drain TOYOTA AVENSIS 2002 Service Manual

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)

141CM±01
A78459
A78461
1ZZ±FE
A78497
3ZZ±FE
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
14±81
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE(See page 11±1)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
3.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
6.REMOVE ENGINE UNDER COVER RH (See page 14±27)
7.DRAIN ENGINE COOLANT(See page 16±7)
8.REMOVE CYLINDER HEAD COVER NO.2
(a)Remove the 2 nuts and 2 clips and detach the cylinderhead cover No.2.
9.SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a)Loosen the nut and separate the accelerator control cable.
10.REMOVE AIR CLEANER HOSE NO.1
(a)Disconnect the VSV connector.
(b)Disconnect the fuel vapor feed No. 1 hose from the VSV.
(c)Disconnect the fuel vapor feed hose from the VSV.
(d)Loosen the 2 air cleaner hose clamp bolts and remove the air cleaner hos\
e.
11.DISCONNECT WATER BY±PASS HOSE
(a)Disconnect the water by±pass hose from the throttle body.
12.DISCONNECT WATER BY±PASS HOSE NO.2
(a)Disconnect the water by±pass hose from the throttle body.
13.REMOVE EFI FUEL PIPE CLAMP (See page 11±11)

141BF±01
A77281
A77301
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.

141C4±01
A80094
14±286
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEELS
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.DRAIN ENGINE COOLANT (See page 16±44)
8.DRAIN ENGINE OIL (See page 14±342)
9.DRAIN MANUAL TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
11.REMOVE BATTERY
12.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap together with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
13.DISCONNECT UNION TO CONNECTOR TUBE HOSE
14.REMOVE FUEL FILTER ASSY
(a)Disconnect the 2 fuel hose from the fuel filter (STD).
(b)Disconnect the 3 fuel hose from the fuel filter (COLD).
(c)Disconnect the connector (STD).
(d)Disconnect the 2 connectors (COLD).
(e)Remove the 2 bolts and the fuel filter.
15.REMOVE RADIATOR HOSE INLET
16.REMOVE RADIATOR HOSE OUTLET
17.DISCONNECT WATER BY±PASS HOSE NO.2
18.REMOVE ENGINE ROOM RELAY BLOCK NO.3
(a)Remove the 2 bolts and the engine room relay block.
19.REMOVE RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
20. DISCONNECT HEATER INLET WATER HOSE
21. DISCONNECT HEATER OUTLET WATER HOSE
22. DISCONNECT FUEL HOSE NO.2
23. REMOVE AIR TUBE NO.2
(a) Loosen the hose clamp and disconnect the air hose No.3.
(b) Remove the 2 bolts and the air tube No. 2.

A78516
A78459
14±28
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
7.REMOVE ENGINE UNDER COVER RH
(a)Remove the 6 screws and 3 clips, then detach the engine under cover.
8.DRAIN ENGINE COOLANT(See page 16±7)
9. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil. Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
10.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (See page 41±15)
11.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±42)
12. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, then detach cylinder headcover No.2.
13.REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
14. REMOVE AIR CLEANER FILTER ELEMENT SUB±ASSY
15. REMOVE AIR CLEANER CASE SUB±ASSY
(a) Remove the 3 bolts and the air cleaner case.
16. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the radiator.
17. DISCONNECT RADIATOR HOSE OUTLET
(a) Disconnect the radiator hose outlet from the radiator.
18. DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
19. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.

110UC±01
A79148
SST
A79143
SST
11±78
±
FUEL COMMON RAIL ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50) 5. REMOVE FUEL INLET PIPE SUB±ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and the injection pump with vinyl tape to prevent dust from
being introduced.
(a) Using SST, remove the fuel inlet pipe from the commonrail.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and the 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.

110UD±01
A79188
A80091SST
A79190
11±82
± FUELFUEL FILTER ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL FILTER ASSY (1CD±FTV)
REPLACEMENT
1. REMOVE AIR CLEANER ASSY
(a) Disconnect the connector.
(b) Remove the air cleaner cap with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and the air cleaner case.
2. REMOVE FUEL FILTER ASSY
(a) Disconnect the 2 fuel hose from the fuel filter. (STD or COLD)
(b) Disconnect the 3 fuel hose from the fuel filter. (W/ ADDTIONAL HEATER)
(c) Disconnect the 2 connectors.
(d) Remove the 2 bolts and the fuel filter.
3. DRAIN FUEL
(a) Loosen the drain plug, and drain the fuel from the fuel filter.
4. REMOVE LEVEL WARNING SWITCH
(a) Clamp the fuel filter in a soft jaw vise.
(b) Using pliers, remove the level warning switch.
NOTICE:
Be careful not to damage the level warning switch.
5. REMOVE FUEL FILTER ELEMENT
(a) Using SST, remove the fuel filter element.
SST 09228±64030
6. INSTALL FUEL FILTER ELEMENT
(a) Check and clean the fuel filter installation surface.
(b) Apply fuel to a gasket of a new fuel filter element.
(c) Lightly screw the fuel filter element into place, and tighten
it until the gasket comes into contact with the seat.
(d) Tighten it additional 3/4 turn by hand.

110UW±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUEL FUEL SYSTEM(1AZ±FE)
11±15
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2)Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.

110UT±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUEL FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
11±1
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec-
tion to catch any fuel that may spill.

110UZ±01
A75339
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
11±30
±
FUEL FUEL SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FSE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts. 2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.