Page 4657 of 5135
A85634
SST
A85623
A85914
SST
A85915
A85916
SST
14−11 6− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(c) Using SST, remove the exhaust gas temperature sensor
on up stream.
SST 09023−38400
(d) Remove the 3 nuts, then detach the wire harness from the
clamp.
(e) Disconnect the connector.
(f) Using SST, remove the exhaust gas temperature sensor
on down stream.
SST 09023−38400
78. REMOVE VACUUM TRANSMITTING PIPE SUB−ASSY
NO.1
(a) Remove the bolt.
(b) Using SST, remove the vacuum pipe.
SST 09023−38200
Page 4658 of 5135
A85917
A85918
SST
A85624
A85625
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 7
AVENSIS Supplement (RM1045E)
79. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY
NO.2
(a) Remove the 2 bolts.
(b) Using SST, remove the vacuum pipe. SST 09023 −38200
80. REMOVE MANIFOLD STAY NO.2 (See page 13 −12)
81. REMOVE MANIFOLD STAY (See page 13 −12)
82. REMOVE MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
83. REMOVE TURBOCHARGER STAY (See page 13 −12)
84. DISCONNECT TURBO WATER HOSE NO.1 (See page 13 −12)
85. DISCONNECT TURBO WATER HOSE NO.2 (See page 13 −12)
86. REMOVE TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
87. REMOVE TURBOCHARGER SUB −ASSY (See page 13 −12)
88. DISCONNECT WATER BY −PASS HOSE NO.3
89. REMOVE EGR PIPE SUB −ASSY NO.1
(a) Remove the bolt and 4 nut, then detach the EGR pipe and
2 gaskets.
Page 4659 of 5135
A84296
A80118
A85626
A85627
(a)(a)
(b)
(b)
(b) 14−11 8
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
90. REMOVE OIL COOLER ASSY (See Pub. No. RM1018E on page 17−32)
91. REMOVE VACUUM PUMP OIL PIPE
(a) Disconnect the 2 hoses.
(b) Remove the bolt and nut, then remove the vacuum pump
oil pipe.
92. REMOVE EXHAUST MANIFOLD
(a) Remove the 8 nuts, exhaust manifold and gasket.
93. REMOVE INTAKE AIR CONNECTOR
(a) Remove the 3 bolts, intake air connector together with the
diesel throttle body and gasket.
94. REMOVE EGR VALVE ASSY
(a) Disconnect the 2 hoses.
(b) Remove the bolt and 2 nuts, then remove the EGR valve
and gasket.
Page 4660 of 5135
A84293
A09660
A85628
(a)
(a)(b)
(b)
A93407SST
A85630
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−11 9
AVENSIS Supplement (RM1045E)
95. REMOVE WATER OUTLET SUB−ASSY
(a) Remove the 2 bolts, water outlet and gasket.
96. REMOVE VACUUM PUMP ASSY
(a) Remove the 2 bolts, vacuum pump and 2 O−rings.
97. REMOVE NOZZLE LEAKAGE PIPE NO.2
(a) Disconnect the 2 hoses.
(b) Remove the 2 bolts, nozzle leakage pipe No. 2.
98. REMOVE FUEL INLET PIPE SUB−ASSY
(a) Using SST, remove the fuel inlet pipe from the common
rail side.
SST 09023−12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023−12700
99. REMOVE FUEL PIPE NO.3
(a) Remove the fuel pipe insulator.
Page 4661 of 5135

A85631
SST
A85632
A93406
SST
14−120− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, remove the fuel pipe No.
3 from the injector side.
SST 09023−12700
(c) Remove the bolt and 3 nuts, then remove the fuel pipe No.
3 and 2 gaskets.
100. REMOVE INJECTION PIPE SUB−ASSY NO.1
(a) Remove the 2 upper injection pipe clamps from the intake
manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023−12700
(c) Using SST, remove the injection pipe from the injector
side.
SST 09023−12700
(d) After removing the fuel pipe, in order to prevent dust or
foreign objects from being introduced, cover the common
rail with vinyl tape and protect the injector inlet with a vinyl
or plastic bag.
(e) Remove the 2 lower injection pipe clamps from the intake
manifold.
101. REMOVE INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
102. REMOVE INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
103. REMOVE INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
Page 4662 of 5135

A79150
A09671
A84294
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −121
AVENSIS Supplement (RM1045E)
104. REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a) Remove the 2 bolts and intake manifold insulator.
105. REMOVE COMMON RAIL ASSY (See page 11 −67)
106. REMOVE INTAKE MANIFOLD
(a) Remove the 8 bolts and 2 nuts, then remove the intake manifold and gasket.
107. REMOVE INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
108. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, then remove the timing belt cover.
109. REMOVE OIL LEVEL GAGE GUIDE (See page 17 −11 )
110. REMOVE INJECTION PUMP STAY NO.1 (See page 11 −58)
111. REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
112. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
(a) Remove the 4 bolts and compressor mounting bracket.
113. REMOVE WATER INLET (See Pub. No. RM1018E on page 16 −50)
114. REMOVE THERMOSTAT
115. REMOVE OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, remove the union bolt,oil cooler pipe and gasket.
Page 4663 of 5135

A84380
A84378
14−122−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
116. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and fuel pipe.
117. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
118. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor. 119. REM O VE ENG I NE CO O L ANT TEM PERAT URESENSOR
120. REPLACE PARTIAL ENGINE ASSY
121. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Torque: 20 N m (200 kgf cm, 14 ft lbf)
122. INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N m (90 kgf cm, 78 in. lbf)
123. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N m (90 kgf cm, 78 in. lbf)
124. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE
Torque:
8.8 Nm (90 kgf cm, 78 in. lbf) for M6
21 N m (209 kgf cm, 15 ft lbf) for M8
125. INSTALL OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 56 N m (575 kgf cm, 42 ft lbf)
126. INSTALL THERMOSTAT (See Pub. No. RM1018E on page 16 −50)
127. INSTALL WATER INLET (See Pub. No. RM1018E on page 16 −50)
128. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
Torque: 42 N m (428 kgf cm, 31 ft lbf)
129. INSTALL INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
130. INSTALL INJECTION PUMP STAY NO.1 (See page 11 −58)
131. INSTALL OIL LEVEL GAGE GUIDE (See page 17 −11 )
132. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N m (75 kgf cm, 65 in. lbf)
Page 4664 of 5135

A87959
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −123
AVENSIS Supplement (RM1045E)
133. INSTALL INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
134. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts. Torque: 21 N m (209 kgf cm, 15 ft lbf)
135. INSTALL COMMON RAIL ASSY (See page 11 −67)
136. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
137. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
SIn case of replacing the injectors, the injection pipes
must be replaced, too.
SWhen assembling the pipes, perform the operation
with the engine cold at room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Temporarily install a new injection pipe.
(c) 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.