vin TOYOTA AVENSIS 2002 Repair Manual

F42258
G24222
± BRAKEBRAKE FLUID
32±5
AVENSIS REPAIR MANUAL (RM1018E)
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal depressed.
(c) At the point when the fluid stops, coming out tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
Torque: 10 N
m (102 kgf
cm, 7 ft.
lbf)
4. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary.
Fluid: SAE J1704 or FMVSS No. 116 DOT4

3201A±12
± BRAKEBRAKE SYSTEM
32±1
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE SYSTEM
PRECAUTION

Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the ones with parts having the same part number
or equivalent.

It is very important to keep the parts and the area clean when repairing the brake system.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
INTRODUCTION.

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)

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 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 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 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 inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.

300JY±01

F45751
SST
C80291
F44775
C67088
30±22
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replace the RH side by the same procedures as the LH side.
1. REMOVE FRONT WHEEL
2.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6) 3. REMOVE FRONT AXLE HUB LH NUT
(a) Using SST and a hammer, unstake the staked part of theaxle hub LH nut.
SST 09930±00010
(b) While applying the brakes, remove the axle hub LH nut.
4. DISCONNECT SPEED SENSOR FRONT LH
(a) Remove the bolt, and disconnect the speed sensor wire and flexible hose from the shock absorber.
(b) Remove the bolt, separate the speed sensor front LH from the steering knuckle.
NOTICE:

Be careful not to damage the speed sensor.

Prevent foreign matter from attaching to the speed
sensor.
5. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts, separate the disc brake caliper assy LH from the steering knuckle.
NOTICE:
Use a string or other device to keep the brake caliper from
hanging down.

C67088
F44775
C80291
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
30±27
AVENSIS REPAIR MANUAL (RM1018E)
25. INSTALL FRONT DISC BRAKE CALIPER ASSY LH
(a) Install the disc brake caliper assy with the 2 bolts to the
steering knuckle.
Torque: 104 N
m (1,040 kgf
cm, 75 ft
lbf)
26. INSTALL FRONT AXLE HUB LH NUT
(a) Using a socket wrench (30 mm), install a new axle hub LH nut. Torque: 216 N
m (2,200 kgf
cm, 159 ft
lbf)
27. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts, separate the disc brake caliper assy from the stee\
ring knuckle.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down\
.
28. REMOVE FRONT DISC
29.INSPECT BEARING BACKLASH (See page 30±2)
30.INSPECT AXLE HUB DEVIATION (See page 30±2)
31. INSTALL FRONT DISC
32. INSTALL FRONT DISC BRAKE CALIPER ASSY LH
(a) Install the disc brake caliper assy with the 2 bolts to the steering knu\
ckle. Torque: 104 N
m (1,040 kgf
cm, 75 ft
lbf)
33. CONNECT SPEED SENSOR FRONT LH
(a) Install the speed sensor front LH to the steering knuckle with the bolt.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(b) Connect the speed sensor wire and flexible hose to the shock absorber with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
NOTICE:

Be careful not to damage the speed sensor.

Keep the speed sensor clean.

Do not twist the sensor wire when installing the sen-
sor.

300JZ±01
F45267
F44818

F45752
SST
±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB±ASSY LH
30±31
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replace the RH side by the same procedures as the LH side.
1. INSPECT REAR AXLE CARRIER SUB±ASSY LH
(a) Check that there is no looseness on the ball joint by shaking the lower arm up and down with a force
of 294 N (30kgf, 66 lbf).
2. REMOVE REAR WHEEL
3. DISCONNECT SKID CONTROL SENSOR WIRE
(a) Remove the bolt, disconnect the skid control sensor wire.
(b) Disconnect the connector.
4. SEPARATE REAR DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts and rear disc brake caliper assy.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down\
.
5. REMOVE REAR DISC
6.REMOVE PARKING BRAKE ADJUSTER KIT (See page 33±14)
7.REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (See page 33±14)
8.REMOVE PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
9.REMOVE PARKING BRAKE SHOE LEVER LH (See page 33±14)
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Using needle±nose pliers, and disconnect the parkingbrake cable assy No.3 from the backing plate.
11. SEPARATE LOWER CONTROL ARM ASSY LH
(a) Loosen the lower control arm assy bolt (member side).
(b) Remove the clip and nut.
(c) Using SST, separate the lower control arm assy from the axle carrier.
SST 09610±20012


F45753HoldTurn
SST
G21537
G21542
G20965
30±32
± DRIVE SHAFT / PROPELLER SHAFTREAR AXLE CARRIER SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
12. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH
(a) Remove the clip and nut.
(b) Using SST, separate the rear suspension arm assy No.1
(ball joint side).
SST 09628±62011
(c) Remove the bolt and nut, separate the rear suspension
arm assy No.1.
NOTICE:
When removing the bolt, hold the nut not to rotate.
13. SEPARATE UPPER CONTROL ARM ASSY
(a) Remove the bolt and nut, separate the upper control arm
assy from the axle carrier.
NOTICE:
When removing the bolt, hold the nut not to rotate.
14. REMOVE REAR AXLE CARRIER SUB±ASSY LH
(a) Remove the 4 bolts and nut, hub & bearing assy and axle
carrier sub±assy.

300K0±01

F45577
Hold
Turn
SST

F45578
Hold
Turn
Nut
Washer
30±36
±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE LH HUB BOLT
AVENSIS REPAIR MANUAL (RM1018E)
REAR AXLE LH HUB BOLT
REPLACEMENT
HINT:

COMPONENTS: See page 30±30

Replace the RH side by the same procedures as the LH side.
1. REMOVE REAR WHEEL
2. SEPARATE REAR DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts and rear disc brake caliper assy.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down\
.
3. REMOVE REAR DISC
4. REMOVE REAR AXLE LH HUB BOLT
(a) Turn the axle hub to move the LH hub bolt and SST, thatare to be removed, to the place shown in the illustration.
NOTICE:
Do not replace the hub bolt in any places other than that in
the illustration.
(b) Using SST and a hammer handle or an equivalent to hold the axle hub, remove the LH hub bolt.
SST 09628±10011
5. INSTALL REAR AXLE LH HUB BOLT
(a) Install a washer and nut to a new LH hub bolt as shown in the illustration.
(b) Using a hammer handle or an equivalent to hold the axle
hub, install the LH hub bolt by torquing the nut.
6. INSTALL REAR DISC
7. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper assy with the 2 bolts. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
8. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

1209E±02
A65749
E1
OX2BOX1B
ECM
A77114
12±6
± EMISSION CONTROLEMISSION CONTROL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT AIR±FUEL RATIO COMPENSATION SYS-
TEM
HINT:
You can also check the system by choosing ºDATA MONITOR/
O
2 SENSOR OUTPUT VOLTAGEº on the monitor of the hand±
held tester.
(a) Connect the hand±held tester to terminals 21 (OX1B) and
7 (E1) and to terminals 29 (OX2B) and 7 (E1) of the ECM.
CAUTION:
Connect test leads from the back side of the connector with
the ECM connected.
(b) Warm up the heated oxygen sensor with the engine
speed at 2,500 rpm for approximately 2 minutes.
(c) Confirm that the voltage output varies between 0V to 1V
with the engine speed at 2,500 rpm.
OK:
The voltage output varies more than 8 times in 10 se-
conds.
CAUTION:

Perform the check immediately after the warming up.

If the voltage variation could not be verified, warm up
the heated oxygen sensor again.
2. INSPECT FUEL CUT OFF RPM
(a) Increase the engine speed to at least 3,500 rpm.
(b) Use a sound scope to check for injector operating sounds.
(c) Check that injector operating sounds stops momentarily and then resumes when the throttle lever is
released.
3. INSPECT EVAPORATIVE EMISSION CONTROL SYS-
TEM
(a) After starting the engine, disconnect the vacuum hose
shown in the illustration.
(b) Check if vacuum occurs at the VSV port when choosing
ºACTIVE TESTº and ºPURGE VSVº according to the dis-
play on hand±held tester.
(c) Finish ºACTIVE TESTº, then reconnect the vacuum hose.
(d) After entering to ºECU DATA MONITORº on the hand±
held tester, choose ºPURGE VSVº to check the operation
of the purge VSV.
(e) After driving the vehicle with a warm engine, confirm that
the VSV turns from off to on.