TOYOTA AVENSIS 2002 Repair Manual

100FB±01
A78454
N´m (kgf´cm, ft´lbf) : Specified torqueClip
Cylinder Head Cover No.2
Fuel
Vapor Feed Hose No.1
VSV
Connector
Mass Air Flow
Meter Connector Accelerator Control
Cable Assy
Fuel Vapor Feed Hose
No.3 Engine Room Cover Side
Radiator Support Opening Cover
Clip
Retainer
7.0 (71, 62 in.´lbf)
Clip
1.5 (15, 13 in.´lbf)
13 (129, 9)
Air Cleaner Cap
Sub±assy
x2
x4
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1ZZ±FE)
10±7
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (1ZZ±FE)
COMPONENTS

A78455

Throttle Body Gasket

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueISC Valve
Throttle Body Cover Gasket Accelerator
Control Cable BracketThrottle Position
SensorWater By±pass
Hose Water By±pass
Hose No.2
Throttle Body Bracket ISC Valve ConnectorThrottle Body Assy
M/T:
Manifold Stay No.2Ventilation Hose
Throttle Position
Sensor Connector
13 (133, 10)
30 (306, 22)
30 (306, 22)
3.7 (38, 33 in.´lbf)
2.0 (20, 18 in.´lbf)
13 (133, 10)
x3 x2x2 x2 10±8
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

100FC±01
A784575 Claws
A78458
A78459
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1ZZ±FE)
10±9
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER
(a)Remove the retainer and 4 clips.
(b)Unfasten the 5 claws and remove the radiator support
opening cover.
2.REMOVE ENGINE ROOM COVER SIDE
(a)Remove the 2 clips, and then remove the engine room cover side.
3.DRAIN ENGINE COOLANT (See page 16±7)
4. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, and then remove the cylin- der head cover No. 2.

A78460
(a)
(b)(c)
(c)
(d)
(e)
(f)
(g)
(h)
Air Cleaner clamp
A78461
A78462
(a)
(b)
(c)
A78463
(d)
(e)
(M/T) 10±10
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE AIR CLEANER CAP SUB±ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the VSV connector.
(c) Remove the 2 wire harness clamps.
(d) Disconnect the fuel vapor feed hose No. 1.
(e) Disconnect the fuel vapor feed hose No. 3.
(f) Remove the accelerator control cable from the accelera-
tor control cable support No. 2.
(g) Loosen the hose clamp.
(h) Raise the air cleaner clamp up, slide it to the air cleaner
cap.
(i) Remove the air cleaner cap together with the air cleaner
hose No. 1.
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator control
cable.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the water by±pass hose.
(b) Disconnect the water by±pass hose No. 2.
(c) Disconnect the ventilation hose.
(d) Disconnect the throttle position sensor connector.
(e) Disconnect the ISC valve connector.
(f) Remove the 3 bolts and 2 nuts, and then remove the
throttle body bracket and the throttle body. (A/T)
(g) Remove the 5 bolts and 2 nuts, and then remove the
throttle body bracket and the throttle body. (M/T)
(h) Remove the gasket from the intake manifold.

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)

A78463
A
A
A
A
BB
A
(d)
(c)
A78468
65.1 mm
(2.563 in.)
Rotation
Center of
Throttle Link
18

10±12
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the throttle body bracket with the 3 bolts and 2 nuts. (A/T)
Torque:
30 N
m (306 kgf
cm, 22 ft
lbf) for bolt and nut A
(c)Install the throttle body and the throttle body bracket with
the 5 bolts and 2 nuts. (M/T)
Torque:
30 N
m (306 kgf
cm, 22 ft
lbf) for bolt and nut A
13 N
m (133 kgf
cm, 10 ft
lbf) for bolt B
(d)Connect the ISC valve connector.
(e)Connect the throttle position sensor connector.
(f)Connect the ventilation hose.
(g)Connect the water by±pass hose No. 2.
(h)Connect the water by±pass hose.
15.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)
16.INSTALL AIR CLEANER CAP SUB±ASSY Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
17.INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±7)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER

100FD±01
A78454
N´m (kgf´cm, ft´lbf) : Specified torqueClip
Cylinder Head Cover No.2
Fuel
Vapor Feed Hose No.1
VSV
Connector
Mass Air Flow
Meter Connector Accelerator Control
Cable Assy
Fuel Vapor Feed Hose
No.3 Engine Room Cover Side
Radiator Support Opening Cover
Clip
Retainer
7.0 (71, 62 in.´lbf)
Clip
1.5 (15, 13 in.´lbf)
13 (129, 9)
Air Cleaner Cap
Sub±assy
x2
x4
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3ZZ±FE)
10±13
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (3ZZ±FE)
COMPONENTS

A78504

Throttle Body Gasket

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueISC Valve
Throttle Body Cover
GasketThrottle Position
SensorWater By±pass
Hose Water By±pass
Hose No.2
ISC Valve ConnectorThrottle Body Assy Ventilation Hose
Throttle Position
Sensor Connector
30 (306, 22)
30 (306, 22)
Accelerator
Control Cable Bracket
3.7 (38, 33 in.´lbf)
2.0 (20, 18 in.´lbf)
x2
x2
x4 10±14
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

100FE±01
A78497
A78498
(a)
(b)
(c)
A78499
(d)
(e)
A78500
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(3ZZ±FE)
10±15
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
3.DRAIN ENGINE COOLANT (See page 16±7)
4.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
5.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±9)
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator controlcable.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the ventilation hose.
(b) Disconnect the water by±pass hose.
(c) Disconnect the water by±pass hose No. 2.
(d) Disconnect the throttle position sensor.
(e) Disconnect the ISC valve connector.
(f) Remove the bolt and 2 nuts, and then remove the acceler- ator control bracket and the throttle body.
(g) Remove the gasket from the intake manifold.
8. REMOVE ISC VALVE
(a) Remove the 4 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.

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