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A77384
Mark Link
Timing Mark
Timing Mark
Mark Link
A77385
Groove
A77386
Groove
A77387
90
14±146
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Align the mark links (yellow colored links) with the timing marks of each gear as shown in the illustration.
(d) Install the gears to the crankshaft and oil pump shaft with
the chain wrapped.
(e) Temporarily tighten the oil pump drive shaft gear with the nut.
(f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the bolt.
Torque: 12 N m (122 kgf cm, 9.0 ftlbf)
(g) Align an adjusting hole of the sprocket with the groove of the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the sprocket to lock in position, and tighten the nut.
Torque: 30 N m (301 kgf cm, 22 ftlbf)
(i) Rotate the crankshaft clockwise 90 , and position the
crankshaft key upward.
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A77285
Unleaded Gasoline
Timing
Marks
Leaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
A52505
A77388
SST
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±147
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
40. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the camshafts with a wrench on the hexagonal lobe,and align the timing marks of the camshaft timing gear
with each timing mark located on the No. 1 and No. 2
bearing caps as shown in the illustration.
(b) Using the crankshaft pulley bolt, turn the crankshaft and position the key on the crankshaft upward.
41. INSTALL CHAIN VIBRATION DAMPER NO.1 42. INSTALL CHAIN SUB±ASSY
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A77389
Timing MarksMark Links
Timing Mark
A77290
Hold
Stopper
A32629
A77390Seal Packing
14±148
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Align the mark links (gold or yellow colored links) with each timing mark located on the camshaft timing gears,
and install the chain.
43. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
44. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt. Torque: 19 N m (195 kgf cm, 14 ftlbf)
(b) Check that the chain tensioner slipper is hold on the cylin- der block stopper.
45. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the plate with the ºFº mark facing forward.
46. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
NOTICE:
Remove any oil from the contact surface.
Install the chain cover within 3 minutes after applying
seal packing.
Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing
chain cover.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent.
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A77391
Seal Packing
4mm
2.5 mm
A
A
AA
3 to 4 mm
A77251
Nut
Nut
C
C C
C
B
B
B
B B
B
B
B
AC
A13759
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±149
AVENSIS REPAIR MANUAL (RM1018E)
(c) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to
0.157 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent
(d) Install the timing chain cover with the 14 bolts and 2 nuts. Torque:
Bolt A 9.0 N m (92 kgfcm, 80 in. lbf)
Bolt B 21 N m (214 kgfcm, 15 ftlbf)
Bolt C 43 N m (438 kgfcm, 32 ftlbf)
Nut 9.0 N m (92 kgfcm, 80 in. lbf)
47. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the bolt and nut. Torque: 60 N m (610 kgf cm, 44 ftlbf)
NOTICE:
As the drive tensioner should be fastened together with the
timing chain cover, so be sure install it within 15 minutes
after the timing chain cover is installed.
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A77392
Seal Packing6mm
A64641
A77393
SST
A77394
Raise
Pin Hook
Push
14±150
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
48. INSTALL OIL PAN SUB±ASSY
NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal
packing.
Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b) Apply a continuous bead (Diameter 3 mm to 4 mm (0.157 in.)) of seal packing as shown in the illustration, and install
the oil pan.
Seal packing: part No. 08826 ± 00080 or equivalent
(c) Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
49. INSTALL CRANKSHAFT POSITION SENSOR 50. INSTALL CRANKSHAFT PULLEY
(a) Using SST, tighten the set bolt.SST 09213±54015 (91651±60855), 09330±00021
Torque: 170 N m (1,733 kgfcm, 125 ft lbf)
51. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap- ply the hook to the pin so that the plunger is located in
position.
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A77395
Engine
Front
A77396
Hook
PinTurn
Disconnect
A77397
Push Turn
Plunger
A77398
A
B
A
A
±
ENGINE MECHANICAL CHAIN SUB±ASSY (1AZ±FE)
14±151
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install a new gasket chain tensioner with the 2 nuts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
NOTICE:
If the hook is released wile inserting, apply the hook again,
and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise, and check that the
hook is disengaged from the plunger knock pin.
(d) Turn the crankshaft clockwise, and check that the plunger is extended.
52. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N m (530 kgf cm, 38 ftlbf)
53. INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N m (530 kgf cm, 38 ftlbf)
B 113 N m (1,152 kgf cm, 83 ft lbf)
54. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.
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A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply seal packing to the 2 locations as shown in the il- lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after
applying seal packing.
Do not expose the seal to engine oil 2 hours after
installing.
(c)install the cylinder head cover with the 8 bolts and 2 nuts. Torque:
Bolt A 11 Nm (112 kgfcm, 8 ftlbf)
Bolt B 14 Nm (143 kgfcm, 10 ftlbf)
Bolt C 21 Nm (214 kgfcm, 15 ftlbf)
Nut 11 N m (112 kgfcm, 8 ft lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgfcm,80 in. lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N m (92 kgfcm,80 in. lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N m (71 kgfcm,62 in. lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgfcm,71 in. lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N m (82 kgfcm,71 in. lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgfcm,80 in. lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgfcm,27 ftlbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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141B8±01
A77281
A77292
A77299
±
ENGINE MECHANICALCHAIN SUB±ASSY(1AZ±FE)
14±139
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE ENGINE UNDER COVER LH
6.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining the engine oil.
Torque: 25 N m (255 kgfcm,18 ftlbf)
7.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
8.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
9.REMOVE GENERATOR ASSY (See page 19±20)
10.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
11. SEPARATE VANE PUMP ASSY
(a) Remove the 2 through bolts and separate the vane pump.
12. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove 3 bolts and separate the return tube as shownin the illustration.
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