Page 2057 of 5135
A76713
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90
A62838SST
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±41
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
113. INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts.
Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni-
formly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgfcm, 36 ftlbf)
(e) Mark each bolt head with paint.
(f) Retighten the bolts by an additional 90 in the same se-
quence as step (d).
(g) Check that the paint marks are at 90 angle about the
original position.
114. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
Page 2058 of 5135

A62204
1
5
3
82
6
4
7
A76719
A76718
A76717
14±42
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 88 N m (897 kgf cm, 65 ft lbf)
115.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
116.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
117.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)(See page 41±15)
118.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
119.INSTALL STARTER ASSY(See page 19±3)
120. INS TALL FRO NT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen- sion crossmember and the engine mounting member.
(b) Install the bolt which is used to secure the rear engine
mounting bracket to the mounting insulator.
Torque: 87 N m (887 kgf cm, 64 ft lbf)
(c) Install the bolt which is used to secure the front engine mounting bracket to the mounting insulator.
Torque: 52 N m (530 kgf cm, 38 ft lbf)
121. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670±00010
(a) Set the engine assembly with transaxle on the engine lift- er.
(b) Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N m (816 kgf cm, 59 ft lbf)
(d) Install the engine mounting insulator RH. Torque: 52 N m (530 kgf cm, 38 ft lbf)
Page 2059 of 5135

A76717
A
B
A
B
A76716
AA
BBBBBB
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±43
AVENSIS REPAIR MANUAL (RM1018E)
(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 Nm (459 kgf cm, 33 ft lbf) for Bolt A
133 N m (1,356 kgf cm, 98 ft lbf) for Nut B
(f) Install the front suspension member brace LH and RH with the 8 bolts.
Torque:
133 N m (1,356 kgf cm, 98 ft lbf) for Bolt A
80 N m (816 kgf cm, 59 ft lbf) for Bolt B
NOTICE:
When installing the crossmember, check that the position-
ing holes on the crossmember and on the vehicle are
aligned with each other.
122.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
123. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
124.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
125. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
127. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
128.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
129. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
130.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±2)
131. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N m (306 kgf cm, 22 ft lbf)
132.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
133.INSTALL GENERATOR ASSY (See page 19±7)
134. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:
1ZZ±FE (See page 55±74)
3ZZ±FE (See page 55±70)
135. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
136. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)
Page 2060 of 5135

A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N m (131 kgf cm, 9 ft lbf)
138. INSTALL BATTERY Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N m (194 kgf cm, 14 ft lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
145. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL
Page 2061 of 5135
141CF±01
A76700
Cylinder Head
Cover No. 2 Radiator Support
Upper
Radiator Support Upper
Radiator
Hose Inlet
Radiator Hose Outlet
Radiator AssyClip
7.0 (71, 62 in.lbf)
19 (194, 14)
Engine Under Cover LH Engine Under Cover RH
Clip
Clip
N´m (kgf´cm, ft´lbf)
: Specified torque
Clip
Engine Under Cover No.1
19 (194, 14)
Retainer
Clip
Clip
Engine Room Cover Side
Radiator Suport Opening Cover
5.0 (51, 44)
Relay Block
Oil Cooler Inlet Tube No.1 Oil Cooler
Outlet Tube No.1
x2
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
Page 2062 of 5135
A76702
Accelerator Control Cable Assy
Heater Inlet Water Hose
Fuel Pipe Clamp
Fuel Tube Sub±assy
Heater Outlet Water Hose
Air Cleaner Cap
W/ Hose
Air Cleaner Filter
Element Sub±assy
Air Cleaner Case Sub±assy Battery Clamp
Sub±assy
Battery
Battery Tray
Battery Carrier
12.8 (131, 9)
N´m (kgf´cm, ft´lbf)
: Specified torque
Union to Connector Tube Hose
Air Cleaner Clamp
Bracket
5.0 (51, 44 in.lbf)
Fuel Vapor Feed Hose No.1
Fuel Vapor Feed Hose No.3
5.0 (51, 44 in.lbf)
Oil Cooler
Inlet Hose
Oil Cooler
Outlet Hose
X4
VSV Connector
Mass Air Flow
Meter Connector
14±20
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2063 of 5135
A76703
Fan and Generator V Belt
Cooler Compressor Assy
N´m (kgf´cm, ft´lbf) : Specified torque
29 (296, 21)
A/T:
Floor Shift Transmission
Control Cable Assy Clip
Clutch Release Cylinder Assy
Floor Shift Cable Transmission
Control Shift
Floor Shift Cable Transmission
Control Select
Clip
Clip
25 (255, 18)
12 (122, 9)
25 (255, 18)
12 (122, 9)
54 (551, 40)
25 (255, 18)
Generator Assy Terminal Cap
No. 19.8 (100, 7)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±21
AVENSIS REPAIR MANUAL (RM1018E)
Page 2064 of 5135
A76704
Grove Compartment Door Assy Cowl Side Trim Board RH
Front Door Scuff Plate RH
Clip
Clip
Column Hole Cover Silencer Sheet
Steering Intermediate Shaft
Cotter Pin
Tie Rod End Sub±assy LH
Front Suspension Arm
Sub±assy Lower No. 1 LH
Front Drive Shaft Assy LH
Front Stabilizer Link Assy LH
Exhaust Pipe Assy Front
Floor Panel Brace FrontCompression
Spring
Compression Spring Gasket
Gasket
89 (908, 66)
216 (2,203, 160)
49 (500, 36)
74 (755, 55)
35 (357, 26)
89 (908, 66) Front Axle Hub LH Nut
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
43 (440, 32)
30 (306, 22)
43 (440, 32)
Front Floor Footrest (RHD)
Instrument Panel Under
Cover Sub±assy No. 2
14±22
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)