Page 2103 of 5135
141CO±01
A62838SST
A62838SST
A62202
Cut Position
A62203
SST
14±98
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 5. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
6. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
7. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grid sandpa-
per.
8. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223±15020, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
Page 2104 of 5135
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90
A62838SST
A62204
1
5
3
82
6
4
7
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
14±99
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a)Fix the crankshaft with SST.
SST09960±10010 (09962±01000, 09963±01000)
(b)Clean the bolt and bolt hole.
(c)Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d)Using several steps, Install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 49 N m (500 kgf cm, 36 ft lbf)
(e)Mark the bolts with paint as shown in the illustration.
(f)Retighten the bolts by an additional 90 in the same se-
quence as step (d).
(g)Check that the paint marks of each bolt are at 90 angle
from the original position.
10.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
11. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
12. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Fix the crankshaft with SST. SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
(e) Fix the crankshaft with SST.
Torque: 88 N m (897 kgf cm, 65 ft lbf)
Page 2107 of 5135
A62183
Cut Position
Pry
A62184
SST
A62837SST
A64005
± ENGINE MECHANICALTIMING CHAIN OR BELT COVER OIL
SEAL (1ZZ±FE/3ZZ±FE)14±97
AVENSIS REPAIR MANUAL (RM1018E)
9. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpa-
per.
10. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223±22010
NOTICE:
Wipe off extra grease on the crankshaft.
11. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft and slide the pulley into place.
(b) Using SST, install the crankshaft pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
Torque: 138 Nm (1,407 kgfcm, 102 ftlbf)
12. INSTALL ENGINE MOUNTING INSULATOR
SUB±ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 Nm (530 kgfcm, 38 ftlbf)
13. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgfcm, 76 ftlbf)
14. CHECK FOR ENGINE OIL LEAKS
Page 2113 of 5135
A12816
A76692
A62178
Push
A10076
A30848
14±86
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and the transverse engine engine
mounting bracket.
39. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts which are used to secure the crank-
shaft position sensor.
40. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and the chain tensioner.
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
41. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 11 bolts and nuts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying between the cyl-
inder head and the cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the timing chain cover, the cylin-
der head and the cylinder block.
42. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.
43. REMOVE CRANKSHAFT POSITION SENSOR PLATE
NO.1
44. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and the chain tensioner slipper.
45. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolt and the chain vibration damper.
Page 2114 of 5135
A30857
A62814
4 2531
A62816
2
5 3
110 8 4 796
A62827
Lot No.
A62820
Overall Length
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±87
AVENSIS REPAIR MANUAL (RM1018E)
46. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain by prying the crankshaft timing
gear using screwdrivers as shown in the illustration.
NOTICE:
Put shop rag to protect the engine.
In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise to prevent the valves from touch-
ing the pistons.
47. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 19 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 9 bearing caps, and both the intake and
exhaust camshafts.
48. 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.
49. REMOVE CYLINDER HEAD GASKET
50. 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 with the bottom part of the
head.
51. 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.
Page 2119 of 5135
A12816
A11858
A62837SST
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
14±92
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
62.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)
63.INSTALL WATER PUMP ASSY (See page 16±9)
64. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 Nm (296 kgf cm, 21 ft lbf) for Nut
69 N m (704 kgf cm, 51 ft lbf) for Bolt
65. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft and 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 and take the hook off the knock pin to release the plunger.
(d) Turn the crankshaft clockwise, and check that the plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
Page 2132 of 5135
141BI±01
A77421
Cut Position
A77422SST
14±180
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1AZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
5.REMOVE ENGINE REAR OIL SEAL
(a)Using a knife, cut off the engine rear oil seal lip.
(b)Using a screwdriver with the tip wrapped in tape, pry outthe engine rear oil seal.
HINT:
After the removal, check if the crankshaft is not damaged.
If is damaged, smooth the surface with 400±grit sandpaper.
6.INSTALL ENGINE REAR OIL SEAL
(a)Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
7.INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
8.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
9.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
10.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
Page 2134 of 5135
A77418
Cut Position
A77419
SST
A77420
SST
SST
±
ENGINE MECHANICAL TIMING GEAR CASE OR TIMING CHAIN CASE OIL
SEAL(1AZ±FE)14±179
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE TIMING GEAR CASE OR TIMING CHAIN
CASE OIL SEAL
(a)Using a screwdriver with tip wrapped in the tape, pry out
the oil seal.
HINT:
After removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpaper.
9.INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
(a)Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the oil seal until its sur- face is flush with the rear oil seal retainer edge.
SST09223±22010
NOTICE:
Wipe off extra grease on the crankshaft.
10.INSTALL CRANKSHAFT PULLEY
(a)Align the pulley set key with the key groove of the pulley.
(b)Using SST, install the pulley bolt. SST09213±54015 (91651±60855), 09330±00021
Torque: 170 N m (1,733 kgf cm, 125 ft lbf)
11.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
12. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
13. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
14. CHECK FOR ENGINE OIL LEAKS