Page 2209 of 5135

A77332
23
145
A77350
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±213
AVENSIS REPAIR MANUAL (RM1018E)
106.INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a)Install a new gasket and the exhaust manifold converter
with the 5 nuts.
Torque: 37 N m (378 kgf cm, 27 ft lbf)
(b)Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 N m (449 kgf cm, 32 ft lbf)
107.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N m (122 kgf cm,9.0 ft lbf)
108.INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 60 N m (607 kgf cm,44 ft lbf)
109.INSTALL IGNITION COIL ASSY
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
110.INSTALL FUEL INJECTOR ASSY (See page 11±42)
111.INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±42)
112.INSTALL NOZZLE HOLDER CLAMP (See page 11±42)
113. INSTALL SURGE TANK STAY NO.1
(a) Install the surge tank stay with insulator No. 2. Torque: 21 N m (210 kgf cm, 15 ft lbf)
114. INSTALL INTAKE MANIFOLD
(a) Install a new gasket on the cylinder head.
(b) Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N m (306 kgf cm, 22 ft lbf)
115.INSTALL FUEL PUMP ASSY (See page 11±52)
116.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
117.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±49)
118.INSTALL THROTTLE BODY ASSY (See page 10±44)
119. INSTALL THROTTLE BODY BRACKET Torque: 21 N m (210 kgf cm, 15 ft lbf)
120. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Apply a light coat of engine oil to the new O±ring and install it to the c\
amshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt. Torque: 9.0 N m (92 kgf cm, 79 in. lbf)
Page 2210 of 5135

A77333SST
A77403
15
3
7
2
6
4 8
A63273
14±214
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
121.INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL
(a)Hold the crankshaft with SST.
SST09213±54015 (91651±60855), 09330±00021
Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
(b)Install the drive plate. (A/T) (1)Clean the bolt and bolt hole.
(2)Apply adhesive to the bolts.
(3)Using several steps, install and tighten the 8 bolts
uniformly in the sequence shown in the illustration.
Torque: 98 N m (1,000 kgf cm, 72 ft lbf)
(c)Install the flywheel. (M/T) (1)Clean the bolt hole.
(2)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 130 N m (1,327 kgf cm, 96 ft lbf)
NOTICE:
Do not reuse the flywheel bolt.
122.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
123.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
124.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
125.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
126.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
127.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
128.INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Install the engine mounting insulator FR with the through bolt and nut. Torque: 87 N m (887 kgf cm,64 ft lbf)
(b)Install the engine mounting insulator RR with the through bolt and nut. Torque: 87 N m (887 kgf cm,64 ft lbf)
129.INSTALL STARTER ASSY (See page 19±12)
130. INSTALL VANE PUMP ASSY Torque: 37 N m (370 kgf cm, 27 ft lbf)
131. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the 2 bolts and 2 nuts as shown in the illustration. Torque:
Bolt 45 N m (459 kgf cm, 33 ft lbf)
Nut 133 N m (1,356 kgf cm, 98 ft lbf)
Page 2211 of 5135
A77404
B
A
BBBB
A
B
A77304
A77305
A77405
A
B
A
A
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±215
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the front suspension member braces with the 8
bolts.
Torque:
Bolt A 133 N m (1,356 kgf cm, 98 ft lbf)
Bolt B 80 N m (816 kgf cm, 59 ft lbf)
132.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N m (887 kgf cm, 64 ft lbf)
133.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N m (530 kgf cm, 38 ft lbf)
134.INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N m (530 kgf cm, 38 ft lbf)
B 113 N m (1,152 kgf cm, 83 ft lbf)
135.REMOVE ENGINE HANGERS
136.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
137.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
138.INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
Page 2212 of 5135

A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±216
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
139.INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
Torque:
Bolt A 12 N m (122 kgf cm, 89 ft lbf)
Bolt B 9.0 N m (92 kgf cm,79 in. lbf)
Bolt C 5.0 N m (51 kgf cm,44 in. lbf)
140.INSTALL FRONT AXLE ASSY LH
Torque: 294 N m (3,000 kgf cm,217 ft lbf)
141.INSTALL FRONT AXLE ASSY RH Torque: 294 N m (3,000 kgf cm,217 ft lbf)
142.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
Torque: 142 N m (1,448 kgf cm,104 ft lbf)
143.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) Torque: 142 N m (1,448 kgf cm,104 ft lbf)
144.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 N m (1,448 kgf cm,104 ft lbf)
145.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 N m (1,448 kgf cm,104 ft lbf)
146.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N m (755 kgf cm,55 ft lbf)
147.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N m (755 kgf cm,55 ft lbf)
148.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
149. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
150.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
151. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
152.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
153.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
154. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N m (306 kgf cm, 22 ft lbf)
155. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
156. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
157. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
Page 2213 of 5135

±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±217
AVENSIS REPAIR MANUAL (RM1018E)
158.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N m (82 kgf cm,71 in. lbf)
159.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N m (82 kgf cm,71 in. lbf)
160.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N m (51 kgf cm,44 in. lbf)
161.INSTALL BATTERY CARRIER
162.INSTALL AIR CLEANER ASSEMBLY WITH HOSE
Torque: 5.0 N m (51 kgf cm,44 in. lbf)
163.INSTALL COMPRESSOR AND MAGNETIC CLUTCH Torque: 25 N m (255 kgf cm,18 in. lbf)
164.INSTALL GENERATOR ASSY (See page 19±20)
165.INSTALL FAN AND GENERATOR V BELT (See page 14±185)
166.INSTALL RADIATOR ASSY (See page 16±36)
167. INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
168. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
169. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
170. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
171. ADD ENGINE OIL
172.ADD COOLANT (See page 16±31)
173.ADD POWER STEERING FLUID (See page 51±4)
174. BLEED POWER STEERING FLUID
175. CHECK FOR ENGINE OIL LEAKS
176.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
177.CHECK FOR FUEL LEAKS (See page 11±30)
178. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
179.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
180.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±204)
181. INSPECT CO/HC
182. CHECK ABS SPEED SENSOR SIGNAL
Page 2214 of 5135
141BE±01
A77310
Engine Room
Cover Side
Radiator Support
Opening CoverEngine Cover Sub±assy No. 1
Fan and Generator V Belt
Engine Under Cover LH
7.0 (71, 62 in.lbf)
7.0 (71, 62 in.lbf)
Engine Under Cover RH
N´m (kgf´cm, ft´lbf)
: Specified torque 14±192
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1AZ±FSE)
COMPONENTS
Page 2215 of 5135
A77521
Generator Assy Cooler Refrigerant
Suction Hose No. 1
(RHD Steering Position Type)
Radiator Hose Inlet
Radiator Hose OutletCooler Refrigerant Suction Hose No. 1
(LHD Steering Position Type)
Union to Connector
Tube Hose
Charcoal Canister Assy
Battery TrayBatteryRadiator Assy
Compressor and
Magnetic Clutch
Battery Clamp
Battery CarrierAir Cleaner Assembly with Hose
Radiator Relay Block
52 (530, 38)
9.8 (100, 7.2)
5.0 (51, 44 in.lbf)
5.0 (51, 44 in.lbf)
13 (133, 10)
25 (250, 18)
5.0 (51, 44 in.lbf)
21 (214, 16)
7.0 (71, 62 in.lbf)
7.0 (71, 62 in.lbf)
19 (194, 14)
19 (194, 14)
N´m (kgf´cm, ft´lbf)
: Specified torque
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±193
AVENSIS REPAIR MANUAL (RM1018E)
Page 2216 of 5135
A80059
30 (306, 22)
Radiator Reserve
Tank Sub±assy
Fuel Tube Sub±assy
Exhaust Pipe Assy center
Gasket
Gasket Gasket
Floor Panel Brace Front Vane Pump Oil
Reservoir Assy
Accelerator Control
Cable Sub±assy
Fuel Pipe Clamp
Exhaust Pipe Assy Front
8.0 (82, 44 in.lbf)
8.0 (82, 44 in.lbf)
8.0 (82, 44 in.lbf)
Return Tube
Sub±assy
43 (440, 32)
5.0 (51, 44 in.lbf)
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
43 (440, 32)
43 (440, 32)
43 (440, 32)
43 (440, 32)
43 (440, 32)
5.0 (51, 44 in.lbf)
14±194
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)