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ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
76. INSTALL V–RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt.
Torque: 39 N ⋅m (400 kgf ⋅cm, 29 ft ⋅lbf)
77. INSTALL FAN AND GENERATOR V BELT
(See Pub. No. RM1018E on page 14–5)
78. INSTALL AIR CLEANER HOSE NO.1
Torque: 1.5 N ⋅m (15 kgf ⋅cm, 13 in. ⋅lbf)
79. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N ⋅m (71 kgf ⋅cm, 62 in. ⋅lbf)
80. INSTALL FRONT WHEEL RH
Torque: 103 N ⋅m (1,050 kgf ⋅cm, 76 ft ⋅lbf)
81. ADD ENGINE COOLANT (See page 16–5)
82. INSPECT COMPRESSION (See Pub. No. RM1018E on page 14–1)
SST 09992–00500
83. INSPECT CO/HC (See Pub. No. RM1018E on page 14–1)
84. INSPECT IGNITION TIMING (See Pub. No. RM1018E on page 14–1)
SST 09843–18040
85. CHECK FOR ENGINE COOLANT LEAKS (See page 16–1)
86. CHECK FOR ENGINE OIL LEAKS
87. CHECK FOR EXHAUST GAS LEAKS
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February, 2004)14–9
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See Pub. No. RM1018E on page 11–1)
2. REMOVE RADIATOR SUPPORT OPENING COVER
(a) Remove the retainer and 4 clips.
(b) Unfasten the 5 claws, then remove the radiator support
opening cover.
3. REMOVE ENGINE ROOM COVER SIDE
(a) Remove the 2 clips and engine room cover side.
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER SUB–ASSY NO.1
(a) Remove the 5 clips, 2 screws and bolt, then detach the
engine under cover.
6. REMOVE ENGINE UNDER COVER LH
(a) Remove the 6 screws and 5 clips, then detach the engine
under cover.
Page 5067 of 5135
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ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
7. REMOVE ENGINE UNDER COVER RH
(a) Remove the 6 screws and 3 clips, then detach the engine under cover.
8. DRAIN ENGINE COOLANT (See page 16–5)
9. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil.
Torque: 37 N ⋅m (377 kgf ⋅cm, 27 ft ⋅lbf)
10. DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (See Pub. No. RM1018E on p\
age 41–15)
11. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–42)
12. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, then detach cylinder head
cover No.2.
13. REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 10–6)
14. REMOVE AIR CLEANER FILTER ELEMENT SUB–ASSY
15. REMOVE AIR CLEANER CASE SUB–ASSY
(a) Remove the 3 bolts and air cleaner case.
16. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the radiator.
17. DISCONNECT RADIATOR HOSE OUTLET
(a) Disconnect the radiator hose outlet from the radiator.
18. DISCONNECT OIL COOLER INLET HOSE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet hose from the radiator.
19. DISCONNECT OIL COOLER OUTLET HOSE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet hose from the radiator.
20. DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
21. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.
Page 5068 of 5135
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February, 2004)14–11
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
22. REMOVE RADIATOR ASSY
(a) Remove the 2 bolts and relay block.
(b) Disconnect the connector and 2 harness clamps.
(c) Remove the 2 bolts, 2 radiator support uppers and radia-
tor.
23. REMOVE BATTERY
24. REMOVE BATTERY TRAY
25. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts, battery carrier and bracket.
26. REMOVE EFI FUEL PIPE CLAMP
(See Pub. No. RM1018E on page 11–11)
27. DISCONNECT FUEL TUBE SUB–ASSY
(See Pub. No. RM1018E on page 11–11)
28. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose.
29. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose from the heater core inlet tube.
30. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose from the heater core outlet tube.
31. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
32. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
33. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
34. SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
35. REMOVE GLOVE COMPARTMENT DOOR ASSY (See Pub. No. RM1018E on page 71–11)
36. REMOVE INSTRUMENT PANEL UNDER COVER SUB–ASSY NO.2
37. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junction
block.
(b) Pull out the engine wire.
(c) Remove the engine room relay block No.2 cover.
(d) Remove a nut, then disconnect a connector as shown in
the illustration.
Page 5069 of 5135
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(f)
(e)
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February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(e) Remove the bolt, then disconnect the ground terminal.
(f) Disconnect the ground terminal connector.
(g) Remove the nut and disconnect battery terminal B.
38. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V–ribbed belt tensioner clockwise slowly and
loosen it. Then, remove the fan and generator V belt and
put back the V–ribbed belt tensioner carefully.
39. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19–7)
40. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:
Secure the compressor and hoses off to the side instead of discharging the A/C system.
1ZZ–FE (See Pub. No. RM1018E on page 55–74)
3ZZ–FE (See Pub. No. RM1018E on page 55–70)
41. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and column hole cover silencer sheet.
42. SEPARATE STEERING INTERMEDIATE SHAFT (See Pub. No. RM1018E on page 50–9)
43. REMOVE FRONT DOOR SCUFF PLATE RH (See Pub. No. RM1018E on page 71–11)
44. REMOVE COWL SIDE TRIM BOARD RH (See Pub. No. RM1018E on page 71–11)
45. REMOVE FRONT FLOOR FOOTREST (RHD STEERING POSITION TYPE)
46. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and floor panel brace front.
47. REMOVE EXHAUST PIPE ASSY FRONT (See Pub. No. RM1018E on page 15–2)
48. REMOVE FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30–6)
SST 09930–00010
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February, 2004)14–13
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
49. REMOVE FRONT AXLE HUB RH NUT
SST 09930–00010
HINT:
Perform the same procedure as above on the opposite side.
50. SEPARATE TIE ROD END SUB–ASSY LH (See Pub. No. RM1018E on page 30–6)
SST 09628–62011
51. SEPARATE TIE ROD END SUB–ASSY RH
SST 09628–62011
HINT:
Perform the same procedure as above on the opposite side.
52. SEPARATE FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30–6)
53. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
54. SEPARATE FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30–6)
55. SEPARATE FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
56. SEPARATE FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30–6)
57. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts and 2 nuts, then detach the engine
mounting insulator.
(c) Remove the through bolt and nut, then detach the engine
mounting insulator from the vehicle.
Page 5071 of 5135
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February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(d) Remove the 2 bolts and 2 nuts as shown in the illustration.
(e) Remove the 8 bolts and front suspension member brace
rear RH and LH.
(f) Carefully remove the engine with transaxle from the en-
gine compartment.
(g) Install the engine hanger No. 1 (12281–15040) and bolt
(91512–B1016).
Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf)
(h) Install the engine hanger (12281–22021) and bolt
(91512–B1016).
Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf)
HINT:
Securely install the front engine hanger (12281–22021) and
rear engine hanger No. 1 (12281–15040) onto the engine as-
sembly.
(i) Attach the engine sling, then hang the engine with the
chain block.
59. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Remove the through bolt and nut, then detach the engine
mounting insulator FR from the engine mounting bracket.
Page 5072 of 5135
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February, 2004)14–15
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Remove the through bolt, then detach the engine mount-
ing insulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the
suspension crossmember and engine mounting member.
60. REMOVE STARTER ASSY (See Pub. No. RM1018E on page 19–3)
61. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
62. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
63. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
64. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
65. REMOVE FLYWHEEL SUB–ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
flywheel.
SST 09960–10010 (09962–01000, 09963–01000)
66. REMOVE DRIVE PLATE & RING GEAR SUB–ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
drive plate & ring gear.
SST 09960–10010 (09962–01000, 09963–01000)
67. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
(b) Remove the 2 nuts which are used to secure the engine
wire.