Page 2206 of 5135
A77331
SST
A77353
14±210
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
61.SEPARATE VANE PUMP ASSY
(a)Disconnect the PS oil pressure switch connector.
(b)Remove the 2 bolts and separate the vane pump from the engine.
62.REMOVE STARTER ASSY (See page 19±12)
63. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a) Remove the through bolt and nut from the engine mounting insulator FR.
(b) Remove the through bolt and nut from the engine mounting insulator RR.
64.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
65.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
66.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
67.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
68.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
69.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 70. REMOVE DRIVE PLATE AND RING GEAR ORFLYWHEEL
(a) Using SST, fix the crankshaft pulley and remove the drive plate and ring gear or flywheel.
SST 09213±54015 (91651±60855), 09330±00021
71. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt, O±ring and the camshaft timing oil control valve.
72. REMOVE THROTTLE BODY BRACKET
(a) Separate the engine wire.
(b) Remove the 4 bolts and the throttle body bracket.
73.REMOVE THROTTLE BODY ASSY (See page 10±44)
74. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
75. DISCONNECT FUEL TUBE SUB±ASSY
76.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52)
77.REMOVE FUEL PUMP ASSY (See page 11±52)
78. REMOVE WATER BY±PASS HOSE 79. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts.
(b) Remove the intake manifold and the insulator.
Page 2207 of 5135
A32676
A77350
A52497
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±211
AVENSIS REPAIR MANUAL (RM1018E)
80.REMOVE INTAKE AIR CONTROL VALVE ASSY
(a)Remove the intake air control valve and a gasket.
81.REMOVE SURGE TANK STAY NO.1
(a)Remove the 3 bolts and the surge tank stay.
82.REMOVE INTAKE MANIFOLD INSULATOR NO.2
83.REMOVE NOZZLE HOLDER CLAMP
84.REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±42)
85.REMOVE FUEL INJECTOR ASSY (See page 11±42)
86. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, and then detach the V±ribbedbelt tensioner.
87. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and the ignition coils.
88. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
(a) Remove the 3 bolts and the exhaust manifold heat insulator. 89. REMOVE EXHAUST MANIFOLD CONVERTERSUB±ASSY
(a) Remove the 2 bolts and 2 nuts, then detach the No. 1 and No. 2 exhaust manifold stay.
(b) Remove the 5 nuts, the exhaust manifold converter and gasket.
90. REMOVE OIL LEVEL GAGE SUB±ASSY
91. REMOVE OIL LEVEL GAGE GUIDE
92. REMOVE WATER INLET
(a) Remove the 2 nuts and the water inlet.
93. REMOVE THERMOSTAT
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 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 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)
Page 2226 of 5135
141BL±01
A77339
A77343
No. 1 Cylinder TDC / CompressionIN
EX
14±186
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1AZ±FSE)
ADJUSTMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±33)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH 5.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
6.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
7.REMOVE FUEL TUBE SUB±ASSY (See page 11±33)
8.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
9. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and the ignition coils.
10.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±240)
11.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±240)
12. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and the camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
(b) Turn the crankshaft clockwise 1 revolution (360 ) and set
No. 4 cylinder to TDC/compression.
