Page 1993 of 5135
A79159
A79156
A79157
A79160
13±12
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
10.REMOVE HEATER BRACKET (W/ COLD AREA)
(a)Remove the bolt and the heater bracket.
11.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
12.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10) 13. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA)
(a) Remove the 2 nuts.
(b) Remove the 2 nuts and the exhaust pipe sub±assy.
14. REMOVE TURBO INSULATOR NO.2
(a) Remove the 4 bolts and the turbo insulator.
Page 1994 of 5135
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A79162
A79163
A79164
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± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
13±13
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE TURBO INSULATOR NO.1
(a) Remove the 2 bolts and nut, and then remove the turbo
insulator.
16. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.2
(a) Remove the 2 bolts and the exhaust manifold heat insula-
tor.
17. REMOVE MANIFOLD STAY NO.2
(a) Remove the bolt and nut and then remove the manifold
stay.
18. REMOVE MANIFOLD STAY
(a) Remove the 4 bolts and the manifold stay.
19. REMOVE EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a) Remove the 3 nuts, the manifold converter and the gas-
ket.
Page 1995 of 5135
A79165
A79166
A79167
B13094
B13095
13±14
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE TURBOCHARGER STAY
(a) Remove the 2 bolts and 2 nuts, and then remove the
turbocharger stay.
21. DISCONNECT TURBO WATER HOSE NO.1
22. DISCONNECT TURBO WATER HOSE NO.2
23. SEPARATE TURBO OIL INLET PIPE SUB±ASSY
(a) Remove the 2 nuts, the turbo oil pipe and the gasket.
24. REMOVE TURBOCHARGER SUB±ASSY
(a) Remove the 3 nuts, the turbocharger and the gasket.
Page 1996 of 5135
B13096
A79165
B
BAA
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
13±15
AVENSIS REPAIR MANUAL (RM1018E)
25. REMOVE TURBO WATER PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts, the turbo water pipe and the gasket.
26. INSTALL TURBO WATER PIPE SUB±ASSY NO.1
(a) Install a new gasket and the turbo water pipe with the 2 nuts.
Torque: 13 Nm (135 kgfcm, 9.7 ftlbf)
27. INSTALL TURBOCHARGER SUB±ASSY
(a) Install a new gasket and the turbocharger with the 3 nuts.
Torque: 53 Nm (540 kgfcm, 39 ftlbf)
28. INSTALL TURBO OIL INLET PIPE SUB±ASSY
(a) Install a new gasket and the oil pipe with the 2 nuts.
Torque: 13 Nm (135 kgfcm, 9.7 ftlbf)
29. INSTALL TURBOCHARGER STAY
(a) Install the turbocharger stay, and temporarily tighten bolt
A.
(b) Temporarily tighten nut B while pushing the cylinder head
toward the turbocharger stay.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
(c) Tighten bolt A.
Torque: 56 Nm (571 kgfcm, 41 ftlbf)
(d) Tighten nut B.
Torque: 56 Nm (571 kgfcm, 41 ftlbf)
30. INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a) Install the manifold stay, and temporarily tighten the cylin-
der block side of the manifold stay.
Page 1997 of 5135
A80106
A
A
B
B
A79163
13±16
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INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket and the manifold converter, and tem- porarily tighten bolts A and bolts B while pushing the up-
per portion of the converter toward the turbocharger.
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
(c)Tighten the 3 nuts. Torque: 25 N m (255 kgf cm, 18 ft lbf)
(d)Tighten bolts A.
Torque: 61 N m (622 kgf cm, 45 ft lbf)
(e)Tighten bolts B. Torque: 61 N m (622 kgf cm, 45 ft lbf)
31.INSTALL MANIFOLD STAY NO.2
(a)Install the manifold stay No. 2, and temporarily tighten the bolt.
(b)Temporarily tighten the nut while pushing the manifold stay No. 2 toward the cylinder head.
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
HINT:
No clearance between the stay and the cylinder head should be
confirmed.
(c)Tighten the bolt. Torque: 56 N m (571 kgf cm, 41 ft lbf)
(d)Tighten the nut. Torque: 56 N m (571 kgf cm, 41 ft lbf)
32.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 12 N m (122 kgf cm, 8.9 ft lbf)
33.INSTALL TURBO INSULATOR NO.1 Torque: 20 N m (204 kgf cm, 15 ft lbf)
34.INSTALL TURBO INSULATOR NO.2
Torque: 20 N m (204 kgf cm, 15 ft lbf)
35.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 N m (76 kgf cm, 66 in. lbf)
36.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
37.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
38. INSTALL HEATER BRACKET (W/ COLD AREA) Torque: 7.5 N m (76 kgf cm, 66 in. lbf)
39. INSTALL HEATER PUMP ASSY (W/ COLD AREA) Torque: 7.5 N m (76 kgf cm, 66 in. lbf)
40.INSTALL FUEL FILTER ASSY(See page 11±82)
Page 1998 of 5135
A64328
2 to 7 mm0 to 2 mm
A78274
Upward90
Clamp
Bolt
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
13±17
AVENSIS REPAIR MANUAL (RM1018E)
41.INSTALL INTERCOOLER AIR HOSE
(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)
42.INSTALL AIR CLEANER ASSY Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
43.INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N m (85 kgf cm, 73 in. lbf)
44.INSTALL ENGINE COVER NO.1
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
45.ADD ENGINE COOLANT(See page 16±44)
46. CHECK ENGINE OIL LEVEL
47.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
48. CHECK FOR ENGINE OIL LEAKS
49.CHECK FOR FUEL LEAKS(See page 11±60)
50. CHECK FOR EXHAUST GAS LEAKS
Page 1999 of 5135
1306Y±01
A79439
8.0 (82, 71 in.lbf)
Engine Cover No. 1Radiator Support Opening Cover
N´m (kgf´cm, ft´lbf)
: Specified torque
7.0 (71, 62 in.lbf)
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Engine Under Cover Sub±assy No. 1
Clip
Retainer
Clip
13±8
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
TURBOCHARGER SUB±ASSY (1CD±FTV)
COMPONENTS
Page 2000 of 5135
A79440
Union To Connector Tube Hose
Fuel Filter Assy Vacuum Reservoir Sub±assy
43 (440, 32)
43 (440, 32)
Gasket
GasketCompression Spring
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
Intercooler Air Hose
Gasket
7.5 (76, 66 in.lbf)
Exhaust Pipe Assy
30 (302, 22)
7.5 (76, 66 in.lbf)
Heater Bracket
Heater Pump Assy25 (255, 18)
25 (255, 18)
7.5 (76, 66 in.lbf)
18 (178, 13)
7.5 (76, 66 in.lbf)
w/ Cold Area:
w/ Cold Area:
w/ Cold Area:
8.3 (85, 73 in.lbf)
Air Tube No. 1
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
13±9
AVENSIS REPAIR MANUAL (RM1018E)