TOYOTA AVENSIS 2002 Repair Manual

A64328
2 to 7 mm0 to 2 mm
A78274
Upward
90

Clamp
Bolt
A64328
2 to 7 mm 0 to 4 mm
A64007
Front
90

Clamp
Bolt
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±303
AVENSIS REPAIR MANUAL (RM1018E)
184.INSTALL AIR TUBE NO.1
(a)Install the new air hose No. 1 and new hose clamp as
shown in the illustration.
(b)Tighten the hose clamp as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
185.INSTALL INJECTOR DRIVER Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
186.CONNECT ENGINE WIRE Torque: 8.4 N
m (85 kgf
cm,74 in.
lbf)
187.INSTALL AIR TUBE NO.2
(a)Install the air hose and hose clamps as shown in the il- lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm,53 ft
lbf)
(c)Install the 2 bolts and the air tube No.2 assy.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
188.INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
189. INSTALL ENGINE ROOM RELAY BLOCK NO.3 Torque: 5.3 N
m (54 kgf
cm, 46 in.
lbf)
190. INSTALL FUEL FILTER ASSY Torque: 18 N
m (178 kgf
cm, 13 ft
lbf)

14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)

141CF±01
A76700
Cylinder Head
Cover No. 2 Radiator Support
Upper
Radiator Support Upper
Radiator
Hose Inlet
Radiator Hose Outlet
Radiator AssyClip
7.0 (71, 62 in.
lbf)
19 (194, 14)
Engine Under Cover LH Engine Under Cover RH
Clip
Clip
N´m (kgf´cm, ft´lbf)
: Specified torque
Clip
Engine Under Cover No.1
19 (194, 14)
Retainer
Clip
Clip
Engine Room Cover Side
Radiator Suport Opening Cover
5.0 (51, 44)
Relay Block
Oil Cooler Inlet Tube No.1 Oil Cooler
Outlet Tube No.1
x2
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS

A76702
Accelerator Control Cable Assy
Heater Inlet Water Hose
Fuel Pipe Clamp
Fuel Tube Sub±assy
Heater Outlet Water Hose
Air Cleaner Cap
W/ Hose
Air Cleaner Filter
Element Sub±assy
Air Cleaner Case Sub±assy Battery Clamp
Sub±assy
Battery
Battery Tray
Battery Carrier
12.8 (131, 9)
N´m (kgf´cm, ft´lbf)
: Specified torque
Union to Connector Tube Hose
Air Cleaner Clamp
Bracket
5.0 (51, 44 in.
lbf)
Fuel Vapor Feed Hose No.1
Fuel Vapor Feed Hose No.3
5.0 (51, 44 in.
lbf)
Oil Cooler
Inlet Hose
Oil Cooler
Outlet Hose
X4
VSV Connector
Mass Air Flow
Meter Connector
14±20
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A76703
Fan and Generator V Belt
Cooler Compressor Assy
N´m (kgf´cm, ft´lbf) : Specified torque
29 (296, 21)
A/T:
Floor Shift Transmission
Control Cable Assy Clip
Clutch Release Cylinder Assy
Floor Shift Cable Transmission
Control Shift
Floor Shift Cable Transmission
Control Select
Clip
Clip
25 (255, 18)
12 (122, 9)
25 (255, 18)
12 (122, 9)
54 (551, 40)
25 (255, 18)
Generator Assy Terminal Cap
No. 19.8 (100, 7)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±21
AVENSIS REPAIR MANUAL (RM1018E)

A76704
Grove Compartment Door Assy Cowl Side Trim Board RH
Front Door Scuff Plate RH
Clip
Clip
Column Hole Cover Silencer Sheet
Steering Intermediate Shaft

Cotter Pin
Tie Rod End Sub±assy LH
Front Suspension Arm
Sub±assy Lower No. 1 LH
Front Drive Shaft Assy LH
Front Stabilizer Link Assy LH
Exhaust Pipe Assy Front
Floor Panel Brace FrontCompression
Spring
Compression Spring
Gasket

Gasket
89 (908, 66)
216 (2,203, 160)
49 (500, 36)
74 (755, 55)
35 (357, 26)
89 (908, 66)
Front Axle Hub LH Nut

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
43 (440, 32)
30 (306, 22)
43 (440, 32)
Front Floor Footrest (RHD)
Instrument Panel Under
Cover Sub±assy No. 2
14±22
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A76705N´m (kgf´cm, ft´lbf) : Specified torque Engine Mounting
Insulator RH
Engine Assembly with Transaxle
Front Suspension
Crossmember
W/ Center Member
80 (816, 59)
133 (1,356, 98)45 (459, 33)
52 (530, 38)
52 (530, 38)
87 (887, 64)
52 (530, 38)
Front Suspension
Member Brace RH
133 (1,356, 98)
80 (816, 59)
Front Suspension
Member Brace RH
133 (1,356, 98)
80 (816, 59)
X3
X3
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±23
AVENSIS REPAIR MANUAL (RM1018E)

A79349N´m (kgf´cm, ft´lbf): Specified torqueAutomatic Transaxle Assy
Drive Plate Spacer
RR
Drive Plate & Ring Gear Sub±assy
Drive Plate Spacer
FR
A/T:
28 (286, 21)
88 (897, 65)
Clutch Disk Assy
Clutch Cover Assy
Manual Transaxle Assy
Starter Assy
Flywheel Sub±assy
See page 14±27
1st 49 (500, 36)
2nd Turn 90

37 (377, 27)
37 (377, 27)
64 (653, 47)
19 (194, 14)
64 (653, 47)
9.8 (100, 7)
47 (479, 35)
47 (479, 35)
14±24
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A76706
Fuel Delivery Pipe Sub±assy
No. 1 Spacer
Ignition Coil Assy
V±Ribbed Belt Tensioner Assy

Gasket
Intake Manifold
Clamp Bracket
Oil Level Gage Guide

O±ring
Oil Level Gage
Sub±assy
Crankshaft Position
Sensor
Gasket Thermostat Knock Sensor
Engine Oil Pressure
Switch AssyCamshaft Position Sensor
Gasket Water By±pass Pipe No. 1

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
Water Inlet
19 (194, 14)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)29 (296, 21)
69 (704, 51)
15 (153, 11)
20 (204, 15)
11 (112, 8)
30 (306, 22)
9.0 (92, 80 in.
lbf)
Transverse Engine
Engine Mounting Bracket
13 (133, 10)
47 (479, 35)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±25
AVENSIS REPAIR MANUAL (RM1018E)

A76707
Water By±pass Hose No. 2
Radiator Hose Inlet
Heater Inlet Water Hose

Gasket
Exhaust Manifold
Manifold StayExhaust Manifold
Heat Insulator No. 1

Gasket
Engine Coolant
Temperature Sensor

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
20 (204, 15)
9.0 (92, 80 in.
lbf)
37 (377, 27)
18 (184, 13)
49 (500, 36)
Clamp Bracket
10 (102, 7)
Radio Setting Condenser
V±Ribbed Idler Assy No. 1
Tube
18 (184, 13)
12 (122, 9)
Manifold Stay No. 2
49 (500, 36)
37 (377, 27)18 (184, 13)
39.2 (400, 29)
14±26
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)