oil level TOYOTA AVENSIS 2002 Repair Manual

F45419
Cylinder Slide Pin
Lithium soap base glycol grease
F45421
Union Bolt
±
BRAKE FRONT BRAKE
32±45
AVENSIS REPAIR MANUAL (RM1018E)
24. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Apply lithium soap base glycol grease to the a new front
disc brake cylinder slide bush.
(b) Install the front disc brake cylinder slide bush to the bot- tom side of the front disc brake cylinder slide pin (No.2).
(c) Apply lithium soap base glycol grease to the sliding part
and the sealing surface of the 2 cylinder slide pins.
(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting LH.
25. INSTALL FRONT DISC BRAKE PAD KIT
(a) Install the 2 front disc brake pad support plates (No.1) and 2 front disc bra\
ke pad support plates (No.2) to the front disc brake cylinder mounting LH.
(b) Install the disc brake pad kit front to the front disc brake cylinder mo\
unting LH.
NOTICE:
There should be no oil or grease on the friction surfaces of the pads an\
d the disc.
26. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder assy LH with the 2 bolts.Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(b) Install a new gasket and flexible hose with the union bolt.
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the disc
brake cylinder assy LH.
27.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
28.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
29.BLEED BRAKE LINE (See page 32±4)
30.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
31. CHECK BRAKE FLUID LEAKAGE
32. INSTALL FRONT WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

160N1±01
A78433
± COOLINGCOOLING SYSTEM (1AZ±FE)
16±13
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 137 kPa (1.4 kgf/cm
2, 19.9 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

160MY±01
A78433
± COOLINGCOOLING SYSTEM (1AZ±FSE)
16±25
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

160N6±01
A78434
Radiator Cap Tester
± COOLINGCOOLING SYSTEM (1CD±FTV)
16±37
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 137 kPa (1.4 kgf/cm
2, 19.9 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

160N4±01
A79037
± COOLINGCOOLING SYSTEM (1ZZ±FE/3ZZ±FE)
16±1
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1ZZ±FE/3ZZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant level should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

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)

A09580
8 mm
Hexagon
Wrench
A79170
A79170
A09581
8 mm
Hexagon
Wrench
Plate Washer
±
COOLING WATER PUMP ASSY(1CD±FTV)
16±47
AVENSIS REPAIR MANUAL (RM1018E)
29.REMOVE INJECTION PUMP DRIVE PULLEY(See page 11±69)
SST09960±10010 (09962±01000, 09963±01000), 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
30.REMOVE INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
31.REMOVE TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, remove the idler pulleyshaft, the idler pulley and the plate washer.
32.REMOVE WATER PUMP ASSY
(a)Remove the 7 bolts, then remove the water pump and the gasket.
33.INSTALL WATER PUMP ASSY
(a)Install a new gasket and the water pump with the 7 bolts. Torque: 31 N
m (320 kgf
cm, 23 ft.
lbf)
34.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, install the plate washer and the idler pulley with the idler pulley shaft.
Torque: 35 N
m (357 kgf
cm, 26 ft
lbf)
(b)Check that the pulley bracket moves smoothly.
35.INSTALL INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
36.INSTALL INJECTION PUMP DRIVE PULLEY(See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
37.INSTALL WATER INLET(See page 16±50)
38.INSTALL OIL LEVEL GAGE GUIDE(See page 17±22)

90

A09683
TDC Mark
Dot Mark
A09624
A09625
A09626
Alignment Mark
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
14±321
AVENSIS REPAIR MANUAL (RM1018E)
40. 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.
41. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, damage to the cylinder head or
the camshaft may result. To avoid this, the following proce-
dures should be carried out.
(a) Place the camshaft carrier on the cylinder head.
(b) Install the camshaft sub±assy No. 1.
(c) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(d) Place the intake camshaft on the camshaft carrier as
shown in the illustration so that the No. 3 and No. 4 of cyl-
inder cam lobes face downward.
42. INSTALL NO.2 CAMSHAFT
(a) Install the camshaft sub±assy No. 2.
(b) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(c) Engage the exhaust camshaft gear and the intake cam-
shaft gear by aligning the alignment marks on each gear.
(d) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.

A77328
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
30 (301, 22)

O±ring
Bearing Cap No. 1
Bearing Cap No. 2
9.0 (92, 80 in.
lbf)
Bearing Cap No. 3
Camshaft
No. 2 Camshaft
Camshaft Bearing No. 2
Camshaft Timing
Oil Control Valve Assy
Cylinder Head

Cylinder Head Gasket
9.0 (92, 80 in.
lbf)
Oil Level Gauge
Sub±assy
9.0 (92, 80 in.
lbf)

O±ring
Oil Level Gauge
Guide
1st: 79 (800, 58)
2nd: Turn 90

30 (301, 22)
9.0 (92, 79 in.
lbf)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FE)
14±159
AVENSIS REPAIR MANUAL (RM1018E)

A76712
Camshaft
Camshaft No. 2
Plate Washer Camshaft Bearing Cap No. 1
Camshaft Bearing Cap No. 3
Cylinder Head Sub±assy Camshaft Timing
Oil Control Valve Assy
 Cylinder Head Gasket
Manifold Stay No. 1 Intake Manifold
Clamp Bracket
Oil Level Gage Guide
 O±ring Oil Level Gage
Sub±assy

Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
13 (133, 10)
23 (235, 17)
30 (306, 22)
9.0 (92, 80 in.
lbf)
1st 49 (500, 36)
2nd Turn 90

See page 14±81
49 (500, 36)

Gasket
Manifold Stay No. 2
37 (377, 27)
 O±ring
9.0 (92, 80 in.
lbf)
13 (133, 10)
49 (500, 36)
14±80
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)