Page 2164 of 5135
A77286
Push
A64641
A00019
A77288
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±143
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, the chain tensioner No. 1 and gasket.
NOTICE:
Do not turn the crankshaft.
27. REMOVE CRANKSHAFT POSITION SENSOR
28. REMOVE OIL PAN SUB±ASSY
(a) Remove the 12 bolts and 2 nuts.
(b) Insert the blade of SST between the crank case, timing
chain cover and oil pan, cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, crank case and oil pan.
29. REMOVE V±RIBBED BELT TENSIONER ASSY
Page 2166 of 5135
A77382
Groove90
A77383
Groove
A66833
B11424
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±145
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil
pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner
and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
38. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Orient the flat portion of the drive shaft upward.
Page 2167 of 5135
A77384
Mark Link
Timing Mark
Timing Mark
Mark Link
A77385
Groove
A77386
Groove
A77387
90 14±146
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Align the mark links (yellow colored links) with the timing
marks of each gear as shown in the illustration.
(d) Install the gears to the crankshaft and oil pump shaft with
the chain wrapped.
(e) Temporarily tighten the oil pump drive shaft gear with the
nut.
(f) Insert the damper spring into the adjusting hole, and
install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgfcm, 9.0 ftlbf)
(g) Align an adjusting hole of the sprocket with the groove of
the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the
sprocket to lock in position, and tighten the nut.
Torque: 30 Nm (301 kgfcm, 22 ftlbf)
(i) Rotate the crankshaft clockwise 90, and position the
crankshaft key upward.
Page 2169 of 5135
A77389
Timing MarksMark Links
Timing Mark
A77290
Hold
Stopper
A32629
A77390Seal Packing 14±148
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Align the mark links (gold or yellow colored links) with
each timing mark located on the camshaft timing gears,
and install the chain.
43. INSTALL TIMING CHAIN GUIDE
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
44. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (195 kgfcm, 14 ftlbf)
(b) Check that the chain tensioner slipper is hold on the cylin-
der block stopper.
45. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing forward.
46. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
NOTICE:
Remove any oil from the contact surface.
Install the chain cover within 3 minutes after applying
seal packing.
Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover.
(b) Apply a continuous bead (Diameter 2 mm (0.09 in.)) of
seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent.
Page 2171 of 5135
A77392
Seal Packing6mm
A64641
A77393
SST
A77394
Raise
PinHook
Push 14±150
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
48. INSTALL OIL PAN SUB±ASSY
NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal
packing.
Do not start the engine within 2 hours after installing.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b) Apply a continuous bead (Diameter 3 mm to 4 mm (0.157
in.)) of seal packing as shown in the illustration, and install
the oil pan.
Seal packing: part No. 08826 ± 00080 or equivalent
(c) Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
49. INSTALL CRANKSHAFT POSITION SENSOR
50. INSTALL CRANKSHAFT PULLEY
(a) Using SST, tighten the set bolt.
SST 09213±54015 (91651±60855), 09330±00021
Torque: 170 Nm (1,733 kgfcm, 125 ftlbf)
51. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger is located in
position.
Page 2173 of 5135
A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply seal packing to the 2 locations as shown in the il- lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after
applying seal packing.
Do not expose the seal to engine oil 2 hours after
installing.
(c)install the cylinder head cover with the 8 bolts and 2 nuts. Torque:
Bolt A 11 N m (112 kgf cm, 8 ft lbf)
Bolt B 14 N m (143 kgf cm, 10 ft lbf)
Bolt C 21 N m (214 kgf cm, 15 ft lbf)
Nut 11 N m (112 kgf cm, 8 ft lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N m (71 kgf cm,62 in. lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm,71 in. lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N m (82 kgf cm,71 in. lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgf cm,80 in. lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgf cm,27 ft lbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
Page 2175 of 5135
A77319
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part Gasket
Cooler Bracket
(LHD (w/ Air Conditioner)
Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant
Suction Hose No. 1
(LHD (w/ Air Conditioner)
Steering Position Type)
8.0 (82, 44 in.lbf)
8.0 (82, 44 in.lbf)
8.0 (82, 44 in.lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator ASSY
Exhaust Pipe Assy Front
43 (440, 32)
Gasket
43 (440, 32)
7.0 (71, 62 in.lbf)
52 (530, 38)
7.0 (71, 62 in.lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.lbf)
5.0 (51, 44 in.lbf)
5.0 (51, 44 in.lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
Vane Pump Assy
37 (377, 27)
14±136
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2176 of 5135
A77320
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
Ignition Coil Assy
9.0 (90, 80 in.lbf)
14 (143, 10)
11 (115, 8.0)
Cylinder Head Cover Sub±assy
Gasket
11 (115, 8.0)
Ventilation Hose Ventilation Hose No. 2
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±137
AVENSIS REPAIR MANUAL (RM1018E)
