clock TOYOTA AVENSIS 2002 Repair Manual

320VI±01
G23173
Stop Lamp Switch Assy
Push Rod
Pedal Height
F43108
Stop Lamp Switch Assy Cushion
1.5 ± 2.5 mm (0.059 ± 0.098 in.) 32±6
± BRAKEBRAKE PEDAL SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE PEDAL SUB±ASSY
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height.
Pedal height from dash panel:
RHD: 142.5 to 152.5 mm (5.610 to 6.004 in.)
LHD:
M/T: 148.1 to 158.1 mm (5.831 to 6.224 in.)
A/T: 149.9 to 159.9 mm (5.902 to 6.295 in.)
(b) Adjust brake pedal height.
(1) Remove the instrument finish panel lower.
(2) Disconnect the connector from the stop lamp switch
assy.
(3) Turn the stop lamp switch assy counterclokwise and
remove the stop lamp switch assy.
(4) Loosen the brake master cylinder push rod clevis
lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
HINT:
If the pedal height is incorrect, check and adjust the stop lamp
switch clearance.
(c) Disconnect the stop lamp switch assy connector from the
stop lamp switch assy.
(d) Turn the stop lamp switch assy counterclockwise and re-
move the stop lamp switch assy.
(e) Insert the stop lamp switch assy until the body hits the
cushion.
NOTICE:
When inserting the stop lamp switch assy, support the ped-
al from behind so that the pedal is not pushed in.
(f) Make a quarter turn clockwise to install the stop lamp
switch assy.
NOTICE:
The turning torque for installing the stop lamp switch assy.
Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf) or less
(g) Connect the stop lamp switch connector to the stop lamp
switch assy.

320VT±01
G23220
G23175
F43108
Stop Lamp Switch Assy
Cushion
1.5 ± 2.5 mm (0.059 ± 0.098 in.)
±
BRAKE BRAKE PEDAL SUB±ASSY
32±9
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE COMBINATION METER ASSEMBLY (See page 71±21)
2. REMOVE BRAKE PEDAL SUPPORT SUB±ASSY
(a) Remove the bolt from the brake pedal support sub±assy.
(b) Disconnect the stop lamp switch connector.
(c) Remove the clip and clevis pin, and disconnect the brakemaster cylinder push rod clevis from the brake pedal sub±
assy.
(d) Remove the 4 nuts and brake pedal support sub±assy.
3. REMOVE BRAKE PEDAL SUB±ASSY
(a) Remove the brake pedal shaft and nut from the brake pedal support sub±\
assy.
(b) Remove the brake pedal sub±assy and 2 bushes.
4. REMOVE STOP LAMP SWITCH ASSY
(a) Turn the stop lamp switch assy counterclockwise and remove the stop lamp \
switch assy.
(b) Remove the stop lamp switch mounting adjuster from the brake pedal suppo\
rt sub±assy.
5. REMOVE BRAKE PEDAL PAD
(a) Remove the brake pedal pad from the brake pedal sub±assy.
6. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal sub±assy. 7. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch mounting adjuster to thebrake pedal support sub±assy.
(b) Install the stop lamp switch assy until the body hits the cushion.
NOTICE:
When inserting the stop lamp switch assy, support the ped-
al from behind so that the pedal is not pushed in.
(c) Make a quarter turn clockwise to install the stop lamp switch assy.
NOTICE:
The turning torque for installing the stop lamp switch assy. Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf) or less

320W2±01
G24251
Vacuum Hose
Oil Hose
F45364
F08966
F08967
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±35
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
1. REMOVE AIR CLEANER CAP SUB±ASSY
2. REMOVE VACUUM PUMP ASSY
(a) Disconnect the 2 vacuum hoses and oil hose from the
vacuum pump assy.
(b) Remove the 2 bolts and vacuum pump assy.
(c) Remove the 2 O±rings from the vacuum pump assy.
3. INSPECT VACUUM PUMP ASSY
(a) Turn the coupling counterclockwise direction by hand
when seeing from the coupling direction and check for
any abnormality such as dragging or torque fluctuation.
NOTICE:
Pay coupling attention, because the engine oil remained in
the pump escapes while coupling is turning.
4. REMOVE VACUUM PUMP UNION
(a) Using soft jaws on a vise, hold the vacuum pump assy in
a vise.
NOTICE:
Do not tighten the vise excessively and perform the work
while holding the vacuum pump assy by hand.
(b) Remove the union bolt, vacuum pump union and 2 gas-
kets.
5. REMOVE CHECK VALVE SUB±ASSY
(a) Remove the check valve sub±assy and gasket.

F08969
F08984
New Gasket
F08985
New Gasket
New Gasket
F45364
32±38
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(h) Using soft jaws on the vise, hold the vacuum pump in the
vise.
NOTICE:
Do not tighten the vise to tightly.
(i) Tighten the 3 bolts.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
14. INSTALL CHECK VALVE SUB±ASSY
(a) Install the check valve sub±assy and a new gasket.
Torque: 74 N
m (750 kgf
cm, 54 ft
lbf)
15. INSTALL VACUUM PUMP UNION
(a) Install the vacuum pump union and 2 new gaskets with
the union bolt.
Torque: 14 N
m (140 kgf
cm, 10 ft
lbf)
HINT:
Align and insert the pin of the union into the matching hole of
the casing.
16. INSPECT VACUUM PUMP ASSY
(a) Turn the gear counterclockwise direction by hand when
seeing from the vacuum pump gear direction and check
for any abnormality such as dragging or torque fluctua-
tion.

A77879
45

A77880
83.8 mm
(3.299 in.)
Rotation
Center of
Throttle Link
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1AZ±FE)
10±29
AVENSIS REPAIR MANUAL (RM1018E)
11.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that throttle valve is fully closed.
(b)With the throttle position sensor rotated 45
counter-
clockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure
it with the 2 screws.
12.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 3 screws.
13.INSTALL FUEL VAPOR FEED HOSE NO.2
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the fuel pipe support with the 3 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c)Install the fuel tube to the fuel pipe support.
(d)Connect the water by±pass hose.
(e)Connect the water by±pass hose No. 2.
(f)Connect the ISC valve connector.
(g)Connect the throttle position sensor connector.
15.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Instal the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
16.INSTALL AIR CLEANER CAP SUB±ASSY
17.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±19)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER

A78464
A78465
A78466
A78467
30
to 45

± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1ZZ±FE)
10±11
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE ACCELERATOR CONTROL CABLE
BRACKET
(a) Remove the 2 bolts, and then remove the accelerator
control cable bracket.
9. REMOVE ISC VALVE
(a) Remove the 3 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.
10. REMOVE THROTTLE POSITION SENSOR
(a) Remove the 2 screws, and then remove the throttle posi-
tion sensor.
11. INSTALL THROTTLE POSITION SENSOR
(a) Make sure that the throttle valve is fully closed.
(b) With the throttle position sensor rotated 30
to 45
coun-
terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c) Rotate the throttle position sensor clockwise and secure
it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
12. INSTALL ISC VALVE
(a) Install a new gasket to the throttle body.
(b) Install the ISC valve with the 3 screws.
Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
13. INSTALL ACCELERATOR CONTROL CABLE
BRACKET
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)

A78501
A78503
30
to 45

A78469
66.3 mm
(2.610 in.)
Rotation
Center of
Throttle Link
11

10±16
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE THROTTLE POSITION SENSOR
(a)Remove the 2 screws, and then remove the throttle posi- tion sensor.
10.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that the throttle valve is fully closed.
(b)With the throttle position sensor rotated 30
to 45
coun-
terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
11.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 4 screws.
Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
12.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the accelerator control brack- et with the bolt and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
13.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
14.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±9)
15.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
16.ADD ENGINE COOLANT (See page 16±7)
17.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
18. INSTALL ENGINE ROOM COVER SIDE
19. INSTALL RADIATOR SUPPORT OPENING COVER

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.

A77396
HookPin
Turn
Disconnect
A77397
Push
Turn
Plunger
A77399
Seal Packing
A77400NutNut
A
BC A
AAAB
± ENGINE MECHANICALCAMSHAFT (1AZ±FE)
14±177
AVENSIS REPAIR MANUAL (RM1018E)
(c) Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d) Turn the crankshaft clockwise, and check the plunger is
extended.
18. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 5 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
Bolt A 11 N
m (112 kgf
cm, 8.0 ft
lbf)
Bolt B 14 N
m (143 kgf
cm, 10 ft
lbf)
Bolt C 21 N
m (214 kgf
cm, 15 ft
lbf)
Nut 11 N
m (112 kgf
cm, 8.0 ft
lbf)
19. INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
20. CHECK FOR ENGINE OIL LEAKS
21. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

A77309
15973
481062
A56228
A77413
Advance
Side Port
A31032
14±242
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 10 camshaft
bearing cap bolts uniformly in the sequence shown in the
illustration.
(b) Remove 5 camshaft bearings.
(c) Remove the camshaft.
(d) Tie the timing chain as shown in the illustration.
NOTICE:

Be careful not to drop anything inside the timing
chain cover.

Do not expose the chain to water, and prevents dust.
16. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Clamp the camshaft in a vise, and make sure the cam-
shaft timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except an advance
side port shown in the illustration.
(c) Put air pressure into the oil port with 150 kpa (1.5 kgf/cm
2
21 psi), and turn the camshaft timing gear to the advance
direction (counterclockwise) by hand.
CAUTION:
Cover the ports 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.