Page 5057 of 5135

A62816
2
5 3
110 8 4 796
A96569
Lot No.
A62820
Under head Length
A62816
84 2 59
7 3 1 6 10
A62823
Paint Mark
90
Front
14–38– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
47. REMOVE CYLINDER HEAD SUB–ASSY
(a) Using several steps, loosen and remove the 10 cylinder
head bolts with a 10 mm hexagon wrench uniformly in the
sequence shown in the illustration. Remove the 10 cylin-
der head bolts and 10 plate washers.
(b) Remove the cylinder head.
48. REMOVE CYLINDER HEAD GASKET
49. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the Lot No. stamp facing upward.
NOTICE:
Pay attention to the mounting orientation.
Place the cylinder head on the gasket gently in order
not to damage the gasket.
50. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of cylinder
head bolt from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum length: 148.5 mm (5.846 in.)
If the length exceeds the maximum, replace the bolt.
51. INSTALL CYLINDER HEAD SUB–ASSY
HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil to the threads of the cylin-
der head bolts.
(b) Using several steps, install and tighten the 10 cylinder
head bolts and plate washers with a 10 mm hexagon
wrench uniformly in the sequence shown in the illustra-
tion.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts by an additional 90 in
the same sequence as step (b).
(e) Check that the paint mark of each bolt is at a 90 angle
to the front.
Page 5058 of 5135

A62150
Camshaft No. 2
Camshaft
A62825
62 4 8
51 3 7 11
10
9
A10079
A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–39
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
52. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the camshaft journals.
(b) Place the 2 camshafts on the cylinder head as shown in
the illustration.
(c) Examine the front marks and numbers, then tighten the
bolts in the sequence shown in the illustration.
Torque:
23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bearing cap No. 1
13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) for bearing cap No. 3
53. INSTALL CHAIN SUB–ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Using a wrench, turn the camshafts until the timing
marks of the 2 camshaft timing sprockets are
aligned.
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain onto the crankshaft timing sprock-
et with the yellow color link and the timing mark on the
crankshaft timing sprocket aligned.
HINT:
Three yellow color links are on the chain.
Page 5059 of 5135

A62172
SST
A62173
Yellow Color Mark
Timing Mark
A30867
A62174
SST
A62175
Seal Width
4 to 5 mm
Seal Packing
14–40– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(c) Using SST, install the crankshaft timing sprocket.
SST 09223–22010
(d) Install the timing chain onto the camshaft timing sprockets
with the yellow color links and timing marks on the cam-
shaft timing sprockets aligned.
54. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
55. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)
56. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ”F” mark facing forward.
57. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
(a) Apply multi–purpose grease to a new oil seal lip.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223–22010
NOTICE:
Keep the lip free of foreign objects.
58. INSTALL TIMING CHAIN OR BELT COVER SUB–ASSY
(a) Remove any old packing material (FIPG) from the contact
surface.
Page 5060 of 5135

A65676
Timing Chain Cover Side:
3 (0.118)3 (0.118)
A
A’BB’
C
C’
7 (0.276)
4.5 (0.177)
12 (0.472)6 (0.236)
3 (0.118)
Width 4 (0.157)
A – A’B – B’
C – C’
08826–00100 or equivalent
08826–00080 or equivalent
(mm (in.))
A65677
A
A
AA
A
A
AAA B
B
B
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–41
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Apply a continuous bead of seal packing (Diameter 3.5
mm to 4.5 mm (0.1379 to 0.177 in.)) as shown in the il-
lustration.
Seal packing:
Water pump part: part No. 08826–00100 or equivalent
Other part: part No. 08826–00080 or equivalent.
NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal
packing.
Do not expose the seal to engine oil for at least 2
hours after installation.
Do not apply seal packing too much more than the
specified amount.
(c) Install the timing chain cover with the 10 bolts and 2 nuts.
Torque:
13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) for A
19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) for B
(d) Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.5 N⋅m (97 kgf⋅cm, 84 in.⋅lbf)
Page 5061 of 5135

A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
A12816
A11858
14–42– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
59. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check that the O–ring is clean, then set the hook as
shown in the illustration.
(b) Apply engine oil to the chain tensioner and install it with
the 2 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
NOTICE:
If the hook released the plunger during installation, re–
hook the plunger.
60. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of the engine oil to the O–ring on the
crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
61. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the transverse engine engine mounting bracket
with the 3 bolts.
Torque: 47 N⋅m (479 kgf⋅cm, 35 ft⋅lbf)
62. INSTALL WATER PUMP ASSY
(See Pub. No. RM1018E on page 16–9)
63. INSTALL V–RIBBED BELT TENSIONER ASSY
(a) Install the V–ribbed belt tensioner with the nut and bolt.
Torque:
29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf) for nut
69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf) for bolt
Page 5062 of 5135

A62837SST
A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A62182
Seal Packing
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–43
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
64. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
(b) Using SST, install the crankshaft pulley bolt.
SST 09960–10010 (09962–01000, 09963–01000)
Torque: 138 N⋅m (1,407 kgf⋅cm, 102 ft⋅lbf)
(c) Turn the crankshaft counterclockwise, then take the hook
off the knock pin to release the plunger.
(d) Turn the crankshaft clockwise, then check that the plung-
er is extended.
HINT:
If the plunger is not extended, press the slipper into the chain
tensioner using a screwdriver so that the hook is taken off from
the knock pin and the plunger can be extended.
65. INSTALL CYLINDER HEAD COVER SUB–ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes of ap-
plying seal packing.
Do not expose the seal to engine oil for at least 2
hours after installation.
Page 5063 of 5135
A65687
A
A
A
A A A
A A
B
B A
A64005
A76720
AAB
A76721
14–44– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(c) Install the cylinder head cover and 3 cable brackets with
the 9 bolts, 2 seal washers and 2 nuts. Tighten the bolts
and nuts uniformly in several steps.
Torque:
11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) for A
9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for B
66. INSTALL ENGINE MOUNTING INSULATOR
SUB–ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
67. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque:
37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) for bolt A
49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) for bolt B
68. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay with the 3 bolts.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
69. INSTALL EXHAUST PIPE ASSY FRONT
(See Pub. No. RM1018E on page 15–2)
Page 5064 of 5135

B06777
A64026
A93668
A64023
A76713
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–45
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
70. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Apply a light coat of engine oil on a new O–ring, then
install it onto the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
71. INSTALL WATER BY–PASS PIPE NO.1
(a) Install a new gasket and water by–pass pipe with the 2
nuts and 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
72. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil on a new O–ring, then
install it onto the oil level gage guide.
(b) Install the oil level gage guide with the bolt.
Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)
73. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.
(b) Install the intake manifold and the throttle body assembly
with the 2 brackets, 4 bolts and 2 nuts.
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
(c) Connect the vacuum hose to water by–pass pipe No. 1.
(d) Connect the throttle motor connector.
74. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
75. INSTALL GENERATOR ASSY
(See Pub. No. RM1018E on page 19–7)