TOYOTA AVENSIS 2002 Repair Manual

A77403
15
3
7
2
6
4 8
A63273
A77404
B
A
BBBB
A
B
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±131
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the drive plate. (A/T)
(1)Clean the bolt and bolt hole.
(2)Apply adhesive to the bolts.
(3)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 98 N
m (1,000 kgf
cm, 72 ft
lbf)
(c)Install the flywheel. (M/T)
(1)Clean the bolt hole.
(2)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 130 N
m (1,327 kgf
cm, 96 ft
lbf)
NOTICE:
Do not reuse the flywheel bolt.
110.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
111.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
112.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
113.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
114.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
115.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
116.INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Install the engine mounting insulator FR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
(b)Install the engine mounting insulator RR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
117.INSTALL STARTER ASSY (See page 19±12)
118. INSTALL VANE PUMP ASSY
Torque: 37 N
m (370 kgf
cm, 27 ft
lbf)
119. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the 2 bolts and 2 nuts as shown in the illustration. Torque:
Bolt 45 N
m (459 kgf
cm, 33 ft
lbf)
Nut 133 N
m (1,356 kgf
cm, 98 ft
lbf)
(b) Install the front suspension member braces with the 8 bolts.
Torque:
Bolt A 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B 80 N
m (816 kgf
cm, 59 ft
lbf)

A77304
A77305
A77405
A
B
A
A
A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±132
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
120.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
121.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
122.INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
123.REMOVE ENGINE HANGERS
124.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
125.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (
See page 41±24)

126.INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25) 127. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
Torque:
Bolt A 12 N
m (122 kgf
cm, 89 ft
lbf)
Bolt B 9.0 N
m (92 kgf
cm, 79 in.
lbf)
Bolt C 5.0 N
m (51 kgf
cm, 44 in.
lbf)

±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±133
AVENSIS REPAIR MANUAL (RM1018E)
128.INSTALL FRONT AXLE ASSY LH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
129.INSTALL FRONT AXLE ASSY RH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
130.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
131.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE)
Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
132.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
133.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
134.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
135.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
136.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
137.INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
138.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
139.INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
140.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
141.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
142.INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
143.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
144.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
145.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
146.INSTALL COOLER REFRIGE RANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
147.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
148.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
149.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
150.INSTALL BATTERY CARRIER
151.INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
152.INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
Torque: 25 N
m (255 kgf
cm,18 in.
lbf)
153.INSTALL GENERATOR ASSY (See page 19±20)
154.INSTALL FAN AND GENERATOR V BELT (See page 14±105)

14±134
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
155.INSTALL RADIATOR ASSY (See page 16±24)
156.INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
157.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
158.ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
159.ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
160.ADD ENGINE OIL
161.ADD COOLANT (See page 16±19)
162. ADD POWER STEERING FLUID
163. BLEED POWER STEERING FLUID
164. CHECK FOR ENGINE OIL LEAKS
165.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
166.CHECK FOR FUEL LEAKS (See page 11±15)
167. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
168.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
169.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±101)
170.INSPECT CO/HC (See page 14±101)
171. CHECK ABS SPEED SENSOR SIGNAL

141C3±01
A79198N´m (kgf´cm, ft´lbf)
: Specified torque
5.0 (51, 44 in.
lbf)
19 (194, 14)
3.0 to 4.0 (31 to 41, 27 to 35 in.
lbf)
7.0 (71, 62 in.
lbf)
5.3 (54, 47in.
lbf)
Engine Room Relay Block No. 3
8.0 (82, 71 in.
lbf)
Engine Room Cover Side
Radiator Support Opening Cover
Radiator Support Upper
Radiator Hose Inlet
Engine Cover No. 1
Radiator Hose Outletw/ A/C:
Radiator Assy
Battery
Battery Tray
Engine Under Cover RHEngine Under Cover Sub±assy No. 1
Engine Under Cover LH
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Clip
Clip
Clip
Retainer
Clip
Clip
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±277
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1CD±FTV)
COMPONENTS

A79418N´m (kgf´cm, ft´lbf)
: Specified torque
25 (255, 18)
18 (178, 13)
Injector Driver
Air Tube No. 2Union To Connector Tube Hose
Fuel Filter AssyHeater Inlet Water Hose Heater Outlet Water Hose Vacuum Reservoir Sub±assy
8.3 (85, 73 in.
lbf)
5.0 (51, 44 in.
lbf)
14±278
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

A79419
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
29 (296, 21)
80 (816, 59)
133 (1,348, 97)
43 (440, 32)
30 (302, 22)
43 (440, 32)

Gasket
74 (755, 55)
49 (500, 36)

Gasket
Cotter Pin V (Cooler Compressor
to Crankshaft pulley)
Belt No. 1Glove Compartment Door Assy
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silencer Sheet
Front Stabilizer Link Assy LHClip
Tie Rod End Sub±assy LH
Front Axle Hub LH Nut
Front Suspension Member
Brace Rear LH
Compression
Spring
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring w/ A/C:
Compressor And Magnetic ClutchFront Drive Shaft Assy LHClip Transmission Control
Cable Assy
Clip
Clutch Accumulator Assy
Clutch Release Cylinder Assy
Transmission Control Cable Assy
35 (357, 26)
142 (1,448, 105)
Clip
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±279
AVENSIS REPAIR MANUAL (RM1018E)

A79420N´m (kgf´cm, ft´lbf)
: Specified torque
52 (530, 38)
52 (530, 38)
52 (530, 38)
52 (530, 38)
87 (887, 64)
80 (816, 59)
133 (1,356, 98)52 (530, 38)
72 (734, 53)
39 (398, 29)
Engine Mounting Insulator
Sub±assy RHAir Tube No. 1
Front Suspension Crossmember
Sub±assy25 (255, 18)
25 (255, 18)
14±280
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

A79421N´m (kgf´cm, ft´lbf)
: Specified torque
88 (897, 65)
19 (195, 14)
64 (653, 47)
37 (377, 27)
Drive Shaft Bearing Bracket
Flywheel Sub±assy
Clutch Cover Assy
Starter Assy
Manual Transaxle
Clutch Disc Assy
64 (653, 47)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±281
AVENSIS REPAIR MANUAL (RM1018E)

A79422
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket

Gasket
Gasket
20 (204, 15)
20 (204, 15)
53 (540, 39)
13 (135, 9.7)
36 (367, 27)61 (622, 45)
56 (571, 41)
25 (255, 18)
Turbo Insulator No. 1
Exhaust Manifold Heat Insulator No. 2
Turbocharger Stay
Turbocharger Sub±assy
Turbo Oil Inlet Pipe
Sub±assy
Manifold Stay Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy Turbo Insulator
No. 2


20 (204, 15)
12 (122, 8.9)
56 (571, 41)

Gasket
12 (122, 8.9)
14±282
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)