TOYOTA AVENSIS 2002 Repair Manual

F45155
A
B
F44620
26±28
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
21. INSTALL FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID: Install the front stabilizer bracket No.1 RH and the height
control sensor (Front) with the 3 bolts.
Torque:
Bolt A: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
Bolt B: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b) w/o HID: Install the front stabilizer bracket No.1 RH with the 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
22.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
23.INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
24. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
25. INSTALL RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
26.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
27. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
28.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
29. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side.
30. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the 2 nuts.Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
31. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
32. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
33.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
34.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)

110UB±01
A79437
8.0 (82, 71 in.
lbf)
Engine Cover No. 1Radiator Support Opening Cover
N´m (kgf´cm, ft´lbf)
: Specified torque
6.0 (61, 53 in.
lbf)
Radiator Reserve
Tank Assy
Clip
Ratainer
11±76
± FUELCOMMON RAIL ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
COMMON RAIL ASSY (1CD±FTV)
COMPONENTS

A79438
5.0 (51, 44 in.
lbf)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
* Use SST
Common Rail Assy
Intake Manifold
Insulator No. 1
Fuel Hose No. 4

Fuel Inlet Pipe Sub±assy
5.0 (51, 44 in.
lbf)
43 (438, 32)
* 31 (316, 23)
34 (347, 25)
± FUELCOMMON RAIL ASSY (1CD±FTV)
11±77
AVENSIS REPAIR MANUAL (RM1018E)

110UC±01
A79148
SST
A79143
SST
11±78
±
FUEL COMMON RAIL ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50) 5. REMOVE FUEL INLET PIPE SUB±ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and the injection pump with vinyl tape to prevent dust from
being introduced.
(a) Using SST, remove the fuel inlet pipe from the commonrail.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and the 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.

A79154
A79147
30 cm
(11.81 in.)
SST
±
FUEL COMMON RAIL ASSY(1CD±FTV)
11±79
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10.DISCONNECT FUEL HOSE NO.4
(a)Disconnect the fuel hose from the common rail.
11.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
12.REMOVE COMMON RAIL ASSY
(a)Disconnect the engine wire connector from the bracket.
(b)Remove the 2 bolts and the common rail.
13.INSTALL COMMON RAIL ASSY Torque: 43 N
m (438 kgf
cm, 32 ft
lbf)
14.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
15. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:

In case of having the common rail replaced, must re-
place the injection pipes, too.

When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.

11±80
± FUELCOMMON RAIL ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec-
tor side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
16. INSTALL INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
17. INSTALL INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
18. INSTALL INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.

A79149
30 cm
(11.81 in.)
SST
±
FUEL COMMON RAIL ASSY(1CD±FTV)
11±81
AVENSIS REPAIR MANUAL (RM1018E)
19.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the common rail replaced, must re-
place fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the injec-
tion pump side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
20.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
21. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
22.ADD ENGINE COOLANT(See page 16±44)
23.CHECK FOR ENGINE COOLANT LEAKS(See page 16±37)
24.CHECK FOR FUEL LEAKS(See page 11±60)

110UD±01
A79188
A80091SST
A79190
11±82
± FUELFUEL FILTER ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL FILTER ASSY (1CD±FTV)
REPLACEMENT
1. REMOVE AIR CLEANER ASSY
(a) Disconnect the connector.
(b) Remove the air cleaner cap with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and the air cleaner case.
2. REMOVE FUEL FILTER ASSY
(a) Disconnect the 2 fuel hose from the fuel filter. (STD or COLD)
(b) Disconnect the 3 fuel hose from the fuel filter. (W/ ADDTIONAL HEATER)
(c) Disconnect the 2 connectors.
(d) Remove the 2 bolts and the fuel filter.
3. DRAIN FUEL
(a) Loosen the drain plug, and drain the fuel from the fuel filter.
4. REMOVE LEVEL WARNING SWITCH
(a) Clamp the fuel filter in a soft jaw vise.
(b) Using pliers, remove the level warning switch.
NOTICE:
Be careful not to damage the level warning switch.
5. REMOVE FUEL FILTER ELEMENT
(a) Using SST, remove the fuel filter element.
SST 09228±64030
6. INSTALL FUEL FILTER ELEMENT
(a) Check and clean the fuel filter installation surface.
(b) Apply fuel to a gasket of a new fuel filter element.
(c) Lightly screw the fuel filter element into place, and tighten
it until the gasket comes into contact with the seat.
(d) Tighten it additional 3/4 turn by hand.

±
FUEL FUEL FILTER ASSY(1CD±FTV)
11±83
AVENSIS REPAIR MANUAL (RM1018E)
7.INSTALL LEVEL WARNING SWITCH
(a)Install a new O±ring to the level warning switch.
(b)Apply fuel to the O±ring of the level warning switch.
(c)Install the level warning switch to the fuel filter by hand.
8.INSTALL FUEL FILTER ASSY
Torque: 18 N
m (178 kgf
cm, 13 ft
lbf)
9.INSTALL AIR CLEANER ASSY
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
10.CHECK FOR FUEL LEAKS(See page 11±60)

110U0±01
A79730
Mass Air Flow
Meter Connector
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Cover Sub±assy
No. 1
7.0 (71, 62 in.
lbf)
Fuel Vapor Feed Hose
No. 2
Air Cleaner Cap
Sub±assyVSV
Connector Fuel Vapor Feed Hose
11±24
± FUELFUEL INJECTOR ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL INJECTOR ASSY (1AZ±FE)
COMPONENTS