Page 4617 of 5135

A85925
A09566
1
234 5
67 89
10 11
12 13
14 15
16
1718
A61194
Pry
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −169
AVENSIS Supplement (RM1045E)
71. REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 14 −151)
72. REMOVE INJECTOR ASSY (See page 11 −46)
HINT:
Since each injector assembly has characteristic fuel injecting behavior, keep them in the correct order so
that they can be returned to the original locations when reassembling. 73. REM O VE EXHAUST F UEL ADDI TI O N I NJECTO R
ASSY
(a) Using a Torx socket wrench (T40), remove the Torx screw.
NOTICE:
Be careful that the tools do not interfere with the resin part
when removing.
(b) Remove the nozzle holder clamp, addition injector and gasket.
74. REMOVE CAMSHAFT OIL SEAL RETAINER (See page 14 −151)
75. REMOVE CAMSHAFT (See page 14 −151)
76. REMOVE NO.2 CAMSHAFT (See page 14 −151)
77. REMOVE CYLINDER HEAD SUB −ASSY
(a) Using several steps, loosen the 18 cylinder head bolts
uniformly in the sequence shown in the illustration. Re-
move the 18 cylinder head bolts and plate washers.
NOTICE:
Removing the bolts in a wrong order could cause warpage
or cracks of the cylinder head.
(b) Lift the cylinder head from the dowels on the cylinder block, then place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
To lift the cylinder head, pry between the cylinder head and cyl-
inder block using a screwdriver.
78. REMOVE CYLINDER HEAD GASKET
Page 4618 of 5135

A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring Tip
Protrusion Height
A09571
Front
X Measuring Point 14−170
− ENGINE MECHANICALCYLINDER HEAD GASKET (1CD−FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
79. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolts.
Standard outside diameter:
10.40 to 11.00 mm (0.4094 to 0.4331 in.)
If the diameter is less than minimum, replace the bolt.
80. INSTALL CYLINDER HEAD GASKET
(a) Measure the protrusion height of the piston heads.
(1) Clean the cylinder block with solvent.
(2) Set the piston to measure to slightly before the
TDC.
(3) Place a dial indicator on the cylinder block, then cali-
brate the dial indicator at 0 mm (0 in.).
HINT:
SPlace the measuring tip of the dial indicator as shown in
the illustration.
SMake sure that the measuring tip is square to the cylinder
block gasket and piston head when measuring.
(4) Find the most overhung position of the piston head
by slowly turning the crankshaft clockwise and
counterclockwise.
(5) Measure the protrusion height of the piston head for
each cylinder at 2 places as shown in the illustra-
tion. (Total of 8 measurements.)
(6) Record the higher protrusion height of the 2 mea-
surements at each cylinder.
(b) Select a new cylinder head gasket.
HINT:
There are 5 sizes of new cylinder head gaskets, marked ”A”,
”B”, ”C”, ”D”, and ”E”.
New cylinder head gasket thickness:
A0.85 to 0.95 mm (0.0335 to 0.0374 in.)
B0.90 to 1.00 mm (0.0354 to 0.0394 in.)
C0.95 to 1.05 mm (0.0374 to 0.0413 in.)
D1.00 to 1.10 mm (0.0394 to 0.0433 in.)
E1.05 to 1.15 mm (0.0413 to 0.0453 in.)
(1) Find the highest protrusion height among the 4
measurement records. It is used to select a new cyl-
inder head gasket.
Page 4619 of 5135

A80117
A
B
C
D
E
A90797
Front
A61189
10 11
12 1314
1516 1718 2 1
4 56 3
78 9(A) (A) (A)
(B) (B) (B) (B)
(B) (B) (B)(B) (B) (B)(A)
− ENGINE MECHANICALCYLINDER HEAD GASKET (1CD−FTV)(From
September, 2003)14−171
AVENSIS Supplement (RM1045E)
(2) Select a new gasket among A to E using the matrix
below.
New gasket matrix:
Piston Protrusion mm (in.)Gasket Size
0.165 to 0.220 (0.0065 to 0.0087)A
0.220 to 0.270 (0.0087 to 0.0106)B
0.270 to 0.320 (0.0106 to 0.0126)C
0.320 to 0.370 (0.0126 to 0.0146)D
0.370 to 0.425 (0.0146 to 0.0167)E
(c) Place the selected new cylinder head gasket on the cylin-
der block.
NOTICE:
Pay attention to the mounting orientation.
81. INSTALL CYLINDER HEAD SUB−ASSY
HINT:
SThe cylinder head bolts are tightened in 4 successive
steps (steps (c), (e), (f) and (g)).
SIf the cylinder head bolt is broken or deformed, replace it
with a new bolt.
(a) Apply a light coat of engine oil to the threads of the cylin-
der head bolts and plate washers.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 18 cylinder
head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 45 Nm (459 kgfcm, 33 ftlbf)
HINT:
See the table below for the bolt length.
Bolt TypeBolt Length
(A)160mm (6.30 in.)
(B)104mm (4.09 in.)
If the cylinder head bolt does not meet the specified torque, re-
place the cylinder head bolt with a new bolt.
Page 4620 of 5135

A61190
90_ 90
_
90_90
_ 90
_
90_
Paint Mark
Front
A85427
TDC Mark
Dot Mark
90 _
A85942
New O −ring
14 −172−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 _ in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by an additional 90 _ in
the same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional
90_ in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man-
ifold side.
82. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing gear at the position
of 90_ BTDC.
NOTICE:
If the timing belt is disengaged, the crankshaft timing gear
placed at wrong angle can cause contact of the piston head
with the valve head.
83. INSTALL CAMSHAFT (See page 14 −151)
84. INSTALL NO.2 CAMSHAFT (See page 14 −151)
85. REMOVE CAMSHAFT OIL SEAL (See page 14 −151)
86. INSTALL CAMSHAFT OIL SEAL (See page 14 −151)
SST 09223 −46011
87. INSTALL CAMSHAFT OIL SEAL RETAINER (See page 14 −151)
88. I NSTALL EXHAUST F UEL ADDI TI O N I NJECTO R ASSY
(a) Install a new gasket to the cylinder head.
(b) Install a new O −ring to the injector.
(c) Apply a light coat of engine oil to the O −ring on the injec-
tor.
(d) Install the addition injector and nozzle holder clamp.
(e) Using a Torx socket wrench (T40), install the Torx screw. Torque: 12 N m (117 kgf cm, 8.5 ft lbf)
NOTICE:
Be careful that the tools do not interfere with the resin part
when installing.
89. INSTALL CAMSHAFT TIMING PULLEY (See page 14 −151)
SST 09960 −10010 (09962 −01000, 09963 −01000)
90. INSTALL CAMSHAFT POSITION SENSOR (See page 14 −108)
91. INSTALL INJECTOR ASSY (See page 11 −46)
92. INSTALL NOZZLE LEAKAGE PIPE ASSY (See page 14 −151)
SST 09992 −00242
Page 4621 of 5135

A09663
:Seal Packing
A87959
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −173
AVENSIS Supplement (RM1045E)
93. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as illustrated. Seal packing: Part No. 08826 −00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N m (135 kgf cm, 9.7 ft lbf)
94. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
95. INSTALL NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
96. INSTALL VACUUM PUMP ASSY (See page 14 −108)
97. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold at room temperature.
(a) Remove the vinyl or plastic bag from the injector and the vinyl tape from the common rail.
(b) Install the 2 lower injection pipe clamps to the intake man- ifold.
(c) Temporarily install the injection pipe.
(d) Using SST, tighten the nut of the injection pipe on the common rail side.
SST 09023 −12700
Torque:
31 N m (316 kgf cm, 23 ft lbf) with SST
34 N m (347 kgf cm, 25 ft lbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
Page 4622 of 5135

14−174−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
(e) Using SST, tighten the nut of the injection pipe on the in- jector side.
SST 09023 −12700
Torque:
For used pipe:
36 N m (372 kgf cm, 27 ft lbf) with SST
40 N m (408 kgf cm, 30 ft lbf) without SST
For new pipe:
31 N m (316 kgf cm, 23 ft lbf) with SST
34 N m (347 kgf cm, 25 ft lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
(f) Install the 2 upper injection pipe clamps.
98. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
99. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
100. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
101. INSTALL FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
102. INSTALL FUEL INLET PIPE SUB −ASSY
NOTICE:
SIn case of replacing the cylinder head gasket, the fuel
inlet pipe must be replaced, too.
SWhen assembling the pipe, perform the operation
with the engine cold at room temperature.
(a) Temporarily install a new fuel inlet pipe.
Page 4623 of 5135

A87960
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −175
AVENSIS Supplement (RM1045E)
(b) Using SST, tighten the nut of the fuel inlet pipe on the
common rail side.
SST 09023 −12700
Torque:
31 N m (316 kgf cm, 23 ft lbf) with SST
34 N m (347 kgf cm, 25 ft lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe on the pump side.
SST 09023 −12700
Torque:
31 N m (316 kgf cm, 23 ft lbf) with SST
34 N m (347 kgf cm, 25 ft lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
103. INSTALL TURBOCHARGER SUB −ASSY (See page 13 −12)
104. INSTALL TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
105. INSTALL TURBOCHARGER STAY (See page 13 −12)
106. INSTALL MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
107. INSTALL MANIFOLD STAY NO.2 (See page 13 −12)
108. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
109. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
110. INSTALL EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
111. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
112. INSTALL EGR PIPE INSULATOR (See page 13 −12)
113. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
114. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
115. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
116. INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13 −12)
117. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
118. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
119. INSTALL HEATER BRACKET (W/ COLD AREA) (See page 13 −12)
120. INSTALL HEATER PUMP ASSY (W/ COLD AREA) (See page 13 −12)
121. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
Page 4624 of 5135

14−176−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
122. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
123. INSTALL TIMING BELT (See page 14 −138)
124. CHECK VALVE TIMING (See page 14 −138)
125. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
126. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
127. INSTALL TIMING BELT GUIDE (See page 14 −138)
128. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
129. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
130. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
131. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
132. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
133. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
134. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
135. INSTALL INJECTOR DRIVER (See page 14 −108 )
136. INSTALL AIR TUBE NO.1 (See page 14 −108)
137. INSTALL AIR TUBE NO.2 (See page 14 −108)
138. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
139. INSTALL BATTERY (See page 14 −108)
140. INSTALL AIR CLEANER ASSY (See page 14 −108)
141. INSTALL VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
142. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
143. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
144. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
145. ADD ENGINE COOLANT (See page 16 −19)
146. CHECK FOR FUEL LEAKS (See page 11 −46)
147. CHECK FOR ENGINE OIL LEAKS
148. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
149. CHECK FOR EXHAUST GAS LEAKS