lock TOYOTA AVENSIS 2002 Owners Manual

A77408
Lot No.
A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
12.5 to 1.5 mm
A7741012
3 4
109 85
67
A00976A77411
90
Engine
Front
Paint Mark
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FE)
14±165
AVENSIS REPAIR MANUAL (RM1018E)
58. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:

Remove any oil from contact surface.

Be careful of the installation direction.

Place the cylinder head gently in order not to damage
the gasket with the bottom part of the head.
59. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head set bolts are tightened in 2 successive steps.
(a) Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to
0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Install the cylinder head within 3 minutes after apply-
ing seal packing.

After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.

Do not start the engine within 2 hours after installing.
(b) Apply a light coat of engine oil on the threads of the cylin-
der head bolts.
(c) Install the bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d) Using several steps, install and tighten the 10 cylinder
head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e) Mark the front side of the cylinder head set bolts with
paint.
(f) Retighten the cylinder head set bolts by 90 in the same
sequence as step (A).
(g) Check that each paint mark is now at a 90 angle to the
front.

A77350
A52497
A32664
A56213
14±258
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
53.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a)Remove the 2 bolts and 2 nuts, and then detach the No.
1 and No. 2 exhaust manifold stay.
(b)Disconnect the 3 oxygen sensor connectors.
(c)Remove the 5 nuts, the exhaust manifold and gasket.
54.REMOVE NO.2 CAMSHAFT (See page 14±240)
55.REMOVE CAMSHAFT (See page 14±240)
56. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt and the oil control valve. 57. REMOVE CAMSHAFT BEARING NO.2
58. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub±assy.
(b) Set the jack under the engine assembly w/ transaxle, andplace a wooden block on the jack.
(c) Remove the chain block and sling devise.

A7740612 3
4 109
8 56 7
A77407
Overall Length
A77408
Lot No.
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±259
AVENSIS REPAIR MANUAL (RM1018E)
59. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 10 cylinder head bolts,
with 10 mm bi±hexagon wrench uniformly in the se-
quence shown in the illustration.
(b) Remove 10 cylinder head bolts and plate washers.
NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cranking could result from remov-
ing bolts and installing incorrect order.
60. REMOVE CYLINDER HEAD GASKET
61. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of the cylin-
der head set bolts from the seat to the end.
Standard bolt length:
161.3 to 162.3 mm (6.350 to 6.390 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the cylinder head
set bolts.
62. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:

Remove any oil from contact surface.

Be careful of the installation direction.

Place the cylinder head gently in order not to damage
the gasket with the bottom part of the head.
63. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head set bolts are tightened in 2 successive steps.

A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
12.5 to 1.5 mm
A7741012
3
4
10 9
85
67
A00976A77411
90
Engine
Front Paint Mark
14±260
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(a)Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Install the cylinder head within 3 minutes after apply-
ing seal packing.

After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.

Do not start the engine within 2 hours after installing.
(b)Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(c)Install bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d)Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e)Mark the front side of the cylinder head set bolts with paint.
(f)Retighten the cylinder head set bolts by 90  in the same
sequence as a step (d).
(g)Check that each paint mark is now at a 90  angle to the
front.
64.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm,79 in.
lbf)
65.INSTALL CAMSHAFT (See page 14±240)
66.INSTALL NO.2 CAMSHAFT (See page 14±240)

A61194
Pry
A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring Tip
Protrusion Hight
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±335
AVENSIS REPAIR MANUAL (RM1018E)
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
67. REMOVE CYLINDER HEAD GASKET
68. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolts.
Standard outside diameter:
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
69. INSTALL CYLINDER HEAD GASKET
(a) Measure protrusion height of the piston heads.
(1) Clean the cylinder block with solvent.
(2) Set the piston to be measured to slightly before
TDC.
(3) Place a dial indicator on the cylinder block, and cali-
brate the dial indicator at 0 mm (0 in.).
HINT:

Place measuring tip of the dial indicator as shown in the
illustration.

Make sure that the measuring tip is square to the cylinder
block gasket and the piston head when measuring.
(4) Find the most overhung position of the piston head
by slowly turning the crankshaft clockwise and
counterclockwise.

A09571
Front
X Measuring Point
A80117
A
B
C
D
E
A56055
14±336
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Measure a protrusion height of the piston head for
each cylinder at 2 places as shown in the illustra-
tion. (Total of 8 measurements.)
(6) Record the highest protrusion height from the 2
measurements at each cylinder.
(b) Select new cylinder head gasket.
HINT:
There are 5 sizes of new cylinder head gaskets, marked ºAº,
ºBº, ºCº, ºDº, or ºEº.
New cylinder head gasket thickness:
A0.85 to 0.95 mm (0.0335 to 0.0374 in.)
B0.90 to 1.00 mm (0.0354 to 0.0394 in.)
C0.95 to 1.05 mm (0.0374 to 0.0413 in.)
D1.00 to 1.10 mm (0.0394 to 0.0433 in.)
E1.05 to 1.15 mm (0.0413 to 0.0453 in.)
(1) Find the highest protrusion height among the 4
measurement records. It is used to select a new cyl-
inder head gasket.
(2) Select the new gasket among A to E using the ma-
trix below.
New gasket matrix:
Piston protrusion mm (in.)Gasket size
0.165 to 0.220 (0.0065 to 0.0087)A
0.220 to 0.270 (0.0087 to 0.0106)B
0.270 to 0.320 (0.0106 to 0.0126)C
0.320 to 0.370 (0.0126 to 0.0146)D
0.370 to 0.425 (0.0146 to 0.0167)E
(c) Place new cylinder head gasket on the cylinder block.
NOTICE:
Pay attention to mounting orientation.

A60622
A79324
A76713
A64023
14±82
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±11) SST09268±21010
15.DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a)Disconnect the union to connector tube hose from the hose to hose tube.
16.DISCONNECT RADIATOR HOSE INLET
(a)Disconnect radiator hose inlet from the cylinder head.
17.DISCONNECT HEATER INLET WATER HOSE
(a)Disconnect the heater inlet water hose from the cylinder head.
18.REMOVE FAN AND GENERATOR V BELT
(a)Turn the V±ribbed belt tensioner clockwise slowly andloosen it. Remove the fan and generator V belt and put
back the V±ribbed belt tensioner carefully.
19.REMOVE V±RIBBED IDLER ASSY NO.1
(a)Remove the nut, bolt, tube and idler.
20.REMOVE GENERATOR ASSY (See page 19±7)
21. DISCONNECT IGNITION COIL ASSY
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.
(d) Remove the 4 bolts and the 4 ignition coils.

B06777
A76720
A76721
A01045
A64005
14±84
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
28. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Remove the bolt and the camshaft timing oil control valve.
29. SEPARATE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs which are
used to secure the front side of exhaust pipe.
(b) Remove the gasket.
30. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and the manifold stay.
31. REMOVE MANIFOLD STAY NO.2
(a) Remove the 3 bolts and the manifold stay No. 2.
32. REMOVE ENGINE MOUNTING INSULATOR
SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine.
Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.

A12816
A76692
A62178
Push
A10076
A30848
14±86
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and the transverse engine engine
mounting bracket.
39. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts which are used to secure the crank-
shaft position sensor.
40. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and the chain tensioner.
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
41. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 11 bolts and nuts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying between the cyl-
inder head and the cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the timing chain cover, the cylin-
der head and the cylinder block.
42. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.
43. REMOVE CRANKSHAFT POSITION SENSOR PLATE
NO.1
44. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and the chain tensioner slipper.
45. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolt and the chain vibration damper.

A30857
A62814
4 2531
A62816
2
5 3
110 8 4 796
A62827
Lot No.
A62820
Overall Length
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±87
AVENSIS REPAIR MANUAL (RM1018E)
46. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain by prying the crankshaft timing
gear using screwdrivers as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise to prevent the valves from touch-
ing the pistons.
47. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 19 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 9 bearing caps, and both the intake and
exhaust camshafts.
48. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen and remove the 10 cylinder
head bolts with a 10 mm hexagon wrench uniformly in the
sequence shown in the illustration. Remove the 10 cylin-
der head bolts and 10 plate washers.
(b) Remove the cylinder head.
49. REMOVE CYLINDER HEAD GASKET
50. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the Lot No. stamp facing upward.
NOTICE:

Pay attention to the mounting orientation.

Place the cylinder head on the gasket gently in order
not to damage the gasket with the bottom part of the
head.
51. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of cylinder
head bolt from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum length: 148.5 mm (5.846 in.)
If the length exceeds the maximum, replace the bolt.