Page 2201 of 5135
A77335
A77302
A77300
A77299
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±205
AVENSIS REPAIR MANUAL (RM1018E)
21. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a) Disconnect the 2 connectors.
(b) Disconnect the 2 vacuum hoses.
(c) Disconnect the ventilation hose.
(d) Disconnect the air cleaner hose from the throttle body.
(e) Raise a clamp up, and slide it toward the air cleaner cap,
then remove the air cleaner cap from its case.
(f) Remove the air cleaner element.
(g) Remove the 4 bolts and the air cleaner case.
22. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and the battery carrier.
23. REMOVE RADIATOR RESERVE TANK SUB±ASSY
(a) Remove the 2 bolts and the radiator reserve tank.
24. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts shown in the illustration.
Page 2202 of 5135
A77308
A77303
A77340
14±206
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
25.SEPARATE VANE PUMP OIL RESERVOIR ASSY 26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove the 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSENO.1 (LHD STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the suction hose.
28.REMOVE COOL ER BRACKET (LHD STEER ING
POSITION TYPE)
(a)Remove the nut and separate the cooler bracket.
29.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
30.DISCONNECT HEATER INLET WATER HOSE
31.DISCONNECT HEATER OUTLET WATER HOSE
32.REMOVE CHARCOAL CANISTER ASSY
33.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±30)
34. DISCONNECT UNION TO CONNECTOR TUBE HOSE
35.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
36.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
38.REMOVE FRONT AXLE HUB LH NUT (See page 30±6) SST 09330±00030
Page 2203 of 5135
A77298
LHD Steering Position typeRHD Steering Position type
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±207
AVENSIS REPAIR MANUAL (RM1018E)
39.REMOVE FRONT AXLE HUB RH NUT
SST09330±00030
HINT:
Perform the same procedure as above on the opposite side.
40.SEPARATE TIE ROD END SUB±ASSY LH (See page 51±36)
41.SEPARATE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
42.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
43.SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
44.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
(See page 26±21)
45.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) (See page 26±16)
46.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
47.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
48.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
49.SEPARATE FRONT AXLE ASSY RH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side. 50.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
(a)Remove the 7 bolts shown in the illustration.
51.SEPARATE TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
52.SEPARATE TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
Page 2204 of 5135
A77338
A77337
A77336
A57550
Engine Hanger No. 1Engine Hanger No. 2
14±208
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
53.SEPARATE ENGINE ROOM RELAY BLOCK NO.2
(a)Remove the nut and disconnect the connector shown in the illustration.
54.SEPARATE ENGINE WIRE
(a)Remove the bolt and separate the grand terminal.
(b)Separate the grand terminal connector.
(c)Remove the glove compartment door panel.
(d)Separate the engine wire.
55.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9) 56. INSTALL ENGINE HANGERS
(a) Install the engine hanger No. 1 (12281±28010, 28020,28030) with the bolt (91512±61020).
Torque: 38 N m (387 kgf cm, 28 ft lbf)
(b) Install the engine hanger No. 2 (12282±28010, 28020, 28030) with the bolt (91512±61020).
Torque: 38 N m (387 kgf cm, 28 ft lbf)
Page 2205 of 5135
A66202
A77305
A77304
A59793
A63273
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±209
AVENSIS REPAIR MANUAL (RM1018E)
57. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
(a) Set the engine lifter.
(b) Remove the 2 bolts and 2 nuts, and then detach the
mounting bracket No. 2.
58. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 3 bolts and the engine mounting insulator.
59. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the through bolt and nut, and then detach the en-
gine mounting insulator.
60. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Remove the 8 bolts and the front suspension member
braces.
(b) Remove the 2 bolts and 2 nuts shown in the illustration.
(c) Carefully remove the engine assembly with transaxle
from the vehicle.
Page 2206 of 5135
A77331
SST
A77353
14±210
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
61.SEPARATE VANE PUMP ASSY
(a)Disconnect the PS oil pressure switch connector.
(b)Remove the 2 bolts and separate the vane pump from the engine.
62.REMOVE STARTER ASSY (See page 19±12)
63. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a) Remove the through bolt and nut from the engine mounting insulator FR.
(b) Remove the through bolt and nut from the engine mounting insulator RR.
64.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
65.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
66.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
67.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
68.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
69.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 70. REMOVE DRIVE PLATE AND RING GEAR ORFLYWHEEL
(a) Using SST, fix the crankshaft pulley and remove the drive plate and ring gear or flywheel.
SST 09213±54015 (91651±60855), 09330±00021
71. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt, O±ring and the camshaft timing oil control valve.
72. REMOVE THROTTLE BODY BRACKET
(a) Separate the engine wire.
(b) Remove the 4 bolts and the throttle body bracket.
73.REMOVE THROTTLE BODY ASSY (See page 10±44)
74. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
75. DISCONNECT FUEL TUBE SUB±ASSY
76.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52)
77.REMOVE FUEL PUMP ASSY (See page 11±52)
78. REMOVE WATER BY±PASS HOSE 79. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts.
(b) Remove the intake manifold and the insulator.
Page 2207 of 5135
A32676
A77350
A52497
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±211
AVENSIS REPAIR MANUAL (RM1018E)
80.REMOVE INTAKE AIR CONTROL VALVE ASSY
(a)Remove the intake air control valve and a gasket.
81.REMOVE SURGE TANK STAY NO.1
(a)Remove the 3 bolts and the surge tank stay.
82.REMOVE INTAKE MANIFOLD INSULATOR NO.2
83.REMOVE NOZZLE HOLDER CLAMP
84.REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±42)
85.REMOVE FUEL INJECTOR ASSY (See page 11±42)
86. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, and then detach the V±ribbedbelt tensioner.
87. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and the ignition coils.
88. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
(a) Remove the 3 bolts and the exhaust manifold heat insulator. 89. REMOVE EXHAUST MANIFOLD CONVERTERSUB±ASSY
(a) Remove the 2 bolts and 2 nuts, then detach the No. 1 and No. 2 exhaust manifold stay.
(b) Remove the 5 nuts, the exhaust manifold converter and gasket.
90. REMOVE OIL LEVEL GAGE SUB±ASSY
91. REMOVE OIL LEVEL GAGE GUIDE
92. REMOVE WATER INLET
(a) Remove the 2 nuts and the water inlet.
93. REMOVE THERMOSTAT
Page 2208 of 5135
A78645
Oil Pressure Switch
14±212
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
94.REMOVE WATER BY±PASS PIPE NO.1
(a)Remove the 2 bolts and 2 nuts.
(b)Remove the water by±pass pipe No. 1 and a gasket.
95.REMOVE KNOCK SENSOR
(a)Remove the nut and the knock sensor. 96.REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a)Using SST, remove the engine oil pressure switch.SST09268±46021
97.REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
(a)Using a SST, remove the coolant temperature sensor SST09817±33190
98.REPLACE PARTIAL ENGINE ASSY
99.INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
(a)Install a new gasket to the engine coolant temperature sensor.
(b)Using SST, install the engine coolant temperature sensor. SST09817±33190
Torque: 20 N m (208 kgf cm,15 ft lbf)
100.INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a)Clean the threads of the oil pressure switch, apply adhesive there.
Adhesive: Part No. 08833 ± 00080 THREE BOND 1344 or equivalent.
(b)Install the oil pressure switch. Torque: 15 N m (153 kgf cm,11 ft lbf)
SST09268±46021
101.INSTALL KNOCK SENSOR Torque: 20 N m (208 kgf cm,15 ft lbf)
102.INSTALL WATER BY±PASS PIPE NO.1
(a)Install the water by±pass pipe No. 1 and a new gasket.
(b)Install the 2 bolts and 2 nuts. Torque: 9.0 N m (92 kgf cm,80 in. lbf)
103.INSTALL THERMOSTAT (See page 16±35)
104. INSTALL WATER INLET Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
105. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil\
level gauge guide.
(b) Install the oil level gauge and guide with the bolt. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)