Page 2152 of 5135
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FE)
14±167
AVENSIS REPAIR MANUAL (RM1018E)
69.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
70.INSTALL CHAIN SUB±ASSY (See page 14±139)
71.INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
72.INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N m (195 kgf cm,15 ft lbf)
73.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±171)
74.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
75.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
76.INSTALL OIL PAN SUB±ASSY (See page 14±139)
77.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
78.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST09213±54015 (91651±60855), 09330±00021
79.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
80.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N m (530 kgf cm,38 ft lbf)
81.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
82.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
83.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
84.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
85.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
86.INSTALL ENGINE WIRE
87.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm,71 in. lbf)
88.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
89.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgf cm,71 in. lbf)
90.INSTALL IGNITION COIL ASSY
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
91.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm,62 in. lbf)
92.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgf cm,27 ft lbf)
93.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
94.INSTALL GENERATOR ASSY (See page 19±20)
95.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
96.ADD COOLANT (See page 16±19)
97. ADD ENGINE OIL
98.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
99. CHECK FOR ENGINE OIL LEAKS
100. CHECK FOR FUEL LEAKS
101. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
Page 2155 of 5135
A77325
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part Gasket
Accelerator Control
Cable Sub±assy
30 (305, 22)
30 (305, 22)
Throttle Body Assy
Heater Inlet Water Hose
Union To Connector
Tube Hose
Fuel Tube Sub±assy
Fuel Pipe ClampRadiator Hose Inlet
Battery Clamp
Battery
Battery Tray
Air Cleaner Assembly
w/ Hose
30 (305, 22)
5.0 (51, 44 in.lbf)5.0 (51, 44 in.lbf)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FE)
14±155
AVENSIS REPAIR MANUAL (RM1018E)
Page 2179 of 5135
A77374
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part Gasket
Cylinder Head Cover Sub±assy
11 (115, 8.0)
Ventilation Hose No. 1 Gasket
Fuel Tube Sub±assy Gasket Fuel Pipe
Sub±assy No. 1
Fuel Pressure
Pulsation Damper
Assy
Fuel Pump Assy
Gasket14 (143, 10)
Ignition Control
9.0 (90, 80 in.lbf)
9.0 (90, 80 in.lbf)
O±ring
Ventilation Hose No. 2
33 (331, 24)
25 (255, 18)
Fuel Pipe No. 1
Fuel Injector
Back±up Ring No. 1
Fuel Injector Back±up
Ring No. 3 Fuel Injector
Back±up Ring No. 2
30 (306, 22)
14±238
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2181 of 5135
141BD±01
A77339
A77292
14±222
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgf cm,18 ft lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16. SEPARATE VANE PUMP ASSY
(a) Remove the 2 through bolts and separate the vane pump.
Page 2194 of 5135
A77399
Seal Packing
A77346
AA
A AA
BB
C
C
Nut Nut
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FSE)
14±235
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 9 bolts and 2 nuts. Torque:
Nut 11 N m (112 kgf cm, 8 ft lbf)
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, 16 ft lbf)
59.INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
60.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
61.INSTALL ENGINE WIRE
Torque: 7.0 N m (71 kgf cm,62 in. lbf)
62.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm,71 in. lbf)
63.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
64.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N m (82 kgf cm,71 in. lbf)
65.INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgf cm,80 in. lbf)
66.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgf cm,27 ft lbf)
67.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
68.INSTALL GENERATOR ASSY (See page 19±20)
69.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
70.INSTALL FUEL PUMP ASSY (See page 11±52)
71.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
72.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
73.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
74. ADD ENGINE OIL
75. CHECK FOR ENGINE OIL LEAKS
76. CHECK FOR FUEL LEAKS
Page 2198 of 5135
A77374
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part Gasket
Cylinder Head Cover Sub±assy
11 (115, 8.0)
Ventilation Hose No. 1 Gasket
Fuel Tube Sub±assy Gasket Fuel Pipe
Sub±assy No. 1
Fuel Pressure
Pulsation Damper
Assy
Fuel Pump Assy
Gasket14 (143, 10)
Ignition Control
9.0 (90, 80 in.lbf)
9.0 (90, 80 in.lbf)
O±ring
Ventilation Hose No. 2
33 (331, 24)
25 (255, 18)
Fuel Pipe No. 1
Fuel Injector
Back±up Ring No. 1
Fuel Injector Back±up
Ring No. 3 Fuel Injector
Back±up Ring No. 2
30 (306, 22)
14±220
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2200 of 5135
141BM±01
A77339
A77301
14±204
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±33)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±31)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgf cm,18 ft lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N m (500 kgf cm,36 ft lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove the 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD STEERING POSITION TYPE)
(a)Remove the bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±36)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±185)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(a) Remove the 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
20. REMOVE BATTERY
Page 2202 of 5135
A77308
A77303
A77340
14±206
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
25.SEPARATE VANE PUMP OIL RESERVOIR ASSY 26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove the 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSENO.1 (LHD STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the suction hose.
28.REMOVE COOL ER BRACKET (LHD STEER ING
POSITION TYPE)
(a)Remove the nut and separate the cooler bracket.
29.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
30.DISCONNECT HEATER INLET WATER HOSE
31.DISCONNECT HEATER OUTLET WATER HOSE
32.REMOVE CHARCOAL CANISTER ASSY
33.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±30)
34. DISCONNECT UNION TO CONNECTOR TUBE HOSE
35.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
36.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
38.REMOVE FRONT AXLE HUB LH NUT (See page 30±6) SST 09330±00030
