TOYOTA AVENSIS 2002 Repair Manual

A76713
A78459
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
14±75
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
24. 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)
25. CHECK FOR ENGINE OIL LEAKS

141B7±01
A77310
Engine Cover Sub±assy No. 1
Radiator Support
Opening Cover
Engine Room
Cover Side
Fan and Generator V Belt
Engine Under Cover RH
Engine Under Cover LH
N´m (kgf´cm, ft´lbf)
: Specified torque
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±135
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1AZ±FE)
COMPONENTS

A77319
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Cooler Bracket
(LHD (w/ Air Conditioner)
Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant
Suction Hose No. 1
(LHD (w/ Air Conditioner)
Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator ASSY
Exhaust Pipe Assy Front
43 (440, 32)

Gasket
43 (440, 32)
7.0 (71, 62 in.
lbf)
52 (530, 38)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
Vane Pump Assy
37 (377, 27)
14±136
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A77320
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Ignition Coil Assy
9.0 (90, 80 in.
lbf)
14 (143, 10)
11 (115, 8.0)
Cylinder Head Cover Sub±assy

Gasket
11 (115, 8.0)
Ventilation Hose Ventilation Hose No. 2
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±137
AVENSIS REPAIR MANUAL (RM1018E)

A77321
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
43 (440, 32)

Gasket
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover
Sub±assy
Crankshaft Position
Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt
Tensioner Assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
43 (440, 32)
170 (1,735, 125)
Crank Shaft Pulley

Oil Seal
43 (440, 32)
Chain Sub±assy
Chain Tensioner
Slipper
Chain Vibration
Damber No. 1
Crankshaft
Timing Gear
or Sprocket
19 (195, 14)
Crankshaft Position
Sensor Plate No. 1
Timing Chain Guide
Oil Pump
Drive Gear
12 (122, 9.0)
Spring
Chain Tensioner
Oil Pump Drive Shaft Gear
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
30 (301, 22)
No. 2 Chain Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
14±138
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

141B8±01
A77281
A77292
A77299
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FE)
14±139
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE ENGINE UNDER COVER LH
6.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining the engine oil.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
7.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
8.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
9.REMOVE GENERATOR ASSY (See page 19±20)
10.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
11. SEPARATE VANE PUMP ASSY
(a) Remove the 2 through bolts and separate the vane pump.
12. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove 3 bolts and separate the return tube as shownin the illustration.

A77303
A77308
A77306
A77307
14±140
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
13. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
14. SEPARATE VANE PUMP OIL RESERVOIR ASSY
NOTICE:
Do not disconnect the 2 hoses.
15. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil pump reservoir bracket No.
1.
16. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the clamp and engine wire.
17. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove the bolt and the engine service cover bracket RH.
18. REMOVE COOLER BRACKET (LHD(W/ AIR
CONDITIONER) STEERING POSITION TYPE)
(a) Remove the bolt and cooler bracket.

A77283
A77284
A77285
Unleaded Gasoline
Timing
Marks

eaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±141
AVENSIS REPAIR MANUAL (RM1018E)
19. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the bolt and the engine service cover bracket RH.
20. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
21. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Disconnect the 2 PCV hoses from the cylinder head cov-
er.
(b) Remove the 8 bolts and 2 nuts, and then remove the cylin-
der head cover and gasket.
22. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its timing notch with
timing mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing gear
are aligned with the timing marks located on the No. 1 and
No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.

A61184
A66202
A77305
A77380
SST
A77381
SST 14±142
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
23. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
(a) Place the jack underneath the engine, and put a wooden
block on the jack.
(b) Remove the 2 bolts and 2 nuts, and then detach the
mounting bracket No. 2 RH.
24. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 3 bolts and the engine mounting insulator.
25. REMOVE CRANKSHAFT PULLEY
(a) Using SST, fix the crankshaft pulley and loosen a crank-
shaft pulley bolt.
SST 09213±54015 (91651±60855), 09330±00021
(b) Using a crankshaft pulley bolt and SST, remove the crank-
shaft pulley.
SST 09950±50013 (09951±05010, 09952±05010,
09953±05020, 09954±05021)

A77286
Push
A64641
A00019
A77288
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±143
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner No. 1 and gasket.
NOTICE:
Do not turn the crankshaft.
27. REMOVE CRANKSHAFT POSITION SENSOR
28. REMOVE OIL PAN SUB±ASSY
(a) Remove the 12 bolts and 2 nuts.
(b) Insert the blade of SST between the crank case, timing
chain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, crank case and oil pan.
29. REMOVE V±RIBBED BELT TENSIONER ASSY