Page 2281 of 5135
A61186
SST
A79183
1
7
5
8
4
3
26
14±346
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL FLYWHEEL SUB±ASSY
(a)Hold the crankshaft with SST. SST09213±54015 (90105±08076), 09330±00021
(b)Clean the bolt and the bolt hole.
(c)Apply Adhesive to the bolts. Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
(d)Using several steps, install and tighten the 8 screws with a torx socket wrench (T55) uniformly in the sequence
shown in the illustration.
Torque: 71 N m (720 kgf cm, 52 ft lbf)
10.INSTALL CLUTCH DISC ASSY (See page 42±26) SST 09301±00220
11.INSTALL CLUTCH COVER ASSY (See page 42±26)
12.INSTALL MANUAL TRANSAXLE ASSY (See page 41±33) SST 09670±00010
Page 2282 of 5135
141CB±01
A61184
A79179
14±342
±
ENGINE MECHANICAL CRANKSHAFT SEAL(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT SEAL(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 34 N m (350 kgf cm,25 ft lbf)
2.REMOVE FRONT WHEEL RH
3.REMOVE ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE INJECTOR DRIVER (See page 14±286)
8.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
9.REMOVE GENERATOR V BELT (See page 14±269)
10.REMOVE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11.REMOVE ENGINE MOUNTIN G INSULATOR
SUB±ASSY RH
(a)Place a wooden block on a jack underneath the engine.
(b)Remove the 3 bolts and 3 nuts, and then detach the en- gine mounting insulator sub assy.
12.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
13.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
14.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
15.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
16. REMOVE TIMING BELT GUIDE
17.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
18.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
19.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
Page 2283 of 5135
SST
A09582
B07973
Cut PositionPry
SST
A08528
SST
A09583
Angle
SensorInward
±
ENGINE MECHANICAL CRANKSHAFT SEAL(1CD±FTV)
14±343
AVENSIS REPAIR MANUAL (RM1018E)
20.REMOVE TIMING BELT(See page 14±307)
21.REMOVE CRANKSHAFT TIMING PULLEY
(a)If the timing pulley cannot be removed by hand, use SSTto remove the pulley.
SST09950±50013 (09951±05010, 09952±05010, 09953±05010, 09953±05020, 09954±05021)
22.REMOVE CRANKSHAFT SEAL
(a)Using a knife, cut off the oil seal lip.
(b)Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Warp tip of the
screwdriver with tape.
23.INSTALL CRANKSHAFT SEAL
(a)Using SST and a hammer, tap in the oil seal until its sur- face is flush with the oil pump edge.
SST09316±60011 (09316±00011)
24.INSTALL CRANKSHAFT TIMING PULLEY
(a)Align the keyway of the timing pulley with the key located on the crankshaft, slide the pulley into place.
(b)Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
SST09223±46011
25.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
26.INSTALL TIMING BELT(See page 14±307)
27.CHECK VALVE TIMING(See page 14±307)
28.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
Page 2284 of 5135
14±344
±
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
29.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
30.INSTALL TIMING BELT GUIDE(See page 14±307)
31.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
32.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
33.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
34.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
35.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
36.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
37. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
38.INSTALL INJECTOR DRIVER (See page 14±286)
39. INSTALL ENGINE COVER NO.1
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
40. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
41. ADD ENGINE OIL
42. CHECK FOR ENGINE OIL LEAKS
Page 2285 of 5135
141CA±01
14±332
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.DRAIN ENGINE COOLANT (See page 16±44)
6.DRAIN ENGINE OIL (See page 14±342)
7. REMOVE RADIATOR SUPPORT OPENING COVER
8. REMOVE ENGINE ROOM COVER SIDE
9. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
10.REMOVE VACUUM RESERVOIR SUB±ASSY (See page 13±11)
11.REMOVE AIR CLEANER ASSY (See page 14±286)
12. REMOVE BATTERY
13.REMOVE AIR TUBE NO.2 (See page 14±286)
14.REMOVE AIR TUBE NO.1(See page 14±270)
15.REMOVE INJECTOR DRIVER (See page 14±286)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
17.REMOVE GENERATOR V BELT (See page 14±269)
18.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
19.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
20.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
21.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
22.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
23.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
24. REMOVE TIMING BELT GUIDE
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
27.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
28.REMOVE TIMING BELT(See page 14±307)
HINT:
If re±using the timing belt, draw a direction arrow on the timing belt (\
in direction of engine revolution), and
place matchmarks on the pulleys and the timing belt.
29.REMOVE FUEL FILTER ASSY (See page 11±82)
30.REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13±11)
31.REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13±11)
32.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
34.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
35. DISCONNECT RADIATOR HOSE INLET
36. DISCONNECT HEATER INLET WATER HOSE
37. DISCONNECT HEATER OUTLET WATER HOSE
38. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
39. DISCONNECT OIL COOLER HOSE
40.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
41.REMOVE TURBO INSULATOR NO.1 (See page 13±11)
Page 2286 of 5135
A79148
SST
A79143
SST
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±333
AVENSIS REPAIR MANUAL (RM1018E)
42.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
43.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
44.REMOVE MANIFOLD STAY (See page 13±11)
45.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
46.REMOVE TURBOCHARGER STAY (See page 13±11)
47.REMOVE TURBO WATER HOSE NO.1 (See page 13±11)
48.REMOVE TURBO WATER HOSE NO.2 (See page 13±11)
49.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
50.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11)
51.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
52.REMOVE CAMSHAFT TIMING PULLEY (See page 14±318)
SST 09960±10010 (09962±01000, 09963±01000)
53. REMOVE FUEL INLET PIPE SUB±ASSY
(a) Using SST, remove the fuel inlet pipe from the commonrail side.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023±12700
NOTICE:
After removing the fuel pipe, cover the common rail and the
injector mounting holes with vinyl tape to prevent dust
from being introduced.
54. REMOVE INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
SST 09023±12700
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector
side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or a
plastic bag.
55. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
Page 2287 of 5135
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A09566
1
234 5
67 89
1011
12 13
1415
16
1718
14±334
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
57.REMOVE INJECTION PIPE SUB±ASSY NO.4 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
58.REMOVE VACUUM PUMP ASSY (See page 14±318)
59. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
60. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, the cylinder head cover and thegasket.
61.REMOVE NOZZLE LEAKAGE PIPE ASSY(See page 11±60)
62.REMOVE INJECTOR ASSY(See page 11±60)
HINT:
Since each injector assembly has a characteristic fuel injecting behavior, store them in correct order so that
they can be returned to the original locations when re±assembling.
63.REMOVE CAMSHAFT OIL SEAL RETAINER (See page 14±318)
64.REMOVE NO.2 CAMSHAFT (See page 14±318)
65.REMOVE CAMSHAFT (See page 14±318) 66. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 18 cylinder head boltsuniformly in the sequence shown in the illustration. Re-
move the 18 cylinder head bolts and the plate washers.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
Page 2288 of 5135
A61194
Pry
A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring Tip
Protrusion Hight
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±335
AVENSIS REPAIR MANUAL (RM1018E)
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
67. REMOVE CYLINDER HEAD GASKET
68. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolts.
Standard outside diameter:
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
69. INSTALL CYLINDER HEAD GASKET
(a) Measure protrusion height of the piston heads.
(1) Clean the cylinder block with solvent.
(2) Set the piston to be measured to slightly before
TDC.
(3) Place a dial indicator on the cylinder block, and cali-
brate the dial indicator at 0 mm (0 in.).
HINT:
Place measuring tip of the dial indicator as shown in the
illustration.
Make sure that the measuring tip is square to the cylinder
block gasket and the piston head when measuring.
(4) Find the most overhung position of the piston head
by slowly turning the crankshaft clockwise and
counterclockwise.