Page 2305 of 5135

A09601
Seal Packing
A09627
A09650
12
3
5
49
6
8
7
13
10
11
15
14 12
A09600
Seal Width
2 to 4 mm
Seal Packing
14±322
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(e)Install the camshaft bearing caps. (1)Remove any oil packing (FIPG) material from theNo. 5 camshaft bearing cap.
(2)Apply seal packing to the No. 5 camshaft bearing cap as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(3)Place the 5 bearing caps in their proper locations.
(4)Using several steps, install and tighten the 15 bear- ing cap bolts uniformly in the sequence shown in the
illustration.
Torque: 20 N m (204 kgf cm, 15 ft lbf)
43.INSPECT VALVE CLEARANCE (See page 14±270)
44.ADJUST VALVE CLEARANCE (See page 14±270) 45. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be carefulnot to drop any oil on the contact surfaces of the oil seal
retainer and the cylinder block.
(1) Thoroughly clean all components to remove all theloose material.
(2) Using non±residue solvent, clean both sealing sur- faces.
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
(1) Install a nozzle that has been cut to a 2 to 4 mm(0.08 to 0.16 in.) opening.
(2) Parts must be assembled within 15 minutes of ap- plication. Otherwise the material must be removed
and reapplied.
(3) Immediately remove nozzle from the tube and rein- stall the cap.
Page 2306 of 5135

A62592
SST
A09663
:Seal Packing
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
14±323
AVENSIS REPAIR MANUAL (RM1018E)
(c)Install the oil seal retainer with the 4 bolts. Tighten the 4
bolts uniformly in several steps.
Torque: 8.8 N m (90 kgf cm, 78 in. lbf)
46.INSTALL CAMSHAFT TIMING PULLEY
(a)Install the pulley set key to the groove of the camshaft.
(b)Align the keyway of the timing pulley with the key located on the camshaft, slide the pulley into place.
(c)Using SST, install the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
Torque: 88 N m (899 kgf cm, 65 ft lbf)
47.INSTALL CAMSHAFT POSITION SENSOR (See page 10±63)
48.INSTALL INJECTOR ASSY (See page 11±60)
49.INSTALL NOZZLE LEAKAGE PIPE ASSY(See page 11±60) SST09992±00242
50.INSTALL CYLINDER HEAD COVER SUB±ASSY
(a)Remove any old packing (FIPG) material.
(b)Apply seal packing to the cylinder head.Seal packing: Part No. 08826±00080 or equivalent
(c)Install the gasket to the cylinder head cover.
(d)Install the cylinder head cover with the 10 bolts.
Torque: 13 N m (135 kgf cm, 9.7 ft lbf)
51.INSTALL NOZZLE HOLDER SEAL
(a)Install 4 new nozzle holder seals.
52.INSTALL VACUUM PUMP ASSY Torque: 21 N m (214 kgf cm,15 ft lbf)
53.INSTALL INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
Page 2307 of 5135

A79147
Fulcrum
Length
30 cm
SST
14±324
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c)Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d)Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e)Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
54.INSTALL INJECTION PIPE SUB±ASSY NO.2 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
55.INSTALL INJECTION PIPE SUB±ASSY NO.3 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56.INSTALL INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
57.INSTALL TIMING BELT(See page 14±307)
58.CHECK VALVE TIMING(See page 14±307)
Page 2308 of 5135

±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±325
AVENSIS REPAIR MANUAL (RM1018E)
59.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
60.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
61.INSTALL TIMING BELT GUIDE(See page 14±307)
62.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
63.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
64.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
65.INSTALL CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021
66.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
67.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
68. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
69.INSTALL INJECTOR DRIVER (See page 14±286)
70.INSTALL AIR TUBE NO.1 (See page 14±270)
71. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N m (85 kgf cm, 73 in. lbf)
72.INSTALL AIR CLEANER ASSY (See page 14±286)
73. INSTALL ENGINE COVER NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
74. INSTALL FRONT WHEEL RH
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
75.CHECK FOR FUEL LEAKS(See page 11±60)
Page 2309 of 5135
141C7±01
A79426N´m (kgf´cm, ft´lbf)
: Specified torque
8.0 (82, 71 in.lbf)
7.0 (71, 62 in.lbf)
39 (398, 29)
72 (734, 53)
Engine Cover No. 1Engine Room Cover Side
Radiator Support Opening Cover
Power Steering
Idle Pulley Bracket
Engine Under Cover Sub±assy No. 1
Air Cleaner Cap w/ Hose
Air Cleaner Element
AIr Cleaner Case
Engine Under Cover RH
V (Cooler
Compressor to
Crankshaft
Pulley) Belt No. 1Clip
Clip
Retainer
Clip
Clip
14±314
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1CD±FTV)
COMPONENTS
Page 2310 of 5135
A79427N´m (kgf´cm, ft´lbf)
: Specified torque
52 (530, 38)52 (530, 38)
52 (530, 38)
Injector DriverEngine Mounting Insulator Sub±assy RH
Vacuum Reservoir Sub±assy
Union To Connector Tube Hose
Air Tube No. 1
25 (255, 18)
8.3 (85, 73 in.´lbf)
25 (255, 18)
5.0 (51, 44 in.´lbf)
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
14±315
AVENSIS REPAIR MANUAL (RM1018E)
Page 2311 of 5135
A61211
: Specified torqueN´m (kgf´cm, ft´lbf)
* Replace only if damagedTiming Belt No. 2 Cover
Transverse Engine
Engine Mounting Bracket
Seal Washer Timing Belt No.1 Cover
Crankshaft Pulley Seal Washer
x 5 Generator V belt
Glow Plug
Screw Grommet Timing Belt GuideTiming Belt * Gasket
x 7
Glow Plug Assy * Gasket Timing Chain Cover Plate
Timing Belt
Tensioner
180 (1,837, 133)
21 (214, 15)
9.0 (92, 80 in.´lbf)
37 (375, 27)
64 (650, 47)
2.2 (22, 19 in.´lbf)
7.4 (76, 66 in.´lbf)
7.4 (76, 66 in.´lbf)
Idler Pulley
40 (408, 30)Glow Plug
No.1 Connector
14±316
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2312 of 5135
A79428
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part Gasket
18 (184, 13)
27 (270, 20)22 (224, 16)13 (135, 9.7)
Gasket
O±ring Fuel Injector
Back±up Ring No. 1
Injection Nozzle Seat
8.8 (90, 78 in.lbf)
Oil Seal
8.8 (90, 78 in.lbf)
20 (204, 15)
Washer
Nozzle Holder ClampNozzle Leakage
Pipe Assy
Injector AssyCylinder Head Cover Sub±assy
Gasket
Camshaft Bearing Cap
No. 2 CamshaftCamshaft
Camshaft Carrier
Camshaft Oil Seal
Retainer
88 (899, 65)
Camshaft Timing PulleySet Key
20 (204, 15)
* 42 (428, 31)
46 (469, 34)
Injection Pipe
Clamp No. 2
Injection Pipe
Sub±assy O±ring
21 (214, 15)
Vacuum Pump Assy
5.0 (51, 44 in.lbf)
Nozzle Holder Seal
* Use SST
* 42 (428, 31)
46 (469, 34)
± ENGINE MECHANICALCAMSHAFT (1CD±FTV)
14±317
AVENSIS REPAIR MANUAL (RM1018E)