TOYOTA AVENSIS 2002 Repair Manual

A79187
O±ringBack±up ring
B08249
A80111
180
90 11±62
± FUELINJECTOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install new back±up rings and O±rings to each injector.
(c) Apply a light coat of engine oil onto the O±rings on each
injector.
(d) Install the injector to the cylinder head.
NOTICE:
Fit the injectors to the nozzle seat.
(e) Install the nozzle holder clamp as shown in the illustration.
Tighten the camshaft bearing cap bolt by hand to fix the
nozzle holder clamp.
NOTICE:

Pay attention to the mounting orientation of the wash-
er.

When temporarily attaching the nozzle holder clamp
and the mounting bolt, be careful not to orient them
at an angle.
HINT:
Apply a light coat of engine oil on the threads of the nozzle hold-
er clamp bolts.
(f) Install the injection pipe No. 1, No. 2, No. 3 and No. 4,
tighten the nuts by hand.
(g) Install new 5 gaskets and the leakage pipe No. 1. Tighten
the 4 hollow screws by hand.
(h) Tighten the 4 nozzle holder clamp bolts.
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
(i) Remove the 4 injection pipes.
18. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Install the nozzle leakage pipe and 5 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint portion of the
gasket comes within the ranges shown in the illustration.
(b) Apply a light coat of oil onto the 4 hollow screws and the
union bolt.
(c) Tighten the 4 hollow screws and the union bolt by hand.
(d) Tighten the 4 hollow screws and the union bolt.
Torque:
18 N
m (184 kgf
cm, 13 ft
lbf) for hollow screw
22 N
m (224 kgf
cm, 16 ft
lbf) for union bolt
(e) Check that there are no leaks from the nozzle leakage
pipe connection.
(1) Disconnect the fuel hose, and remove the bolt, the
check valve and the nozzle leakage No. 2 pipe and
the gasket.

A80119
New Gasket
Hollow
Screw
Union
Bolt
SST
Nozzle Leakage
No. 2 Pipe
New Gasket
SST
A79146
Check
Valve
Nozzle Leakage
No. 2 Pipe
New Gasket
A09663
:Seal Packing
± FUELINJECTOR ASSY (1CD±FTV)
11±63
AVENSIS REPAIR MANUAL (RM1018E)
(2) Install the bolt, the nozzle leakage No. 2 pipe and
the gasket to the cylinder head with SST.
SST 09280±00010
Torque:
8.8 N
m (90 kgf
cm, 79 in.
lbf) for bolt
21 N
m (214 kgf
cm, 15 ft
lbf) for SST
(3) Apply a light coat of soapy water (any fluid to detect
fuel leakage) on the nozzle leakage pipe No. 2 con-
nection.
(4) Using SST (turbocharger pressure gauge), attach
SST to the fuel return side of the nozzle leakage No.
2 pipe, and maintain 100 kPa (1.0 kgf/cm
2, 14.5 psi)
of pressure for 60 seconds to check that there are
no bubbles from the pipe connection.
SST 09992±00242
(5) After checking fuel leaks, wipe off soapy water from
the pipe connection.
(6) Remove 2 SSTs, and then remove the bolt, the
nozzle leakage No.2 pipe and the gasket.
(7) Place a new gasket and reinstall the nozzle leakage
No. 2 pipe with the check valve and the bolt.
Torque:
8.8 N
m (90 kgf
cm, 79 in.
lbf) for bolt
21 N
m (214 kgf
cm, 15 ft
lbf) for check valve
HINT:
Do not disassemble the check valve on the engine.
(8) Reconnect the fuel hose to the nozzle leakage No.
2 pipe.
19. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the cylinder head cover with the 10 bolts.
Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)

A79147
SST
30 cm
(11.81 in.)
11±64
±
FUEL INJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
20.INSTALL NOZZLE HOLDER SEAL
(a)Install new 4 nozzle holder seals.
21.INSTALL TIMING BELT NO.2 COVER(See page 14±307) 22. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:

In case of having the injectors replaced, must replace
the injection pipes, too.

When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and
vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)

±
FUEL INJECTOR ASSY(1CD±FTV)
11±65
AVENSIS REPAIR MANUAL (RM1018E)
23.INSTALL INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
24.INSTALL INJECTION PIPE SUB±ASSY NO.3
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
25.INSTALL INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
26.INSTALL AIR TUBE NO.1 (See page 14±270)
27. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
28. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
29. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
30. CHECK FOR FUEL LEAKS
NOTICE:
Under ACTIVE TEST mode, fuel pressure increases. Take precautions to prevent fuel from spraying
on you or inside the engine compartment.
HINT:
During ACTIVE TEST mode, engine speed goes high and combustion noise bec\
omes loud.
(a) Check that there are no fuel leaks from any part of the fuel system at t\
he engine stops.
HINT:
If fuel leakage could be found on specific parts, replace them with new \
parts.
(b) While cranking or when starting the engine, check that there is no leaks from\
any part of the fuel sys-
tem.
HINT:
If fuel leakage could be found on specific parts, replace them with new pa\
rts.
(c) Disconnect the fuel hose from the common rail.
(d) While cranking the engine, check fuel leaks from the return pipe.
HINT:
If there is fuel leakage, replace the common rail.
(e) Connect the hand±held tester to the DLC3.
(f) Start the engine and push the hand±held tester main switch ON.
(g) Select the FUEL LEAK test of ACTIVE TEST mode on the hand±held tester\
.
(h) If you do not have the hand±held tester, depress the accelerator pedal quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this opera\
tion several times.
(i) Check that there are no leaks from any part of the fuel system.
NOTICE:
If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in\
a minute, it is acceptable.
HINT:
If fuel leakage could be found on specific parts, replace them with new \
parts.
(j) Reconnect the fuel hose to the common rail.

550YT±01
I35273
Manual A/C:
Heater Control HousingAir Conditioning Control Assy
Air Conditioning Control Bulb
Heater Control Housing Sub±assy
Heater Control Lens Assy
Heater Control Housing
Heater Control Knob No.2
Heater Control Knob No.3Heater Control Knob
Cooler Wire No.1
Air Conditioning Panel Sub±assy 55±48
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING CONTROL ASSY
COMPONENTS

I35274
Auto A/C:
Air Conditioning Control Assy
Cooler Wire No.1 Heater Control Housing
Control Knob Sub±assy
Air Conditioning Panel Sub±assy
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
55±49
AVENSIS REPAIR MANUAL (RM1018E)

550YU±01
I37428
I352826 Claws
I352864 Claws
55±50
±
HEATER & AIR CONDITIONER AIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±48
1.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
2.REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
4.REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (See page 67±5)
5.REMOVE RADIO BRACKET NO.1 (See page 67±5)
6.REMOVE RADIO BRACKET NO.2 (See page 67±5) 7. REMOVE AIR CONDITIONING CONTROL ASSY
(a) Remove the air conditioning control assy as shown in theillustration.
8. REMOVE AIR CONDITIONING PANEL SUB±ASSY
(a) Remove the 4 screws.
(b) Manual A/C: Release the 6 claw fittings and disconnect the air condi-
tioning panel sub±assy.
(c) Auto A/C: Release the 4 claw fittings and disconnect the air condi-
tioning panel sub±assy.

I35287
Auto A/C:
I35283
Manual A/C:
I35284
I35285
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
55±51
AVENSIS REPAIR MANUAL (RM1018E)
(d) Disconnect the cooler wire No.1 as shown in the illustra-
tion.
9. REMOVE HEATER CONTROL KNOB NO.3 (MANUAL AIR CONDITIONING)
10. REMOVE CONTROL KNOB SUB±ASSY (AUTO AIR CONDITIONING)
11. REMOVE HEATER CONTROL KNOB (MANUAL AIR CONDITIONING)
12. REMOVE HEATER CONTROL KNOB NO.2 (MANUAL AIR CONDITIONING)
13. REMOVE HEATER CONTROL HOUSING (MANUAL
AIR CONDITIONING)
(a) Release the 4 claw fittings and remove the 4 screws and
the heater control housing.
14. REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)
15. REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)
16. REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)
17. REMOVE AIR CONDITIONING CONTROL BULB
(MANUAL AIR CONDITIONING)
(a) Remove the 4 air conditioning control bulbs.

I35833
Manual A/C:
Auto A/C:

I35834
Manual A/C:
Auto A/C: 55±52
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE HEATER CONTROL HOUSING SUB±ASSY (MANUAL AIR CONDITIONING)
19. REMOVE HEATER CONTROL HOUSING
(a) Remove the 4 screws and the heater control housing.
20. REMOVE COOLER WIRE NO.1
(a) Remove the cooler wire No.1 as shown in the illustration.

550YV±01
I35275
N
m (kgf
cm, ft
lbf) : Specified torque
9.8 (100, 87 in.
lbf)
9.8 (100, 87 in.
lbf)
Defroster Nozzle Assy
Heater To Register Duct No.1
Blower Assy
Air Conditioning Radiator Assy
Instrument Panel Brace Sub±assy No.1
Air Duct Rear No.3Air Duct Rear No.4
9.8 (100, 87 in.
lbf)
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±53
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING RADIATOR ASSY
COMPONENTS