belt TOYOTA AVENSIS 2002 Owner's Guide

A77286
Push
A64641
A00019
A77288
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±143
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner No. 1 and gasket.
NOTICE:
Do not turn the crankshaft.
27. REMOVE CRANKSHAFT POSITION SENSOR
28. REMOVE OIL PAN SUB±ASSY
(a) Remove the 12 bolts and 2 nuts.
(b) Insert the blade of SST between the crank case, timing
chain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, crank case and oil pan.
29. REMOVE V±RIBBED BELT TENSIONER ASSY

A77289
Pry
A77243
14±144
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
30. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Using a screwdriver, pry between the timing chain cover
and cylinder head or cylinder block.
(c) Remove the timing chain cover.
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, cylinder head and cylinder block.
31. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
32. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the 2 bolts and the chain tensioner slipper.
33. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the bolt and the chain vibration damper No. 1
34. REMOVE TIMING CHAIN GUIDE
(a) Remove the bolt and the timing chain guide.
35. REMOVE CHAIN SUB±ASSY
36. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

A77389
Timing MarksMark Links
Timing Mark
A77290
Hold
Stopper
A32629
A77390Seal Packing 14±148
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Align the mark links (gold or yellow colored links) with
each timing mark located on the camshaft timing gears,
and install the chain.
43. INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
44. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
(b) Check that the chain tensioner slipper is hold on the cylin-
der block stopper.
45. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing forward.
46. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the chain cover 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 surfaces of the timing
chain cover.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of
seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent.

A77391
Seal Packing
4mm
2.5 mm
A
A
AA

3 to 4 mm
A77251
Nut
Nut
C
CC
C
B
B
B
BB
B
B
B
AC
A13759
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±149
AVENSIS REPAIR MANUAL (RM1018E)
(c) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to
0.157 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent
(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in.
lbf)
Bolt B 21 N
m (214 kgf
cm, 15 ft
lbf)
Bolt C 43 N
m (438 kgf
cm, 32 ft
lbf)
Nut 9.0 N
m (92 kgf
cm, 80 in.
lbf)
47. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the bolt and nut.
Torque: 60 N
m (610 kgf
cm, 44 ft
lbf)
NOTICE:
As the drive tensioner should be fastened together with the
timing chain cover, so be sure install it within 15 minutes
after the timing chain cover is installed.

A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(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 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 ft
lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

141B8±01
A77281
A77292
A77299
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FE)
14±139
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE ENGINE UNDER COVER LH
6.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining the engine oil.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
7.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
8.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
9.REMOVE GENERATOR ASSY (See page 19±20)
10.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
11. SEPARATE VANE PUMP ASSY
(a) Remove the 2 through bolts and separate the vane pump.
12. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove 3 bolts and separate the return tube as shownin the illustration.

A77286
Push
A64641
A00019
A77288
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±143
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner No. 1 and gasket.
NOTICE:
Do not turn the crankshaft.
27. REMOVE CRANKSHAFT POSITION SENSOR
28. REMOVE OIL PAN SUB±ASSY
(a) Remove the 12 bolts and 2 nuts.
(b) Insert the blade of SST between the crank case, timing
chain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, crank case and oil pan.
29. REMOVE V±RIBBED BELT TENSIONER ASSY

A77289
Pry
A77243
14±144
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
30. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Using a screwdriver, pry between the timing chain cover
and cylinder head or cylinder block.
(c) Remove the timing chain cover.
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, cylinder head and cylinder block.
31. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
32. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the 2 bolts and the chain tensioner slipper.
33. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the bolt and the chain vibration damper No. 1
34. REMOVE TIMING CHAIN GUIDE
(a) Remove the bolt and the timing chain guide.
35. REMOVE CHAIN SUB±ASSY
36. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

A77389
Timing MarksMark Links
Timing Mark
A77290
Hold
Stopper
A32629
A77390Seal Packing 14±148
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Align the mark links (gold or yellow colored links) with
each timing mark located on the camshaft timing gears,
and install the chain.
43. INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
44. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
(b) Check that the chain tensioner slipper is hold on the cylin-
der block stopper.
45. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing forward.
46. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the chain cover 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 surfaces of the timing
chain cover.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of
seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent.

A77391
Seal Packing
4mm
2.5 mm
A
A
AA

3 to 4 mm
A77251
Nut
Nut
C
CC
C
B
B
B
BB
B
B
B
AC
A13759
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±149
AVENSIS REPAIR MANUAL (RM1018E)
(c) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to
0.157 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent
(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in.
lbf)
Bolt B 21 N
m (214 kgf
cm, 15 ft
lbf)
Bolt C 43 N
m (438 kgf
cm, 32 ft
lbf)
Nut 9.0 N
m (92 kgf
cm, 80 in.
lbf)
47. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the bolt and nut.
Torque: 60 N
m (610 kgf
cm, 44 ft
lbf)
NOTICE:
As the drive tensioner should be fastened together with the
timing chain cover, so be sure install it within 15 minutes
after the timing chain cover is installed.