Page 4721 of 5135
A85753
A79164
A79444
A92433
−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)13 −15
AVENSIS Supplement (RM1045E)
21. REMOVE EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
22. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
23. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
24. REMOVE MANIFOLD STAY NO.2
(a) Remove the bolt and nut, then remove the manifold stayNo. 2.
25. REMOVE MANIFOLD STAY
(a) Remove the 4 bolts and manifold stay.
26. REMOVE EXHAUST MANIFOLD CONVERTER SUB−ASSY
(a) Remove the 3 nuts, manifold converter and gasket.
27. REMOVE TURBOCHARGER STAY
(a) Remove the 2 bolts and 2 nuts, then remove the turbo-
charger stay.
Page 4722 of 5135
A92429
A79167
A92432
A92430
A92431
13−16− INTAKETURBOCHARGER SUB−ASSY (1CD−FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
28. DISCONNECT TURBO WATER HOSE NO.1
29. DISCONNECT TURBO WATER HOSE NO.2
30. SEPARATE TURBO OIL INLET PIPE SUB−ASSY
(a) Remove the 2 nuts, turbo oil pipe and gasket.
31. REMOVE TURBOCHARGER SUB−ASSY
(a) Remove the 3 nuts, turbocharger and gasket.
32. REMOVE TURBO WATER PIPE SUB−ASSY NO.1
(a) Remove the 2 nuts, turbo water pipe and gasket.
Page 4723 of 5135
A92433
B
B
AA
A79444A79164A80106
A
A
B
B
− INTAKETURBOCHARGER SUB−ASSY (1CD−FTV)(From
September, 2003)13−17
AVENSIS Supplement (RM1045E)
33. INSTALL TURBO WATER PIPE SUB−ASSY NO.1
(a) Install a new gasket and the turbo water pipe with the 2 nuts.
Torque: 13 Nm (135 kgfcm, 9.8 ftlbf)
34. INSTALL TURBOCHARGER SUB−ASSY
(a) Install a new gasket and the turbocharger with the 3 nuts.
Torque: 60 Nm (612 kgfcm, 44 ftlbf)
35. INSTALL TURBO OIL INLET PIPE SUB−ASSY
(a) Install a new gasket and the oil pipe with the 2 nuts.
Torque: 13 Nm (135 kgfcm, 9.8 ftlbf)
36. INSTALL TURBOCHARGER STAY
(a) Install the turbocharger stay, then temporarily tighten
bolts A.
(b) Temporarily tighten nuts B while pushing the cylinder
head toward the turbocharger stay.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
(c) Tighten bolts A.
Torque: 56 Nm (571 kgfcm, 41 ftlbf)
(d) Tighten nuts B.
Torque: 56 Nm (571 kgfcm, 41 ftlbf)
37. INSTALL EXHAUST MANIFOLD CONVERTER
SUB−ASSY
(a) Install the manifold stay, then temporarily tighten the cyl-
inder block side of the manifold stay.
(b) Install a new gasket and the manifold converter, then tem-
porarily tighten bolts A and bolts B while pushing the up-
per portion of the converter toward the turbocharger.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
(c) Tighten the 3 nuts.
Torque: 25 Nm (255 kgfcm, 18 ftlbf)
(d) Tighten bolts A.
Torque: 61 Nm (622 kgfcm, 45 ftlbf)
(e) Tighten bolts B.
Torque: 61 Nm (622 kgfcm, 45 ftlbf)
Page 4724 of 5135
A85753
13−18−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
38. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay No. 2, then temporarily tighten the bolt.
(b) Temporarily tighten the nut while pushing the manifold
stay No. 2 toward the cylinder head.
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
HINT:
No clearance between the stay and cylinder head should be
confirmed.
(c) Tighten the bolt.
Torque: 56 N m (571 kgf cm, 41 ft lbf)
(d) Tighten the nut. Torque: 56 N m (571 kgf cm, 41 ft lbf)
39. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
40. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
41. INSTALL EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
42. INSTALL EGR PIPE INSULATOR Torque: 12 N m (122 kgf cm, 8.9 ft lbf)
43. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
44. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 Torque: 12 N m (122 kgf cm, 8.9 ft lbf)
45. INSTALL TURBO INSULATOR NO.1 Torque: 20 N m (204 kgf cm, 15 ft lbf)
46. INSTALL TURBO INSULATOR NO.2 Torque: 20 N m (204 kgf cm, 15 ft lbf)
47. INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 N m (76 kgf cm, 66 in. lbf)
48. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
49. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
50. INSTALL HEATER BRACKET (W/ COLD AREA)
Torque: 7.5 N m (76 kgf cm, 66 in. lbf)
51. INSTALL HEATER PUMP ASSY (W/ COLD AREA)
Torque: 7.5 N m (76 kgf cm, 66 in. lbf)
52. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
Page 4725 of 5135
A84387
2to7mm
(0.0787 to
0.2756 in.) 0to5mm
(0 to 0.1969 in.) 0to2mm
(0 to 0.0787 in.) *1*2
*2: *1:
Turbocharger Side
Intercooler Side
A93662
Turbocharger Side:
Intercooler Side: Upward
90_
Cl a m p
Bolt
90_
Cl a m p
Bolt
Front
−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)13 −19
AVENSIS Supplement (RM1045E)
53. INSTALL AIR TUBE NO.1
(a) Install the air hose and hose clamps as shown in the il-
lustration.
(b) Tighten the hose clamps as shown in the illustration. Torque: 6.0 N m (61 kgf cm, 53 in. lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N m (255 kgf cm, 18 ft lbf)
54. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
55. INSTALL AIR CLEANER ASSY
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
56. INSTALL VACUUM RESERVOIR SUB −ASSY
Torque: 8.3 N m (85 kgf cm, 73 in. lbf)
57. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
58. ADD ENGINE COOLANT (See page 16 −19)
59. CHECK ENGINE OIL LEVEL
60. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
61. CHECK FOR ENGINE OIL LEAKS
62. CHECK FOR FUEL LEAKS (See page 11 −46)
63. CHECK FOR EXHAUST GAS LEAKS
Page 4726 of 5135
3211F−01
G24211
F46213
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
−
BRAKE BRAKE BOOSTER ASSY (RHD) (2AZ −FSE)
32 −3
AVENSIS Supplement (RM1045E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface.
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE COVER NO. 1
4. REMOVE CYLINDER HEAD COVER SUB −ASSY (SEE PAGE 14− 79)
5. REMOVE IGNITION COIL ASSY (SEE PAGE 14− 79)
6. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14− 23)
7. REMOVE BRAKE MASTER CYLINDER SUB −ASSY
SST 09023 −00100
8. REMOVE BRAKE TUBE
(a) Using SST, disconnect the 6 brake tubes from the brakeactuator.
SST 09023 −00100
(b) Use tags or make a memo to identify the place to recon- nect.
Page 4727 of 5135
C80802
C80806
F45361F46832
F45362F46833
F46183
32−4
− BRAKEBRAKE BOOSTER ASSY (RHD) (2AZ−FSE)
AVENSIS Supplement (RM1045E)
(c) Using SST and a spanner, disconnect the brake tube from
the flexible hose of the front brake RH.
SST 09023−00100
(d) Remove the 2 bolts and disconnect the 2 brake tube
clamps.
(e) Using SST, disconnect the 3 brake tubes from the ways.
SST 09023−00100
(f) Disconnect the clamp from the stud bolt and remove the
brake tubes.
9. REMOVE BRAKE BOOSTER ASSY
(a) Disconnect the vacuum hose from the brake booster
assy.
(b) Remove the clip, the clevis pin and the wave washer.
Page 4728 of 5135
C80805
C80805
F46183
F45362F46833
− BRAKEBRAKE BOOSTER ASSY (RHD) (2AZ−FSE)
32−5
AVENSIS Supplement (RM1045E)
(c) Remove the 4 nuts.
(d) Pull out the brake booster assy.
(e) Remove the brake master cylinder clevis from the brake
booster assy.
10. REMOVE BRAKE BOOSTER GASKET
(a) Pull out the brake booster gasket.
11. REMOVE CHECK VALVE
(a) Remove the check valve and grommet from the brake booster assy.
12. INSTALL CHECK VALVE
(a) Install the check valve and grommet to the brake booster assy.
13. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assy.
14. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake master cylinder clevis to the brake boost-
er assy.
Torque: 22 Nm (224 kgfcm,16ftlbf)
(b) Install the brake booster assy with the 4 nuts.
Torque:13Nm(133 kgfcm,10ftlbf)
(c) Install the clevis pin, the clip and the wave washer.
(d) Connect the vacuum hose to the check valve.
15. INSTALL BRAKE TUBE
(a) Connect the clamp to the stud bolt.