Page 4652 of 5135
A79140
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 1
AVENSIS Supplement (RM1045E)
30. REMOVE CLUTCH ACCUMULATOR ASSY (See Pub. No. RM1018E on page 42 −22)
SST 09023 −00100
31. REMOVE CLUTCH RELEASE CYLINDER ASSY (See Pub. No. RM1018E on page 42 −17)
32. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
33. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(See Pub. No. RM1018E on page 55 −86)
HINT:
Secure the hoses off to the side instead of detaching.
34. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
35. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
36. SEPARATE RETURN TUBE SUB −ASSY
(a) Remove the 2 clamp bolts, then separate the return tube
sub−assembly.
37. SEPARATE VANE PUMP OIL RESERVOIR ASSY
38. REMOVE FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30 −6)
SST 09930 −00010
HINT:
Perform the same procedure as above on the opposite side.
39. SEPARATE TIE ROD END SUB −ASSY LH (See Pub. No. RM1018E on page 30 −6)
SST 09628 −62011
HINT:
Perform the same procedure as above on the opposite side.
40. SEPARATE FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
41. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and column hole cover silencer sheet.
42. REMOVE STEERING COLUMN HOLE COVER SUB −ASSY NO.1
43. REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See Pub. No. RM1018E on page 51 −36)
44. SEPARATE FRONT SUSPENSION ARM SUB −ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
45. SEPARATE FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
Page 4656 of 5135
A84290
A84291
A15985
A84397
(a)
(a)
(b)
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 5
AVENSIS Supplement (RM1045E)
70. REMOVE V −RIBBED BELT TENSIONER ASSY
(a) Remove the 3 bolts and V −ribbed belt tensioner.
71. REMOVE V −RIBBED BELT TENSIONER BRACKET
(a) Remove the bolt and V −ribbed belt tensioner bracket.
72. REMOVE OIL FILTER BRACKET SUB −ASSY
(a) Remove the bolt and 2 nuts, then remove the oil filter
bracket and gasket.
73. REMOVE TURBO INSULATOR NO.2 (See page 13 −12)
74. REMOVE TURBO INSULATOR NO.1 (See page 13 −12)
75. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
76. REMOVE EGR PIPE INSULATOR (See page 13 −12)
77. REMOVE EXHAUST GAS TEMPERATURE SENSOR
(a) Remove the 2 nuts, then detach the wire harness from the clamp.
(b) Disconnect the connector.
Page 4658 of 5135
A85917
A85918
SST
A85624
A85625
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 7
AVENSIS Supplement (RM1045E)
79. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY
NO.2
(a) Remove the 2 bolts.
(b) Using SST, remove the vacuum pipe. SST 09023 −38200
80. REMOVE MANIFOLD STAY NO.2 (See page 13 −12)
81. REMOVE MANIFOLD STAY (See page 13 −12)
82. REMOVE MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
83. REMOVE TURBOCHARGER STAY (See page 13 −12)
84. DISCONNECT TURBO WATER HOSE NO.1 (See page 13 −12)
85. DISCONNECT TURBO WATER HOSE NO.2 (See page 13 −12)
86. REMOVE TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
87. REMOVE TURBOCHARGER SUB −ASSY (See page 13 −12)
88. DISCONNECT WATER BY −PASS HOSE NO.3
89. REMOVE EGR PIPE SUB −ASSY NO.1
(a) Remove the bolt and 4 nut, then detach the EGR pipe and
2 gaskets.
Page 4659 of 5135
A84296
A80118
A85626
A85627
(a)(a)
(b)
(b)
(b) 14−11 8
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
90. REMOVE OIL COOLER ASSY (See Pub. No. RM1018E on page 17−32)
91. REMOVE VACUUM PUMP OIL PIPE
(a) Disconnect the 2 hoses.
(b) Remove the bolt and nut, then remove the vacuum pump
oil pipe.
92. REMOVE EXHAUST MANIFOLD
(a) Remove the 8 nuts, exhaust manifold and gasket.
93. REMOVE INTAKE AIR CONNECTOR
(a) Remove the 3 bolts, intake air connector together with the
diesel throttle body and gasket.
94. REMOVE EGR VALVE ASSY
(a) Disconnect the 2 hoses.
(b) Remove the bolt and 2 nuts, then remove the EGR valve
and gasket.
Page 4662 of 5135
A79150
A09671
A84294
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −121
AVENSIS Supplement (RM1045E)
104. REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a) Remove the 2 bolts and intake manifold insulator.
105. REMOVE COMMON RAIL ASSY (See page 11 −67)
106. REMOVE INTAKE MANIFOLD
(a) Remove the 8 bolts and 2 nuts, then remove the intake manifold and gasket.
107. REMOVE INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
108. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, then remove the timing belt cover.
109. REMOVE OIL LEVEL GAGE GUIDE (See page 17 −11 )
110. REMOVE INJECTION PUMP STAY NO.1 (See page 11 −58)
111. REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
112. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
(a) Remove the 4 bolts and compressor mounting bracket.
113. REMOVE WATER INLET (See Pub. No. RM1018E on page 16 −50)
114. REMOVE THERMOSTAT
115. REMOVE OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, remove the union bolt,oil cooler pipe and gasket.
Page 4663 of 5135
A84380
A84378
14−122−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
116. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and fuel pipe.
117. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
118. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor. 119. REM O VE ENG I NE CO O L ANT TEM PERAT URESENSOR
120. REPLACE PARTIAL ENGINE ASSY
121. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Torque: 20 N m (200 kgf cm, 14 ft lbf)
122. INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N m (90 kgf cm, 78 in. lbf)
123. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N m (90 kgf cm, 78 in. lbf)
124. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE
Torque:
8.8 Nm (90 kgf cm, 78 in. lbf) for M6
21 N m (209 kgf cm, 15 ft lbf) for M8
125. INSTALL OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 56 N m (575 kgf cm, 42 ft lbf)
126. INSTALL THERMOSTAT (See Pub. No. RM1018E on page 16 −50)
127. INSTALL WATER INLET (See Pub. No. RM1018E on page 16 −50)
128. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
Torque: 42 N m (428 kgf cm, 31 ft lbf)
129. INSTALL INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
130. INSTALL INJECTION PUMP STAY NO.1 (See page 11 −58)
131. INSTALL OIL LEVEL GAGE GUIDE (See page 17 −11 )
132. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N m (75 kgf cm, 65 in. lbf)
Page 4668 of 5135
A85918
SST
A85916SST
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −127
AVENSIS Supplement (RM1045E)
149. INSTALL VACUUM PUMP OIL PIPE
Torque:
21 Nm (214 kgf cm, 15 ft lbf) for bolt
8.8 N m (90 kgf cm, 78 in. lbf) for nut
150. INSTALL OIL COOLER ASSY (See Pub. No. RM1018E on page 17 −32)
151. INSTALL EGR PIPE SUB −ASSY NO.1
(a) Install 2 new gaskets and the EGR pipe with the bolt and 4 new nuts. Torque:
37 Nm (375 kgf cm, 27 ft lbf) for bolt
25 N m (250 kgf cm, 18 ft lbf) for nut
152. INSTALL TURBOCHARGER SUB −ASSY (See page 13 −12)
153. INSTALL TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
154. INSTALL TURBOCHARGER STAY (See page 13 −12)
155. INSTALL MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
156. INSTALL MANIFOLD STAY NO.2 (See page 13 −12)
157. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY
NO.2
(a) Temporarily install the vacuum pipe.
(b) Using SST, tighten the nut of the vacuum pipe on the man- ifold converter side.
SST 09023 −38200
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Install the 2 bolts. Torque: 25 N m (255 kgf cm, 18 ft lbf)
158. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY
NO.1
(a) Temporarily install the vacuum pipe.
(b) Using SST, tighten the nut of the vacuum pipe on the man- ifold converter side.
SST 09023 −38200
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Install the bolt.
Torque: 25 N m (255 kgf cm, 18 ft lbf)
Page 4669 of 5135
A85921
5mm
(0.20 in.)
A85914
SST
A8592215 mm (0.59 in.)
A87961
SST
14−128−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
159. INSTALL EXHAUST GAS TEMPERATURE SENSOR
(a) Temporarily install the 3 nuts and exhaust gas tempera- ture sensor on down stream as shown in the illustration.
NOTICE:
Keep 5 mm (0.20 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(b) Using SST, tighten the sensor on the manifold converter
side.
SST 09023 −38400
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Tighten the 3 nuts.
Torque: 6.4 N m (65 kgf cm, 57 in. lbf)
(d) Temporarily install the 2 nuts and exhaust gas tempera- ture sensor on up stream as shown in the illustration.
NOTICE:
Keep 15 mm (0.59 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(e) Using SST, tighten the sensor on the manifold converter side.
SST 09023 −38400
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(f) Tighten the 2 nuts.
Torque: 6.4 N m (65 kgf cm, 57 in. lbf)
160. INSTALL EGR PIPE INSULATOR (See page 13 −12)
161. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
162. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
163. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
164. INSTALL OIL FILTER BRACKET SUB −ASSY
(a) Install a new gasket and the oil filter bracket with the bolt and 2 nuts.
Torque: 34 N m (347 kgf cm, 25 ft lbf)
165. INSTALL V −RIBBED BELT TENSIONER BRACKET
Torque: 20 N m (204 kgf cm, 15 ft lbf)
