Page 4665 of 5135

A85632
14−124− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(d) Using SST, tighten the nut of the injection pipe on the in-
jector side.
SST 09023−12700
Torque:
For used pipe:
36 Nm (372 kgfcm, 27 ftlbf) with SST
40 Nm (408 kgfcm, 30 ftlbf) without SST
For new pipe:
31 Nm (316 kgfcm, 23 ftlbf) with SST
34 Nm (347 kgfcm, 25 ftlbf) 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.
(e) Install the 2 upper injection pipe clamps.
138. INSTALL INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
139. INSTALL INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
140. INSTALL INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
141. INSTALL FUEL PIPE NO.3
(a) Install 2 new gaskets, then temporarily install the bolt, 3
nuts and fuel pipe No. 3.
Page 4666 of 5135

A85631
SST
A85632
A
A
BA
A87960
Fulcrum Length
30 cm (11.81 in.)
SST
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−125
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, tighten the nut of the fuel
pipe No. 3 on the injector side.
SST 09023−12700
Torque:
22 Nm (223 kgfcm, 16 ftlbf) with SST
23.5 Nm (240 kgfcm, 17 ftlbf) 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.
(c) Tighten the bolt and 3 nuts.
Torque:
5.0 Nm (51 kgfcm, 44 in.lbf) for bolt and nut A
27 Nm (275 kgfcm, 20 ftlbf) for nut B
(d) Install the fuel pipe insulator.
142. INSTALL FUEL INLET PIPE SUB−ASSY
NOTICE:
SIn case of replacing the cylinder head, 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.
(b) Using SST, tighten the nut of the fuel inlet pipe on the
common rail side.
SST 09023−12700
Torque:
31 Nm (316 kgfcm, 23 ftlbf) with SST
34 Nm (347 kgfcm, 25 ftlbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter 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.
Page 4667 of 5135

A79196
New O−ring
New O−ring
A79182
Collar
Groove
14−126− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(c) Using SST, tighten the nut of the fuel inlet pipe on the
pump side.
SST 09023−12700
Torque:
31 Nm (316 kgfcm, 23 ftlbf) with SST
34 Nm (347 kgfcm, 25 ftlbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter 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.
143. INSTALL NOZZLE LEAKAGE PIPE NO.2
Torque: 8.8 Nm (90 kgfcm, 78 in.lbf)
144. INSTALL VACUUM PUMP ASSY
(a) Install 2 new O−rings to the vacuum pump.
(b) Align the key of the vacuum pump with the keyway of the
exhaust camshaft, then insert the vacuum pump into
place. Secure the pump with the 2 bolts.
Torque: 21 Nm (214 kgfcm, 15 ftlbf)
145. INSTALL WATER OUTLET SUB−ASSY
(a) Install a new gasket and the water outlet with the 2 bolts.
Torque: 21 Nm (209 kgfcm, 15 ftlbf)
146. INSTALL EGR VALVE ASSY
(a) Install a new gasket and the EGR valve with the bolt and 2 nuts.
Torque: 18 Nm (184 kgfcm, 13 ftlbf)
147. INSTALL INTAKE AIR CONNECTOR
(a) Install a new gasket and the intake air connector together with the diesel throttle body with the 3 bolts.
Torque: 21 Nm (209 kgfcm, 15 ftlbf)
148. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket, the exhaust manifold and 8 collars
with new 8 nuts.
Torque: 47 Nm (474 kgfcm, 34 ftlbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. The ring groove of the collar should be outward. Re-
fer to the illustration on the left.
Page 4668 of 5135

A85918
SST
A85916SST
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −127
AVENSIS Supplement (RM1045E)
149. INSTALL VACUUM PUMP OIL PIPE
Torque:
21 Nm (214 kgf cm, 15 ft lbf) for bolt
8.8 N m (90 kgf cm, 78 in. lbf) for nut
150. INSTALL OIL COOLER ASSY (See Pub. No. RM1018E on page 17 −32)
151. INSTALL EGR PIPE SUB −ASSY NO.1
(a) Install 2 new gaskets and the EGR pipe with the bolt and 4 new nuts. Torque:
37 Nm (375 kgf cm, 27 ft lbf) for bolt
25 N m (250 kgf cm, 18 ft lbf) for nut
152. INSTALL TURBOCHARGER SUB −ASSY (See page 13 −12)
153. INSTALL TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
154. INSTALL TURBOCHARGER STAY (See page 13 −12)
155. INSTALL MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
156. INSTALL MANIFOLD STAY NO.2 (See page 13 −12)
157. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY
NO.2
(a) Temporarily install the vacuum pipe.
(b) Using SST, tighten the nut of the vacuum pipe on the man- ifold converter side.
SST 09023 −38200
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Install the 2 bolts. Torque: 25 N m (255 kgf cm, 18 ft lbf)
158. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY
NO.1
(a) Temporarily install the vacuum pipe.
(b) Using SST, tighten the nut of the vacuum pipe on the man- ifold converter side.
SST 09023 −38200
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Install the bolt.
Torque: 25 N m (255 kgf cm, 18 ft lbf)
Page 4669 of 5135

A85921
5mm
(0.20 in.)
A85914
SST
A8592215 mm (0.59 in.)
A87961
SST
14−128−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
159. INSTALL EXHAUST GAS TEMPERATURE SENSOR
(a) Temporarily install the 3 nuts and exhaust gas tempera- ture sensor on down stream as shown in the illustration.
NOTICE:
Keep 5 mm (0.20 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(b) Using SST, tighten the sensor on the manifold converter
side.
SST 09023 −38400
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Tighten the 3 nuts.
Torque: 6.4 N m (65 kgf cm, 57 in. lbf)
(d) Temporarily install the 2 nuts and exhaust gas tempera- ture sensor on up stream as shown in the illustration.
NOTICE:
Keep 15 mm (0.59 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(e) Using SST, tighten the sensor on the manifold converter side.
SST 09023 −38400
Torque:
27 N m (275 kgf cm, 20 ft lbf) with SST
30 N m (306 kgf cm, 22 ft lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(f) Tighten the 2 nuts.
Torque: 6.4 N m (65 kgf cm, 57 in. lbf)
160. INSTALL EGR PIPE INSULATOR (See page 13 −12)
161. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
162. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
163. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
164. INSTALL OIL FILTER BRACKET SUB −ASSY
(a) Install a new gasket and the oil filter bracket with the bolt and 2 nuts.
Torque: 34 N m (347 kgf cm, 25 ft lbf)
165. INSTALL V −RIBBED BELT TENSIONER BRACKET
Torque: 20 N m (204 kgf cm, 15 ft lbf)
Page 4670 of 5135

A61186
SST
A57108
Adhesive
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −129
AVENSIS Supplement (RM1045E)
166. INSTALL V −RIBBED BELT TENSIONER ASSY
Torque: 31 N m (316 kgf cm, 23 ft lbf)
167. INSTALL GENERATOR BRACKET NO.1 Torque: 37 N m (377 kgf cm, 27 ft lbf)
168. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
169. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
170. INSTALL TIMING BELT (See page 14 −138)
171. CHECK VALVE TIMING (See page 14 −138)
172. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
173. INSTALL TIMING BELT GUIDE (See page 14 −138)
174. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
175. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
176. INSTALL IDLER PULLEY SUB −ASSY
Torque: 40 N m (408 kgf cm, 30 ft lbf)
177. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
178. INSTALL GLOW PLUG ASSY (See Pub. No. RM1018E on page 19 −33)
179. INSTALL ENGINE MOUNTING BRACKET RR
Torque: 64 N m (653 kgf cm, 47 ft lbf)
180. INSTALL ENGINE MOUNTING BRACKET FR Torque: 64 N m (653 kgf cm, 47 ft lbf)
181. INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N m (653 kgf cm, 47 ft lbf)
182. INSTALL REAR END PLATE Torque: 8.4 N m (86 kgf cm, 74 in. lbf)
183. INSTALL FLYWHEEL SUB −ASSY
(a) Using SST, hold the crankshaft. SST 09213 −54015 (09213 −70020), 09330 −00021
(b) Clean the bolts and their bolt holes.
(c) Apply adhesive to the 2 or 3 threads of the bolt end. Adhesive: Part No. 08833 −00070, THREE BOND 1324
or equivalent
Page 4671 of 5135

A79183
2
1
3
4
5
6
7
8
A79180
A62711
A61175
BA
A 14−130
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(d) Using a Torx socket wrench (T55), uniformly install and
tighten the 8 Torx screws in several steps in the sequence
shown in the illustration.
Torque: 71 Nm (720 kgfcm, 52 ftlbf)
184. INSTALL CLUTCH DISC ASSY (See Pub. No. RM1018E on page 42−26)
SST 09301−00210
185. INSTALL CLUTCH COVER ASSY (See Pub. No. RM1018E on page 42−26)
186. INSTALL MANUAL TRANSAXLE (See Pub. No. RM1018E on page 41−33)
187. INSTALL STARTER ASSY (See Pub. No. RM1018E on page 19−24)
188. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB−ASSY
(a) Attach the engine together with the transaxle to the sus-
pension crossmember and engine mounting member.
(b) Install the bolt which secures the rear engine mounting
bracket to the mounting insulator.
Torque: 87 Nm (887 kgfcm, 64 ftlbf)
(c) Install the bolt which secures the front engine mounting
bracket to the mounting insulator.
Torque: 52 Nm (530 kgfcm, 38 ftlbf)
189. I N S TA L L P O W E R S T E E R I N G I D L E P U L L E Y
BRACKET
(a) Install the power steering idle pulley bracket with the 3
bolts.
Torque:
72 Nm (734 kgfcm, 53 ftlbf) for bolt A
39 Nm (398 kgfcm, 29 ftlbf) for bolt B
190. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine together with the transaxle on the engine
lifter.
Page 4672 of 5135
A59792
A61177
A85928
A59792
AA
BB
A59793
AA
BB
BBB
B
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−131
AVENSIS Supplement (RM1045E)
(b) Temporarily install the suspension crossmember with the
2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 Nm (816 kgfcm, 59 ftlbf)
(d) Install the engine mounting insulator RH.
Torque: 52 Nm (530 kgfcm, 38 ftlbf)
(e) Install the front suspension crossmember with the 2 bolts
and 2 nuts.
Torque:
45 Nm (459 kgfcm, 33 ftlbf) for bolt A
133 Nm (1,356 kgfcm, 98 ftlbf) for nut B
(f) Install the front suspension member brace LH and RH
with the 8 bolts.
Torque:
133 Nm (1,356 kgfcm, 98 ftlbf) for bolt A
80 Nm (816 kgfcm, 59 ftlbf) for bolt B
NOTICE:
After installing the crossmember, check that the position-
ing holes on the crossmember and vehicle are aligned.