length TOYOTA AVENSIS 2002 Repair Manual
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Page 185 of 1690
A79148
SST
A79149
SST
16±48
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
39.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69) 40. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
In case of having the water pump replaced, must re-
place fuel inlet pipe, too.
When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a) Temporarily install the new fuel inlet pipe.
(b) Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 Nm (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 inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe to the injec- tion pump side.
SST 09023±12700
Torque:
42 Nm (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 inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
Page 364 of 1690
A79147
Fulcrum
Length
30 cm
SST
14±324
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c)Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST09023±12700
Torque:
42 Nm (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 side.
SST09023±12700
Torque:
42 Nm (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)
54.INSTALL INJECTION PIPE SUB±ASSY NO.2 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
55.INSTALL INJECTION PIPE SUB±ASSY NO.3 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56.INSTALL INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
57.INSTALL TIMING BELT(See page 14±307)
58.CHECK VALVE TIMING(See page 14±307)
Page 436 of 1690
A32664
A56213
A7740612 3
4 109
8 56 7
A77407
Overall Length 14±164
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
53. REMOVE CAMSHAFT BEARING NO.2
54. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub±assy.
(b) Set the jack under the engine assembly w/ transaxle, and
place a wooden block on the jack.
(c) Remove the chain block and sling devise.
55. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 10 cylinder head bolts,
with 10 mm bi±hexagon wrench uniformly in the se-
quence shown in the illustration.
(b) Remove the 10 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cranking could result from remov-
ing bolts and installing in incorrect order.
56. REMOVE CYLINDER HEAD GASKET
57. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of the cylin-
der head set bolts from the seat to the end.
Standard bolt length:
161.3 to 162.3 mm (6.350 to 6.390 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the cylinder head
set bolts.
Page 445 of 1690
A7740612 3
4 109
8 56 7
A77407
Overall Length
A77408
Lot No.
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±259
AVENSIS REPAIR MANUAL (RM1018E)
59. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 10 cylinder head bolts,
with 10 mm bi±hexagon wrench uniformly in the se-
quence shown in the illustration.
(b) Remove 10 cylinder head bolts and plate washers.
NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cranking could result from remov-
ing bolts and installing incorrect order.
60. REMOVE CYLINDER HEAD GASKET
61. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of the cylin-
der head set bolts from the seat to the end.
Standard bolt length:
161.3 to 162.3 mm (6.350 to 6.390 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the cylinder head
set bolts.
62. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
Remove any oil from contact surface.
Be careful of the installation direction.
Place the cylinder head gently in order not to damage
the gasket with the bottom part of the head.
63. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head set bolts are tightened in 2 successive steps.
Page 460 of 1690
A61189
10
11
12
13 14
15 16
17
18
2
1
4
5 6
3
7 8
9
(A) (A)
(A)
(A) (A)
(A)
(A)
(B) (B) (B) (B) (B) (B) (B)
(B)
(B)
(B) (A)
A61190
90
90
9090
90
90
Front Paint Mark
90
A09683
TDC Mark
Dot Mark
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±337
AVENSIS REPAIR MANUAL (RM1018E)
70. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 4 successive
steps (steps (c), (e), (f) and (g)).
If the cylinder head bolt is broken or deformed, replace it
with a new bolt.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts and the plate washers.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 18 cylinder head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 45 N m (459 kgf cm, 33 ft lbf)
HINT:
See the table below for the bolt length.
Bolt TypeBolt Length
(A)160mm (6.30 in.)
(B)104mm (4.09 in.)
If the cylinder head bolt does not meet the torque specification,
replace the cylinder head bolt with a new bolt.
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by additional 90 in the
same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional 90 in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man- ifold side.
71. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing pulley at the position
of 90 BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
72.INSTALL CAMSHAFT (See page 14±318)
73.INSTALL NO.2 CAMSHAFT (See page 14±318)
74.REMOVE CAMSHAFT OIL SEAL (See page 14±318)
75.INSTALL CAMSHAFT OIL SEAL (See page 14±318) SST 09223±46011
Page 462 of 1690
A79147
Fulcrum
Length
30 cm
SST
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±339
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 Nm (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgfcm, 25 ftlbf) 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 side.
SST 09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 Nm (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgfcm, 25 ftlbf) 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 Nm (51 kgfcm, 44 in.lbf)
85. INSTALL INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
86. INSTALL INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
87. INSTALL INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
Page 463 of 1690
A79148
SST
A79149
SST
14±340
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
88.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
In case of having the cylinder head gasket replaced,
must replace fuel inlet pipe, too.
When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the new fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com- mon rail side.
SST09023±12700
Torque:
42 Nm (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 inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the pump side.
SST09023±12700
Torque:
42 Nm (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 inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
89.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
90.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
91.INSTALL TURBOCHARGER STAY (See page 13±11)
92.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
93.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
94.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
Page 476 of 1690
A30857
A62814
4 2531
A62816
2
5 3
110 8 4 796
A62827
Lot No.
A62820
Overall Length
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±87
AVENSIS REPAIR MANUAL (RM1018E)
46. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain by prying the crankshaft timing
gear using screwdrivers as shown in the illustration.
NOTICE:
Put shop rag to protect the engine.
In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise to prevent the valves from touch-
ing the pistons.
47. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 19 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 9 bearing caps, and both the intake and
exhaust camshafts.
48. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen and remove the 10 cylinder
head bolts with a 10 mm hexagon wrench uniformly in the
sequence shown in the illustration. Remove the 10 cylin-
der head bolts and 10 plate washers.
(b) Remove the cylinder head.
49. REMOVE CYLINDER HEAD GASKET
50. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the Lot No. stamp facing upward.
NOTICE:
Pay attention to the mounting orientation.
Place the cylinder head on the gasket gently in order
not to damage the gasket with the bottom part of the
head.
51. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of cylinder
head bolt from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum length: 148.5 mm (5.846 in.)
If the length exceeds the maximum, replace the bolt.
Page 554 of 1690
A61175
AA
B
A79147
Fulcrum
Length
30 cm
SST
14±296
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
123.INSTALL POWER STEERING IDLE PULLEY BRACKET
(a)Install the idle w/ bracket pulley with the 3 bolts.
Torque:
72 Nm (734 kgf cm, 53 ft lbf) for bolt A
39 N m (398 kgf cm, 29 ft lbf) for bolt B
124.INSTALL COMMON RAIL ASSY (See page 11±78)
125. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
126. 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) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST 09023±12700
Torque:
42 Nm (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.
Page 555 of 1690
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±297
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using SST, tighten the nut of the injection pipe to the injec-
tor side.
SST 09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 Nm (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgfcm, 25 ftlbf) 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 Nm (51 kgfcm, 44 in.lbf)
127. INSTALL INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
128. INSTALL INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
129. INSTALL INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
130. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
When assembling the pipe, perform the operation with the
engine cold under room temperature.
(a) Temporarily install the inlet pipe.