2002 Toyota Avalon XLSFACTORY OEM SERVICE PROCEDURE

Basic Repairs

  1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage.
  2. During disassembly, keep parts in the appropriate order to facilitate reassembly.
  3. Installation and removal of battery terminal:
    1. Before performing electrical work, disconnect the negative (-) terminal cable from the battery.
    2. If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (-) terminal cable.
    3. When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it.
    4. Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects
    5. Install the cable ends to the battery terminals after loosening the nut and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals.
    6. Be sure the cover for the positive (+) terminal is properly in place.
  4. Check hose and wiring connectors to make sure that they are connected securely and correctly.
  5. Non-reusable parts:
    1. Always replace cotter pins, gaskets, O-rings, oil seals; etc. with new ones.
    2. Non-reusable parts are indicated in component illustrations.
  6. Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory, see Fig 1:
    1. If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.
    2. When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.
    3. Precoated parts are indicated in the component illustrations.
    7. Fig 1: Identifying Pre-Coated Part
    G00372031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. When necessary, use a sealer on gaskets to prevent leaks.
  8. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
  9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure.
  10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.
    Fig 2: Locating Fuse Amperage Rating
    G00372032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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