air filter TOYOTA AVENSIS 2002 Repair Manual

320VU±01
F45162
Vacuum Hose
ClipBrake Vacuum
Check Valve
Check Valve
Grommet
Clevis Pin
Clip Wave Washer
13 (130, 9)
Engine Room Relay Block Way
Clutch Reservoir Tube M/T Transaxle:
Front Brake
Tube No.5
15 (155, 11) *1
29 (296, 21) *2
Brake Fluid Level
Switch Connector

Brake Booster Gasket
20 (204, 15)
20 (204, 15)
Brake Master
Cylinder Sub±assy

Brake Booster Assy
Brake Master
Cylinder clevis
15 (155, 11)
Fuel Filter Assy Diesel Engine Type: Heater Assy w/ Cold Area:
Air Cleaner Assembly
With Hose
Clutch Tube M/T Transaxle:Gasoline Engine Type:
15 (155, 11)
*1
w/ ABS:
*2
w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
5.4 (55, 48 in.
lbf)
Charcoal Canister
Assy
32±18
± BRAKEBRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

320W7±01
F40019
F42620
±
BRAKE BRAKE BOOSTER ASSY (LHD)
32±19
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
3. SEPARATE ENGINE ROOM RELAY BLOCK
4. REMOVE CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
5.REMOVE FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
6.REMOVE BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
7.REMOVE HEATER ASSY (W/ COLD AREA) (See page 55±100)
8. REMOVE FRONT WHEEL LH
9. DISCONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, disconnect the brake line fromthe flexible hose of the front brake LH.
SST 09023±00100
10. REMOVE BRAKE BOOSTER ASSY
(a) Disconnect the vacuum hose from the brake booster assy.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts.
(d) Pull out the brake booster assy.
11. REMOVE BRAKE BOOSTER GASKET
(a) Pull out the brake booster gasket from the brake booster assy.
12. REMOVE CHECK VALVE
(a) Remove the check valve and grommet from the brake booster assy.
13. INSTALL CHECK VALVE
(a) Install the check valve and grommet to the brake booster assy.
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assy.

F42620
F40019
32±20
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Install the clevis pin and clip to the brake master cylinder clevis.
(c) Connect the vacuum hose to the brake booster assy.
16. CONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, connect the brake tube to the flexible hose.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
17. INSTALL FRONT WHEEL LH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18.INSTALL HEATER ASSY (W/ COLD AREA) (See page 55±100)
19.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
20. INSTALL CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
21.INSTALL FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
22. CONNECT ENGINE ROOM RELAY BLOCK
23. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
24.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
25.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
26.BLEED BRAKE LINE (See page 32±4)
27.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
28.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
29.CHECK PEDAL FREE PLAY (See page 32±6)
30.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
31. CHECK FUEL LEAK
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
33. CHECK BRAKE FLUID LEAKAGE

320W5±01
G24285
LHD Steering Position Type:
Charcoal Canister Assy
Brake Fluid Level
Switch Connector
Clutch Reservoir
Tube M/T Transaxle:Brake Booster Assy
Clip
Way
20 (204, 15)
15 (155, 11)
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Brake Master
Cylinder Sub±assy
20 (204, 15)
Engin Room Relay Block
RHD Steering Position Type:Air Cleaner Cap Sub±assy
Brake Fluid Level
Switch ConnectorBrake Master
Cylinder Sub±assy
Clip
Accelerator Control
Cable Support
20 (204, 15)
*1

w/ ABS:*2 w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Clutch Reservoir
Tube M/T Transaxle:
Brake Booster Assy
5.4 (55, 48 in.
lbf)
Fuel Filter Assy Diesel Engin Type:
± BRAKEBRAKE MASTER CYLINDER SUB±ASSY
32±11
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE MASTER CYLINDER SUB±ASSY
COMPONENTS

320W6±01
G24218
G24217
F45393
± BRAKEBRAKE MASTER CYLINDER SUB±ASSY
32±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface.
2. REMOVE ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
3. REMOVE AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
4. REMOVE CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
5. REMOVE FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
(a) Diesal engine type:
Remove the fuel filter assy with the 3 bolts.
6. REMOVE BRAKE MASTER CYLINDER SUB±ASSY
(LHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle:
Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Using SST, disconnect the 2 brake lines from the way.
SST 09023±00100
(f) Remove the 2 nuts, and pull out the way and brake master
cylinder sub±assy.
(g) Remove the O±ring from the brake master cylinder sub±
assy.

G24225
32±16
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(c) w/o VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(d) w/ VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±38400
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
(e) M/T transaxle: Slide the clip and connect the clutch reservoir tube.
(f) Connect the brake fluid level switch connector.
12. INSTALL CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
13. INSTALL ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
14. INSTALL AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
15. INSTALL FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
16.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
17.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
18.BLEED BRAKE LINE (See page 32±4)
19.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
20.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
21. CHECK BRAKE FLUID LEAKAGE

160ME±01
A79148
SST
16±46
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.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)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)

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)

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)

±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±341
AVENSIS REPAIR MANUAL (RM1018E)
95.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
96.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
97.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
98.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
99.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
100.INSTALL HEATER BRACKET (W/ COLD AREA)(See page 13±11)
101.INSTALL HEATER PUMP ASSY (W/ COLD AREA)(See page 13±11)
102.INSTALL FUEL FILTER ASSY(See page 11±82)
103.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
SST 09960±10010 (09962±01000, 09963±01000)
104.INSTALL TIMING BELT(See page 14±307)
105.CHECK VALVE TIMING(See page 14±307)
106.TIMING CHAIN COVER PLATE(See page 14±307)
107.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
108.INSTALL TIMING BELT GUIDE(See page 14±307)
109.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
110.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
111.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
112.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
113.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
114.INSTALL POWER STEERING IDLE PULLEY BRACKET(See page 14±307)
115. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
116.INSTALL INJECTOR DRIVER (See page 14±286)
117.INSTALL AIR TUBE NO.1(See page 14±270)
118.INSTALL AIR TUBE NO.2 (See page 14±286)
119.INSTALL AIR CLEANER ASSY (See page 14±286)
120.INSTALL VACUUM RESERVOIR SUB±ASSY (See page 13±11)
121. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
122. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
123. ADD ENGINE OIL
124.ADD ENGINE COOLANT(See page 16±44)
125.CHECK FOR FUEL LEAKS(See page 11±60)
126. CHECK FOR ENGINE OIL LEAKS
127.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
128. CHECK FOR EXHAUST GAS LEAKS