2002 TOYOTA AVENSIS width

C62956
D30058
1CD±FTV Engine Type: Others:
Transaxle Side


D25281
AB
C62958
± CLUTCHCLUTCH UNIT (MTM)
42±27
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE CLUTCH DISC ASSY
NOTICE:
Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub±assy
away from oil and foreign attachment.
9. INSPECT CLUTCH DISC ASSY
(a) Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assy as necessary.
(b) Install the clutch disc assy to the transaxle assy.
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
(c) Using a dial gage, check the clutch disc assy runout.
Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assy as necessary.
10. INSPECT CLUTCH COVER ASSY
(a) Using vernier calipers, inspect the diaphragm spring for
the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assy as necessary.
11. INSPECT FLYWHEEL SUB±ASSY
(a) Using a dial gage, inspect the flywheel sub±assy runout.
Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub±assy as necessary.

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
16±22
±
COOLING WATER PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the con- tact surface.
(b)Apply seal packing to the water pump as shown in the il- lustration.
Seal packing: Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 2.2 to 2.5 mm
(0.09 to 0.10 in.) opening.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c)Install the water pump and wire clamp with 4 bolts and 2
nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d)Install the crankshaft position sensor wire harness clamp to the water pump.
(e)Install the crankshaft position sensor wire to the wire clamp on the water pump.
10.INSTALL WATER PUMP PULLEY
(a)Using SST, install the pump pulley with 4 bolts. SST09960±10010 (09962±01000, 09963±00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
13.ADD COOLANT (See page 16±19)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±17)

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
16±34
±
COOLING WATER PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the contact surface.
(b)Apply seal packing to the water pump as shown in the il- lustration.
Seal packing: Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 2.2 to 2.5 mm
(0.09 to 0.10 in.) opening.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c)Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d)Install the crankshaft position sensor wire harness clamp to the water pump.
(e)Install the crankshaft position sensor wire to the wire clamp on the water pump.
10.INSTALL WATER PUMP PULLEY
(a)Using SST, install the pump pulley with 4 bolts. SST09960±10010 (09962±01000, 09963±00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
13.ADD COOLANT (See page 16±31)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS(See page 16±25)

A09601
Seal Packing
A09627
A09650
12
3
5
49
6
8
7
13
10
11
15
14 12
A09600
Seal Width
2 to 4 mm
Seal Packing
14±322
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(e)Install the camshaft bearing caps. (1)Remove any oil packing (FIPG) material from theNo. 5 camshaft bearing cap.
(2)Apply seal packing to the No. 5 camshaft bearing cap as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(3)Place the 5 bearing caps in their proper locations.
(4)Using several steps, install and tighten the 15 bear- ing cap bolts uniformly in the sequence shown in the
illustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
43.INSPECT VALVE CLEARANCE (See page 14±270)
44.ADJUST VALVE CLEARANCE (See page 14±270) 45. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the oil seal
retainer and the cylinder block.
(1) Thoroughly clean all components to remove all theloose material.
(2) Using non±residue solvent, clean both sealing sur- faces.
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 2 to 4 mm(0.08 to 0.16 in.) opening.
(2) Parts must be assembled within 15 minutes of ap- plication. Otherwise the material must be removed
and reapplied.
(3) Immediately remove nozzle from the tube and rein- stall the cap.

A62174
SST
A62175
Seal Width
4 to 5 mm
Seal Packing
A65676
Timing Chain Cover side:
3 (0.118)3 (0.118)
A
ABB
C
C
7 (0.276)
4.5 (0.177)
12 (0.472)6 (0.236)
3 (0.118)
Width 4 (0.157)
A ± AB ± B
C ± C
08826±00100 or equivalent
08826±00080 or equivalent
(mm (in.)) 14±90
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
58. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to a new oil seal lip.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip free of foreign objects.
59. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material (FIPG) from the contact
surface.
(b) Apply a continuous bead of seal packing (Diameter 3.5
mm to 4.5 mm (0.1379 to 0.177 in.)) as shown in the il-
lustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent.
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal to engine oil within 2 hours af-
ter installing.

710CN±02
I34628
C10±19
C10±5
± INSTRUMENT PANEL/METERCOMBINATION METER
71±3
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT SPEEDOMETER
(a) Check the operation.
(1) Using a speedometer tester, inspect the speedometer for acceptable indication error and check
the operation of the odometer.
Reference: km/h (Europe)
Standard indicationAcceptable range
20 km/h21.0 ± 25.0 km/h
40 km/h41.7 ± 46.2 km/h
60 km/h62.7 ± 67.2 km/h
80 km/h83.4 ± 88.4 km/h
100 km/h104.3 ± 109.3 km/h
120 km/h125.1 ± 130.6 km/h
140 km/h145.8 ± 151.8 km/h
160 km/h166.2 ± 173.2 km/h
180 km/h186.9 ± 194.5 km/h
200 km/h207.7 ± 215.7 km/h
220 km/h228.4 ± 236.8 km/h
240 km/h249.2 ± 258.0 km/h
Reference: MPH (Europe)
Standard indicationAcceptable range
20 mph21.0 ± 23.5 mph
40 mph42.0 ± 44.5 mph
60 mph62.5 ± 66.0 mph
80 mph83.1 ± 87.1 mph
100 mph103.9 ± 108.4 mph
120 mph124.7 ± 129.6 mph
140 mph145.4 ± 150.7 mph
NOTICE:
Tire wear and over or under inflation will affect the indication error.
(2) Check the deflection width of the speed meter indicator.
Reference: Below 0.5 km/h (0.3 mph)
2. INSPECT OUTPUT SIGNAL OF VEHICLE SPEED
(a) Check for the signal.
(1) While driving the vehicle at the speed of 10 km/h,
check the voltage between the terminal C11±15 of
the combination meter assy and the body ground.
Standard: Fluctuation between 10 to 14 V or less is re-
peated 7 times within 1 sec.
NOTICE:
Check it with the ignition switch ON and the connector con-
nected.

± INTRODUCTIONTERMS
01±39
AVENSIS REPAIR MANUAL (RM1018E)Abbreviations Meaning
H±FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HWSHeated Windshield System
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission (Transaxle)
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O2SOxygen Sensor
O/DOverdrive

A56700
SST
B07987
New Gasket
Seal
Packing Seal Width
2 to 4 mm
B08024
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±25
AVENSIS REPAIR MANUAL (RM1018E)
35. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316±60011 (09316±00011, 09316±00021)
36. INSTALL OIL PUMP ASSY
(a) Remove any old packing (FIPG) and be careful not to
drop any oil on the contact surfaces of the oil pump and
the cylinder block.
(1) Using a razor blade and a gasket scraper, remove
all the old packing from the gasket surfaces and the
sealing groove.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non±residue solvent, clean both the sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
(1) Install a nozzle that has been cut to a 2 to 4 mm
(0.08 to 0.16 in.) opening.
(2) Parts must be set within 3 minutes and assembled
within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3) Immediately remove nozzle from the tube and rein-
stall the cap.
(c) Install a new gasket to the oil pump.
(d) Pour in 0.5 cm
3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Apply engine oil to the cylinder block side where it con-
tacts with the oil pump driven rotor.