TOYOTA AVENSIS 2002 Repair Manual

A77303
A77308
A77306
A77307
14±140
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
13. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
14. SEPARATE VANE PUMP OIL RESERVOIR ASSY
NOTICE:
Do not disconnect the 2 hoses.
15. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil pump reservoir bracket No.
1.
16. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the clamp and engine wire.
17. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove the bolt and the engine service cover bracket RH.
18. REMOVE COOLER BRACKET (LHD(W/ AIR
CONDITIONER) STEERING POSITION TYPE)
(a) Remove the bolt and cooler bracket.

A77283
A77284
A77285
Unleaded Gasoline
Timing
Marks

eaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±141
AVENSIS REPAIR MANUAL (RM1018E)
19. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the bolt and the engine service cover bracket RH.
20. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
21. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Disconnect the 2 PCV hoses from the cylinder head cov-
er.
(b) Remove the 8 bolts and 2 nuts, and then remove the cylin-
der head cover and gasket.
22. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its timing notch with
timing mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing gear
are aligned with the timing marks located on the No. 1 and
No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.

A61184
A66202
A77305
A77380
SST
A77381
SST 14±142
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
23. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
(a) Place the jack underneath the engine, and put a wooden
block on the jack.
(b) Remove the 2 bolts and 2 nuts, and then detach the
mounting bracket No. 2 RH.
24. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 3 bolts and the engine mounting insulator.
25. REMOVE CRANKSHAFT PULLEY
(a) Using SST, fix the crankshaft pulley and loosen a crank-
shaft pulley bolt.
SST 09213±54015 (91651±60855), 09330±00021
(b) Using a crankshaft pulley bolt and SST, remove the crank-
shaft pulley.
SST 09950±50013 (09951±05010, 09952±05010,
09953±05020, 09954±05021)

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

A77382
Groove90

A77383
Groove
A66833
B11424
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±145
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90
, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil
pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner
and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
38. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Orient the flat portion of the drive shaft upward.

A77384
Mark Link
Timing Mark
Timing Mark
Mark Link
A77385
Groove
A77386
Groove
A77387
90
14±146
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Align the mark links (yellow colored links) with the timing
marks of each gear as shown in the illustration.
(d) Install the gears to the crankshaft and oil pump shaft with
the chain wrapped.
(e) Temporarily tighten the oil pump drive shaft gear with the
nut.
(f) Insert the damper spring into the adjusting hole, and
install the chain tensioner plate with the bolt.
Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
(g) Align an adjusting hole of the sprocket with the groove of
the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the
sprocket to lock in position, and tighten the nut.
Torque: 30 N
m (301 kgf
cm, 22 ft
lbf)
(i) Rotate the crankshaft clockwise 90
, and position the
crankshaft key upward.

A77285
Unleaded Gasoline
Timing
Marks
Leaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
A52505
A77388
SST
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±147
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
40. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the camshafts with a wrench on the hexagonal lobe,
and align the timing marks of the camshaft timing gear
with each timing mark located on the No. 1 and No. 2
bearing caps as shown in the illustration.
(b) Using the crankshaft pulley bolt, turn the crankshaft and
position the key on the crankshaft upward.
41. INSTALL CHAIN VIBRATION DAMPER NO.1
42. INSTALL CHAIN SUB±ASSY

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.