TOYOTA AVENSIS 2002 Repair Manual

A64641
A00019
B11673
17±16
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
29.REMOVE CRANKSHAFT PULLEY (See page 14±222) SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
30.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
31.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17) 32.REMOVE OIL PAN SUB±ASSY
(a)Remove 12 bolts and 2 nuts.
(b)Insert the blade of SST between the crank case, timingchain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST09032±00100
NOTICE:
Be careful not to damage the contact surface of timing
chain cover, crank case and oil pan.
33.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
34.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
35.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
36.REMOVE CHAIN TENSIONER SLIPPER
37.REMOVE CHAIN VIBRATION DAMPER NO.1
38.REMOVE TIMING CHAIN GUIDE (See page 14±139)
39.REMOVE CHAIN SUB±ASSY
40.REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
41.REMOVE NO.2 CHAIN SUB±ASSY (See page 14±139) 42.REMOVE OIL PUMP ASSY
(a)Remove 3 bolts, the oil pump and gasket.
43.INSTALL OIL PUMP ASSY
(a)Install a new gasket and oil pump with 3 bolts. Torque: 19 N
m (195 kgf
cm,15 ft
lbf)
44.INSTALL NO.2 CHAIN SUB±ASSY (See page 14±139)
45. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

A77392Seal Packing6mm
A64641
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±17
AVENSIS REPAIR MANUAL (RM1018E)
46.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
47.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
48.INSTALL CHAIN SUB±ASSY (See page 14±139)
49.INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
50.INSTALL CHAIN TENSIONER SLIPPER (See page 14±139)
51.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±139)
52.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
53.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
54.INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a)Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b)Apply seal packing in the shape of bead (Diameter 3 to 4
mm (0.157 in.)) as shown in the illustration, and install the
oil pan.
Seal Packing: Part No. 08826 ± 00080 or equivalent
(c)Insert the oil pan with 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
55.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
56.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST 09213±54015 (91651±60855), 09330±00021
57. INSTALL CHAIN TENSIONER ASSY NO.1
58. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
60.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
61. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
62. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
63. INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

17±18
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
64.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
65.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
66.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
67.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
68.INSTALL VANE PUMP ASSY Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
69.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
70.INSTALL GENERATOR ASSY (See page 19±20)
71.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
72.INSTALL FUEL PUMP ASSY (See page 11±52)
73.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
74.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
75.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
76. ADD ENGINE OIL
77. CHECK FOR ENGINE OIL LEAKS
78. CHECK FUEL LEAK
79. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
80. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

170FP±01
SST
A09582
17±22
±
LUBRICATION OIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL(See page 17±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER(See page 14±307)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17.REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22.REMOVE TIMING BELT IDLER SUB±ASSY NO.2(See page 14±307)
23.REMOVE CRANKSHAFT TIMING PULLEY
(a)If the timing pulley can not be removed by hand, use SSTto remove the pulley.
SST09950±50013 (09951±05010, 09952±05010, 09953±05010, 09953±05020, 09954±05021)
24.REMOVE GENERATOR ASSY(See page 19±29)
25. REMOVE TIMING BELT IDLER SUB±ASSY NO.1
26. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the 2 bolts and the V±ribbed belt tensioner.

A79173
A79174
A56695
A79175
A56696
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±23
AVENSIS REPAIR MANUAL (RM1018E)
27. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt which is used to secure the oil level gage
guide to the cylinder block.
(b) Pull out the oil level gage guide together with the oil level
gage from the No. 1 oil pan.
(c) Remove the O±ring from the oil level gage guide.
28. REMOVE ENGINE OIL LEVEL SENSOR
(a) Remove the 4 bolts and the level sensor.
NOTICE:
Be careful not to drop the oil level sensor when removing.
29. REMOVE OIL PAN SUB±ASSY NO.2
(a) Remove the 17 bolts and 2 nuts.
(b) Insert the blade of SST between the No. 1 and No. 2 oil
pans, and cut off applied sealer and remove the No. 2 oil
pan.
SST 09032±00100
NOTICE:
Be careful not to damage the No. 1 and No. 2 oil pans.
30. REMOVE OIL STRAINER SUB±ASSY
(a) Remove the 2 bolts and 2 nuts, then remove the oil strain-
er and the gasket.

B08009
A56697
A56698
A56699
17±24
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
31. REMOVE OIL PAN INSULATOR
(a) Remove the bolt and the oil pan insulator.
32. REMOVE OIL PAN SUB±ASSY
(a) Remove the 19 bolts and 3 nuts.
(b) Using a screwdriver, remove the oil pan by prying be-
tween the cylinder block and the No. 1 oil pan.
NOTICE:
Be careful not to damage the cylinder block and No. 1 oil
pan.
33. REMOVE CRANKSHAFT POSITION SENSOR
34. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying between the oil pump and
the main bearing cap with a screwdriver.
(c) Remove the gasket.

A56700
SST
B07987
New Gasket
Seal
Packing Seal Width
2 to 4 mm
B08024
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±25
AVENSIS REPAIR MANUAL (RM1018E)
35. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316±60011 (09316±00011, 09316±00021)
36. INSTALL OIL PUMP ASSY
(a) Remove any old packing (FIPG) and be careful not to
drop any oil on the contact surfaces of the oil pump and
the cylinder block.
(1) Using a razor blade and a gasket scraper, remove
all the old packing from the gasket surfaces and the
sealing groove.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non±residue solvent, clean both the sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
(1) Install a nozzle that has been cut to a 2 to 4 mm
(0.08 to 0.16 in.) opening.
(2) Parts must be set within 3 minutes and assembled
within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3) Immediately remove nozzle from the tube and rein-
stall the cap.
(c) Install a new gasket to the oil pump.
(d) Pour in 0.5 cm
3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Apply engine oil to the cylinder block side where it con-
tacts with the oil pump driven rotor.

A57099
A56702
17±26
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(f) Install the oil pump with the 9 bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
(g) Measure the oil pump rotating torque.
(1) Check that the pump rotates smoothly without
noise.
(2) Using a torque wrench, check the pump rotating
torque.
Rotating torque: 3.0 N
m (31 kgf
cm, 27 in.
lbf) or less
37. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
38. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing (FIPG) and be careful not to
drop any oil on the contact surfaces of the No. 1 oil pan,
the cylinder block and the oil pump and the rear oil seal
retainer.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non±residue solvent, clean both the sealing
surfaces.

A56703
Seal Width
4 to 7 mm
A
AB
B
A56697
AA
A
A
AA B B DBBB
BC C
C CC
CCDD
A56696
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±27
AVENSIS REPAIR MANUAL (RM1018E)
(b) Apply a seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 4 to 7 mm
(0.16 to 0.28 in.) opening.
(2) Parts must be set within 3 minutes and assembled
within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3) Immediately remove nozzle from the tube and rein-
stall the cap.
(c) Install the oil pan with the 19 bolts and 3 nuts.
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for bolt A
21 N
m (214 kgf
cm, 15 ft
lbf) for bolt B
11 N
m (112 kgf
cm, 8 ft
lbf) for bolt C
12 N
m (122 kgf
cm, 9 ft
lbf) for nut D
39. INSTALL OIL PAN INSULATOR
(a) Install the oil pan insulator with the bolt.
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
40. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (209 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
41. INSTALL OIL PAN SUB±ASSY NO.2
(a) Remove any old packing and be careful not to drop any
oil on the contact surfaces of the No. 1 and No. 2 oil pans.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.

A56704
Seal Width
4 to 7 mm
A
B B
A
A79173New O±ring
17±28
±
LUBRICATION OIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(3)Using a non±residue solvent, clean both the sealing surfaces.
NOTICE:
Do not use a solvent, which will affect the painted surfaces.
(b)Apply a seal packing to the oil pan as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
(1)Install a nozzle that has been cut to a 4 to 7 mm
(0.16 to 0.28 in.) opening.
(2)Parts must be set within 3 minutes and assembled within 15 minutes of application. Otherwise the ma-
terial must be removed and reapplied.
(3)Immediately remove nozzle from the tube and rein- stall the cap.
(c)Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
Torque: 12 N m (119 kgf cm, 9ft lbf)
42.INSTALL ENGINE OIL LEVEL SENSOR Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
43.INSTALL OIL LEVEL GAGE GUIDE
(a)Install a new O±ring to the oil level gage guide.
(b)Apply engine oil to the O±ring.
(c)Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d)Install the oil level gage guide with the bolt. Torque: 18 N m (184 kgf cm, 13 ft lbf)
(e)Apply engine oil to the O±ring on the oil level gage.
(f)Install the oil level gage.
44.INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 31 N m (320 kgf cm,23 ft lbf)
45.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
Torque: 35 N m (357 kgf cm,26 ft lbf)
46.INSTALL GENERATOR ASSY(See page 19±29)