Page 2337 of 5135
A79183
2
1
3
4
5
6
7
8
A79180
A62711
A59792
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±301
AVENSIS REPAIR MANUAL (RM1018E)
(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)
166.INSTALL CLUTCH DISC ASSY (See page 42±26) SST 09301±00210
167.INSTALL MANUAL TRANSAXLE (See page 41±33)
168.INSTALL STARTER ASSY (See page 19±24)
169. INS TALL FRO NT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Attach the engine and the transaxle assembly to the sus- pension crossmember and 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)
170. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(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 2338 of 5135
A59792
BB
AA
A59793
AA
BBBBB
B
14±302
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(e)Install the front suspension crossmember with 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 nut B
NOTICE:
After installing the crossmember, check that the position-
ing holes on the crossmember and the vehicle are aligned.
171.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
172.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 26±21)
HINT:
Perform the same procedure as above on the opposite side.
173.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
174.INSTALL FRONT STABILIZER LINK ASSY LH (See page 26±26)
HINT:
Perform the same procedure as above on the opposite side. SST 99999±70037
175.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
176.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
177. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
178.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±10)
179.INSTALL FLOOR PANEL BRACE FRONT (See page 15±10)
180. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See page 55±86)
181.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269 )
182.INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 42±17)
183.INSTALL CLUTCH ACCUMULATOR ASSY (See page 42±17) SST 09023±00100
Page 2339 of 5135
A64328
2 to 7 mm0 to 2 mm
A78274
Upward
90
Clamp
Bolt
A64328
2 to 7 mm 0 to 4 mm
A64007
Front
90
Clamp
Bolt
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±303
AVENSIS REPAIR MANUAL (RM1018E)
184.INSTALL AIR TUBE NO.1
(a)Install the new air hose No. 1 and new hose clamp as
shown in the illustration.
(b)Tighten the hose clamp as shown in the illustration. Torque: 6.0 N m (61 kgf cm, 53 in. lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N m (255 kgf cm, 18 ft lbf)
185.INSTALL INJECTOR DRIVER Torque: 5.0 N m (51 kgf cm,44 in. lbf)
186.CONNECT ENGINE WIRE Torque: 8.4 N m (85 kgf cm,74 in. lbf)
187.INSTALL AIR TUBE NO.2
(a)Install the air hose and hose clamps as shown in the il- lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N m (61 kgf cm,53 ft lbf)
(c)Install the 2 bolts and the air tube No.2 assy.
Torque: 25 N m (255 kgf cm,18 ft lbf)
188.INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
189. INSTALL ENGINE ROOM RELAY BLOCK NO.3 Torque: 5.3 N m (54 kgf cm, 46 in. lbf)
190. INSTALL FUEL FILTER ASSY Torque: 18 N m (178 kgf cm, 13 ft lbf)
Page 2340 of 5135
14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)
Page 2341 of 5135
160MV±01
A77341
Radiator Drain Cock Plug Radiator Cap
Cylinder Bllock Drain Cock Plug
Drain Pipe
± COOLINGENGINE COOLANT (1AZ±FE)
16±19
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1AZ±FE)
REPLACEMENT
1. DRAIN ENGINE COOLANT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(a) Remove the radiator cap.
(b) Loosen the radiator plug and drain the coolant.
Page 2342 of 5135
16±20
±
COOLING ENGINE COOLANT(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
2.ADD ENGINE COOLANT
(a)Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD6.0 (6.3, 5.3)
M/TRHD6.1 (6.4, 5.4)
A/TLHD6.3 (6.7, 5.5)
A/TRHD6.4 (6.8, 5.6)
NOTICE:
Do not use an alcohol type coolant or plain water alone.
The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:
Use of improper coolants may damage engine cooling system.
Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's directions.
Using of coolant with includes more than 50 % (freezing protection down to ±\
35 C (±31 F)) or 60 %
(freezing protection down to ±50 C (±58 F)) of ethylene±glycol is recommended but not more than
70 %.
Press the radiator inlet and outlet hose several times with hard.
If the coolant level gets lower, pour coolant.
(b)Reinstall the radiator cap.
(c)Pour engine coolant into the reservoir tank until it reaches full line.
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times with hard during \
the warming up.
(e)Stop the engine and wait until the coolant temp. Gets cold. Then remove the radiator cap to check the coolant level.
HINT:
If the level gets lower, perform the procedures above again.
If the level does not gets lower, adjust the reservoir tank coolant level.
3.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
Page 2343 of 5135
160N3±01
E34090
A30519
E34090
16±18
± COOLINGCOOLING FAN SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT COOLING FAN RELAY
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
2. INSPECT COOLING FAN RELAY NO.2
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2
3 ± 4Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
3. INSPECT COOLING FAN RELAY NO.3
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
Page 2344 of 5135
1600R±13
± COOLINGCOOLING FAN SYSTEM (1AZ±FE)
16±17
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 77C (171F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check for disconnection of
connectors or wire break between the cooling fan relay and engine coolant temperature sensor.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 95.5C (204F))
(a) Start the engine, and raise coolant temperature to above 95.5C (204F).
HINT:
Coolant temperature is the detected value by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20C (68F) (M/T)
8.3 to 11.3 A at 20C (68F) (A/T)
(d) Reconnect the cooling fan connector.
4. INSPECT COOLING FAN No.2 (With Air Conditioner)
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20C (68F) (M/T)
8.3 to 11.3 A at 20C (68F) (A/T)
(d) Reconnect the cooling fan connector.