Page 2208 of 5135
A78645
Oil Pressure Switch
14±212
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
94.REMOVE WATER BY±PASS PIPE NO.1
(a)Remove the 2 bolts and 2 nuts.
(b)Remove the water by±pass pipe No. 1 and a gasket.
95.REMOVE KNOCK SENSOR
(a)Remove the nut and the knock sensor. 96.REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a)Using SST, remove the engine oil pressure switch.SST09268±46021
97.REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
(a)Using a SST, remove the coolant temperature sensor SST09817±33190
98.REPLACE PARTIAL ENGINE ASSY
99.INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
(a)Install a new gasket to the engine coolant temperature sensor.
(b)Using SST, install the engine coolant temperature sensor. SST09817±33190
Torque: 20 N m (208 kgf cm,15 ft lbf)
100.INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a)Clean the threads of the oil pressure switch, apply adhesive there.
Adhesive: Part No. 08833 ± 00080 THREE BOND 1344 or equivalent.
(b)Install the oil pressure switch. Torque: 15 N m (153 kgf cm,11 ft lbf)
SST09268±46021
101.INSTALL KNOCK SENSOR Torque: 20 N m (208 kgf cm,15 ft lbf)
102.INSTALL WATER BY±PASS PIPE NO.1
(a)Install the water by±pass pipe No. 1 and a new gasket.
(b)Install the 2 bolts and 2 nuts. Torque: 9.0 N m (92 kgf cm,80 in. lbf)
103.INSTALL THERMOSTAT (See page 16±35)
104. INSTALL WATER INLET Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
105. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil\
level gauge guide.
(b) Install the oil level gauge and guide with the bolt. Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
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 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 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)
Page 2217 of 5135
A77313
Cooler Bracket
(LHD Steering Position Type)
Oil Reservoir
Bracket No. 1Heater Outlet Water Hose
Heater Inlet Water Hose
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silercer Sheet
Front Stabilizer Link Assy
Front Axle Assy
35 (360, 26)
7.0 (71, 62 in.lbf)
74 (755, 55)
216 (2,203,159 )
142 (1,448,105 )
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part Front Axle Hub Nut
Tie Rod End Sub±assy
5.0 (51, 44 in.lbf)
5.0 (51, 44 in.lbf)
Cotter Pin
49 (500, 36)
Front Suspension Arm
Sub±assy Lower No. 1
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±195
AVENSIS REPAIR MANUAL (RM1018E)
Page 2223 of 5135
A77498
Engine Wire
Engine Wire
Ignition Coil
Ventilation Hose No. 2
V±ribbed Belt Tensioner
ASSYFuel Pipe Sub±assy No. 1
Gasket
Gasket
Gasket Fuel Pump AssyFuel Pressure
Pulsation Damper
ASSY
9.0 (90, 80 in.lbf)
60 (607, 44)
25 (255, 18)
33 (331, 24)
9.0 (90, 80 in.lbf)
Fuel Pipe No. 1
Fuel Injector
Back±up Ring No. 1
O±ring
Fuel Injector
Back±up Ring No. 3 Fuel Injector
Back±up Ring No. 2
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
30 (306, 22)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±201
AVENSIS REPAIR MANUAL (RM1018E)
Page 2224 of 5135
A77499
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part GasketWater By±pass
Pipe No. 1 Gasket
Thermostat
9.0 (90, 80 in.lbf)
Water Inlet
37 (378, 27)Oil Level Gauge
Guide
O±ring
Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy Manifold Stay No. 1
9.0 (90, 80 in.lbf)
9.0 (90, 80 in.lbf)
Gasket
9.0 (90, 80 in.lbf)
12 (122, 9.0)12 (122, 9.0)
12 (122, 9.0)
44 (449, 32)
44 (449, 32)
Oil Level Gauge Sub±assy
14±202
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2225 of 5135
A77370
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part O±ring
13 (127, 9.0)
E±ring
O±ring
Nozzle Holder Clamp
Fuel Injector
Gasket
Fuel Injector Seal
Fuel Delivery Pipe Sub±assy
19 (194, 14)
Camshaft Timing
Oil Control Valve
O±ring
20 (208, 15)
Knock Sensor
Insulator No. 2
15 (153, 11)
Engine Oil Pressure
Switch Assy
20 (208, 15)
E. F. I. Engine Coolant
Temperature Sensor
Surge Tank Stay No. 1
9.0 (92, 79 in.lbf)
21 (210, 15)
Back Up Ring No. 3
Back Up Ring No. 2
Back Up Ring No. 1
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±203
AVENSIS REPAIR MANUAL (RM1018E)
