heater TOYOTA AVENSIS 2002 User Guide

10±36
±
ENGINE CONTROL SYSTEM KNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
18.INSTALL INTAKE MANIFOLD INSULATOR NO.1
19.INSTALL INTAKE MANIFOLD
(a)Install a new gasket to the intake manifold.
(b)Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c)Install the wire harness clamp.
(d)Connect the union to connector tube hose.
20.CONNECT HEATER INLET WATER HOSE
21.INSTALL CHARCOAL CANISTER ASSY
22.INSTALL VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
23.INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
24.CONNECT FUEL TUBE SUB±ASSY (See page 11±26)
25.INSTALL THROTTLE BODY ASSY (See page 10±26)
26.INSTALL ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
27. INSTALL AIR CLEANER CAP SUB±ASSY
28.ADD ENGINE COOLANT (See page 16±19)
29.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
30.CHECK FOR FUEL LEAKS (See page 11±19)
31.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
32. INSTALL ENGINE ROOM COVER SIDE
33. INSTALL RADIATOR SUPPORT OPENING COVER

A77916
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
30 (306, 22)
Heater Inlet Water Hose
Knock Sensor
ConnectorKnock Sensor
20 (204, 15)
Intake Manifold Insulator No. 1

Intake Manifold
to Head Gasket No. 1
Intake Manifold
LHD Steering Position Type,
Leaded Gasoline:
Variable Resister
5.0 (51, 44 in.
lbf)
Charcoal Canister Assy
Variable Resister Connector
Charcoal Canister
Outlet Hose No. 1
Fuel Hose
x5
± ENGINE CONTROL SYSTEMKNOCK SENSOR (1AZ±FE)
10±33
AVENSIS REPAIR MANUAL (RM1018E)

100FL±01
A77917
A77918
(a)
(b)
A77919
10±34
±
ENGINE CONTROL SYSTEM KNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4.ENGINE COOLANT (See page 16±19)
5.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
7.SEPARATE ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
8.REMOVE THROTTLE BODY ASSY (See page 10±26)
9.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26) SST 09268±21010
10.REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
11. REMOVE VARIABLE RESISTOR (LHD STEERINGPOSITION TYPE, LEADED GASOLINE)
(a) Disconnect the variable resistor connector.
(b) Remove the bolt, and then remove the variable resistor.
12. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the charcoal canister outlet hose No. 1.
(b) Disconnect the fuel hose.
(c) Pull up and remove the charcoal canister.
13. DISCONNECT HEATER INLET WATER HOSE

10±36
±
ENGINE CONTROL SYSTEM KNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
18.INSTALL INTAKE MANIFOLD INSULATOR NO.1
19.INSTALL INTAKE MANIFOLD
(a)Install a new gasket to the intake manifold.
(b)Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c)Install the wire harness clamp.
(d)Connect the union to connector tube hose.
20.CONNECT HEATER INLET WATER HOSE
21.INSTALL CHARCOAL CANISTER ASSY
22.INSTALL VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
23.INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
24.CONNECT FUEL TUBE SUB±ASSY (See page 11±26)
25.INSTALL THROTTLE BODY ASSY (See page 10±26)
26.INSTALL ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
27. INSTALL AIR CLEANER CAP SUB±ASSY
28.ADD ENGINE COOLANT (See page 16±19)
29.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
30.CHECK FOR FUEL LEAKS (See page 11±19)
31.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
32. INSTALL ENGINE ROOM COVER SIDE
33. INSTALL RADIATOR SUPPORT OPENING COVER

A77325
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Accelerator Control
Cable Sub±assy
30 (305, 22)
30 (305, 22)
Throttle Body Assy
Heater Inlet Water Hose
Union To Connector
Tube Hose
Fuel Tube Sub±assy
Fuel Pipe ClampRadiator Hose Inlet
Battery Clamp
Battery
Battery Tray
Air Cleaner Assembly
w/ Hose
30 (305, 22)
5.0 (51, 44 in.
lbf)5.0 (51, 44 in.
lbf)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FE)
14±155
AVENSIS REPAIR MANUAL (RM1018E)

A77302
14±162
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
22.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the engine service cover bracket RH.
23.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
24.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
25.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
26.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)
27.REMOVE CRANKSHAFT PULLEY (See page 14±139)
SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
28.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
29.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17)
30.REMOVE OIL PAN SUB±ASSY (See page 14±139) SST09032±00100
31.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
32.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
33.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
34.REMOVE CHAIN TENSIONER SLIPPER
35.REMOVE CHAIN VIBRATION DAMPER NO.1
36.REMOVE TIMING CHAIN GUIDE (See page 14±139)
37.REMOVE CHAIN SUB±ASSY
38.REMOVE BATTERY 39.REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a)Disconnect the 2 connectors.
(b)Disconnect the air cleaner hose from the throttle body.
(c)Raise a clamp up, and slide it toward the air cleaner cap,then remove the air cleaner cap from its case.
(d)Remove the air cleaner element.
(e)Remove the 4 bolts and the air cleaner case.
40.DISCONNECT RADIATOR HOSE INLET
41.DISCONNECT UNION TO CONNECTOR TUBE HOSE
42.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
43.SEPARATE FUEL TUBE SUB±ASSY (See page 11±26)
44. SEPARATE ENGINE WIRE

A77302
A77353
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
14±257
AVENSIS REPAIR MANUAL (RM1018E)
(e)Raise a clamp up, and slide it toward the air cleaner cap,
then remove the air cleaner cap from its case.
(f)Remove the air cleaner element.
(g)Remove the 4 bolts and the air cleaner case.
43.DISCONNECT RADIATOR HOSE INLET
44.DISCONNECT UNION TO CONNECTOR TUBE HOSE
45.DISCONNECT HEATER INLET WATER HOSE
46.SEPARATE FUEL TUBE SUB±ASSY
47.SEPARATE ENGINE WIRE
48.REMOVE THROTTLE BODY ASSY (See page 10±44)
49. REMOVE CHARCOAL CANISTER ASSY 50. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts.
(b) Disconnect the 2 vacuum hoses.
(c) Remove the 2 stud bolts.
(d) Remove the intake manifold and insulator.
51. REMOVE INTAKE AIR CONTROL VALVE ASSY
(a) Remove the intake air control valve and gasket.
52. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts and nut, and then remove the manifold insulator.

A79430
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
52 (530, 38)
52 (530, 38)
7.5 (76, 66 in.
lbf)
7.5 (76, 66 in.
lbf)
52 (530, 38)
25 (255, 18)
25 (255, 18)
43 (440, 32)
18 (178, 13)
30 (302, 22)
7.5 (76, 66 in.
lbf)
7.5 (76, 66 in.
lbf)
43 (440, 32)
Gasket

Gasket
Gasket
Injector DriverEngine Mounting Insulator
Sub±assy RH
Vacuum Reservoir Sub±assy
w/ Cold Area:
Heater Bracket
Radiator Hose Inlet
Radiator Hose Outlet
Fuel Filter Assy Air Tube No. 1
Air Tube No. 2
Exhaust Pipe Assy Front
Floor Panel Brace Front
w/ Cold Area:
Exhaust PIpe Assy
Union To Connector Tube Hose
w/ Cold Area:
Heater Pump Assy
Compression Spring
Compression Spring
8.3 (85, 73 in.
lbf)
25 (255, 18)
5.0 (51, 44 in.
lbf)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±327
AVENSIS REPAIR MANUAL (RM1018E)

141CA±01
14±332
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.DRAIN ENGINE COOLANT (See page 16±44)
6.DRAIN ENGINE OIL (See page 14±342)
7. REMOVE RADIATOR SUPPORT OPENING COVER
8. REMOVE ENGINE ROOM COVER SIDE
9. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
10.REMOVE VACUUM RESERVOIR SUB±ASSY (See page 13±11)
11.REMOVE AIR CLEANER ASSY (See page 14±286)
12. REMOVE BATTERY
13.REMOVE AIR TUBE NO.2 (See page 14±286)
14.REMOVE AIR TUBE NO.1(See page 14±270)
15.REMOVE INJECTOR DRIVER (See page 14±286)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
17.REMOVE GENERATOR V BELT (See page 14±269)
18.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
19.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
20.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
21.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
22.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
23.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
24. REMOVE TIMING BELT GUIDE
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
27.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
28.REMOVE TIMING BELT(See page 14±307)
HINT:
If re±using the timing belt, draw a direction arrow on the timing belt (\
in direction of engine revolution), and
place matchmarks on the pulleys and the timing belt.
29.REMOVE FUEL FILTER ASSY (See page 11±82)
30.REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13±11)
31.REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13±11)
32.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
34.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
35. DISCONNECT RADIATOR HOSE INLET
36. DISCONNECT HEATER INLET WATER HOSE
37. DISCONNECT HEATER OUTLET WATER HOSE
38. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
39. DISCONNECT OIL COOLER HOSE
40.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
41.REMOVE TURBO INSULATOR NO.1 (See page 13±11)

±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±341
AVENSIS REPAIR MANUAL (RM1018E)
95.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
96.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
97.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
98.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
99.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
100.INSTALL HEATER BRACKET (W/ COLD AREA)(See page 13±11)
101.INSTALL HEATER PUMP ASSY (W/ COLD AREA)(See page 13±11)
102.INSTALL FUEL FILTER ASSY(See page 11±82)
103.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
SST 09960±10010 (09962±01000, 09963±01000)
104.INSTALL TIMING BELT(See page 14±307)
105.CHECK VALVE TIMING(See page 14±307)
106.TIMING CHAIN COVER PLATE(See page 14±307)
107.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
108.INSTALL TIMING BELT GUIDE(See page 14±307)
109.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
110.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
111.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
112.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
113.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
114.INSTALL POWER STEERING IDLE PULLEY BRACKET(See page 14±307)
115. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
116.INSTALL INJECTOR DRIVER (See page 14±286)
117.INSTALL AIR TUBE NO.1(See page 14±270)
118.INSTALL AIR TUBE NO.2 (See page 14±286)
119.INSTALL AIR CLEANER ASSY (See page 14±286)
120.INSTALL VACUUM RESERVOIR SUB±ASSY (See page 13±11)
121. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
122. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
123. ADD ENGINE OIL
124.ADD ENGINE COOLANT(See page 16±44)
125.CHECK FOR FUEL LEAKS(See page 11±60)
126. CHECK FOR ENGINE OIL LEAKS
127.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
128. CHECK FOR EXHAUST GAS LEAKS