2 bolts holding the door glass to the window
regulator.
(c) Remove the door glass in the direction indicated by the
arrows in the illustration.
NOTICE:

Do not damage the glass.

When the bolts are removed, the glass may fall and
become deformed.
(d) Remove the glass run.
15. REMOVE FRONT DOOR WINDOW REGULATOR
SUB±ASSY LH
(a) Disconnect the window regulator connector.
(b) Remove the 6 bolts and window regulator.
NOTICE:
When the bolts are removed, the window regulator may fall
and become deformed.
HINT:
Remove the window regulator through the service hole.
16. REMOVE FRONT DOOR FRAME SUB±ASSY REAR
LOWER LH
(a) Remove the bolt and frame.
HINT:
Remove the frame through the service hole.
17. REMOVE FRONT DOOR OUTSIDE HANDLE COVER
(a) Remove the hole plug.
(b) Using a torx socket wrench (T30), loosen the screw and
remove the cover with the door lock key cylinder installed.

B65961
Rod
B66894
Adhesive
Adhesive

B68932Hole Plug
B62425
B66972
75±14
± ENGINE HOOD/DOORFRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(c) Insert the control rod into the door lock, and then set it to
the door panel.
NOTICE:
Make sure that the handle link is securely engaged with the
lock.
(d) Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(e) Using a torx socket wrench (T30), install the door lock with
the 3 screws.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(f) Connect the door lock connector.
27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER
(a) Using a torx socket wrench (T30), install the cover with the
door lock key cylinder installed with the screw.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
(b) Install the hole plug.
28. INSTALL FRONT DOOR FRAME SUB±ASSY REAR
LOWER LH
(a) Install the frame with the bolt.
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
29. I N S TA L L F R O N T D O O R W I N D O W R E G U L ATO R
SUB±ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
window regulator.
NOTICE:
Do not apply grease to the spring of the window regulator.

A31032
A32639
A77414
Straight
Pin
Key
Groove 14±174
± ENGINE MECHANICALCAMSHAFT (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Put air pressure into the oil port with 150 kpa (1.5 kgf/cm2
21 psi), and turn the camshaft timing gear to the advance
direction (counterclockwise) by hand.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
HINT:
Depending on the air pressure, the camshaft timing gear will
turn to the advance angle side without applying force by hand.
Also, under the condition that the pressure can be hardly ap-
plied because of the air leakage from the port, there may be the
case that the lock pin could be hardly released.
(d) Remove the fringe bolt of camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If reusing the camshaft timing gear, release the
straight pin lock first, and then install the gear.
13. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET (LEADED GASOLINE)
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
14. INSTALL CAMSHAFT TIMING GEAR ASSY
(UNLEADED GASOLINE)
(a) Put the camshaft timing gear and the camshaft together
with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) while lightly pushing it to-
ward the camshaft. Push further at the position where the
pin gets into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right direction).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
(e) Check that the camshaft timing gear can move to the re-
tard angle side (to the right direction), and is locked at the
most retarded position.

A32639
A77414
Straight
Pin
Key
Groove
A77284
A77415Bearing Cap No. 1Bearing Cap No. 3 5
312 4
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
14±243
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove a fringe bolt of camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If reusing the camshaft timing gear, release the
straight pin lock first, and then install the gear.
17. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear and the camshaft together
with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) while lightly pushing it to-
ward the camshaft. Push further at the position where the
pin gets into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right direction).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
(e) Check that the camshaft timing gear can move to the re-
tard angle side (to the right direction), and is locked at the
most retarded position.
18. INSTALL CAMSHAFT
(a) Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
(b) Install the timing chain on the camshaft timing gear, with
the painted links aligned with the timing marks on the
camshaft timing gear.
(c) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
19. INSTALL NO.2 CAMSHAFT
(a) Put the No. 2 camshaft on the cylinder head with the
painted links of chain aligned with the timing mark on the
camshaft timing gear.

A79428
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
18 (184, 13)
27 (270, 20)22 (224, 16)13 (135, 9.7)

Gasket

O±ring Fuel Injector
Back±up Ring No. 1


Injection Nozzle Seat
8.8 (90, 78 in.
lbf)

Oil Seal
8.8 (90, 78 in.
lbf)
20 (204, 15)
Washer
Nozzle Holder ClampNozzle Leakage
Pipe Assy
Injector AssyCylinder Head Cover Sub±assy
Gasket
Camshaft Bearing Cap
No. 2 CamshaftCamshaft
Camshaft Carrier
Camshaft Oil Seal
Retainer
88 (899, 65)
Camshaft Timing PulleySet Key
20 (204, 15)
* 42 (428, 31)
46 (469, 34)
Injection Pipe
Clamp No. 2
Injection Pipe
Sub±assy
O±ring
21 (214, 15)
Vacuum Pump Assy
5.0 (51, 44 in.
lbf)

Nozzle Holder Seal
* Use SST
* 42 (428, 31)
46 (469, 34)
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
14±317
AVENSIS REPAIR MANUAL (RM1018E)