lock TOYOTA AVENSIS 2002 Service Manual

160MR±01
B12054
SST
B12052
B12053
Pry
PryPry
±
COOLING WATER PUMP ASSY(1AZ±FSE)
16±33
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DRAIN COOLANT (See page 16±31)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE ROOM COVER SIDE
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FAN AND GENERATOR V BELT (See page 14±185)
SST 09249±63010
6.REMOVE GENERATOR ASSY (See page 19±20)
7. REMOVE WATER PUMP PULLEY
(a) Using SST, remove 4 bolts and pump pulley.SST 09960±10010 (09962±01000, 09963±00700)
(b) Disconnect the crankshaft position sensor wire clamp from the water pump.
(c) Disconnect the crankshaft position sensor wire from the clamp on the water pump.
8. REMOVE WATER PUMP ASSY
(a) Remove 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry between the water pump and cyl- inder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.

VTA E2 VC
A35493
± ENGINE CONTROL SYSTEMSFI SYSTEM (1AZ±FE)
10±21
AVENSIS REPAIR MANUAL (RM1018E)
(b) Adjust the throttle stop screw.
NOTICE:
The throttle stop screw adjusting is very, so adjust it only
when the adjusting is really needed.
(1) Loosen the locknut and loosen the screw until it de-
taches the lever.
(2) Confirm that the throttle vale is fully closed.
(3) After the screw touches the lever, tighten it by 1/4
revolution additionally and tighten the lock nut.
(4) Seal the lock nut with yellow paint.
(5) Check that the throttle position sensor operates
normally.
4. INSPECT THROTTLE POSITION SENSOR
(a) Resistance inspection.
(1) Disconnect the throttle position sensor connector.
(2) Using an ohmmeter, measure the resistance be-
tween terminals VC and E2.
Resistance: 2.5 to 5.0 k

(3) Check the change of resistance between terminals
VTA and E2.
Change of resistance:
The resistance value increases in proportion to the
throttle lever opening value.
HINT:
Throttle valveResistance
Fully close0.2 to 5.7 k

Fully open2.0 to 10.2 k

A77873
(a)
(c)
(b)
(d)
(h)
(i)
(g)
(g)
(f)
(e)
Air cleaner clamp
(c)
A77874
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1AZ±FE)
10±27
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 ventilation hose.
(e) Disconnect the fuel vapor feed hose No. 1.
(f) Disconnect the fuel vapor feed hose N0. 2.
(g) Remove the fuel vapor feed hose No. 2 from 2 clamps of
the air cleaner hose.
(h) Lock the hose clamp as shown in the illustration.
(i) Raise the air cleaner clamp up, slide it to the air cleaner
cap.
(j) Remove the air cleaner cap together with air cleaner hose
No. 1.
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator control
cable.

A77879
45

A77880
83.8 mm
(3.299 in.)
Rotation
Center of
Throttle Link
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1AZ±FE)
10±29
AVENSIS REPAIR MANUAL (RM1018E)
11.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that throttle valve is fully closed.
(b)With the throttle position sensor rotated 45
counter-
clockwise 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.
12.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 3 screws.
13.INSTALL FUEL VAPOR FEED HOSE NO.2
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the fuel pipe support with the 3 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c)Install the fuel tube to the fuel pipe support.
(d)Connect the water by±pass hose.
(e)Connect the water by±pass hose No. 2.
(f)Connect the ISC valve connector.
(g)Connect the throttle position sensor connector.
15.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Instal 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
17.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±19)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER

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)

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

750N4±01
B66986
Back Door Trim
Panel Assy Upper
Back Door Trim Board Assy Back Door Side
Garnish LHBack Door Garnish Sub±assy
Outside RH
Floor Finish Plate Center Stop Lamp Assy
Back Door Lock Striker Hook
Back Door Side
Garnish RHBack Door Stay Assy RH
Back Door Lock Assy Rear Wiper Motor Assy
Back Door
Stay Assy LH
Back Door Service
Hole Cover
: Specified torqueN´m (kgf´cm, ft´lbf)
19.5 (200, 14)
5.5 (56, 49 in.´lbf)
Hook Rear Wiper Arm and Blade Assy
Rear Wiper
w/ Packing Washer
Wiper Arm Head Cap
Nut5.5 (56, 49 in.´lbf)
5.5 (56, 49 in.´lbf)
Cushion Rubber
Cushion Rubber
Rope Hook Assy
11.5 (120, 8)
22 (264, 19)
7.0 (71, 62 in.´lbf)
5.5 (56, 49 in.´lbf)
8.0 (82, 71 in.´lbf)
7.0 (71, 62 in.´lbf)22 (264, 19)
Female
Stopper RH
Female
Stopper LH
4.9 (49, 43 in.´lbf)Back Door Damper Assy
5.5 (56, 49 in.´lbf)
± ENGINE HOOD/DOORBACK DOOR (LIFTBACK MODELS)
75±37
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (LIFTBACK MODELS)
COMPONENTS

B66996
B66996
B66991
±
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
75±41
AVENSIS REPAIR MANUAL (RM1018E)
9. REMOVE BACK DOOR LOCK ASSY
(a) Disconnect the connector.
(b) Remove the 3 bolts and door lock.
10.REMOVE BACK DOOR STAY ASSY LH (See page 75±47)
11.REMOVE BACK DOOR STAY ASSY RH (See page 75±47) 12. INSTALL BACK DOOR LOCK ASSY
(a) Install the door lock with the 3 bolts.Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(b) Connect the door lock connector
13. INSTALL BACK DOOR DAMPER ASSY
(a) Install the damper with the 4 bolts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)

750N7±01
B66987
Back Door Trim Panel Assy Upper
Back Door Side Garnish LH Wiper Motor AssyRear Spoiler
Back Door Garnish Sub±assy Outside RH
Back Door Trim Board Assy
Door Pull Handle
Back Door Lock Striker Back Door Side Garnish RH
Door Pull Handle
: Specified torque
N´m (kgf´cm, ft´lbf)
Floor Finish Plate Rear Wiper Arm and Blade Assy
Wiper Arm Head Cap
5.5 (56, 49 in.´lbf)
Rear Wiper w/ Packing
Washer
Back Door
Stay Assy LH
7.0 (71, 62 in.´lbf)
22 (264, 19)
11.5 (120, 8)
Back Door Stay Assy RH
7.0 (71, 62 in.´lbf)
8.0 (82, 71 in.´lbf)
19.5 (200, 14)
Back Door Service Hole Cover
Back Door Lock Assy
4.9 (49, 43 in.´lbf)4.9 (49, 43 in.´lbf)
75±42
± ENGINE HOOD/DOORBACK DOOR (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (WAGON MODELS)
COMPONENTS

B66315
B66315
75±46
±
ENGINE HOOD/DOOR BACK DOOR(WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE BACK DOOR LOCK ASSY
(a)Disconnect the door lock connector.
(b)Remove the 3 bolts and door lock.
10.BACK DOOR STAY ASSY LH (See page 65±26)
11.BACK DOOR STAY ASSY RH (See page 65±26) 12. INSTALL BACK DOOR LOCK ASSY
(a) Install the door lock with the 3 bolts.Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(b) Connect the door lock connector.