Page 4761 of 5135
1509W−02
A85748
30 (302, 22)43 (440, 32)zGasketzGasket
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
43 (440, 32)
Compression Spring
Exhaust Pipe Assy Tail
Air−fuel Ratio Sensor
43 (440, 32)
44 (449, 33)
− EXHAUSTEXHAUST PIPE ASSY (1CD−FTV)(From September,
2003)15−5
AVENSIS Supplement (RM1045E)
EXHAUST PIPE ASSY (1CD−FTV)(From September, 2003)
COMPONENTS
Page 4762 of 5135
141NN−01
A61184
A85928
−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)14 −177
AVENSIS Supplement (RM1045E)
CRANKSHAFT SEAL (1CD −FTV)(From September, 2003)
REPLACEMENT
1. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil.
Torque: 34 N m (350 kgf cm, 25 ft lbf)
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE RADIATOR SUPPORT OPENING COVER
6. REMOVE ENGINE ROOM COVER SIDE
7. REMOVE ENGINE COVER NO.1 (See page 14 −90)
8. REMOVE INJECTOR DRIVER (See page 14 −108)
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
10. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
11. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
12. DISCONNECT ENGINE WIRE (See page 14 −138)
13. DISCONNECT VACUUM HOSE (See page 14 −108)
14. REM O VE ENG I NE M O UNTI NG I NSULATO R SUB−ASSY RH
(a) Place a wooden block on a jack underneath the engine.
(b) Remove the 3 bolts and 3 nuts, then detach the engine mounting insulator sub −assembly.
15. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
16. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
17. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
18. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
19. REMOVE TIMING BELT GUIDE
20. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
Page 4763 of 5135
SST
A09582
B07973
Cut PositionPry
SST
A08528
SST
A09583
Angle
SensorInward
14
−178−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
22. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
23. REMOVE TIMING BELT (See page 14 −138)
24. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the timing pulley cannot be removed by hand, use SST to remove the pulley.
SST 09950 − 50013 ( 09951 − 05010, 09952 − 05010,
09953 −05010, 09953 −05020, 09954 −05021)
25. REMOVE CRANKSHAFT SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Wrap the tip of the
screwdriver with tape.
26. INSTALL CRANKSHAFT SEAL
(a) Apply multipurpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the oil seal until its sur- face is flush with the oil pump edge.
SST 09316 −60011 (09316 −00011)
27. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located on the crankshaft, then slide the pulley into place.
(b) Using SST and a hammer, tap in the timing pulley with the
angle sensor facing inward.
SST 09223 −46011
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
29. INSTALL TIMING BELT (See page 14 −138)
30. CHECK VALVE TIMING (See page 14 −138)
Page 4764 of 5135
−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)14 −179
AVENSIS Supplement (RM1045E)
31. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
32. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
33. INSTALL TIMING BELT GUIDE (See page 14 −138)
34. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
35. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
36. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
37. INSTALL CRANKSHAFT PULLEY (See page 14 −138 )
SST 09213 −54015 (09213 −70020), 09330 −00021
38. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
39. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
40. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
41. INSTALL INJECTOR DRIVER (See page 14 −108)
42. INSTALL ENGINE COVER NO.1 (See page 14 −90)
43. INSTALL FRONT WHEEL RH
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
44. ADD ENGINE OIL
45. CHECK FOR ENGINE OIL LEAKS
Page 4765 of 5135
551AN−01
I35326
I35327
I35328
55 −4
−
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1 . DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(See Pub. No. RM 1018E, page 55 −38)
SST 07110 −58060 ( 07117 −58080, 07117 −58090, 07117 −78050, 07117 −88060, 07117 −88070,
07117 −88080)
2. DI SCO NNECT CO O L ER REFRI G ERANT SUCTI O NHOSE NO. 1
(a) Remove the bolt and disconnect the cooler refrigerant
suction hose No.1 from the w/pulley compressor assy.
(b) Remove the O −ring from the cooler refrigerant suction
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
3. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO. 1
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the w/pulley compressor assy.
(b) Remove the O −ring from the cooler refrigerant discharge
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
4. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14− 5)
5. REMOVE ENGINE ROOM COVER SIDE (See page 14− 5)
6. REMOVE ENGINE UNDER COVER RH (See page 14− 5)
7. REMOVE FAN AND GENERATOR V BELT (See page 14− 5)
SST 09249 −63010
8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
Page 4766 of 5135
I35328
(1)(2)
(3)
(4)
−
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (2AZ −FSE)
55 −5
AVENSIS Supplement (RM1045E)
9. INSPECT COMPRESSOR OIL
(a) When replacing the w/pulley compressor assy with a new one, after gradually removing the refrigerant
gas from the service valve, drain the following amount of oil from the new w/pulley compressor assy
before installation.
Standard:
(Oil capacity inside new w/pulley compressor assy: 90 + 15 cc (3.0 + 0.5 fl. oz.) ) − (Remaining
oil amount in the removed w/pulley compressor assy) = (Oil amount to be removed when replac-
ing)
NOTICE:
S When checking the compressor oil level, observe the precautions on the cooler removal/instal-
lation.
S Since compressor oil remains in the pipes of the vehicle, if a new w/pulley compressor assy
is installed without removing some oil inside, the oil amount becomes excessive, preventing
heat exchange in the refrigerant cycle and causing refrigerant failure.
S If the remaining oil in the removed w/pulley compressor assy is too small in volume, check for
oil leakage.
S Be sure to use ND −OIL 8 for compressor oil.
10. INSTALL W/PULLEY COMPRESSOR ASSY
(a) Install the w/pulley compressor assy with the 4 bolts.
Torque: 29 N m (300 kgf cm, 2 1 ft lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to
install the w/pulley compressor assy.
(b) Connect the connector.
11 . INSTALL FAN AND GENERATOR V BELT (See page 14− 5)
SST 09249 −63010
12. INSTALL COOLER REFRIGERANT DISCHARGE
HOSE NO. 1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O −ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND −OIL 8 or equivalent
(c) Install the O −ring on the cooler refrigerant discharge hose
No.1.
Page 4767 of 5135
I35327
I35326
55−6
− HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
(d) Install the cooler refrigerant discharge hose No.1 on the
w/pulley compressor assy with the bolt.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
13. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O−ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND−OIL 8 or equivalent
(c) Install the O−ring on the cooler refrigerant suction hose
No.1.
(d) Install the cooler refrigerant suction hose No.1 on the w/
pulley compressor assy with the bolt.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
14. CHARGE REFRIGERANT (See Pub. No. RM1018E, page 55−38)
SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050,
07117−88060, 07117−88070, 07117−88080)
Specified amount: 440 á30 g (15.51 á1.06 oz.)
15. WARM UP ENGINE (See Pub. No. RM1018E, page 55−38)
16. INSPECT LEAKAGE OF REFRIGERANT (See Pub. No. RM1018E, page 55−38)
Page 4768 of 5135
4018A−01
D31327
D31328
D31328
D31327
40 −26
−
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION OIL COOLER (U151E)
AVENSIS Supplement (RM1045E)
TRANSMISSION OIL COOLER (U 151E)
REPLACEMENT
1. DRAIN AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
2. DRAIN COOLANT (SEE PAGE 16− 7)
3. REMOVE TRANSMISSION OIL COOLER
(a) Loosen the clips and disconnect the 4 hoses from the transmission oil cooler.
(b) Remove the 3 bolts and the oil cooler from the bracket.
4. INSTALL TRANSMISSION OIL COOLER
(a) Install the oil cooler to the bracket with the 3 bolts. Torque: 12N m( 122 kgf cm, 9 ft lbf)
(b) Connect the 4 hoses with the clips to the transmission.