TOYOTA AVENSIS 2002 Repair Manual

A77299
A77303
A77308
A77306
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±255
AVENSIS REPAIR MANUAL (RM1018E)
19. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts and separate the return tube shown
in the illustration.
20. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD STEERING POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
21. SEPARATE VANE PUMP OIL RESERVOIR ASSY
22. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil reservoir bracket No. 1.
23. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate a clamp and the engine
wire.

A77340
A77335
14±256
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
24.REMOVE COOL ER BRACKET (LHD STEER ING
POSITION TYPE)
(a)Remove the bolt and the cooler bracket.
25.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a)Remove the bolt and the engine service cover bracket RH.
26.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
27.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
28.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (
See page 14±222)
29.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (
See page 14±222 )

30.REMOVE CRANKSHAFT PULLEY (See page 14±222) SST 09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
31.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±222)
32.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17)
33.REMOVE OIL PAN SUB±ASSY (See page 14±222)
SST 09032±00100
34.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±222)
35.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±222)
36.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±222)
37. REMOVE CHAIN TENSIONER SLIPPER
38. REMOVE CHAIN VIBRATION DAMPER NO.1
39.REMOVE TIMING CHAIN GUIDE (See page 14±222)
40. REMOVE CHAIN SUB±ASSY
41. REMOVE BATTERY
42. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a) Disconnect the 2 connectors.
(b) Disconnect the 2 vacuum hoses.
(c) Disconnect the ventilation hose.
(d) Disconnect the air cleaner hose from the throttle body.

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.

A77350
A52497
A32664
A56213
14±258
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
53.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a)Remove the 2 bolts and 2 nuts, and then detach the No.
1 and No. 2 exhaust manifold stay.
(b)Disconnect the 3 oxygen sensor connectors.
(c)Remove the 5 nuts, the exhaust manifold and gasket.
54.REMOVE NO.2 CAMSHAFT (See page 14±240)
55.REMOVE CAMSHAFT (See page 14±240)
56. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt and the oil control valve. 57. REMOVE CAMSHAFT BEARING NO.2
58. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub±assy.
(b) Set the jack under the engine assembly w/ transaxle, andplace a wooden block on the jack.
(c) Remove the chain block and sling devise.

A7740612 3
4 109
8 56 7
A77407
Overall Length
A77408
Lot No.
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±259
AVENSIS REPAIR MANUAL (RM1018E)
59. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 10 cylinder head bolts,
with 10 mm bi±hexagon wrench uniformly in the se-
quence shown in the illustration.
(b) Remove 10 cylinder head bolts and plate washers.
NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cranking could result from remov-
ing bolts and installing incorrect order.
60. REMOVE CYLINDER HEAD GASKET
61. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of the cylin-
der head set bolts from the seat to the end.
Standard bolt length:
161.3 to 162.3 mm (6.350 to 6.390 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the cylinder head
set bolts.
62. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:

Remove any oil from contact surface.

Be careful of the installation direction.

Place the cylinder head gently in order not to damage
the gasket with the bottom part of the head.
63. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head set bolts are tightened in 2 successive steps.

A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
12.5 to 1.5 mm
A7741012
3
4
10 9
85
67
A00976A77411
90
Engine
Front Paint Mark
14±260
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(a)Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from contact surface.

Install the cylinder head within 3 minutes after apply-
ing seal packing.

After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.

Do not start the engine within 2 hours after installing.
(b)Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(c)Install bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d)Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e)Mark the front side of the cylinder head set bolts with paint.
(f)Retighten the cylinder head set bolts by 90  in the same
sequence as a step (d).
(g)Check that each paint mark is now at a 90  angle to the
front.
64.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm,79 in.
lbf)
65.INSTALL CAMSHAFT (See page 14±240)
66.INSTALL NO.2 CAMSHAFT (See page 14±240)

A77332
23
145
A77350
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
14±261
AVENSIS REPAIR MANUAL (RM1018E)
67.INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a)Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(b)Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
68.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
69.INSTALL INTAKE AIR CONTROL VALVE ASSY
(a)Install a new gasket and the intake air control valve.
70.INSTALL INTAKE MANIFOLD
(a)Install the 2 stud bolts. Torque: 10 N
m (97 kgf
cm,84 in.
lbf)
(b)Install the intake manifold and insulator with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
71.INSTALL THROTTLE BODY ASSY (See page 10±44)
72. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
73. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
74.INSTALL CHAIN SUB±ASSY (See page 14±222)
75. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
76. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 N
m (195 kgf
cm, 15 ft
lbf)
77.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±240)
78.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±222)
79.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±222)
80.INSTALL OIL PAN SUB±ASSY (See page 14±222)
81.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
82.INSTALL CRANKSHAFT PULLEY (See page 14±222) SST 09213±54015 (91651±60855), 09330±00021
83.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±222)
84. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
85.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)

14±262
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

141C9±01
A79429N´m (kgf´cm, ft´lbf)
: Specified torque
8.0 (82, 71 in.
lbf)
72 (734, 53)
39 (398, 29)
5.0 (51, 44 in.
lbf)
3.0 to 4.0 (31 to 41, 27 to 35 in.
lbf)
Engine Cover No. 1Engine Room Cover Side
Radiator Support Opening Cover
Power Steering
Idle Pulley Bracket
Battery
Engine Under Cover Sub±assy No. 1
Engine Under Cover LH Battery Tray
Air Cleaner Cap w/ Hose
Air Cleaner Element
AIr Cleaner Case
7.0 (71, 62 in.
lbf)
Engine Under Cover RH
V (Cooler
Compressor to
Crankshaft Pulley)
Belt No. 1
Clip
Clip
Retainer
Clip Clip
Clip
14±326
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CYLINDER HEAD GASKET (1CD±FTV)
COMPONENTS

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)