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A77308
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A77307
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ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
14±161
AVENSIS REPAIR MANUAL (RM1018E)
16. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
17. SEPARATE VANE PUMP OIL RESERVOIR ASSY
NOTICE:
Do not disconnect the 2 hoses. 18. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil reservoir bracket No. 1.
19. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the clamp and the enginewire.
20. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove the bolt and the engine service cover bracket RH. 21. REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a) Remove the bolt and the cooler hose bracket.
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Page 551 of 2234
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ENGINE MECHANICALCYLINDER HEAD GASKET(1AZ±FE)
14±167
AVENSIS REPAIR MANUAL (RM1018E)
69.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
70.INSTALL CHAIN SUB±ASSY (See page 14±139)
71.INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
72.INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N m (195 kgfcm,15 ftlbf)
73.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±171)
74.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
75.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
76.INSTALL OIL PAN SUB±ASSY (See page 14±139)
77.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
78.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST09213±54015 (91651±60855), 09330±00021
79.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
80.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N m (530 kgfcm,38 ftlbf)
81.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
82.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
83.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
84.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
85.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
86.INSTALL ENGINE WIRE
87.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgfcm,71 in. lbf)
88.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
89.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgfcm,71 in. lbf)
90.INSTALL IGNITION COIL ASSY
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
91.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgfcm,62 in. lbf)
92.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgfcm,27 ftlbf)
93.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
94.INSTALL GENERATOR ASSY (See page 19±20)
95.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
96.ADD COOLANT (See page 16±19)
97. ADD ENGINE OIL
98.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
99. CHECK FOR ENGINE OIL LEAKS
100. CHECK FOR FUEL LEAKS
101. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 553 of 2234
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ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
14±255
AVENSIS REPAIR MANUAL (RM1018E)
19. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts and separate the return tube shown
in the illustration.
20. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
21. SEPARATE VANE PUMP OIL RESERVOIR ASSY 22. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil reservoir bracket No. 1.
23. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate a clamp and the enginewire.
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Page 560 of 2234
14±262
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgf cm, 27 ftlbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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Page 624 of 2234
A77521
Generator ASSY
Cooler Refrigerant
Suction Hose No. 1
(RHD (w/ Air Conditioning)
Steering Position Type)
Radiator Hose Inlet
Radiator Hose Outlet
Cooler Refrigerant Suction Hose No. 1
(LHD (w/ Air Conditioning) Steering
Position Type)
Union to Connector
Tube Hose
Charcoal Canister Assy
Battery Tray Battery Radiator ASSY
Compressor and
Magnetic Clutch
(w/ Air Conditioner)
Battery Clamp
Battery Carrier Air Cleaner Assembly with Hose
Radiator Relay Block
52 (530, 38)
9.8 (100, 7.2)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in. lbf)
13 (133, 10)
25 (250, 18)
5.0 (51, 44 in. lbf)
21 (214, 16)
7.0 (71, 62 in. lbf)
7.0 (71, 62 in. lbf)
19 (194, 14)
19 (194, 14)
14±112
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil.
Torque: 25 N m (255 kgfcm,18 ftlbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N m (500 kgfcm,36 ftlbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
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ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±123
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITION ER) STEER ING
POSITION TYPE)
(a)Remove 2 nuts and separate the suction hose.
28.REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a)Remove a bolt and the service cover bracket RH. 29.REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the cooler bracket.
30.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
31.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
32.DISCONNECT HEATER OUTLET WATER HOSE (W/ AIR CONDITIONING)
33.REMOVE CHARCOAL CANISTER ASSY
34.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±15)
35. DISCONNECT UNION TO CONNECTOR TUBE HOSE
36.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
38.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
39.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09330±00030
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ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±133
AVENSIS REPAIR MANUAL (RM1018E)
128.INSTALL FRONT AXLE ASSY LH
Torque: 294 Nm (3,000 kgfcm,217 ftlbf)
129.INSTALL FRONT AXLE ASSY RH
Torque: 294 Nm (3,000 kgfcm,217 ftlbf)
130.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE) Torque: 142 Nm (1,448 kgfcm,104 ftlbf)
131.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE)
Torque: 142 Nm (1,448 kgfcm,104 ftlbf)
132.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 Nm (1,448 kgfcm,104 ftlbf)
133.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 Nm (1,448 kgfcm,104 ftlbf)
134.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N m (755 kgfcm,55 ftlbf)
135.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N m (755 kgfcm,55 ftlbf)
136.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
137.INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
138.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
139.INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
140.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
141.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
142.INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N m (306 kgfcm,22 ftlbf)
143.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
144.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
145.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
146.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
147.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N m (82 kgfcm,71 in. lbf)
148.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgfcm,71 in. lbf)
149.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N m (51 kgfcm,44 in. lbf)
150.INSTALL BATTERY CARRIER
151.INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N m (51 kgfcm,44 in. lbf)
152.INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
Torque: 25 N m (255 kgfcm,18 in. lbf)
153.INSTALL GENERATOR ASSY (See page 19±20)
154.INSTALL FAN AND GENERATOR V BELT (See page 14±105)
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