Page 4694 of 5135
A83481
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
14 −83
AVENSIS Supplement (RM1045E)
(i) Install the water by −pass pipe with a bolt.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
65. INSTALL CAMSHAFT (See page 14 −64)
66. INSTALL NO.2 CAMSHAFT (See page 14 −64)
67. INSTALL EXHAUST MANIFOLD CONVERTER SUB −ASSY (See page 14 −23)
68. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14 −23)
69. INSTALL INTAKE MANIFOLD (See page 11 −13)
70. INSTALL THROTTLE BODY ASSY (See page 10 −8)
71. INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 14 −23)
72. INSTALL BATTERY
Torque:
5.0 Nm (51 kgf cm, 44 in. lbf) for Bolt
3.5 N m (36 kgf cm, 31 in. lbf) for Nut
73. INSTALL CHAIN VIBRATION DAMPER NO.1 (See page 14 −45)
74. INSTALL CHAIN SUB −ASSY (See page 14 −45)
75. INSTALL TIMING CHAIN GUIDE (See page 14 −45)
76. INSTALL CHAIN TENSIONER SLIPPER (See page 14 −45)
77. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14 −45)
78. INSTALL TIMING CHAIN OR BELT COVER SUB −ASSY (See page 14 −45)
79. INSTALL V −RIBBED BELT TENSIONER ASSY (See page 14 −45)
80. INSTALL OIL PAN SUB −ASSY (See page 14 −45)
81. INSTALL CRANKSHAFT POSITION SENSOR (See page 14 −45)
82. INSTALL CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021
83. INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14 −45)
84. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N m (530 kgf cm, 38 ft lbf)
85. INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14 −45)
86. INSTALL CYLINDER HEAD COVER SUB −ASSY (See page 14 −45)
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 −24)
Page 4695 of 5135
14−84
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
AVENSIS Supplement (RM1045E)
94. INSTALL FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
95. INSTALL FUEL TUBE SUB −ASSY (See page 11 −24)
96. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11 −24)
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 ft lbf)
99. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −2)
100. INSTALL GENERATOR ASSY (See page 19 −8)
101. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
102. ADD COOLANT (See page 16 −7)
103. ADD ENGINE OIL (See page 17 −6)
104. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS (See page 11 −4)
107. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
108. ADD POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
109. BLEED POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
110. CHECK POWER STEERING FULUID LEVEL IN RESERVOIR
(See Pub. No. RM1018E on page 51 −4)
111. CHECK FUNCTION OF THROTTLE BODY
Page 4697 of 5135
A89212
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketCooler Bracket
(LHD Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant Suction Hose No. 1
(LHD Steering Position Type)
8.0 (82, 44 in.lbf)
8.0 (82, 44 in.lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub−assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator Assy
Exhaust Pipe Assy Front
43 (440, 32)
43 (440, 32)
7.0 (71, 62 in.lbf)
7.0 (71, 62 in.lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.lbf)
8.0 (82, 71 in.lbf)
8.0 (82, 71 in.lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
52 (530, 38)
Vane Pump Assy
zGasket
8.0 (82, 44 in.lbf)
37 (377, 27)
14−70
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
AVENSIS Supplement (RM1045E)
Page 4708 of 5135
A93084
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
43 (440, 32)
zGasketzGasket
8.0 (82, 71 in.lbf)
8.0 (82, 71 in.lbf)
8.0 (82, 71 in.lbf)
5.0 (51, 44 in.lbf)
Vane Pump Oil
Reservoir Assy
Return Tube
Sub−assy
Radiator Reserve
Tank Sub−assy
43 (440, 32)
43 (440, 32)
30 (306, 22)
43 (440, 32)
Exhaust Pipe Assy FrontExhaust Pipe Assy Center
Floor Panel Brace FrontzGasket
x3
− ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ−FSE)
14−13
AVENSIS Supplement (RM1045E)
Page 4709 of 5135
A93083
Cooler Bracket
(LHD Steering Position Type)
Oil Reservoir
Bracket No. 1Heater Outlet Water Hose
Heater Inlet Water Hose
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silencer Sheet
Front Stabilizer Link Assy
Front Axle Assy
35 (360, 26)
7.0 (71, 62 in.lbf)
74 (755, 55)
216 (2,203,159 )
89 (908, 66)
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzFront Axle Hub Nut
Tie Rod End Sub−assy
8.0 (82, 71 in.lbf)
8.0 (82, 71 in.lbf)
zCotter Pin
49 (500, 36)
Front Suspension Arm
Sub−assy Lower No. 1
14−14
− ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
Page 4718 of 5135
1308N−01
A84393
(a)
(b)
(a)
(a)
(b)
A93661
(a)
(a) (a)
(a) (b)
(a)
(b)
13
−12
−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
2. DRAIN ENGINE COOLANT (See page 16 −19)
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE COVER SUB −ASSY NO.1
(a) Remove the 5 nuts and engine cover.
5. REMOVE VACUUM RESERVOIR SUB −ASSY
(a) Disconnect the 2 vacuum hoses and connector.
(b) Remove the 2 bolts and vacuum reservoir.
6. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
7. DISCONNECT ENGINE WIRE (See page 14 −138)
8. REMOVE AIR CLEANER ASSY
(a) Disconnect the PCV hose and connector.
(b) Remove the air cleaner cap with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and air cleaner case.
9. REMOVE AIR TUBE NO.1
(a) Remove the 3 bolts and nut, then separate the air tubeNo. 1.
(b) Loosen the hose clamp bolts.
10. REMOVE FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
Page 4725 of 5135
A84387
2to7mm
(0.0787 to
0.2756 in.) 0to5mm
(0 to 0.1969 in.) 0to2mm
(0 to 0.0787 in.) *1*2
*2: *1:
Turbocharger Side
Intercooler Side
A93662
Turbocharger Side:
Intercooler Side: Upward
90_
Cl a m p
Bolt
90_
Cl a m p
Bolt
Front
−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)13 −19
AVENSIS Supplement (RM1045E)
53. INSTALL AIR TUBE NO.1
(a) Install the air hose and hose clamps as shown in the il-
lustration.
(b) Tighten the hose clamps as shown in the illustration. Torque: 6.0 N m (61 kgf cm, 53 in. lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N m (255 kgf cm, 18 ft lbf)
54. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
55. INSTALL AIR CLEANER ASSY
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
56. INSTALL VACUUM RESERVOIR SUB −ASSY
Torque: 8.3 N m (85 kgf cm, 73 in. lbf)
57. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
58. ADD ENGINE COOLANT (See page 16 −19)
59. CHECK ENGINE OIL LEVEL
60. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
61. CHECK FOR ENGINE OIL LEAKS
62. CHECK FOR FUEL LEAKS (See page 11 −46)
63. CHECK FOR EXHAUST GAS LEAKS
Page 4730 of 5135
− BRAKEBRAKE BOOSTER ASSY (RHD) (2AZ−FSE)
32−7
AVENSIS Supplement (RM1045E)
20. INSTALL ENGINE COVER NO.1
21. INSTALL FRONT WHEEL RH
Torque:103 Nm(1,050 kgfcm, 76 ftlbf)
22. FILL RESERVOIR WITH BRAKE FLUID
23. BLEED MASTER CYLINDER
SST 09023−00100
24. BLEED BRAKE LINE
25. CHECK AND ADJUST BRAKE PEDAL HEIGHT
26. CHECK PEDAL FREE PLAY
27. CHECK PEDAL RESERVE DISTANCE
28. CHECK FLUID LEVEL IN RESERVOIR
29. CHECK BRAKE FLUID LEAKAGE
