Инструкция по эксплуатации автомобиля тойота авенсис

Toyota Avensis 1997-2003 / Тайота Авенсис 1997-2003

1. Manuals
2. Brands
3. Toyota Manuals
4. Automobile
5. Avensis ZZT251 2003
6. Service and repair manual

• Page 2
  MO-2 NEW MODEL OUTLINE EXTERIOR APPEARANCE 4-Door Sedan 240MO01 240MO02 http://vnx.su…
• Page 3
  MO-3 NEW MODEL OUTLINE 5-Door Liftback 240MO03 240MO04 http://vnx.su…
• Page 4
  MO-4 NEW MODEL OUTLINE 5-Door Wagon 240MO05 240MO06 http://vnx.su…

• Page 5: Model Code

  MO-5 NEW MODEL OUTLINE MODEL CODE ZZT250 L – A E M N K W BASIC MODEL CODE GEAR SHIFT TYPE ZZT250 : With 3ZZ FE Engine M : 5 Speed Manual, Floor ZZT251 : With 1ZZ FE Engine P : 4 Speed Automatic, Floor AZT250 : With 1AZ FSE Engine : With 1AZ FE Engine GRADE…

• Page 6
  MO-6 NEW MODEL OUTLINE MODEL LINE-UP EUROPE TRANSAXLE BODY BODY ENGINE GRADE 5-Speed Manual TYPE TYPE C250 E354 E357 ENTRY ZZT250L(R)-AEMNKW — — — Sedan MID TECHNICAL ZZT250L-AEMEKW — — — 3ZZ-FE MID ELEGANT ZZT250L-AEMGKW — — — Liftback ENTRY ZZT250L(R)-ALMNKW —…

• Page 7: Front View

  MO-7 NEW MODEL OUTLINE EXTERIOR Front View D The front view is dynamically expressive, with innovative headlights and a front bumper design that has a sense of stability with upper and lower thickness. D The headlight low beams feature projectors and have an innovative shape. Sedan and Liftback Models 240MO07 Headlight…

• Page 8: Rear View

  MO-8 NEW MODEL OUTLINE Rear View D The rear combination lens features an elegant, innovative shape. D The luggage compartment door and back door were given a greater sense of volume for a high-quality feel. 4-Door Sedan Taillight Stop Light 240MO11 Back Up or Turn Signal Light…

• Page 9: Side View

  MO-9 NEW MODEL OUTLINE Side View D The side view communicates a sense of balance, with a large cabin structure that expresses a sense of stability and elegance. D The side view has an elegant and dynamic shape thanks to two character lines. 4-Door Sedan 240MO16 5-Door Liftback…

• Page 10
  MO-10 NEW MODEL OUTLINE Tire & Disc Wheel Tire Size 195 / 65 R15 205 / 55 R16 Size 15 x 6 J 16 x 6 1 / 2 J 16 x 6 1 / 2 JJ Disc Wheel Material Steel Steel Aluminum…
• Page 11
  MO-11 NEW MODEL OUTLINE INTERIOR 240MO24 Sedan Model 240MO25 240MO26 Liftback Model Wagon Model http://vnx.su…
• Page 12
  MO-12 NEW MODEL OUTLINE Instrument Panel D The instrument panel’s design, composed of smooth curving lines, expresses the cabin’s spaciousness. D The use of painted, surface-treated, and chrome plated parts, as well as the greatest possible minimization of openings and break lines, express a sense of quality. Chrome plated parts Painted parts and surface-treated parts…

• Page 13: Steering Wheel

  MO-13 NEW MODEL OUTLINE Steering Wheel D ENTRY grade models feature a urethane 4-spoke type steering wheel, and MID TECHNICAL and MID ELEGANT grade models feature a leather 4-spoke type steering wheel. D Europe models feature a steering pad switch that enables drivers to operate the audio system, switch to trip information display, and turn the navigation system’s voice recognition function on and off without removing their hands from the steering wheel.

• Page 14: Front Seat

  MO-14 NEW MODEL OUTLINE Seat D The seat features a high-quality finish with an elegant stitch. D Leather seats are available as an option for MID TECHNICAL and MID ELEGANT grade with the 1AZ-FSE or 1CD-FTV engine models. 240MO34 Front Seat D Power seats are available as a set option with leather seats.

• Page 15: Rear Seat

  MO-15 NEW MODEL OUTLINE Rear Seat D ENTRY grade sedans feature a fixed seat; other models feature seats with a 60:40 separate seat back. D Liftback and wagon models feature a 60:40 separate seat. 240MO40 240MO41 240MO43 Fixed Seat 60:40 Separate Seat Back 60:40 Separate Seat D CRS (Child Restraint System) ISO-FIX bar and CRS tether anchor bracket for securing child seats have been provided on all the vehicle.

• Page 16
  MO-15 NEW MODEL OUTLINE Rear Seat D ENTRY grade sedans feature a fixed seat; other models feature seats with a 60:40 separate seat back. D Liftback and wagon models feature a 60:40 separate seat. 240MO40 240MO41 240MO43 Fixed Seat 60:40 Separate Seat Back 60:40 Separate Seat D CRS (Child Restraint System) ISO-FIX bar and CRS tether anchor bracket for securing child seats have been provided on all the vehicle.

• Page 17: Luggage Cover

  MO-16 NEW MODEL OUTLINE 5-Door Wagon The luggage room features an abundance of items for ease of use. Grocery Bag Hook (Both Side) Auxiliary Box Tie-down Hook (Right / Left) Deck Under Tray Tool Box Tie-down Hook Auxiliary Box CRS Tether Anchor Bracket Auxiliary Box CRS Tether…

• Page 18: Trip Information

  MO-17 NEW MODEL OUTLINE EQUIPMENT Multi Display A multi display is available as an option for MID TECHNICAL and MID ELEGANT grade Europe models. Navigation and trip information can be displayed on the multi display. Navigation System D Through the use of the GPS (Global Positioning System) and map data in a DVD (Digital Versatile Disc), the navigation system analyzes the position of the vehicle and indicates that position on the map that is displayed on this screen.

• Page 19: Audio System

  MO-18 NEW MODEL OUTLINE Audio System D The audio system has a head unit with three built-in functions: CD player, cassette player, and radio. D By adopting new digital sound processing program, this unit can emphasize sound faithfully without phase distortion, and produce extremely clear and powerful sound. Figure for image No distortion Original…

• Page 20
  MO-19 NEW MODEL OUTLINE Location Front Door Speaker Front Tweeter Glass Antenna Rear Tweeter Rear Door Speaker Rear Door Speaker Rear Tweeter Front Door Speaker 240MO69 Sedan Model Glass Antenna Glass Antenna 240MO70 240MO71 Liftback Model Wagon Model Multi-information Display D A multi-information display is standard equipment on MID TECHNICAL and MID ELEGANT grade Europe models…
• Page 21
  MO-19 NEW MODEL OUTLINE Location Front Door Speaker Front Tweeter Glass Antenna Rear Tweeter Rear Door Speaker Rear Door Speaker Rear Tweeter Front Door Speaker 240MO69 Sedan Model Glass Antenna Glass Antenna 240MO70 240MO71 Liftback Model Wagon Model Multi-information Display D A multi-information display is standard equipment on MID TECHNICAL and MID ELEGANT grade Europe models…

• Page 22: Air Conditioner System

  MO-20 NEW MODEL OUTLINE Air Conditioner System D A manual air conditioner is standard equipment on ENTRY grade models and an automatic air conditioner on MID TECHNICAL and MID ELEGANT grade models. 240MO95 240MO96 Manual Air Conditioner Control Panel Automatic Air Conditioner Control Panel for LHD model for LHD model D The automatic air conditioner employs a left/right independent temperature control system.

• Page 23
  MO-21 NEW MODEL OUTLINE Windshield & Door Glass Dark gray privacy glass is available as an option for the rear door glass, rear quarter glass, and back door glass of wagon models. Windshield Back Window Front Door Glass Glass Glass Rear Door 240MO73 240MO74…

• Page 24: Rear Sunshade

  MO-22 NEW MODEL OUTLINE Rear Sunshade A hand-operated rear sun shade is available as an option for Europe sedans and liftback models and is standard equipment on General Countries sedan models. 240MO82 240MO81 Sedan Model Liftback Model Power Outlet The back surface of the console is equipped with a 12V-120W power outlet for MID TECHNICAL and MID ELEGANT grade only.

• Page 25
  MO-23 NEW MODEL OUTLINE PERFORMANCE Power Train Engine Engine 240MO100 Type 1ZZ-FE 3ZZ-FE Valve Mechanism 16-Valve DOHC with VVT-i 16-Valve DOHC with VVT-i Displacement 1794 cm (109.5 cu. in.) 1598 cm (97.5 cu. in.) Max. Output 95 kW / 6000 rpm 81 kW / 6000 rpm Max.
• Page 26
  MO-24 NEW MODEL OUTLINE Transaxle 240MO101 Transaxle Manual Transaxle Type C250 E354 E357 Combination with Engine 3ZZ-FE 1ZZ-FE 1AZ-FE & 1AZ-FSE 1CD-FTV Gear Ratio 1st 3.545 3.545 3.538 3.538 1.904 1.904 2.045 1.913 1.310 1.310 1.333 1.258 0.969 1.031 1.028 0.918 0.815 0.815…
• Page 27
  MO-25 NEW MODEL OUTLINE Chassis Front Suspension Rear Suspension MacPhason Strut Type Double Wishbone Type Type Type Type Independent Suspension Type Suspension 240MO99 EPS Model Steering EPS (Electoronic Power Steering) (for 1ZZ-FE and 3ZZ-FE) Type Ty e Hydraulic Type Power Steering (for 1AZ-FSE, 1AZ-FE and 1CD-FTV) Brake for 15-inch Wheel (for 1ZZ-FE, 3ZZ-FE and 1AZ-FE) Front Brake Type…
• Page 28
  MO-26 NEW MODEL OUTLINE SAFETY SRS (Supplemental Restraint System) Airbag System D A newly developed SRS knee airbag is standard equipment for the driver’s seat on the new Avensis. D The SRS knee airbag is positioned in the lower part of the instrument panel on the driver’s side to receive the impact of the driver’s lower body when he or she shifts forward in the event of a frontal collision, contributing to prevention of secondary impact to the lower body.
• Page 29
  MO-27 NEW MODEL OUTLINE DIMENSIONS mm (in.) 4-Door Sedan 1760 1480 2700 1025 Front: 1505* , 1515* Rear: 1500* , 1515* 240MO92 5-Door Liftback 1760 1480 2700 1025 Front: 1505* , 1515* Rear: 1500* , 1515* 240MO93 5-Door Wagon 1760 1525 2700 1095…
• Page 30
  MO-28 NEW MODEL OUTLINE EQUIPMENT LIST F: Standard OP: Option Europe General General Countries ENTRY TECHNICAL ELEGANT Exterior Rear Spoiler Wagon — Side Protection Moulding Windshield Green — Front Side Green Green Glass Glass Rear Side & Back Rear Side & Back Wagon Privacy —…
• Page 31
  MO-29 NEW MODEL OUTLINE F: Standard OP: Option Europe General General Countries ENTRY TECHNICAL ELEGANT Body Electrical Projector Headlight Headlight HID (High lntensity Discharge) — — Manual — Headlight Beam Level Control System Automatic — — Headlight Cleaner System — Except for 1AZ-FE —…
• Page 32
  MO-30 – MEMO – http://vnx.su…
• Page 33
  AP-2 APPENDIX MAJOR TECHNICAL SPECIFICATIONS Area EUROPE Item Body Type 4-Door Sedan Vehicle Grade ENTRY MID TECHNICAL MID ELEGANT Model Code ZZT250R-AEMNKW ZZT250L-AEMNKW ZZT250L-AEMEKW ZZT250L-AEMGKW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3)
• Page 34
  AP-3 APPENDIX EUROPE 4-Door Sedan ENTRY MID TECHNICAL ZZT251R-AEMNKW ZZT251L-AEMNKW ZZT251R-AEPNKW ZZT251L-AEPNKW ZZT251R-AEMEKW ZZT251L-AEMEKW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1480 (58.3) 1480 (58.3) 1480 (58.3) 1480 (58.3)
• Page 35
  AP-4 APPENDIX Area EUROPE Item Body Type 4-Door Sedan Vehicle Grade MID TECHNICAL MID ELEGANT Model Code ZZT251R-AEPEKW ZZT251L-AEPEKW ZZT251R-AEMGKW ZZT251L-AEMGKW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) Height…
• Page 36
  AP-5 APPENDIX EUROPE 4-Door Sedan MID ELEGANT MID TECHNICAL MID ELEGANT ZZT251R-AEPGKW ZZT251L-AEPGKW AZT250L-AEMEKW AZT250L-AEPEKW AZT250L-AEMGKW AZT250L-AEPGKW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1480 (58.3) 1480 (58.3) 1480 (58.3)
• Page 37
  AP-6 APPENDIX Area EUROPE Item Body Type 4-Door Sedan Vehicle Grade MID TECHNICAL Model Code AZT250R-AEMEHW AZT250L-AEMEHW AZT250R-AEPEHW AZT250L-AEPEHW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) Height mm (in.)
• Page 38
  AP-7 APPENDIX EUROPE 4-Door Sedan MID ELEGANT ENTRY AZT250R-AEMGHW AZT250L-AEMGHW AZT250R-AEPGHW AZT250L-AEPGHW CDT250R-AEMNYW CDT250L-AEMNYW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1480 (58.3) 1480 (58.3) 1480 (58.3) 1480 (58.3)
• Page 39
  AP-8 APPENDIX Area EUROPE Item Body Type 4-Door Sedan Vehicle Grade MID TECHNICAL MID ELEGANT Model Code CDT250R-AEMEYW CDT250L-AEMEYW CDT250R-AEMGYW CDT250L-AEMGYW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) Height…
• Page 40
  AP-9 APPENDIX EUROPE 5-Door Liftback ENTRY ZZT250R-ALMNKW ZZT250L-ALMNKW ZZT251R-ALMNKW ZZT251L-ALMNKW ZZT251R-ALPNKW ZZT251L-ALPNKW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1480 (58.3) 1480 (58.3) 1480 (58.3) 1480 (58.3) 1480 (58.3)
• Page 41
  AP-10 APPENDIX Area EUROPE Item Body Type 5-Door Liftback Vehicle Grade MID TECHNICAL Model Code ZZT251R-ALMEKW ZZT251L-ALMEKW ZZT251R-ALPEKW ZZT251L-ALPEKW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) Height mm (in.)
• Page 42
  AP-11 APPENDIX EUROPE 5-Door Liftback MID ELEGANT MID TECHNICAL ZZT251R-ALMGKW ZZT251L-ALMGKW ZZT251R-ALPGKW ZZT251L-ALPGKW AZT250R-ALMEHW AZT250L-ALMEHW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1480 (58.3) 1480 (58.3) 1480 (58.3) 1480 (58.3)
• Page 43
  AP-12 APPENDIX Area EUROPE Item Body Type 5-Door Liftback Vehicle Grade MID TECHNICAL MID ELEGANT Model Code AZT250R-ALPEHW AZT250L-ALPEHW AZT250R-ALMGHW AZT250L-ALMGHW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) Height…
• Page 44
  AP-13 APPENDIX EUROPE 5-Door Liftback MID ELEGANT ENTRY MID TECHNICAL AZT250R-ALPGHW AZT250L-ALPGHW CDT250R-ALMNYW CDT250L-ALMNYW CDT250R-ALMEYW CDT250L-ALMEYW 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 4630 (182.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1480 (58.3) 1480 (58.3) 1480 (58.3)
• Page 45
  AP-14 APPENDIX Area EUROPE Item Body Type 5-Door Liftback 5-Door Wagon Vehicle Grade MID ELEGANT ENTRY Model Code CDT250R-ALMGYW CDT250L-ALMGYW ZZT250L-AWMNKW ZZT251R-AWMNKW 4630 (182.3) 4630 (182.3) 4700 (185.0) 4700 (185.0) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) Height…
• Page 46
  AP-15 APPENDIX EUROPE 5-Door Wagon ENTRY MID TECHNICAL MID ELEGANT ZZT251L-AWMNKW ZZT251L-AWPNKW ZZT251R-AWMEKW ZZT251L-AWMEKW ZZT251L-AWPEKW ZZT251R-AWMGKW 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1525 (60.0) 1525 (60.0) 1525 (60.0)
• Page 47
  AP-16 APPENDIX Area EUROPE Item Body Type 5-Door Wagon Vehicle Grade MID ELEGANT MID TECHNICAL MID ELEGANT Model Code ZZT251L-AWMGKW ZZT251L-AWPGKW AZT250L-AWPEKW AZT250L-AWPGKW 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3)
• Page 48
  AP-17 APPENDIX EUROPE 5-Door Wagon MID TECHNICAL MID ELEGANT AZT250R-AWMEHW AZT250L-AWMEHW AZT250R-AWPEHW AZT250L-AWPEHW AZT250R-AWMGHW AZT250L-AWMGHW 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1525 (60.0) 1525 (60.0) 1525 (60.0) 1525 (60.0)
• Page 49
  AP-18 APPENDIX Area EUROPE Item Body Type 5-Door Wagon Vehicle Grade MID ELEGANT ENTRY Model Code AZT250R-AWPGHW AZT250L-AWPGHW CDT250R-AWMNYW CDT250L-AWMNYW 4700 (185.0) 4700 (185.0) 4700 (185.0) 4700 (185.0) Length mm (in.) Overall Width mm (in.) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) Height mm (in.)
• Page 50
  AP-19 APPENDIX EUROPE GENERAL COUNTRIES 5-Door Wagon 4-Door Sedan MID TECHNICAL MID ELEGANT ENTRY CDT250L-AWMEYW CDT250L-AWMGYW AZT250L-AEMNK AZT250R-AEPNK AZT250L-AEPNK 4700 (185.0) 4700 (185.0) 4630 (182.3) 4630 (182.3) 4630 (182.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1760 (69.3) 1525 (60.0) 1525 (60.0) 1480 (58.3) 1480 (58.3)
• Page 51
  The connector with a lock should be securely con- nected until it makes a ”click” sound. When checking the connector with a Toyota electri- WRONG cal tester, check it from the backside (harness side) of the connector using a mini test lead.
• Page 52
  01–33 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Checking of the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, check the engaged condition and sliding resistance. Same terminal as a male terminal D25088 REPAIR METHOD OF CONNECTOR TERMINAL If there is on the contact point, clean the contact…
• Page 53
  01–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the continuity. Fig. 2 Disconnect connectors A and C and measure the resistance between them. Resistance: 1 f or less HINT: Sensor Measure the resistance while lightly shaking the wire harness vertically and horizontally.
• Page 54
  01–35 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK SHORT CIRCUIT Fig. 5 If the wire harness is ground shorted as shown in Fig. 5, C SHORT locate the section by conducting a continuity check with the body ground in step (b). Z17008 Check the continuity with the body ground.
• Page 55
  01–36 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK AND REPLACE ECU NOTICE: Start an inspection of the connector from the back- side of the connector on the wire harness side with the connector connected to the ECU. When no measurement condition is specified, per- form the inspection with the engine stopped and also the ignition switch ON.

• Page 56: Table Of Contents

  01–21 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010B6–13 GENERAL INFORMATION There are many ECU controlled systems used in the AVENSIS. In general, ECU controlled system are con- sidered to be very intricate and require a high level of technical knowledge and expert skill to troubleshoot. The fact is, however, that if you proceed by inspecting the circuits one by one, troubleshooting of these sys- tems is not complex.

• Page 57: Introduction – How To Troubleshoot Ecu Controlled

  01–22 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010B7–13 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures on the following page. Here, only the basic procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods for each circuit.

• Page 58
  01–23 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Confirmation test After completing repairs, confirm that the problem has been solved (If the problem does not recur, per- form a confirmation test under the same conditions and in the same environment as when it occurred for the first time).
• Page 59
  01–24 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS HINT: In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all preconcep- tions must be set aside in order to make an accurate judgement. To ascertain what the problem symp- toms are, it is extremely important to ask the customer about the problem and conditions when it oc- curred.

• Page 60: Abs With Ebd System

  01–25 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in AVENSIS has various functions. The first function is the Diagnostic Trouble Code (DTC) Check, in which a malfunction in the signal circuits to the ECU is stored in code form in the ECU memory.

• Page 61
  01–26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Symptoms exist No symptoms exist Go to step 5 Simulation test using the symptom simulation methods DTC check DTC displayed Normal code displayed Troubleshooting of problem indicated by DTC Symptom confirmation No symptoms exist Symptoms exist If a DTC is displayed in the initial DTC check, it indicates that…
• Page 62
  01–27 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occurs. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer’s vehicle should be simulated.
• Page 63
  01–28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Do not apply heat directly to the parts in the ECU. WATER SPRINKLING METHOD: When the malfunc- tion seems to occur on a rainy day or in high–humid- ity. Sprinkle water onto the vehicle and check if the malfunc- tion occurs.
• Page 64
  01–29 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART The inspection procedures are shown in the table below. This table allows efficient and accurate trouble- shooting using the diagnostic trouble codes displayed in the diagnostic trouble code chart. Proceed with troubleshooting in accordance with the inspection procedures listed in the diagnostic chart corresponding to the diagnostic trouble codes displayed.
• Page 65
  01–30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a Normal code is displayed in the diagnostic trouble code chart but the prob- lem is still occurring.

• Page 66: Circuit Inspection

  01–31 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. Y Circuit Description Y Inspection Procedures The major role and, operation of the circuit Use the inspection procedures to determine and its component parts are explained.

• Page 67
  01–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 010B2–13 GENERAL INFORMATION GENERAL DESCRIPTION This manual is made in accordance with SAE J2008. Generally, repair operations can be separated in the following 3 main processes: 1. Diagnosis 2.
• Page 68
  01–2 INTRODUCTION – HOW TO USE THIS MANUAL Tightening torque, grease application area, and non–reusable parts are described as important points in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc.
• Page 69
  01–3 INTRODUCTION – HOW TO USE THIS MANUAL SI UNIT The units given in this manual are primarily expressed according to the SI UNIT (International System of Units), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf) AVENSIS REPAIR MANUAL (RM1018E)

• Page 70: Identification Information

  01–4 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION 010LE–01 VEHICLE IDENTIFICATION AND SERIAL NUMBERS VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped in the en- gine compartment, as shown in the illustration. This num- ber has also been stamped on the manufacturer’s plate. D30402 ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER…

• Page 71
  01–5 INTRODUCTION – REPAIR INSTRUCTION REPAIR INSTRUCTION 010LF–01 PRECAUTION BASIC REPAIR HINT HINTS ON OPERATIONS D25016 Y Always wear a clean uniform. Looks Y Hat and safety shoes must be worn. Y Set a grill cover, fender cover, seat cover and floor mat before starting operation. Vehicle protection Y When working with 2 or more persons, be sure to check the safety of one another.
• Page 72
  01–6 INTRODUCTION – REPAIR INSTRUCTION JACKING UP AND SUPPORTING VEHICLE Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page 01–19). PRECOATED PARTS Precoated parts such as bolts, nuts, etc., are coated with a seal lock adhesive at the factory.
• Page 73
  01–7 INTRODUCTION – REPAIR INSTRUCTION CLIPS The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/Installation Clip…
• Page 74
  01–8 INTRODUCTION – REPAIR INSTRUCTION Shape (Example) Removal/Installation Removal Installation Removal Installation V00012 REMOVAL AND INSTALLATION OF VACUUM HOSES To disconnect vacuum hoses, pull them by holding the end, not the middle of the hose. CORRECT WRONG D25063 When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
• Page 75
  01–9 INTRODUCTION – REPAIR INSTRUCTION TORQUE WHEN USING TORQUE WRENCH WITH EX- TENSION TOOL When the torque wrench is combined with SST or an extension tool to extend the length, and you tighten until the torque wrench reads the specified torque value, the actual torque becomes excessive.
• Page 76
  01–10 INTRODUCTION – REPAIR INSTRUCTION Even in the case of a minor collision where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly and seat belt pretensioner should be inspected (See pages 60–19, 60–19 61–9). Never use the SRS related parts from another vehicle.
• Page 77
  01–11 INTRODUCTION – REPAIR INSTRUCTION When disposing the vehicle or the horn button assembly alone, the airbag should be inflated us- ing an SST before disposal (See page 60–19). Perform the operation in a safe place away from electrical noise. Example: CORRECT WRONG…
• Page 78
  01–12 INTRODUCTION – REPAIR INSTRUCTION Example: Z13951 FRONT SEAT AIRBAG ASSEMBLY Always store a removed or new front seat airbag assembly with the airbag inflating direction fac- ing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.
• Page 79
  01–13 INTRODUCTION – REPAIR INSTRUCTION INSTRUMENT PANEL LOWER AIRBAG ASSEMBLY Always store a removed or new instrument panel lower airbag assembly with the airbag inflating direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.
• Page 80
  01–14 INTRODUCTION – REPAIR INSTRUCTION Grease should not be attached to the curtain shield airbag assembly, and the surface should not be cleared with detergents of any kind. Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.
• Page 81
  01–15 INTRODUCTION – REPAIR INSTRUCTION Oil or water should not be put on the front seat outer belt and the front seat outer belt should be cleaned with the appropriate detergents. Example: D26613 AIRBAG SENSOR ASSEMBLY Never reuse the airbag sensor assembly involved in a collision where the SRS has deployed. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor.
• Page 82
  01–16 INTRODUCTION – REPAIR INSTRUCTION (–) terminal cable is disconnected. If necessary, be sure to initialize the system. HANDLING OF ELECTRONIC PARTS Do not open the cover or case of the ECU unless absolutely necessary (If the IC terminals are touched, the IC may be rendered inoperative by static electricity).
• Page 83
  01–17 INTRODUCTION – REPAIR INSTRUCTION HANDLING OF HOSE CLAMPS Spring Type Clamp Before removing the hose, check the depth of the insert- ing portion and the clamp position to restore it surely. Change a deformed or dented clamp for a new one. In case of reusing a hose, attach the clamp on the clamp track portion of the hose.
• Page 84
  01–18 INTRODUCTION – REPAIR INSTRUCTION NOTICE: Confirm that the VSC warning light blinks. VSC system will be reset when the engine is re- started. Fasten the vehicle with lock chains. NOTICES OF RELATED OPERATIONS TO VSC Do not carry out unnecessary installation and re- moval as it might disorder the adjustment of related parts to VSC.
• Page 85
  01–19 INTRODUCTION – REPAIR INSTRUCTION 010B5–11 VEHICLE LIFT AND SUPPORT LOCATIONS NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP As a rule, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle loaded with things of heavy weight. When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves.
• Page 86
  01–20 INTRODUCTION – REPAIR INSTRUCTION NOTICE FOR USING SWING ARM TYPE LIFT Follow the instruction manual of the lift for a safe operation. Use a cradle with a rubber attachment, as shown in the illustration. Set in the vehicle so as to make its center of gravity as close as possible to the center of the lift. (”L” becomes short.) Place the vehicle horizontally by adjusting the height of the cradle, and match the groove of the cradle and the safety stand support location accurately.
• Page 87
  01–37 INTRODUCTION – TERMS TERMS 010B9–11 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti–Lock Brake System Air Conditioner Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air–Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier…
• Page 88
  01–38 INTRODUCTION – TERMS Abbreviations Meaning Defogger Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatile Disc Electric Brake Force Distribution ECAM Engine Control And Measurement System Electronic Controlled Diesel…
• Page 89
  01–39 INTRODUCTION – TERMS Abbreviations Meaning H–FUSE High Current Fuse High High Intensity Discharge (Head Lamp) Housing Hard Top Heated Windshield System Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Idle Speed Control Junction Block…
• Page 90
  Special Service Tools Standard Cold–Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS TOYOTA Computer–Controlled System Timing Control Valve Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 91
  INTRODUCTION – TERMS Abbreviations Meaning Toyota Free–Tronic Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. Traction Control System TURBO Turbocharge Three–Way Catalyst Underdrive Undersize Vacuum Control Valve VENT Ventilator Vehicle Identification Number…
• Page 92
  – TERMS 010BA–14 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS…
• Page 93
  01–43 INTRODUCTION – TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel–Shutoff – Idle Speed Control –…
• Page 94
  01–44 INTRODUCTION – TERMS Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range – Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalytic (TWC) Three–Way Catalytic Converter Manifold Converter TWC+OC Three–Way + Oxidation Catalytic Converter + CCo Volume Air Flow…
• Page 95
  02–55 PREPARATION – AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 022KX–01 PREPARATION Recomended Tools 09042–00010 Torx Socket T30 NAVIGATION ANTENNA ASSY 09042–00030 Torx Socket T20 CIGARETTE LIGHTER ASSY 09050–00032 Air Drill FRONT NO.1 SPEAKER ASSY REAR SPEAKER ASSY Chuck Set FRONT NO.1 SPEAKER ASSY (09050–00210) REAR SPEAKER ASSY…
• Page 96
  02–36 PREPARATION – AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION / TRANS 022L4–02 PREPARATION 07110–58060 Air Conditioner Service Tool Set TRANSMISSION CONTROL CABLE ASSY (07117–58060) Refrigerant Drain Service Valve TRANSMISSION CONTROL CABLE ASSY (07117–58070) T–Joint TRANSMISSION CONTROL CABLE ASSY Quick Disconnect Adapter TRANSMISSION CONTROL CABLE (07117–58080) ASSY…
• Page 97
  02–37 PREPARATION – AUTOMATIC TRANSMISSION / TRANS (09316–00011) Replacer Pipe FRONT DIFFERENTIAL SEAL(U241E) TOYOTA Automatic Transmission TORQUE CONVERTER CLUTCH 09350–32014 Tool Set AND DRIVE PLATE(ATM) AUTOMATIC TRANSAXLE ASSY(U241E) AUTOMATIC TRANSAXLE ASSY(U341E) (09351–32010) One–way Clutch Test Tool TORQUE CONVERTER CLUTCH AND DRIVE PLATE(ATM)
• Page 98
  02–38 PREPARATION – AUTOMATIC TRANSMISSION / TRANS (09726–02041) Replacer FRONT DIFFERENTIAL SEAL(U341E) Drive Shaft Nut Chisel AUTOMATIC TRANSAXLE 09930–00010 ASSY(U241E) AUTOMATIC TRANSAXLE ASSY(U341E) FRONT DIFFERENTIAL SEAL(U341E) 09950–70010 Handle Set FRONT DIFFERENTIAL SEAL(U241E) FRONT DIFFERENTIAL SEAL(U341E) (09951–07150) Handle 150 FRONT DIFFERENTIAL SEAL(U241E) Handle 200 FRONT…
• Page 99
  02–39 PREPARATION – AUTOMATIC TRANSMISSION / TRANS 09090–04020 Engine Sling Device AUTOMATIC TRANSAXLE ASSY(U241E) AUTOMATIC TRANSAXLE ASSY(U341E) Gas Leak Detector TRANSMISSION CONTROL CABLE 95416–00140 (Halogen Leak Detector) ASSY (DENSO Part No.) Belt Tension Gauge AUTOMATIC TRANSAXLE 09216–00021 ASSY(U151E/U151F) 08833–00080 Adhesive 1344 TRANSMISSION WIRE(U241E) THREE BOND 1344 TRANSMISSION…
• Page 100
  02–33 PREPARATION – BRAKE BRAKE 022KS–01 PREPARATION 09023–00100 Union Nut Wrench 10 mm BRAKE FLUID BRAKE MASTER CYLINDER SUB–ASSY FRONT BRAKE REAR BRAKE BRAKE BOOSTER ASSY(LHD) BRAKE BOOSTER ASSY(RHD) BRAKE ACTUATOR ASSY(W/ VSC) BRAKE ACTUATOR ASSY(W/O VSC) Union Nut Wrench 14mm BRAKE FLUID 09023–38400 BRAKE…
• Page 101
  02–34 PREPARATION – BRAKE Equipment Micrometer Dial indicator w/ magnetic base Brake drum gauge Slide calipers Torque wrench Lubricant Item Capacity Classification Brake fluid – SAE J1704 or FMVSS No. 116 DOT4 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 102
  02–43 PREPARATION – CLUTCH CLUTCH 022KZ–01 PREPARATION 09023–00100 Union Nut Wrench 10 mm CLUTCH ACCUMULATOR ASSY(1CD–FTV) CLUTCH RELEASE CYLINDER ASSY(MTM) CLUTCH MASTER CYLINDER ASSY(MTM) 09301–00220 Clutch Guide Tool CLUTCH UNIT(MTM) 09333–00013 Universal Joint Bearing Remover CLUTCH UNIT(MTM) & Replacer Recomended Tools Hexagon Wrench Set CLUTCH PEDAL SUB–ASSY(MTM) 09040–00011…
• Page 103
  02–56 PREPARATION – COMMUNICATION SYSTEM COMMUNICATION SYSTEM 022L2–01 PREPARATION Recomended Tools 09082–00050 TOYOTA Electrical Tester Set HORN SYSTEM AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 104
  02–18 PREPARATION – COOLING COOLING 022KA–01 PREPARATION 09023–12700 Union Nut Wrench 17mm WATER PUMP ASSY(1CD–FTV) 09213–54015 Crankshaft Pulley Holding Tool WATER PUMP ASSY(1CD–FTV) (90105–08076) Bolt WATER PUMP ASSY(1CD–FTV) Torque Wrench Adaptor WATER PUMP ASSY(1AZ–FE) 09249–63010 THERMOSTAT(1AZ–FE) WATER PUMP ASSY(1AZ–FSE) THERMOSTAT(1AZ–FSE) Companion Flange Holding Tool WATER PUMP ASSY(1CD–FTV) 09330–00021…
• Page 105
  WATER PUMP ASSY(1CD–FTV) Coolant Item Capacity Classification Engine coolant (3ZZ–FE) TOYOTA long life coolant Left–hand drive vehicles 5.8 liters (6.1 US qts, 5.1 lmp. qts) Right–hand drive vehicles 5.9 liters (6.2 US qts, 5.2 lmp. qts) Engine coolant (1ZZ–FE) TOYOTA long life coolant Left–hand drive vehicles…
• Page 106
  POWER STEERING SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SFI SYSTEM(1AZ–FE) ECD SYSTEM(1CD–FTV) SFI SYSTEM(1ZZ–FE/3ZZ–FE) 09992–00242 Turbocharger Pressure Gauge ECD SYSTEM(1CD–FTV) Recomended Tools TOYOTA Electrical Tester COMBINATION METER 09082–00040 SFI SYSTEM(1AZ–FE) SFI SYSTEM(1AZ–FSE) ECD SYSTEM(1CD–FTV) SFI SYSTEM(1ZZ–FE/3ZZ–FE) ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT](U241E(1AZ–FE)) ELECTRONIC…

• Page 107: Abs With Ebd & Ba & Trc & Vsc System

  TRANSAXLE [ECT](U241E(1AZ–FE)) ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT](U241E(1AZ–FSE)) ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT](U341E) 09082–00050 TOYOTA Electrical Tester Set POWER DOOR LOCK CONTROL SYSTEM Test Lead Set AIR CONDITIONING SYSTEM (09083–00150) ABS WITH EBD SYSTEM ELECTRONIC MOTOR POWER STEERING SYSTEM MULTIPLEX COMMUNICATION…

• Page 108
  02–29 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT / PROPELLER SHAFT 022KL–01 PREPARATION 09240–00020 Wire Gauge Set FRONT DRIVE SHAFT 09520–00031 Rear Axle Shaft Puller FRONT AXLE HUB SUB–ASSY LH 09520–01010 Drive Shaft Remover Attachment FRONT DRIVE SHAFT Differential Side Gear Shaft FRONT DRIVE SHAFT 09520–24010…
• Page 109
  02–30 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT 09610–20012 Pitman Arm Puller REAR AXLE CARRIER SUB–ASSY Ball Joint Puller REAR AXLE LH HUB BOLT 09628–10011 FRONT AXLE LH HUB BOLT Boll Joint Puller FRONT AXLE HUB SUB–ASSY LH 09628–62011 REAR AXLE CARRIER SUB–ASSY FRONT DRIVE SHAFT 09710–04081 Base…
• Page 110
  02–31 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT (09955–04061) Claw No.6 FRONT AXLE HUB SUB–ASSY LH Attachment FRONT AXLE HUB SUB–ASSY LH (09957–04010) Holder (J) FRONT AXLE HUB SUB–ASSY LH (09958–04010) 09950–60010 Replacer Set FRONT AXLE HUB SUB–ASSY LH (09951–00370) Replacer 37 FRONT AXLE HUB SUB–ASSY LH (09951–00600)
• Page 111
  02–32 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT 09040–00011 Hexagon Wrench Set FRONT AXLE HUB SUB–ASSY LH FRONT DRIVE SHAFT Socket Hexagon Wrench 6 FRONT AXLE HUB SUB–ASSY LH (09043–20060) FRONT DRIVE SHAFT Expander Set FRONT DRIVE SHAFT 09904–00010 (09904–00050) No.
• Page 112
  PREPARATION – ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 022J5–01 PREPARATION 09268–21010 Fuel Hose Puller KNOCK SENSOR(1AZ–FE) Recomended Tools 09082–00040 TOYOTA Electrical Tester SFI SYSTEM(1AZ–FE) SFI SYSTEM(1AZ–FSE) SFI SYSTEM(1ZZ–FE/3ZZ–FE) (09083–00150) Test Lead Set SFI SYSTEM(1AZ–FE) SFI SYSTEM(1AZ–FSE) SFI SYSTEM(1ZZ–FE/3ZZ–FE) Equipment Ohmmeter…
• Page 113
  02–61 PREPARATION – ENGINE HOOD/DOOR ENGINE HOOD/DOOR 022K8–01 PREPARATION 09812–00010 Door Hinge Set Bolt Wrench FRONT DOOR 09812–00020 Door Hinge Set Bolt Wrench FRONT DOOR Recomended Tools 09042–00010 Torx Socket T30 FRONT DOOR REAR DOOR 09042–00020 Torx Socket T40 FRONT DOOR REAR DOOR LUGGAGE COMPARTMENT DOOR BACK DOOR(LIFTBACK MODELS)
• Page 114
  02–8 PREPARATION – ENGINE MECHANICAL ENGINE MECHANICAL 022KB–01 PREPARATION 09023–00100 Union Nut Wrench 10 mm PARTIAL ENGINE ASSY(1CD–FTV) 09023–12700 Union Nut Wrench 17mm VALVE CLEARANCE(1CD–FTV) CAMSHAFT(1CD–FTV) CYLINDER HEAD GASKET(1CD–FTV) PARTIAL ENGINE ASSY(1CD–FTV) 09023–12900 Union Nut Wrench 19mm VALVE CLEARANCE(1AZ–FSE) PARTIAL ENGINE ASSY(1AZ–FSE) CHAIN SUB–ASSY(1AZ–FSE) CAMSHAFT(1AZ–FSE) CYLINDER…
• Page 115
  02–9 PREPARATION – ENGINE MECHANICAL (91651–60855) Bolt PARTIAL ENGINE ASSY(1AZ–FE) CHAIN SUB–ASSY(1AZ–FE) CYLINDER HEAD GASKET(1AZ–FE) ENGINE REAR OIL SEAL(1AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FE) PARTIAL ENGINE ASSY(1AZ–FSE) CHAIN SUB–ASSY(1AZ–FSE) CYLINDER HEAD GASKET(1AZ–FSE) ENGINE REAR OIL SEAL(1AZ–FSE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FSE) 09223–15020…
• Page 116
  02–10 PREPARATION – ENGINE MECHANICAL 09249–63010 Torque Wrench Adaptor GENERATOR BELT(1AZ–FE) CHAIN SUB–ASSY(1AZ–FE) CYLINDER HEAD GASKET(1AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FE) GENERATOR BELT(1AZ–FSE) CHAIN SUB–ASSY(1AZ–FSE) CYLINDER HEAD GASKET(1AZ–FSE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FSE) 09268–21010 Fuel Hose Puller CYLINDER…
• Page 117
  02–11 PREPARATION – ENGINE MECHANICAL (09330–00030) PARTIAL ENGINE ASSY(1AZ–FE) PARTIAL ENGINE ASSY(1AZ–FSE) Drive Shaft Remover Attachment ENGINE REAR OIL SEAL(1CD–FTV) 09520–01010 Differential Side Gear Shaft ENGINE REAR OIL SEAL(1CD–FTV) 09520–24010 Puller (09520–32040) Shocker Set ENGINE REAR OIL SEAL(1CD–FTV) 09628–62011 Boll Joint Puller ENGINE REAR OIL SEAL(1CD–FTV) PARTIAL ENGINE ASSY(1CD–FTV) PARTIAL…
• Page 118
  02–12 PREPARATION – ENGINE MECHANICAL 09950–50013 Puller C Set CHAIN SUB–ASSY(1AZ–FE) CYLINDER HEAD GASKET(1AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FE) CHAIN SUB–ASSY(1AZ–FSE) CYLINDER HEAD GASKET(1AZ–FSE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FSE) TIMING BELT(1CD–FTV) CAMSHAFT(1CD–FTV) CYLINDER HEAD GASKET(1CD–FTV)
• Page 119
  02–13 PREPARATION – ENGINE MECHANICAL (09953–05020) Center Bolt 150 CHAIN SUB–ASSY(1AZ–FE) CYLINDER HEAD GASKET(1AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FE) CHAIN SUB–ASSY(1AZ–FSE) CYLINDER HEAD GASKET(1AZ–FSE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(1AZ–FSE) TIMING BELT(1CD–FTV) CAMSHAFT(1CD–FTV) CYLINDER HEAD GASKET(1CD–FTV)
• Page 120
  02–14 PREPARATION – ENGINE MECHANICAL (09962–01000) Variable Pin Wrench Arm Assy TIMING BELT(1CD–FTV) CAMSHAFT(1CD–FTV) CYLINDER HEAD GASKET(1CD–FTV) CRANKSHAFT SEAL(1CD–FTV) PARTIAL ENGINE ASSY(1CD–FTV) PARTIAL ENGINE ASSY(1ZZ–FE/3ZZ–FE) CHAIN SUB–ASSY(1ZZ–FE/3ZZ–FE) CYLINDER HEAD GASKET(1ZZ–FE/3ZZ–FE) TIMING CHAIN OR BELT COVER OIL SEAL(1ZZ–FE/3ZZ–FE) ENGINE REAR SEAL(1ZZ–FE/3ZZ–FE) Pin 10 TIMING BELT(1CD–FTV) (09963–01000)
• Page 121
  02–15 PREPARATION – ENGINE MECHANICAL Recomended Tools Socket Wrench 30 mm ENGINE REAR OIL SEAL(1CD–FTV) 09011–12301 PARTIAL ENGINE ASSY(1CD–FTV) PARTIAL ENGINE ASSY(1ZZ–FE/3ZZ–FE) ENGINE REAR SEAL(1ZZ–FE/3ZZ–FE) Deep Socket Wrench 12 mm PARTIAL ENGINE ASSY(1CD–FTV) 09017–38120 09040–00011 Hexagon Wrench Set PARTIAL ENGINE ASSY(1ZZ–FE/3ZZ–FE) Socket Hexagon Wrench 5 PARTIAL…
• Page 122
  02–16 PREPARATION – ENGINE MECHANICAL Vernier calipers Tire pressure gauge Alignment tester Toe–in gauge OBD II scan tool Deep socket wrench 24 mm Slide calipers Sand paper (#400) Wooden block Chain block Spark plug cleaner Angle gauge Universal engine lifter 08826–00080 Seal Packing Black or equivalent VALVE CLEARANCE(1AZ–FE)
• Page 123
  02–17 PREPARATION – EXHAUST EXHAUST 022J7–01 PREPARATION Equipment Torque wrench Vernier calipers Wooden block AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 124
  02–62 PREPARATION – EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 022KP–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover FRONT DOOR BELT MOULDING ASSY LH REAR DOOR BELT MOULDING ASSY LH ROOF HEADLINING ASSY(LIFTBACK MODELS) ROOF HEADLINING ASSY(SEDAN MODELS) ROOF HEADLINING ASSY(WAGON MODELS) Equipment Adhesive tape To avoid surface damage.
• Page 125
  02–25 PREPARATION – FRONT SUSPENSION FRONT SUSPENSION 022KF–01 PREPARATION 09628–62011 Boll Joint Puller LOWER BALL JOINT ASSY FRONT STABILIZER BAR FRONT FRONT SUSPENSION SUB–ASSY LOWER NO.1 LH(ATM) 09727–30021 Coil Spring Compressor FRONT SHOCK ABSORBER WITH COIL SPRING 09729–22031 Front Spring Upper Seat Holder FRONT SHOCK ABSORBER WITH COIL SPRING 09930–00010…
• Page 126
  02–4 PREPARATION – FUEL FUEL 022J6–01 PREPARATION 09023–12700 Union Nut Wrench 17mm INJECTOR ASSY(1CD–FTV) INJECTION OR SUPPLY PUMP ASSY(1CD–FTV) COMMON RAIL ASSY(1CD–FTV) 09213–54015 Crankshaft Pulley Holding Tool INJECTION SUPPLY PUMP ASSY(1CD–FTV) (90105–08076) Bolt INJECTION SUPPLY PUMP ASSY(1CD–FTV) Fuel Filter Wrench FUEL FILTER ASSY(1CD–FTV) 09228–64030 Fuel Hose Puller…
• Page 127
  02–5 PREPARATION – FUEL 09808–14010 Fuel Sender Gauge Tool Assy FUEL TANK ASSY(DIESEL) FUEL PUMP ASSY(GASOLINE) FUEL TANK ASSY(GASOLINE) Wire ”H” EFI Inspection FUEL SYSTEM(1AZ–FE) 09842–30080 FUEL SYSTEM(1ZZ–FE/3ZZ–FE) Puller C Set INJECTION OR SUPPLY PUMP 09950–50013 ASSY(1CD–FTV) (09951–05010) Hanger 150 INJECTION OR SUPPLY PUMP ASSY(1CD–FTV) (09952–05010)
• Page 128
  02–6 PREPARATION – FUEL 09082–00040 TOYOTA Electrical Tester FUEL SYSTEM(1CD–FTV) FUEL SYSTEM(1ZZ–FE/3ZZ–FE) Test Lead Set FUEL SYSTEM(1AZ–FE) (09083–00150) FUEL SYSTEM(1AZ–FSE) FUEL SYSTEM(1ZZ–FE/3ZZ–FE) Water Pump Pliers FUEL FILTER ASSY(1CD–FTV) 09130–00150 09216–00021 Belt Tension Gauge INJECTION OR SUPPLY PUMP ASSY(1CD–FTV) Equipment Clip…
• Page 129
  02–47 PREPARATION – HEATER & AIR CONDITIONER HEATER & AIR CONDITIONER 022KJ–01 PREPARATION 07110–58060 Air Conditioner Service Tool Set REFRIGERANT CONDITIONING RADIATOR ASSY W/RECEIVER CONDENSER ASSY W/PULLEY COMPRESSOR ASSY(1AZ–FE) W/PULLEY COMPRESSOR ASSY(1AZ–FSE) W/PULLEY COMPRESSOR ASSY(1CD–FTV) W/PULLEY COMPRESSOR ASSY(1ZZ–FE) W/PULLEY COMPRESSOR ASSY(2AZ–FSE) W/PULLEY COMPRESSOR…
• Page 130
  02–48 PREPARATION – HEATER & AIR CONDITIONER (07117–58080) Quick Disconnect Adapter REFRIGERANT CONDITIONING RADIATOR ASSY W/RECEIVER CONDENSER ASSY W/PULLEY COMPRESSOR ASSY(1AZ–FE) W/PULLEY COMPRESSOR ASSY(1AZ–FSE) W/PULLEY COMPRESSOR ASSY(1CD–FTV) W/PULLEY COMPRESSOR ASSY(1ZZ–FE) W/PULLEY COMPRESSOR ASSY(2AZ–FSE) W/PULLEY COMPRESSOR ASSY(3ZZ–FE) Quick Disconnect Adapter REFRIGERANT (07117–58090) CONDITIONING RADIATOR…
• Page 131
  02–49 PREPARATION – HEATER & AIR CONDITIONER (07117–88060) Refrigerant Charging Hose REFRIGERANT CONDITIONING RADIATOR ASSY W/RECEIVER CONDENSER ASSY W/PULLEY COMPRESSOR ASSY(1AZ–FE) W/PULLEY COMPRESSOR ASSY(1AZ–FSE) W/PULLEY COMPRESSOR ASSY(1CD–FTV) W/PULLEY COMPRESSOR ASSY(1ZZ–FE) W/PULLEY COMPRESSOR ASSY(2AZ–FSE) W/PULLEY COMPRESSOR ASSY(3ZZ–FE) Refrigerant Charging Hose REFRIGERANT (07117–88070) CONDITIONING RADIATOR…
• Page 132
  02–50 PREPARATION – HEATER & AIR CONDITIONER 09870–00025 A/C Quick Joint Puller No.2 CONDITIONING RADIATOR ASSY Puller C Set CONDITIONING RADIATOR 09950–50013 ASSY BLOWER ASSY Hanger 150 CONDITIONING RADIATOR (09951–05010) ASSY BLOWER ASSY (09952–05010) Slide Arm CONDITIONING RADIATOR ASSY BLOWER ASSY (09953–05020) Center Bolt 150 CONDITIONING…
• Page 133
  02–51 PREPARATION – HEATER & AIR CONDITIONER 95416–00140 Gas Leak Detector REFRIGERANT (Halogen Leak Detector) CONDITIONING RADIATOR (DENSO Part No.) ASSY W/PULLEY COMPRESSOR ASSY(1AZ–FE) W/PULLEY COMPRESSOR ASSY(1AZ–FSE) W/PULLEY COMPRESSOR ASSY(1CD–FTV) W/PULLEY COMPRESSOR ASSY(1ZZ–FE) W/PULLEY COMPRESSOR ASSY(2AZ–FSE) W/PULLEY COMPRESSOR ASSY(3ZZ–FE) Equipment Voltmeter Anmeter Ohmmeter…
• Page 134
  PREPARATION – IGNITION IGNITION 022J8–01 PREPARATION 09249–63010 Torque Wrench Adaptor CRANKSHAFT POSITION SENSOR (1AZ–FE/1AZ–FSE) Recomended Tools 09082–00040 TOYOTA Electrical Tester IGNITION SYSTEM(1AZ–FE) IGNITION SYSTEM(1AZ–FSE) IGNITION SYSTEM (1ZZ–FE/3ZZ–FE) (09083–00150) Test Lead Set IGNITION SYSTEM(1AZ–FE) IGNITION SYSTEM(1AZ–FSE) IGNITION SYSTEM (1ZZ–FE/3ZZ–FE) 09200–00010 Engine Adjust Kit IGNITION SYSTEM(1AZ–FE)
• Page 135
  Center Bolt 150 INSTRUMENT PANEL SUB–ASSY (09953–05020) LOWER Claw No.2 INSTRUMENT PANEL SUB–ASSY (09954–05021) LOWER Recomended Tools 09082–00040 TOYOTA Electrical Tester COMBINATION METER (09083–00150) Test Lead Set COMBINATION METER Torx Driver T30 INSTRUMENT PANEL SUB–ASSY 09041–00030 LOWER Torx Socket T30 INSTRUMENT PANEL SUB–ASSY…
• Page 136
  PREPARATION – INTAKE INTAKE 022KR–01 PREPARATION 09992–00242 Turbocharger Pressure Gauge TURBO CHARGER SYSTEM (1CD–FTV) Recomended Tools 09082–00040 TOYOTA Electrical Tester TURBO CHARGER SYSTEM (1CD–FTV) (09083–00150) Test Lead Set TURBO CHARGER SYSTEM (1CD–FTV) Equipment Vacuum gauge Voltmeter Ohmmeter Service wire harness…
• Page 137
  02–20 PREPARATION – LUBRICATION LUBRICATION 022K9–01 PREPARATION 09023–12900 Union Nut Wrench 19mm OIL PUMP ASSY(1AZ–FSE) 09032–00100 Oil Pan Seal Cutter OIL PUMP ASSY(1AZ–FE) OIL PUMP ASSY(1AZ–FSE) OIL PUMP ASSY(1CD–FTV) 09213–54015 Crankshaft Pulley Holding Tool OIL PUMP ASSY(1AZ–FE) OIL PUMP ASSY(1AZ–FSE) OIL PUMP ASSY(1CD–FTV) Bolt OIL PUMP ASSY(1CD–FTV)
• Page 138
  02–21 PREPARATION – LUBRICATION 09330–00021 Companion Flange Holding Tool OIL PUMP ASSY(1AZ–FE) OIL PUMP ASSY(1AZ–FSE) OIL PUMP ASSY(1CD–FTV) Puller C Set OIL PUMP ASSY(1AZ–FE) 09950–50013 OIL PUMP ASSY(1AZ–FSE) OIL PUMP ASSY(1CD–FTV) Hanger 150 OIL PUMP ASSY(1AZ–FE) (09951–05010) OIL PUMP ASSY(1AZ–FSE) OIL PUMP ASSY(1CD–FTV) (09952–05010) Slide Arm…
• Page 139
  02–22 PREPARATION – LUBRICATION Seal Packing Black or equivalent OIL PUMP ASSY(1CD–FTV) 08826–00080 (FIPG) Lubricant Item Capacity Classification Oil grade (gasoline engine) API grade SJ ”Energy–Conserving”, SL ”Energy– – Conserving” multigrade engine oil or ILSAC multi- grade engine oil Oil grade (Diesel engine) ACEA B1, API CF–4 or CF –…
• Page 140
  02–40 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION/TRANSAXLE 022KY–01 PREPARATION 09023–00100 Union Nut Wrench 10 mm MANUAL TRANSAXLE ASSY(1CD–FTV) 09023–12700 Union Nut Wrench 17mm MANUAL TRANSAXLE ASSY(1AZ–FE/1AZ–FSE) MANUAL TRANSAXLE ASSY(1CD–FTV) 09308–00010 Oil Seal Puller FRONT DIFFERENTIAL SEAL(C50/C250) FRONT DIFFERENTIAL SEAL(E354/E357) Drive Shaft Remover Attachment MANUAL TRANSAXLE 09520–01010…
• Page 141
  02–41 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE 09608–32010 Steering Knuckle Oil Seal FRONT DIFFERENTIAL Replacer SEAL(E354/E357) Boll Joint Puller MANUAL TRANSAXLE 09628–62011 ASSY(1AZ–FE/1AZ–FSE) MANUAL TRANSAXLE ASSY(1CD–FTV) MANUAL TRANSAXLE ASSY(1ZZ–FE/3ZZ–FE) FRONT DIFFERENTIAL SEAL(C50/C250) FRONT DIFFERENTIAL SEAL(E354/E357) 09670–00010 Front Crossmember Guide Tool MANUAL TRANSAXLE ASSY(1AZ–FE/1AZ–FSE) MANUAL TRANSAXLE…
• Page 142
  02–42 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE Equipment Torque wrench Hexagon wrench (6 mm) Lubricant Item Capacity Classification C50, C250 API GL–4 or GL–5 Manual Transaxle oil 1.9 litters (2.0 US qts, 1.7 Imp. qts) SAE 75W–90 (w/ Differential oil) E354, E357 API GL–4 or GL–5 Manual Transaxle oil 2.5 litters (2.6 US qts, 2.2 Imp.
• Page 143
  02–35 PREPARATION – PARKING BRAKE PARKING BRAKE 022JT–01 PREPARATION 09718–00010 Shoe Hold Down Spring Driver PARKING BRAKE ASSY PARKING BRAKE CABLE ASSY NO.3 Recomended Tools 09070–20010 Moulding Remover PARKING BRAKE CABLE ASSY NO.1 PARKING BRAKE LEVER SUB–ASSY Equipment Torque wrench Slide calipers AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 144
  02–45 PREPARATION – POWER STEERING POWER STEERING 022KE–01 PREPARATION 09023–12700 Union Nut Wrench 17mm RACK & PINION POWER STEERING GEAR ASSY VANE PUMP ASSY(1CD–FTV) 09249–63010 Torque Wrench Adaptor VANE PUMP ASSY(AZ Series) 09521–24010 Rear Axle Shaft Puller STEERING GEAR ASSY RACK &…
• Page 145
  02–46 PREPARATION – POWER STEERING Recomended Tools Torque Wrench (30 kgf–cm) STEERING GEAR ASSY 09025–00010 RACK & PINION POWER STEERING GEAR ASSY VANE PUMP ASSY(1CD–FTV) VANE PUMP ASSY(AZ Series) 09090–04020 Engine Sling Device STEERING GEAR ASSY RACK & PINION POWER STEERING GEAR ASSY Snap Ring No.1 Expander VANE PUMP ASSY(1CD–FTV)
• Page 146
  02–26 PREPARATION – REAR SUSPENSION REAR SUSPENSION 022L8–01 PREPARATION 09610–20012 Pitman Arm Puller REAR SUSPENSION ARM ASSY NO.1 LH LOWER CONTROL ARM ASSY LH 09628–62011 Boll Joint Puller REAR SUSPENSION ARM ASSY NO.1 LH 09632–36010 Steering Vane Pump Bearing REAR SUSPENSION ARM ASSY Replacer NO.1 LH Coil Spring Compressor…
• Page 147
  02–27 PREPARATION – REAR SUSPENSION (09955–04051) Claw No.5 REAR SUSPENSION ARM ASSY NO.1 LH Attachment REAR SUSPENSION ARM ASSY (09957–04010) NO.1 LH Holder REAR SUSPENSION ARM ASSY (09958–04011) NO.1 LH Recomended Tools 09040–00011 Hexagon Wrench Set REAR SHOCK ABSORBER WITH COIL SPRING REAR SUSPENSION ARM ASSY NO.1 LH…
• Page 148
  02–59 PREPARATION – SEAT SEAT 022L6–01 PREPARATION Recomended Tools 09082–00050 TOYOTA Electrical Tester Set FRONT POWER SEAT CONTROL SYSTEM SEAT HEATER SYSTEM 09082–00040 TOYOTA Electrical Tester FRONT POWER SEAT CONTROL SYSTEM SEAT HEATER SYSTEM Equipment Hog ring Hog ring pliers…
• Page 149
  02–60 PREPARATION – SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 022KO–01 PREPARATION Recomended Tools 09041–00020 Torx Driver T25 SLIDING ROOF 09082–00040 TOYOTA Electrical Tester SLIDING ROOF SYSTEM Equipment Torque wrench AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 150
  – STARTING & CHARGING STARTING & CHARGING 022J9–01 PREPARATION 09249–63010 Torque Wrench Adaptor GENERATOR ASSY(1AZ–FE/1AZ–FSE) Recomended Tools 09082–00040 TOYOTA Electrical Tester STARTING SYSTEM(1AZ–FE) STARTING SYSTEM(1AZ–FSE) STARTING SYSTEM (1ZZ–FE/3ZZ–FE) (09083–00150) Test Lead Set STARTING SYSTEM(1AZ–FE) STARTING SYSTEM(1AZ–FSE) STARTING SYSTEM (1ZZ–FE/3ZZ–FE) 09216–00021 Belt Tension Gauge GENERATOR ASSY(1CD–FTV)
• Page 151
  02–44 PREPARATION – STEERING COLUMN STEERING COLUMN 022JS–01 PREPARATION 09616–00011 Steering Worm Bearing Adjusting STEERING COLUMN ASSY Socket 09950–50013 Puller C Set STEERING COLUMN ASSY (09951–05010) Hanger 150 STEERING COLUMN ASSY Slide Arm STEERING COLUMN ASSY (09952–05010) Center Bolt 150 STEERING COLUMN ASSY (09953–05020) (09954–05021)
• Page 152
  02–52 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 022L5–01 PREPARATION 09082–00700 SRS Airbag Deployment Tool HORN BUTTON ASSY CURTAIN SHIELD AIR BAG ASSY LH FRONT SEAT AIRBAG ASSY LH INSTRUMENT PANEL PASSENGER AIR BAG ASSY INSTRUMENT PANEL ASSY Airbag Deployment Wire FRONT SEAT AIRBAG ASSY LH 09082–00750 Sub–harness No.3…
• Page 153
  02–53 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM Recomended Tools Torx Socket T30 HORN BUTTON ASSY 09042–00010 SPIRAL CABLE SUB–ASSY Moulding Remover AIR BAG SENSOR ASSY CENTER 09070–20010 Equipment Torque wrench Bolt Length: 35.0 mm (1.378 in.) Pitch: 1.0 mm (0.039 in.) Airbag disposal Diam.: 6.0 mm (0.236 in.) Tire…
• Page 154
  02–28 PREPARATION – TIRE & WHEEL TIRE & WHEEL 022KG–01 PREPARATION Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 155
  02–63 PREPARATION – VEHICLE CONTROL SYSTEM VEHICLE CONTROL SYSTEM 022L3–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester IGNITION OR STARTER SWITCH ASSY 09082–00050 TOYOTA Electrical Tester Set IGNITION OR STARTER SWITCH ASSY AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 156
  02–57 PREPARATION – WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD/WINDOWGLASS/MIRROR 022L7–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover WINDSHIELD GLASS 09082–00040 TOYOTA Electrical Tester POWER WINDOW CONTROL SYSTEM WINDOW DEFOGGER SYSTEM POWER MIRROR CONTROL SYSTEM (09083–00150) Test Lead Set POWER WINDOW CONTROL SYSTEM (09083–00350) AC/DC 400 A Probe…
• Page 157
  Diagnosis Check Wire No.2 WIPER AND WASHER SYSTEM Recomended Tools 09042–00010 Torx Socket T30 WINDSHIELD WIPER MOTOR ASSY 09082–00040 TOYOTA Electrical Tester WIPER AND WASHER SYSTEM (09083–00150) Test Lead Set WIPER AND WASHER SYSTEM Equipment Torque wrench AVENSIS REPAIR MANUAL (RM1018E)
• Page 158
  03–67 SERVICE SPECIFICATIONS – AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 031HB–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Amplifier antenna assy x Body 62 in. lbf Antenna cord sub–assy x Body 62 in. lbf Antenna cord sub–assy No.3 x Body 62 in.
• Page 159
  03–45 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE AUTOMATIC TRANSMISSION / TRANSAXLE 030A9–10 SERVICE DATA U341E (RHD) Line pressure (Wheel locked) Engine idling D range 370 – 410 kPa (3.8 – 4.2 kgf@cm , 54 – 60 psi) R range 540 –…
• Page 160
  03–46 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE Shift schedule D range (Throttle valve fully opened) 53 – 59 km/h (33 – 37 mph) 100 – 108 km/h (62 – 67 mph) 156 – 165 km/h (97 – 103 mph) 119 –…
• Page 161
  03–47 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE Shift schedule D range (Throttle valve fully opened) 53 – 62 km/h (33 – 39 mph) 102 – 111 km/h (63 – 69 mph) 158 – 173 km/h (98 – 108 mph) 150 –…
• Page 162
  03–48 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE Shift schedule(When kick down switch turns ON) D range (Throttle valve fully opened) 53 – 62 km/h (33 – 39 mph) 102 – 111 km/h (63 – 69 mph) 158 – 173 km/h (98 – 108 mph) 150 –…
• Page 163
  03–49 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE U241E (1AZ–FE) (LHD) Line pressure (Wheel locked) Engine idling D range 372 – 412 kPa (3.8 – 4.2 kgf@cm , 53 – 60 psi) R range 672 – 742 kPa (6.9 – 7.6 kgf@cm , 97 –…
• Page 164
  03–50 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE 030AA–10 TORQUE SPECIFICATION U341E Part Tightened kgf cm ft lbf Park/neutral position switch x Transaxle Bolt 48 in. lbf 61 in. lbf Control shaft lever x Park/neutral position switch Battery carrier x Body Engine hanger x Engine Drain plug x Oil pan Transaxle x Engine…
• Page 165
  03–51 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE U241E Part Tightened kgf cm ft lbf Park/neutral position switch x Transaxle Bolt 48 in. lbf 61 in. lbf Control shaft lever x Park/neutral position switch Battery carrier x Body Engine hanger x Engine Drain plug x Oil pan Transaxle x Engine Bolt A:…
• Page 166
  03–41 SERVICE SPECIFICATIONS – BRAKE BRAKE 030MU–02 SERVICE DATA Brake pedal height (from asphalt sheet) RHD: 142.5 – 152.5 mm (5.610 – 6.004 in.) LHD: 148.1 – 158.1 mm (5.831 – 6.224 in.) 149.9 – 159.9 mm (5.902 – 6.295 in.) Brake Pedal free play 1 –…
• Page 167
  03–42 SERVICE SPECIFICATIONS – BRAKE 030MV–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Wheel nut 1,050 Brake line union nut 10 mm 14 mm Brake booster clevis lock nut Brake master cylinder sub–assy x Brake booster assy Charcoal canister bracket x Body 48 in.
• Page 168
  03–55 SERVICE SPECIFICATIONS – CLUTCH CLUTCH 030L1–03 SERVICE DATA Pedal height from asphalt sheet LHD steering position type 1CD–FTV engine type w/ intercooler 154.0 – 164.0 mm (6.063 – 6.457 in.) Others 139.6 – 149.6 mm (5.496 – 5.890 in.) Pedal height from asphalt sheet RHD steering position type 1CD–FTV engine type w/ intercooler…
• Page 169
  03–56 SERVICE SPECIFICATIONS – CLUTCH 030L2–04 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Clutch pedal support x Stopper bolt Clutch pedal sub–assy x Clutch pedal support Clutch pedal support x Body Clutch pedal support x Clutch start switch assy Clutch master cylinder push rod clevis lock nut Clutch master cylinder x Flexible hose tube Clutch master cylinder x Body…
• Page 170
  03–68 SERVICE SPECIFICATIONS – COMMUNICATION SYSTEM COMMUNICATION SYSTEM 031HJ–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf HIGH PITCHED HORN ASSY High pitched horn assy x Body LOW PITCHED HORN ASSY Low pitched horn assy x Body AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 171
  03–24 SERVICE SPECIFICATIONS – COOLING COOLING 031H3–01 SERVICE DATA 1ZZ–FE/3ZZ–FE: Thermostat Valve opening temperature 86 to 90YC (187 to 198YF) Valve lift at 95YC (203YF) 10 mm (0.394 in.) or more Radiator cap sub–assy Standard opening pressure 74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi) Minimum opening pressure 59 kPa (0.6 kgf/cm2, 8.6 psi) Cooling fan…
• Page 172
  03–25 SERVICE SPECIFICATIONS – COOLING Cooling fan Standard amperage at 20YC (68YF) 5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T) Standard amperage (No.2 (With Air Conditioner)) at 20YC (68YF) 5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T) Cooling fan relay Specified condition Between terminals 1 and 2 Continuity…
• Page 173
  03–26 SERVICE SPECIFICATIONS – COOLING 031H4–01 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Radiator drain plug Water pump x Cylinder block Bolt A 8.0 in.lbf Bolt B Water inlet x Cylinder block sub–assy Radiator x Radiator support upper 1AZ–FE: Part Tightened kgf cm…
• Page 174
  03–39 SERVICE SPECIFICATIONS – DRIVE SHAFT / PROPELLER SHAFT / AXLE DRIVE SHAFT / PROPELLER SHAFT / AXLE 030KB–05 SERVICE DATA Front axle hub bearing Backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub sub–assy Deviation Maximum: 0.05 mm (0.0020 in.) Rear axle hub &…
• Page 175
  03–40 SERVICE SPECIFICATIONS – DRIVE SHAFT / PROPELLER SHAFT / AXLE 030KC–06 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Front wheel set nut 1,050 Rear wheel set nut 1,050 Manual transaxle oil drain plug C50/C250: E354/E357: Lower ball joint assy front x Suspension arm sub–assy lower No.1 Tie rod end sub–assy x Steering knuckle Flexible hose and speed sensor front x Shock absorber assy front Speed sensor front x Steering knuckle…

• Page 176: Emission Control

  03–10 SERVICE SPECIFICATIONS – EMISSION CONTROL EMISSION CONTROL 031FP–01 SERVICE DATA 1ZZ–FE/3ZZ–FE: Heated oxygen sensor Resistance Bank 1 sensor 1 5 to 10 ( at 20YC (68YF) 1 (HT1A) – 2 (+B) 1 (HT1A) – 4 (E1) No continuity Heated oxygen sensor Resistance Bank 1 sensor 2 5 to 10 ( at 20YC (68YF)

• Page 177
  03–4 SERVICE SPECIFICATIONS – ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 031DY–01 SERVICE DATA 1ZZ–FE/3ZZ–FE: Power steering oil pressure switch Voltage EMPS – E2 Not spin the steering wheel at engine idling 8 to 14 V 0 to 1.5 V Spin the steering wheel at engine idling Idle air control valve Half open @ fully close @ fully open @ half open Movement…
• Page 178
  03–5 SERVICE SPECIFICATIONS – ENGINE CONTROL SYSTEM 1CD–FTV: Mass air flow meter Resistance 2 (THA) – 1 (E2) at –20YC (–4YF) 12.5 to 16.9 kW at 20YC (68YF) 2.19 to 2.67 kW at 60YC (140YF) 0.50 to 0.68 kW Intake shutter assy Resistance at 20YC (68YF) 18 to 22 W…
• Page 179
  03–6 SERVICE SPECIFICATIONS – ENGINE CONTROL SYSTEM 031DZ–02 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Throttle position sensor x Throttle body assy 18 in. lbf ISC valve x Throttle body assy 33 in. lbf Accelerator control cable bracket x Throttle body assy Throttle body assy x Intake manifold Throttle body bracket x Cylinder block sub–assy (1ZZ–FE) Manifold stay No.
• Page 180
  03–73 SERVICE SPECIFICATIONS – ENGINE HOOD/DOOR ENGINE HOOD/DOOR 031GG–01 TORQUE SPECIFICATION Part Tightened kgf@cm ft@lbf HOOD Hood hinge x Hood Hood hinge x Body 49 in.@lbf Hood lock x Hood 71 in.@lbf FRONT DOOR Door check x Body Door check x Door panel 46 in.@lbf Door frame sub–assy rear lower x Door panel 71 in.@lbf…
• Page 181
  03–74 SERVICE SPECIFICATIONS – ENGINE HOOD/DOOR Part Tightened kgfVcm ftVlbf Back door stay sub–assy x Door panel Center stop lamp assy x Door panel 49 in.Vlbf AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 182
  03–13 SERVICE SPECIFICATIONS – ENGINE MECHANICAL ENGINE MECHANICAL 031H1–01 SERVICE DATA 1ZZ–FE/3ZZ–FE: Ignition timing w/ Terminal TC and CG of DLC3 connected 8 to 12YBTDC W/ Terminal TC and CG of DLC3 disconnected 10 to 18YBTDC (1ZZ–FE) 3.5 to 11.5YBTDC (3ZZ–FE) Idle speed 600 to 700 rpm Compression…
• Page 183
  03–14 SERVICE SPECIFICATIONS – ENGINE MECHANICAL 1CD–FTV: New drive belt deflection Pressing force: 98 N (10 kgf, 22 lbf) For vane pump V belt (A/C equipped) 9.5 to 11.5 mm (0.37 to 0.45 in.) For vane pump V belt (A/C not equipped) 10 to 12 mm (0.39 to 0.47 in.) Used drive belt deflection Pressing force: 98 N (10 kgf, 22 lbf)
• Page 184
  03–15 SERVICE SPECIFICATIONS – ENGINE MECHANICAL 031H2–01 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Camshaft bearing cap No. 3 x Cylinder head sub–assy Camshaft bearing cap No. 1 x Cylinder head sub–assy Camshaft timing gear or sprocket x Camshaft No. 2 Chain tensioner assy No.
• Page 185
  03–16 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Part Tightened kgf cm ft lbf Floor panel brace front x Body Battery carrier x Body 12.8 Battery x Body 44 in. lbf Air cleaner case x Body 44 in. lbf Air cleaner case x Transverse engine engine mounting bracket LH 44 in.
• Page 186
  03–17 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Part Tightened kgf cm ft lbf Engine mounting bracket x No, 2 RH x Transverse engine engine mounting insulator 1,152 Clutch release cylinder x manual transaxle Bolt A Bolt B 80 in. lbf Bolt C 44 in.
• Page 187
  03–18 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Part Tightened kgf cm ft lbf Knock sensor x Cylinder block Engine oil pressure switch assy x Cylinder head Water by–pass pipe No.1 x Cylinder block 80 in. lbf Drive shaft bearing bracket x Cylinder block Oil level gauge guide x Cylinder block 80 in.
• Page 188
  03–19 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Part Tightened kgf cm ft lbf Camshaft timing sprocket x Camshaft Camshaft bearing cap No. 1 x Cylinder head Camshaft bearing cap No. 2 x Cylinder head Camshaft bearing cap No. 3 x Cylinder head 80 in.
• Page 189
  03–20 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Part Tightened kgf cm ft lbf Injection pipe, Fuel inlet pipe x Common rail Used pipe using SST Used pipe not using SST New pipe using SST New pipe not using SST Injection pipe x Injector Used pipe using SST Used pipe not using SST New pipe using SST…
• Page 190
  03–21 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Part Tightened kgf cm ft lbf Air cleaner assy x Body x Engine mounting bracket LH 62 in. lbf Engine cover No.1 x Cylinder head cover sub–assy 71 in. lbf Engine cover No. 1 x Intake manifold 71 in.
• Page 191
  03–22 SERVICE SPECIFICATIONS – EXHAUST EXHAUST 031E2–02 SERVICE DATA 1ZZ–FE/3ZZ–FE: Compression spring Free length Minimum Front x Manifold 41.5 mm (1.634 in.) Front x Tail 38.5 mm (1.516 in.) 1AZ–FE/1AZ–FSE: Compression spring Free length Minimum Front x Manifold 41.5 mm (1.634 in.) Center x Tail 38.5 mm (1.516 in.) 1CD–FTV:…
• Page 192
  03–23 SERVICE SPECIFICATIONS – EXHAUST 031E3–02 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Exhaust pipe assy front x Exhaust manifold Exhaust pipe assy front x Exhaust pipe assy tail Heated oxygen sensor x Exhaust pipe assy front Floor panel brace front x Body 1AZ–FE/1AZ–FSE: Part Tightened kgf cm…
• Page 193
  03–75 SERVICE SPECIFICATIONS – EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 031GY–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FUEL LID CONTROL ASSY Fuel lid control assy x Body 71 in. lbf REAR BUMPER COVER Rear bumper cover x Body 49 in. lbf Rear bumper reinforcement No.
• Page 194
  03–34 SERVICE SPECIFICATIONS – FRONT SUSPENSION FRONT SUSPENSION 0313B–05 SERVICE DATA Vehicle height (Normal package) Front: A – B 92 mm (3.62 in.) Rear: D – C 61 mm (2.40 in.) (Rough road package) Front: A – B 72 mm (2.83 in.) Rear: D –…
• Page 195
  03–35 SERVICE SPECIFICATIONS – FRONT SUSPENSION 0313A–05 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Tie rod end lock nut Steering knuckle x Shock absorber 2,240 Hub nut 1,050 Suspension support x Piston rod Suspension support x Body Suspension crossmember sub–assy x Body 1,360 Suspension crossmember sub–assy x Engine mounting insulator Suspension crossmember sub–assy x Center member…
• Page 196
  03–7 SERVICE SPECIFICATIONS – FUEL FUEL 031E0–01 SERVICE DATA GASOLINE: Compression spring Free length Minimum Front x Manifold (1ZZ–FE/3ZZ–FE) 41.5 mm (1.634 in.) Front x Tail (1ZZ–FE/3ZZ–FE) 38.5 mm (1.516 in.) Center x Tail (1AZ–FE/1AZ–FSE) 38.5 mm (1.516 in.) AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 197
  03–8 SERVICE SPECIFICATIONS – FUEL 031E1–02 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Fuel delivery pipe sub–assy x Cylinder head sub–assy Bolt A Bolt B 80 in. lbf 1AZ–FE: Part Tightened kgf cm ft lbf Fuel delivery pipe sub–assy x Cylinder head sub–assy Fuel pressure pulsation damper assy x Fuel delivery pipe sub–assy 80 in.
• Page 198
  03–9 SERVICE SPECIFICATIONS – FUEL Part Tightened kgf cm ft lbf Injection pipe clamp No. 2 x Intake manifold 44 in. lbf Fuel inlet pipe sub–assy x Common rail assy Used pipe using SST Used pipe not using SST New pipe using SST New pipe not using SST Fuel inlet pipe sub–assy x Injection pump assy Used pipe using SST…

• Page 199: Heater And Air Conditioning

  03–61 SERVICE SPECIFICATIONS – HEATER AND AIR CONDITIONING HEATER AND AIR CONDITIONING 031HH–01 SERVICE DATA Standard: 440 x 30 g (15.51 x 1.06 oz.) Refrigerant charge volume Belt deflection New belt: 11 – 13 mm (0.43 – 0.51 in.) Used belt: 13.5 –…

• Page 200
  03–62 SERVICE SPECIFICATIONS – HEATER AND AIR CONDITIONING 031HI–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 Tighten 22 in. lbf Fully tighten AIR CONDITIONER RADIATOR ASSY Air conditioning tube assy x Cooler evaporator sub–assy No. 1 30 in.
• Page 201
  03–30 SERVICE SPECIFICATIONS – IGNITION IGNITION 031E4–01 SERVICE DATA 1ZZ–FE/3ZZ–FE: Spark plug Recommended spark plug DENSO made K16R–U11 NGK made BKR5EYA11 Electrode gap K16R–U11, BKR5EYA11 1.0 to 1.1 mm (0.039 to 0.043 in.) Camshaft position sensor 835 to 1,400 f Resistance Cold 1,060 to 1,645 f…
• Page 202
  03–31 SERVICE SPECIFICATIONS – IGNITION 031E5–01 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Spark plug x Cylinder head Ignition coil (with igniter) x Cylinder head cover 80 in. lbf Camshaft position sensor x Cylinder head sub–assy 80 in. lbf Crankshaft position sensor x Timing chain cover sub–assy 80 in.
• Page 203
  03–70 SERVICE SPECIFICATIONS – INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 031I3–01 TORQUE SPECIFICATION Part Tightened kgf@cm ft@lbf Instrument Panel Reinforcement Passenger Airbag AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 204
  03–11 SERVICE SPECIFICATIONS – INTAKE INTAKE 031FQ–01 SERVICE DATA 1AZ–FSE: Vacuum switching valve assy No. 1 at 20YC (68 YF) 33 to 39 f Resistance 1CD–FTV: Turbocharging pressure Standard pressure 15 to 45 kPa (0.15 to 0.46 kgf/cm , 2.2 to 6.5 psi) Turbo pressure sensor Voltage 3 (VC) –…
• Page 205
  03–12 SERVICE SPECIFICATIONS – INTAKE 031FR–02 TORQUE SPECIFICATION 1CD–FTV: Part Tightened kgf cm ft lbf Turbo water pipe sub–assy No.1 x Turbocharger sub–assy Turbocharger sub–assy x Exhaust manifold Turbo oil outlet pipe x Turbocharger sub–assy Manifold converter sub–assy x Turbocharger sub–assy 71 in.
• Page 206
  03–65 SERVICE SPECIFICATIONS – LIGHTING LIGHTING 031HC–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Height control sensor sub–assy Fr RH x Body 70 in. lbf Height control sensor sub–assy Fr RH x Stabilizer bar rear 51 in. lbf Height control sensor sub–assy Rr RH x Suspension menber 70 in.
• Page 207
  03–27 SERVICE SPECIFICATIONS – LUBRICATION LUBRICATION 031H5–01 SERVICE DATA 1ZZ–FE/3ZZ–FE: Oil pressure at idle speed 29 kPa (0.3 kgf cm , 4.2 psi) or more at 3,000 r/min 294 to 539 kPa (3.0 to 5.5 kgf cm , 43 to 78 psi) or more Adhesive Part No.
• Page 208
  03–28 SERVICE SPECIFICATIONS – LUBRICATION 031H6–01 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Oil pressure switch x Cylinder head Oil pan drain plug x Oil pan Oil pump x Cylinder block 80 in. lbf 1AZ–FE: Part Tightened kgf cm ft lbf Oil pressure switch x Cylinder head Oil pan drain plug x Oil pan…
• Page 209
  03–29 SERVICE SPECIFICATIONS – LUBRICATION Part Tightened kgf cm ft lbf Crankshaft position sensor x Oil pump assy 78 in. lbf Oil pan sub–assy x Cylinder block Bolt A Bolt B Bolt C Bolt D Oil pan insulator x Oil pan sub–assy 66 in.
• Page 210
  03–52 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE MANUAL TRANSMISSION / TRANSAXLE 030NC–02 SERVICE DATA C50, C250 9.9 x 0.3 mm (0.390 x 0.012 in.) Transmission case oil seal drive in depth 1.9 x 0.3 mm (0.075 x 0.012 in.) Transaxle case oil seal drive in depth E354, E357 3.5 x 0.5 mm (0.138 x 0.020 in.)
• Page 211
  03–53 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE 030ND–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY Floor shift transmission control cable assy x Body 44 in. lbf Front floor heat insulator No.1 x Body 49 in.
• Page 212
  03–54 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE Part Tightened kgf cm ft lbf Battery carrier x Body Battery clamp sub–assy x Body Bolt: 44 in. lbf Nut: 31 in. lbf Air cleaner assy x Body 44 in. lbf Engine cover sub–assy No.1 x Engine 80 in.
• Page 213
  03–43 SERVICE SPECIFICATIONS – PARKING BRAKE PARKING BRAKE 031FV–01 SERVICE DATA Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 6 – 9 clicks Rear brake disc inside diameter Standard 173 mm (6.81 in.) Maximum 174 mm (6.85 in.) Parking brake shoe lining thickness Standard 3.5 mm (0.138 in.)
• Page 214
  03–44 SERVICE SPECIFICATIONS – PARKING BRAKE 031FW–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Wheel nut 1,050 Parking brake lock nut 44 in. lbf Parking brake lever sub–assy x Body Front floor heat insulator No.2 x Body 49 in. lbf Front floor heat insulator No.1 x Body 49 in.
• Page 215
  03–59 SERVICE SPECIFICATIONS – POWER STEERING POWER STEERING 030G6–04 SERVICE DATA POWER STEERING FLUID Fluid level rise Maximum 5 mm (0.20 in.) Fluid pressure at idle speed with valve closed AZ Series: 8,300 to 9,000 kPa (85 to 92 kgf/cm , 1,204 to 1,305 psi) 1CD–FTV: 8,800 to 9,500 kPa (90 to 97 kgf/cm…
• Page 216
  03–60 SERVICE SPECIFICATIONS – POWER STEERING 030G7–04 TORQUE SPECIFICATION Part tightened kgf cm ft lbf VANE PUMP ASSY (AZ Series) Vane pump housing sub–assy rear x Vane pump housing sub–assy front Power steering oil pressure switch Pressure port union sub–assy Power steering suction port union set bolt Vane pump assy x Pump bracket rear Vane pump assy set bolt…
• Page 217
  03–36 SERVICE SPECIFICATIONS – REAR SUSPENSION REAR SUSPENSION 031HF–01 SERVICE DATA Toe–in (total) 0Y18’ x 12’ (0.3Y x 0.2Y, 3.0 x 2.0 mm, 0.12 x 0.08 in.) Normal package: 0Y18’ x 12’ (0.3Y x 0.2Y, 3.0 x 2.0 mm, 0.12 x 0.08 in.) Rough road package: Rear wheel align- Camber…
• Page 218
  03–37 SERVICE SPECIFICATIONS – REAR SUSPENSION 031HG–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Hub nut 1,050 Piston rod set nut Shock absorber x Body Shock absorber x Rear suspension arm 1,632 Parking brake cable set bolt 44 in. lbf Skid control sensor wire harness bracket set bolt 44 in.
• Page 219
  03–71 SERVICE SPECIFICATIONS – SEAT SEAT 031HN–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FRONT SEAT Seat Inner belt assy x Seat adjuster assy Seatback cover bracket x Seat adjuster assy (w/ Side airbag) 53 in. lbf Seat assy x Body Seat position airbag sensor x Seat adjuster assy 71 in.

• Page 220: Seat Belt

  03–64 SERVICE SPECIFICATIONS – SEAT BELT SEAT BELT 031H8–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FRONT SEAT BELT Front seat outer belt assy RH (Upper bolt) x Body 76.5 66 in. lbf Front seat outer belt assy RH (Lower bolt) x Body Front seat inner belt assy RH x Front seat assy Front shoulder belt anchor adjuster assy x Body Front seat outer belt (Floor anchor side) x Body…

• Page 221
  03–72 SERVICE SPECIFICATIONS – SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 031GX–01 TORQUE SPECIFICATION Part Tightened kgf@cm ft@lbf Sliding roof glass assembly Drive cable 35 in.@lbf Sliding roof housing sub–assy Body Bolt 44 in.@lbf 49 in.@lbf AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 222
  03–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT 030LK–05 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/ Washer w/ Washer B06431 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 223
  03–3 SERVICE SPECIFICATIONS – STANDARD BOLT 030LM–05 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class Hexagon Nut Cold Forging Nut Cutting Processed Nut No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 7N (5T) 10N (7T)
• Page 224
  03–2 SERVICE SPECIFICATIONS – STANDARD BOLT 030LL–05 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Class Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 48 in.·lbf 52 in.·lbf 1.25 12.5 1.25 1.25 1,150 – – –…
• Page 225
  03–32 SERVICE SPECIFICATIONS – STARTING & CHARGING STARTING & CHARGING 031E6–01 SERVICE DATA 1ZZ–FE/3ZZ–FE: Starter assy Rated voltage and output power 12 V 1.3 kW Specified current 85 A or less at 11.5 V Starter relay Specified condition 1 – 2 Continuity 3 –…
• Page 226
  03–33 SERVICE SPECIFICATIONS – STARTING & CHARGING 031E7–03 TORQUE SPECIFICATION 1ZZ–FE/3ZZ–FE: Part Tightened kgf cm ft lbf Starter assy x Transaxle housing Starter wire x Starter assy Generator assy x Transverse engine engine mounting bracket Generator assy x Cylinder block sub–assy Generator wire x Generator assy Lead wire of field coil x Terminal C 52 in.
• Page 227
  03–57 SERVICE SPECIFICATIONS – STEERING COLUMN STEERING COLUMN 031FX–01 SERVICE DATA STEERING SYSTEM Steering wheel freeplay Maximum 30 mm (1.18 in.) AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 228
  03–58 SERVICE SPECIFICATIONS – STEERING COLUMN 031FZ–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Steering intermediate shaft assy No. 2 x Oil pressure power steering column assy (LHD steering positoin type) Steering sliding yoke sub–assy x Oil pressure power steering column assy (RHD steering positoin type) Steering intermediate shaft assy No.
• Page 229
  03–63 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 031HM–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Horn button assy x Steering wheel assy 78 in. lbf Steering wheel assy x Steering column assy Instrument panel passenger airbag assy x Instrument panel reinforcement 31 in.
• Page 230
  03–38 SERVICE SPECIFICATIONS – TIRE & WHEEL TIRE & WHEEL 0313C–05 SERVICE DATA Engine type: 3ZZ–FE, 1ZZ–FE, 1AZ–FE Front Rear Tire size kPa (kgf/cm , psi) kPa (kgf/cm , psi) 195/65R16 91V: 205/55R16 91V: 220 (2.2, 32) 220 (2.2, 32) with 4 or less occupants 240 (2.4, 35) 240 (2.4, 35)
• Page 231
  03–69 SERVICE SPECIFICATIONS – WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD/WINDOWGLASS/MIRROR 031HO–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf OUTER REAR VIEW MIRROR ASSY LH Outer rear view mirrror assy x Front door AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 232
  03–66 SERVICE SPECIFICATIONS – WIPER & WASHER WIPER & WASHER 031HA–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Wiper motor x Wiper link 66 in. lbf Wiper link x Body 49 in. lbf Wiper arm x Wiper link Rear wiper motor x Body 49 in.
• Page 233
  10–66 ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ASSY (1AZ–FSE/1CD–FTV) ACCELERATOR PEDAL ASSY (1AZ–FSE/1CD–FTV) 100FM–02 REPLACEMENT REMOVE ACCELERATOR PEDAL Using a clip remover, remove the clip. Open the floor carpet. A78489 Disconnect the accelerator position sensor connector. Remove the 2 bolts, and then remove the accelerator pedal.
• Page 234
  10–63 ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR (1CD–FTV) CAMSHAFT POSITION SENSOR (1CD–FTV) 100FP–01 REPLACEMENT SEPARATE RETURN TUBE SUB–ASSY Remove the bolt and separate the return tube sub–assy. A79139 REMOVE CAMSHAFT POSITION SENSOR Remove the bolt and disconnect the wire harness. Disconnect the connector, remove the bolt and the cam- shaft position sensor.
• Page 235
  10–64 ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR (1CD–FTV) CRANKSHAFT POSITION SENSOR (1CD–FTV) 100FQ–01 REPLACEMENT REMOVE ENGINE UNDER COVER RH REMOVE CRANKSHAFT POSITION SENSOR Disconnect the connector, remove the bolt and the crank- shaft position sensor. A79142 INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N m (90 kgf cm, 78 in.
• Page 236
  10–56 ENGINE CONTROL SYSTEM – ECD SYSTEM (1CD–FTV) 100F0–02 INSPECTION INSPECT MASS AIR FLOW METER Output voltage inspection. Apply battery voltage across terminals 3 (+B) and 4 (E2G) Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (–) tester probe to terminal E2G.
• Page 237
  10–57 ENGINE CONTROL SYSTEM – ECD SYSTEM (1CD–FTV) INSPECT DIESEL ENGINE ENGINE COOLANT Ohmmeter TEMPERATURE SENSOR Resistance inspection. Using an ohmmeter, measure the resistance be- tween each terminal. Resistance: Approx. 20YC (68YF) 2.32 to 2.59 kf Approx. 80YC (176YF) 0.310 to 0.326 kf NOTICE: Acceptable In case of checking the water temperature sensor in the wa-…
• Page 238
  10–58 ENGINE CONTROL SYSTEM – ECD SYSTEM (1CD–FTV) INSPECT CRANKSHAFT POSITION SENSOR Resistance inspection. NE– Using an ohmmeter, measure the resistance be- tween terminals. Resistance: at cold 1630 to 2740 f at hot 2065 to 3225 f NOTICE: ”Cold” and ”Hot” in the following sentences express the A56277 temperature of the sensor itself.
• Page 239
  10–59 ENGINE CONTROL SYSTEM – ECD SYSTEM (1CD–FTV) INSPECT EFI MAIN RELAY Inspect the relay continuity. Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity Check that there is no continuity between terminals 3 and 5.
• Page 240
  10–54 ENGINE CONTROL SYSTEM – ECD SYSTEM (1CD–FTV) ECD SYSTEM (1CD–FTV) 100EZ–02 ON–VEHICLE INSPECTION INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation Connect the hand–held tester to the DLC3. Turn the ignition switch ON. Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the CURRENT DATA shown the standard value.
• Page 241
  10–55 ENGINE CONTROL SYSTEM – ECD SYSTEM (1CD–FTV) Inspect the air assist system. Start the engine and check that the CHK ENG does not light up. Allow the engine to warm up to normal operating temperature. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 800 x 50 rpm NOTICE: Perform inspection under condition without electrical load.
• Page 242
  10–65 ENGINE CONTROL SYSTEM – 100FR–01 REPLACEMENT HINT: 1CD–FTV Engine Type: Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes which are used to optimize fuel injection for the injectors. When replacing the ECM, the compensation codes must be set to the new ECM.
• Page 243
  10–60 ENGINE CONTROL SYSTEM – INTAKE SHUTTER ASSY (1CD–FTV) INTAKE SHUTTER ASSY (1CD–FTV) 100FN–01 COMPONENTS Clip Retainer 8.0 (82, 71 in. lbf) Engine Cover No. 1 Radiator Support Opening Cover 30 to 40 (31 to 41 , 27 to 35 in. lbf) 5.0 (51, 44 in.
• Page 244
  10–61 ENGINE CONTROL SYSTEM – INTAKE SHUTTER ASSY (1CD–FTV) 100FO–01 Removal & Installation and Disassembly & Reassembly REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE BATTERY REMOVE AIR HOSE NO.4 Loosen the 2 hose clamps.
• Page 245
  10–62 ENGINE CONTROL SYSTEM – INTAKE SHUTTER ASSY (1CD–FTV) Tighten the hose clamp as shown in the illustration. Torque: 6.0 N m (61 kgf cm, 53 in. lbf) Front Clamp Bolt A64007 INSTALL ENGINE COVER NO.1 Install the engine cover with the 5 nuts. Torque: 8.0 N m (82 kgf cm, 71 in.
• Page 246
  10–30 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) KNOCK SENSOR (1AZ–FE) 100FK–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose Connector Mass Air Flow Meter Connector Air Cleaner Cap Sub–assy…
• Page 247
  10–31 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) Accelerator Control Cable Assy ISC Valve Connector 13 (129, 9) 30 (306, 22) Throttle Position Sensor Connector Fuel Pipe Support Throttle Body Assy Fuel Tube Sub–assy Water By–pass Hose Y Throttle Body Gasket Water By–pass Hose No.
• Page 248
  10–32 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) Fuel Injector Connector 20 (204, 15) Fuel Delivery Pipe Sub–assy EFI Fuel Pipe Clamp Delivery Pipe No. 1 Spacer Fuel Tube Sub–assy Y Injector Vibration Insulator Ventilation Hose No. 2 N·m (kgf·cm, ft·lbf) : Specified torque Y Non–reusable part A78453 AVENSIS REPAIR MANUAL (RM1018E)
• Page 249
  10–33 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) Charcoal Canister Outlet Hose No. 1 5.0 (51, 44 in. lbf) LHD Steering Position Type, Leaded Gasoline: Variable Resister Variable Resister Connector Y Intake Manifold Fuel Hose to Head Gasket No. 1 Charcoal Canister Assy 30 (306, 22) Intake Manifold…
• Page 250
  10–34 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) 100FL–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE ENGINE ROOM COVER SIDE (See page 10–26) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) ENGINE COOLANT (See page 16–19) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–26) REMOVE AIR CLEANER CAP SUB–ASSY…
• Page 251
  10–35 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) REMOVE INTAKE MANIFOLD LHD: RHD: Disconnect the union to connector tube hose. A77920 Remove the wire harness clamp. Remove the 5 bolts and 2 nuts, and then remove the in- take manifold. Remove the gasket from the intake manifold.
• Page 252
  10–36 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) INSTALL INTAKE MANIFOLD INSULATOR NO.1 INSTALL INTAKE MANIFOLD Install a new gasket to the intake manifold. Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N m (306 kgf cm, 22 ft lbf) Install the wire harness clamp.
• Page 253
  10–30 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) KNOCK SENSOR (1AZ–FE) 100FK–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose Connector Mass Air Flow Meter Connector Air Cleaner Cap Sub–assy…
• Page 254
  10–31 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) Accelerator Control Cable Assy ISC Valve Connector 13 (129, 9) 30 (306, 22) Throttle Position Sensor Connector Fuel Pipe Support Throttle Body Assy Fuel Tube Sub–assy Water By–pass Hose Y Throttle Body Gasket Water By–pass Hose No.
• Page 255
  10–32 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) Fuel Injector Connector 20 (204, 15) Fuel Delivery Pipe Sub–assy EFI Fuel Pipe Clamp Delivery Pipe No. 1 Spacer Fuel Tube Sub–assy Y Injector Vibration Insulator Ventilation Hose No. 2 N·m (kgf·cm, ft·lbf) : Specified torque Y Non–reusable part A78453 AVENSIS REPAIR MANUAL (RM1018E)
• Page 256
  10–33 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) Charcoal Canister Outlet Hose No. 1 5.0 (51, 44 in. lbf) LHD Steering Position Type, Leaded Gasoline: Variable Resister Variable Resister Connector Y Intake Manifold Fuel Hose to Head Gasket No. 1 Charcoal Canister Assy 30 (306, 22) Intake Manifold…
• Page 257
  10–34 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) 100FL–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE ENGINE ROOM COVER SIDE (See page 10–26) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) ENGINE COOLANT (See page 16–19) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–26) REMOVE AIR CLEANER CAP SUB–ASSY…
• Page 258
  10–35 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) REMOVE INTAKE MANIFOLD LHD: RHD: Disconnect the union to connector tube hose. A77920 Remove the wire harness clamp. Remove the 5 bolts and 2 nuts, and then remove the in- take manifold. Remove the gasket from the intake manifold.
• Page 259
  10–36 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FE) INSTALL INTAKE MANIFOLD INSULATOR NO.1 INSTALL INTAKE MANIFOLD Install a new gasket to the intake manifold. Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N m (306 kgf cm, 22 ft lbf) Install the wire harness clamp.
• Page 260
  10–47 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FSE) KNOCK SENSOR (1AZ–FSE) 100F9–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose 1.5 (15, 13 in. lbf) Connector Mass Air Flow Meter Connector…
• Page 261
  10–48 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FSE) Throttle Motor Connector Throttle Body Assy 9.0 (90, 80 in. lbf) Y Throttle Body Gasket Water By–pass Hose No. 2 Water By–pass Hose No. 1 Throttle Body Bracket 21 (210, 15) Ground Terminal 8.4 (86, 74 in.
• Page 262
  10–49 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FSE) Fuel Tube Sub–assy Y Gasket Fuel Pipe Clamp Y Gasket 25 (255, 18) 33 (331, 24) Fuel Pressure Pulsation Fuel Pump Assy Y Fuel Pump Damper Assy Insulator 30 (306, 22) Fuel pipe Sub–assy No. 1 9.0 (92, 80 in.
• Page 263
  10–50 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FSE) 30 (306, 22) Union to Connector Tube Hose 30 (306, 22) Vacuum Hose Intake Manifold Intake Manifold Insulator No. 1 30 (306, 22) Y Gasket Intake Air Control Valve Assy Y Gasket 9.5 (97, 84 in.
• Page 264
  10–51 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FSE) Knock Sensor 20 (204, 15) N·m (kgf·cm, ft·lbf) : Specified torque A79833 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 265
  10–52 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FSE) 100FA–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–30) REMOVE RADIATOR SUPPORT OPENING COVER (See page 18–16) REMOVE ENGINE ROOM COVER SIDE (See page 18–17) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–44) DRAIN ENGINE COOLANT (See page…
• Page 266
  10–53 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1AZ–FSE) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 267
  10–17 ENGINE CONTROL SYSTEM – KNOCK SENSOR (1ZZ–FE/3ZZ–FE) KNOCK SENSOR (1ZZ–FE/3ZZ–FE) 100FF–01 REPLACEMENT REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 Remove the 5 clips, 2 screws and bolt, and then remove the engine under cover. A78505 REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the nut, and then remove the knock sensor.
• Page 268
  10–20 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FE) 100G7–02 INSPECTION INSPECT MASS AIR FLOW METER Output voltage inspection. Apply battery voltage across terminals 1 (+B) and 2 (E2G). Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (–) tester probe to terminal 2 (E2G).
• Page 269
  10–21 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FE) Adjust the throttle stop screw. NOTICE: The throttle stop screw adjusting is very, so adjust it only when the adjusting is really needed. Loosen the locknut and loosen the screw until it de- taches the lever.
• Page 270
  10–22 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FE) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Resistance inspection. Using an ohmmeter, measure the resistance be- tween each terminal. Resistance: Approx. 20YC (68YF) 2.32 to 2.59kW Approx. 80YC (176YF) 0.310 to 0.326kW NOTICE: In case of checking the water temperature sensor in the wa- ter, be careful not to allow water to go into the terminals, and after checking, wipe out the sensor.
• Page 271
  10–23 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FE) INSPECT CIRCUIT OPENING RELAY Inspect the relay continuity. Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity Check that there is no continuity between terminals 3 and 5.
• Page 272
  10–18 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FE) SFI SYSTEM (1AZ–FE) 100G6–02 ON–VEHICLE INSPECTION INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation Connect the hand–held tester to the DLC3. Turn the ignition switch ON. Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the ”DIAGNOSIS / OBD/ MOBD / DATA LIST / ALL”…
• Page 273
  10–19 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FE) INSPECT IDLE AIR CONTROL VALVE NOTICE: Open Close It is impossible to check the resister value and the op- eration of ISCV by itself, because the ISCV has an IC circuit inside it, which transforms the duty signal from the ECM to the derive signal.
• Page 274
  10–39 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FSE) 100G9–02 INSPECTION INSPECT MASS AIR FLOW METER Output voltage inspection. Apply battery voltage across terminals 1 (+B) and 2 (E2G). Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (–) tester probe to terminal 2 (E2G).
• Page 275
  10–40 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FSE) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Resistance inspection. Using an ohmmeter, measure the resistance be- tween each terminal. Resistance: Approx. 20YC (68YF) 2.32 to 2.59kW Approx. 80YC (176YF) 0.310 to 0.326kW NOTICE: In case of checking the water temperature sensor in the wa- ter, be careful not to allow water to go into the terminals, and after checking, wipe out the sensor.
• Page 276
  10–41 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FSE) INSPECT CIRCUIT OPENING RELAY Inspect the relay continuity. Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity Check that there is no continuity between terminals 3 and 5.
• Page 277
  10–37 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FSE) SFI SYSTEM (1AZ–FSE) 100G8–02 ON–VEHICLE INSPECTION INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation Connect the hand–held tester to the DLC3. Turn the ignition switch ON. Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the CURRENT DATA shown the standard value.
• Page 278
  10–38 ENGINE CONTROL SYSTEM – SFI SYSTEM (1AZ–FSE) INSPECT POWER STEERING OIL PRESSURE SEN- Using a voltmeter, measure the voltage between termi- nals PSW and E2. Voltage: Condition Voltage (V) Not spin the steering wheel at engine idling 9 to 14 Spin the steering wheel at engine idling 0 to 3 A53763…
• Page 279
  10–3 ENGINE CONTROL SYSTEM – SFI SYSTEM (1ZZ–FE/3ZZ–FE) 100EY–02 INSPECTION INSPECT MASS AIR FLOW METER Output voltage inspection. Apply battery voltage across terminals 1 (+B) and 2 (E2G). Connect the positive (+) tester probe to terminal 3 (VG), and negative (–) tester probe to terminal 2 (E2G).
• Page 280
  10–4 ENGINE CONTROL SYSTEM – SFI SYSTEM (1ZZ–FE/3ZZ–FE) INSPECT THROTTLE BODY ASSY 1ZZ–FE: Check throttle body. Throttle Stop Screw Check that throttle valve shaft is not rickety. No clearance Check that each port is not stopped up. Check that throttle valve opens and closes smooth- Check that there is no clearance between the throttle stop screw and throttle lever at the throttle Throttle Lever…
• Page 281
  10–5 ENGINE CONTROL SYSTEM – SFI SYSTEM (1ZZ–FE/3ZZ–FE) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Resistance inspection. Using an ohmmeter, measure the resistance be- tween terminals. Resistance: 2.32 to 2.59 kW at 20YC (68YF) 0.310 to 0.326 kW at 80YC (176YF) NOTICE: In case of checking the water temperature sensor in the wa- ter, be careful not to allow water to go into the terminals, and after checking, wipe out the sensor.
• Page 282
  10–6 ENGINE CONTROL SYSTEM – SFI SYSTEM (1ZZ–FE/3ZZ–FE) INSPECT CIRCUIT OPENING RELAY Inspect the relay continuity. Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity Check that there is no continuity between terminals 3 and 5.
• Page 283
  10–1 ENGINE CONTROL SYSTEM – SFI SYSTEM (1ZZ–FE/3ZZ–FE) SFI SYSTEM (1ZZ–FE/3ZZ–FE) 100EX–02 ON–VEHICLE INSPECTION INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation Connect the hand–held tester to the DLC3. Turn the ignition switch ON. Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the ”DIAGNOSIS / OBD/ MOBD / DATA LIST / ALL”…
• Page 284
  10–2 ENGINE CONTROL SYSTEM – SFI SYSTEM (1ZZ–FE/3ZZ–FE) INSPECT IDLE AIR CONTROL VALVE 1ZZ–FE: NOTICE: VaIve It is impossible to check the resister value and the op- eration of ISCV by itself, because the ISCV has an IC Open circuit inside it, which transforms the duty signal from the ECM to the derive signal.
• Page 285
  10–24 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FE) THROTTLE BODY ASSY (1AZ–FE) 100FG–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose Connector Mass Air Flow Meter Connector…
• Page 286
  10–25 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FE) ISC Valve Y ISC Valve Gasket Throttle Position Sensor Fuel Vapor Feed Hose ISC Valve Connector 30 (306, 22) 13 (129, 9) Accelerator Control Cable Throttle Position Sensor Assy Connector Fuel Pipe Support Throttle Body Assy Fuel Tube Sub–assy Water By–pass Hose…
• Page 287
  10–26 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FE) 100FH–01 Removal & Installation and Disassembly & Reassembly REMOVE ENGINE ROOM COVER SIDE Remove the retainer and 4 clips. Unfasten the 5 claws and remove the radiator support opening cover. 5 Claws A77897 REMOVE RADIATOR SUPPORT OPENING COVER Remove the 2 clips, and then remove the engine room…
• Page 288
  10–27 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FE) REMOVE AIR CLEANER CAP SUB–ASSY Disconnect the mass air flow meter connector. Disconnect the VSV connector. Remove the 2 wire harness clamps. Disconnect the ventilation hose. Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose N0.
• Page 289
  10–28 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FE) REMOVE THROTTLE BODY ASSY Disconnect the throttle position sensor connector. Disconnect the ISC valve connector. Disconnect the water by–pass hose No. 2. Disconnect the water by–pass hose. Remove the fuel tube from the fuel pipe support. A77875 Remove the 3 bolts, and then remove the fuel pipe sup- port and the throttle body.
• Page 290
  10–29 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FE) INSTALL THROTTLE POSITION SENSOR Make sure that throttle valve is fully closed. With the throttle position sensor rotated 45Y counter- clockwise about the fully closed position of the throttle valve, install the throttle position sensor to the throttle body.
• Page 291
  10–42 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FSE) THROTTLE BODY ASSY (1AZ–FSE) 100FI–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose 1.5 (15, 13 in.
• Page 292
  10–43 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FSE) Throttle Motor Connector Throttle Body Assy 9.0 (90, 80 in. lbf) Y Throttle Body Gasket Water By–pass Hose No. 2 Water By–pass Hose No. 1 Throttle Body Bracket 21 (210, 15) Ground Terminal 8.4 (86, 74 in.
• Page 293
  10–44 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FSE) 100FJ–01 REPLACEMENT REMOVE ENGINE ROOM COVER SIDE (See page 10–26) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) DRAIN ENGINE COOLANT (See page 16–31) REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts, and then remove the engine cover No.
• Page 294
  10–45 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FSE) Remove the bolt, and then remove the ground terminal. Remove the 4 bolts, and then remove the throttle body bracket. A78511 Disconnect the throttle motor connector. Remove the 4 bolts, and then remove the throttle body. Remove the gasket from the intake manifold.
• Page 295
  10–46 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1AZ–FSE) INSTALL RADIATOR SUPPORT OPENING COVER AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 296
  10–7 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1ZZ–FE) THROTTLE BODY ASSY (1ZZ–FE) 100FB–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover Clip 7.0 (71, 62 in.·lbf) Cylinder Head Cover No.2 Accelerator Control Fuel Cable Assy Vapor Feed Hose No.1 13 (129, 9) Connector…
• Page 297
  10–8 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1ZZ–FE) Ventilation Hose 13 (133, 10) Throttle Body Assy M/T: 30 (306, 22) Manifold Stay No.2 Throttle Position Sensor Connector Water By–pass Hose No.2 Y Throttle Body Gasket Water By–pass Hose ISC Valve Connector Throttle Body Bracket 30 (306, 22) 2.0 (20, 18 in.·lbf)
• Page 298
  10–9 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1ZZ–FE) 100FC–01 Removal & Installation and Disassembly & Reassembly REMOVE RADIATOR SUPPORT OPENING COVER Remove the retainer and 4 clips. Unfasten the 5 claws and remove the radiator support opening cover. 5 Claws A78457 REMOVE ENGINE ROOM COVER SIDE Remove the 2 clips, and then remove the engine room…
• Page 299
  10–10 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1ZZ–FE) REMOVE AIR CLEANER CAP SUB–ASSY Disconnect the mass air flow meter connector. Disconnect the VSV connector. Remove the 2 wire harness clamps. Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 3. Remove the accelerator control cable from the accelera- tor control cable support No.
• Page 300
  10–11 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1ZZ–FE) REMOVE ACCELERATOR CONTROL CABLE BRACKET Remove the 2 bolts, and then remove the accelerator control cable bracket. A78464 REMOVE ISC VALVE Remove the 3 screws, and then remove the ISC valve. Remove the gasket from the throttle body.
• Page 301
  10–12 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (1ZZ–FE) INSTALL THROTTLE BODY ASSY Install a new gasket to the intake manifold. Install the throttle body and the throttle body bracket with the 3 bolts and 2 nuts. (A/T) Torque: 30 N m (306 kgf cm, 22 ft lbf) for bolt and nut A Install the throttle body and the throttle body bracket with the 5 bolts and 2 nuts.
• Page 302
  10–13 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (3ZZ–FE) THROTTLE BODY ASSY (3ZZ–FE) 100FD–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover Clip 7.0 (71, 62 in.·lbf) Cylinder Head Cover No.2 Accelerator Control Fuel Cable Assy Vapor Feed Hose No.1 13 (129, 9) Connector…
• Page 303
  10–14 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (3ZZ–FE) Accelerator Control Cable Bracket 30 (306, 22) Ventilation Hose Throttle Position Y Throttle Body Gasket Sensor Connector Water By–pass Hose No.2 Water By–pass Hose Throttle Body Assy 30 (306, 22) ISC Valve Connector 2.0 (20, 18 in.·lbf) Throttle Position Sensor…
• Page 304
  10–15 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (3ZZ–FE) 100FE–01 Removal & Installation and Disassembly & Reassembly REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–9) REMOVE ENGINE ROOM COVER SIDE (See page 10–9) DRAIN ENGINE COOLANT (See page 16–7) REMOVE CYLINDER HEAD COVER NO.2 (See page 10–9) REMOVE AIR CLEANER CAP SUB–ASSY…
• Page 305
  10–16 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY (3ZZ–FE) REMOVE THROTTLE POSITION SENSOR Remove the 2 screws, and then remove the throttle posi- tion sensor. A78501 INSTALL THROTTLE POSITION SENSOR 30Y to 45Y Make sure that the throttle valve is fully closed. With the throttle position sensor rotated 30Y to 45Y coun- terclockwise about the fully closed position of the throttle valve, install the throttle position sensor to the throttle…
• Page 306
  11–76 FUEL – COMMON RAIL ASSY (1CD–FTV) COMMON RAIL ASSY (1CD–FTV) 110UB–01 COMPONENTS Clip Ratainer 8.0 (82, 71 in. lbf) Radiator Support Opening Cover Engine Cover No. 1 6.0 (61, 53 in. lbf) Radiator Reserve Tank Assy N·m (kgf·cm, ft·lbf) : Specified torque A79437 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 307
  11–77 FUEL – COMMON RAIL ASSY (1CD–FTV) * 31 (316, 23) 34 (347, 25) 5.0 (51, 44 in. lbf) Injection Pipe Clamp No. 2 Y Injection Pipe Sub–assy Y Fuel Inlet Pipe Sub–assy * 31 (316, 23) 34 (347, 25) * 31 (316, 23) 34 (347, 25) Intake Manifold…
• Page 308
  11–78 FUEL – COMMON RAIL ASSY (1CD–FTV) 110UC–01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16–44) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE RADIATOR RESERVE TANK ASSY (See page 16–50) REMOVE FUEL INLET PIPE SUB–ASSY NOTICE: After removing the fuel inlet pipe, cover the common rail…
• Page 309
  11–79 FUEL – COMMON RAIL ASSY (1CD–FTV) REMOVE INJECTION PIPE SUB–ASSY NO.4 09023–12700 HINT: Perform the same procedures as injection pipe No. 1. DISCONNECT FUEL HOSE NO.4 Disconnect the fuel hose from the common rail. REMOVE INTAKE MANIFOLD INSULATOR NO.1 (See page 11–69) REMOVE COMMON RAIL ASSY…
• Page 310
  11–80 FUEL – COMMON RAIL ASSY (1CD–FTV) Using SST, tighten the nut of the injection pipe to the com- mon rail side. 09023–12700 Torque: 42 N m (428 kgf cm, 31 ft lbf) for a used pipe using SST 46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using 31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST 34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using HINT:…
• Page 311
  11–81 FUEL – COMMON RAIL ASSY (1CD–FTV) INSTALL FUEL INLET PIPE SUB–ASSY NOTICE: 30 cm In case of having the common rail replaced, must re- (11.81 in.) place fuel inlet pipe, too. When assembling the pipe, perform the operation with the engine cold under room temperature. Temporarily install the fuel inlet pipe.
• Page 312
  11–82 FUEL – FUEL FILTER ASSY (1CD–FTV) FUEL FILTER ASSY (1CD–FTV) 110UD–01 REPLACEMENT REMOVE AIR CLEANER ASSY Disconnect the connector. Remove the air cleaner cap with the air cleaner hose. Remove the air cleaner filter element. Remove the 3 bolts and the air cleaner case. REMOVE FUEL FILTER ASSY Disconnect the 2 fuel hose from the fuel filter.
• Page 313
  11–83 FUEL – FUEL FILTER ASSY (1CD–FTV) INSTALL LEVEL WARNING SWITCH Install a new O–ring to the level warning switch. Apply fuel to the O–ring of the level warning switch. Install the level warning switch to the fuel filter by hand. INSTALL FUEL FILTER ASSY Torque: 18 N m (178 kgf cm, 13 ft lbf) INSTALL AIR CLEANER ASSY…
• Page 314
  11–24 FUEL – FUEL INJECTOR ASSY (1AZ–FE) FUEL INJECTOR ASSY (1AZ–FE) 110U0–01 COMPONENTS 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose Connector Mass Air Flow Meter Connector Air Cleaner Cap Sub–assy Fuel Vapor Feed Hose No.
• Page 315
  11–25 FUEL – FUEL INJECTOR ASSY (1AZ–FE) Y Fuel Injector O–ring Fuel Injector Connector Fuel Injector Assy 20 (204, 15) Fuel Delivery Pipe Sub–assy EFI Fuel Pipe Clamp Delivery Pipe No. 1 Spacer Fuel Tube Sub–assy Y Injector Vibration Insulator Ventilation Hose No.
• Page 316
  11–26 FUEL – FUEL INJECTOR ASSY (1AZ–FE) 110U1–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–26) REMOVE AIR CLEANER CAP SUB–ASSY (See page 10–26) DISCONNECT FUEL TUBE SUB–ASSY Remove the fuel pipe clamp. Using SST, disconnect the fuel tube.
• Page 317
  11–27 FUEL – FUEL INJECTOR ASSY (1AZ–FE) Remove the 2 wire harness clamps. Disconnect the 4 fuel injector connectors. A77910 Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the delivery pipe.
• Page 318
  11–28 FUEL – FUEL INJECTOR ASSY (1AZ–FE) Apply a light coat of spindle oil or gasoline on the place Turn where a fuel delivery pipe contacts the O–ring. Push Push the fuel injector while twisting it back and forth to install it to the fuel delivery pipe.
• Page 319
  11–37 FUEL – FUEL INJECTOR ASSY (1AZ–FSE) FUEL INJECTOR ASSY (1AZ–FSE) 110TC–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose 1.5 (15, 13 in. lbf) Connector Mass Air Flow Meter Connector…
• Page 320
  11–38 FUEL – FUEL INJECTOR ASSY (1AZ–FSE) Throttle Motor Connector Throttle Body Assy 9.0 (90, 80 in. lbf) Y Throttle Body Gasket Water By–pass Hose No. 2 Water By–pass Hose No. 1 Throttle Body Bracket 21 (210, 15) Ground Terminal 8.4 (86, 74 in.
• Page 321
  11–39 FUEL – FUEL INJECTOR ASSY (1AZ–FSE) Fuel Tube Sub–assy Y Gasket Fuel Pipe Clamp Y Gasket 25 (255, 18) 33 (331, 24) Fuel Pressure Pulsation Fuel Pump Assy Y Fuel Pump Damper Assy Insulator 30 (306, 22) Fuel Pipe Sub–assy No. 1 9.0 (92, 80 in.
• Page 322
  11–40 FUEL – FUEL INJECTOR ASSY (1AZ–FSE) 30 (306, 22) Union to Connector Tube Hose 30 (306, 22) Vacuum Hose Intake Manifold Intake Manifold Insulator No. 1 30 (306, 22) Y Gasket Intake Air Control Valve Assy Y Gasket 9.5 (97, 84 in. lbf) 9.8 (100, 7) Intake Manifold Insulator No.
• Page 323
  11–41 FUEL – FUEL INJECTOR ASSY (1AZ–FSE) Y E–ring Y O–ring Y Fuel Injector Back–up Ring No. 1 Y Fuel Injector Back–up Ring No. 3 Y Fuel Injector Back–up Ring No. 2 Y Gasket Injector Assy Y Fuel Injector Seal 13 (127, 9) Fuel Delivery Pipe Sub–assy…
• Page 324
  11–10 FUEL – FUEL INJECTOR ASSY (1ZZ–FE/3ZZ–FE) FUEL INJECTOR ASSY (1ZZ–FE/3ZZ–FE) 110TY–01 COMPONENTS 1ZZ–FE: Y Fuel Injector O–Ring Fuel Injector Assy 3ZZ–FE: Clip Y Fuel Injector O–Ring Y Fuel Injector Grommet 7.0 (71, 62 in.·lbf) Fuel Injector Assy 19 (189, 14) Cylinder Head Cover No.
• Page 325
  11–11 FUEL – FUEL INJECTOR ASSY (1ZZ–FE/3ZZ–FE) 110TZ–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–1) REMOVE CYLINDER HEAD COVER NO.2 (See page 10–9) SEPARATE FUEL TUBE SUB–ASSY Remove the fuel pipe clamp. Using SST, disconnect the fuel tube. Retainer (at 4 places) 09268–21010 Assemble SST to the connection of the fuel tube as…
• Page 326
  11–12 FUEL – FUEL INJECTOR ASSY (1ZZ–FE/3ZZ–FE) Disconnect the 4 fuel injector connectors. Remove the 3 wire harness clamps. A78473 Remove the 3 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
• Page 327
  11–13 FUEL – FUEL INJECTOR ASSY (1ZZ–FE/3ZZ–FE) INSTALL FUEL INJECTOR ASSY 1ZZ–FE: Install new grommets to each fuel injector. (3ZZ–FE) Apply a light coat of spindle oil or gasoline to new O–rings, and install them to each fuel injector. New O–ring A78477 3ZZ–FE: New O–ring…
• Page 328
  11–14 FUEL – FUEL INJECTOR ASSY (1ZZ–FE/3ZZ–FE) CONNECT FUEL TUBE SUB–ASSY Fuel Pipe Push in the connector to the pipe until it makes ”click” Clamp sound. NOTICE: Push Check if there is any damage or foreign objects on the connected part. After connecting, check if the connector and the pipe are securely connected by pulling on them.
• Page 329
  11–29 FUEL – FUEL PRESSURE PULSATION DAMPER ASSY (1AZ–FE) FUEL PRESSURE PULSATION DAMPER ASSY (1AZ–FE) 110U2–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–26) REMOVE AIR CLEANER CAP SUB–ASSY (See page 10–26) DISCONNECT FUEL TUBE SUB–ASSY (See page 11–26)
• Page 330
  11–49 FUEL – FUEL PUMP ASSY (1AZ–FSE) FUEL PUMP ASSY (1AZ–FSE) 110TA–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Opening Cover 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose 1.5 (15, 13 in. lbf) Connector Mass Air Flow Meter Connector…
• Page 331
  11–50 FUEL – FUEL PUMP ASSY (1AZ–FSE) Throttle Motor Connector Throttle Body Assy 9.0 (90, 80 in. lbf) Y Throttle Body Gasket Water By–pass Hose No. 2 Water By–pass Hose No. 1 Throttle Body Bracket 21 (210, 15) Ground Terminal 8.4 (86, 74 in.
• Page 332
  11–51 FUEL – FUEL PUMP ASSY (1AZ–FSE) Fuel Tube Sub–assy Y Gasket Fuel Pipe Clamp Y Gasket 25 (255, 18) 33 (331, 24) Fuel Pressure Pulsation Fuel Pump Assy Y Fuel Pump Damper Assy Insulator 30 (306, 22) Fuel pipe Sub–assy No. 1 9.0 (92, 80 in.
• Page 333
  11–52 FUEL – FUEL PUMP ASSY (1AZ–FSE) 110TB–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–30) REMOVE RADIATOR SUPPORT OPENING COVER (See page 18–16) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–44) REMOVE AIR CLEANER CAP SUB–ASSY (See page 10–44) REMOVE ENGINE COVER BRACKET Remove the bolt and the engine cover bracket.
• Page 334
  11–53 FUEL – FUEL PUMP ASSY (1AZ–FSE) Remove the 2 bolts first, then remove the fuel pipe sub– assy No. 1 from the fuel delivery pipe sub–assy. NOTICE: Be careful not to damage both the sealing surfaces of the fuel delivery pipe and the fuel pump when removing the fuel pipe No.1.
• Page 335
  11–54 FUEL – FUEL PUMP ASSY (1AZ–FSE) INSTALL FUEL PIPE SUB–ASSY NO.1 Attach a new O–ring, fuel injector back–up ring No. 1, No. 2 and No. 3 to the fuel pipe sub–assy No.1. Apply a small amount of fuel on the O–ring and install the fuel pipe sub–assy No.
• Page 336
  11–55 FUEL – FUEL PUMP ASSY (1AZ–FSE) INSTALL ENGINE COVER BRACKET Install the engine cover bracket with the bolt. Torque: 38 N m (388 kgf cm, 28 ft lbf) INSTALL AIR CLEANER CAP SUB–ASSY (See page 10–44) CHECK FOR FUEL LEAKS INSTALL ENGINE COVER SUB–ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in.
• Page 337
  11–84 FUEL – FUEL PUMP ASSY (GASOLINE) FUEL PUMP ASSY (GASOLINE) 110U3–01 COMPONENTS Seat Fixed Type: Rear Seat Cushion Assembly Rear Floor Service Hole Cover 1AZ–FSE: Fuel Pump Connector Fuel Tank Return Tube Fuel Tank Main Tube Sub–assy Y Fuel Pump Gauge Retainer Fuel Evaporation Tube Sub–assy No.
• Page 338
  11–85 FUEL – FUEL PUMP ASSY (GASOLINE) 110U4–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE HINT: 1ZZ–FE/3ZZ–FE: 11–1 1AZ–FE: 11–15 1AZ–FSE: 11–30 REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72–32) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the 4 screws, and then remove the rear floor ser- vice hole cover.
• Page 339
  11–86 FUEL – FUEL PUMP ASSY (GASOLINE) DISCONNECT FUEL TANK MAIN TUBE SUB–ASSY Pinch the tube connector and pull out the fuel tank main tube. Pinch NOTICE: Check if there is any dirt or mud around the connector before this operation and remove the dirt as neces- sary.
• Page 340
  11–87 FUEL – FUEL PUMP ASSY (GASOLINE) Remove the fuel pump gauge retainer. Remove the fuel suction w/ pump & gage tube. NOTICE: Be careful that the arm of the fuel sender gage should not be bent. Remove the gasket from the tank. A78447 INSTALL FUEL SUCTION W/PUMP &…
• Page 341
  11–88 FUEL – FUEL PUMP ASSY (GASOLINE) CONNECT FUEL EVAPORATION TUBE SUB–ASSY NO.2 Push in the fuel tube connector to the pipe until it makes ”click” sound. NOTICE: Check if there is any damage or foreign objects on the connected part. After connecting, check if the fuel tube connector and Push the pipe are securely connected by pulling on them.
• Page 342
  11–22 FUEL – FUEL SYSTEM (1AZ–FE) 110UY–01 INSPECTION INSPECT FUEL INJECTOR ASSY Inspect injector resistance Using an ohmmeter, measure the resistance be- tween the terminals. Resistance: 13.4 to 14.2 ( at 20YC (68YF) If the resistance is not as specified, replace the injector. Inspect injector inspection CAUTION: This test involves high–pressure fuel and electricity.
• Page 343
  11–23 FUEL – FUEL SYSTEM (1AZ–FE) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. 09842–30080 Injection volume: Injection volume Difference between each injector 60 to 73 cm (3.6 to 4.5 cu in.) 13 cm…
• Page 344
  11–19 FUEL – FUEL SYSTEM (1AZ–FE) 110UX–01 ON–VEHICLE INSPECTION CHECK FUEL PRESSURE Fuel Tube Connector Discharge the pressure in the fuel system and take pre- cautions for possible fuel spillage.(See page 11–15) Check that the battery voltage is above 12 V. Disconnect the negative (–) battery cable.
• Page 345
  11–20 FUEL – FUEL SYSTEM (1AZ–FE) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration. 09268–41047(95336–08070),09268–45014 (Clip) (09268–41250, 09268–41200, 09268–41220) Wipe up any gasoline. SST (T joint) Reconnect the negative (–) battery cable. No.1 Fuel Pipe Connect the hand–hand tester to the DLC3.
• Page 346
  11–21 FUEL – FUEL SYSTEM (1AZ–FE) When not using hand–held tester Connect the positive (+) lead form the battery to ter- minal 4 of the connector and connect the negative (–) lead to terminal 5. Check that the pump operates. Battery A75342 AVENSIS REPAIR MANUAL (RM1018E)
• Page 347
  11–15 FUEL – FUEL SYSTEM (1AZ–FE) FUEL SYSTEM (1AZ–FE) 110UW–01 PRECAUTION PRECAUTION Before working on fuel system, disconnect negative (–) battery cable. Do not smoke or work near fire when handling the fuel system. Keep gasoline away from rubber or leather parts. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: Do not disconnect any part of the fuel system until…
• Page 348
  11–16 FUEL – FUEL SYSTEM (1AZ–FE) Observe the following precautions when removing and CORRECT New O–ring installing fuel injectors. NOTICE: Never reuse the O–ring. Delivery Pipe When installing a new O–ring to the injector, be careful not to damage the injector. Coat the new O–ring with grease or gasoline before WRONG installing.
• Page 349
  11–17 FUEL – FUEL SYSTEM (1AZ–FE) Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector. Slide SST and the connector together towards the fuel tube assembly. Retainer (at 4 places) Insert A50705 Observe these following precautions when disconnecting the fuel tube connector (quick type).
• Page 350
  11–18 FUEL – FUEL SYSTEM (1AZ–FE) Observe these precautions when connecting the fuel tube connectors (Quick Type): Check that there is no damage or foreign objects in the connected part of the pipe. Match the axis of the connector with the axis of the pipe, and push into the connector until the connec- tor makes a ”click”…
• Page 351
  11–56 FUEL – FUEL SYSTEM (1CD–FTV) FUEL SYSTEM (1CD–FTV) 110CX–02 INSPECTION INJECTION OR SUPPLY PUMP ASSY Resistance inspection. Using an ohmmeter, measure the resistance be- tween the terminals. Resistance: 1.5 to 2.3 ( at 20YC (68YF) A75346 INJECTOR ASSY Resistance inspection. Using an ohmmeter, measure the resistance between the terminals.
• Page 352
  11–57 FUEL – FUEL SYSTEM (1CD–FTV) LEVEL WARNING SWITCH Continuity inspection. Using an ohmmeter, check that there is continuity between terminals. Specified condition: There is continuity when raising a float. There is no continuity when letting a float down. FUEL TEMPERATURE SENSOR Resistance inspection.
• Page 353
  11–8 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) 110UV–01 INSPECTION FUEL INJECTOR ASSY Inspect injector resistance Using an ohmmeter, measure the resistance be- tween the terminals. Resistance: Engine Rersistance Condition 13.4 to 14.2 f 20 YC (68 YF) 1ZZ–FE 13.8 to 15.2 f 20 YC (68 YF) 3ZZ–FE If the resistance is not as specified, replace the injector.
• Page 354
  11–9 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. 09842–30080 Injection volume: Difference between each Engine Injection volume injector…
• Page 355
  11–5 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) 110UU–01 ON–VEHICLE INSPECTION CHECK FUEL PRESSURE Fuel Tube Connector Discharge the pressure in the fuel system and take pre- cautions for possible fuel spillage. (See page 11–1) Check that the battery voltage is above 12 V. Disconnect the negative (–) battery cable.
• Page 356
  11–6 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration. 09268–41047(95336–08070),09268–45014 (Clip) (09268–41250, 09268–41200, 09268–41220) Wipe up any gasoline. SST (T joint) Reconnect the negative (–) battery cable. No.1 Fuel Pipe Connect the hand–hand tester to the DLC3.
• Page 357
  11–7 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) When not using the hand–held tester Connect the positive (+) lead form the battery to ter- minal 4 of the connector and connect the negative (–) lead to terminal 5. Check that the pump operates. Battery A75342 AVENSIS REPAIR MANUAL (RM1018E)
• Page 358
  11–1 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) FUEL SYSTEM (1ZZ–FE/3ZZ–FE) 110UT–01 PRECAUTION PRECAUTION Before working on fuel system, disconnect negative (–) battery cable. Do not smoke or work near fire when handling the fuel system. Keep gasoline away from rubber or leather parts. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: Do not disconnect any part of the fuel system until…
• Page 359
  11–2 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) Observe the following precautions when removing and CORRECT O–ring installing fuel injectors. NOTICE: Never reuse the O–ring. When installing a new O–ring on the injector, be Injector Delivery Pipe careful not to damage the injector. WRONG Coat the new O–ring with grease or gasoline before installing.
• Page 360
  11–3 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) Assemble SST to the connection of fuel pipe as shown in the illustration. 09268–21010 A60818 Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector. Slide SST and the connector together towards the fuel tube assembly.
• Page 361
  11–4 FUEL – FUEL SYSTEM (1ZZ–FE/3ZZ–FE) To prevent the disconnected pipe and connector from being damaged and foreign objects from being Vinyl Bag or plastic Bag introduced, cover them with a vinyl or plastic bag. A82344 Observe these precautions when connecting the fuel tube connectors (Quick Type): Check that there is no damage or foreign objects in the connected part of the pipe.
• Page 362
  11–36 FUEL – FUEL SYSTEM (1AZ–FSE) 110V1–01 INSPECTION INSPECT FUEL INJECTOR ASSY NOTICE: This inspection aims at inspecting the fuel injectors for open or short, because the fuel injectors of this vehicle are high–pressure type and do not allow to inspect fuel injection volume. Inspect injector resistance Using an ohmmeter, measure the resistance between the terminals.
• Page 363
  11–33 FUEL – FUEL SYSTEM (1AZ–FSE) 110V0–01 ON–VEHICLE INSPECTION CHECK FUEL PRESSURE Fuel Tube Connector Discharge the pressure in the fuel system and take pre- cautions for possible fuel spillage. (See page 11–30) Check that the battery voltage is above 12 V. Disconnect the negative (–) battery cable.
• Page 364
  11–34 FUEL – FUEL SYSTEM (1AZ–FSE) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration. 09268–41047(95336–08070),09268–45014 (Clip) (09268–41250, 09268–41200, 09268–41220) Wipe up any gasoline. SST (T joint) Reconnect the negative (–) battery cable. No.1 Fuel Pipe Connect the hand–hand tester to the DLC3.
• Page 365
  11–35 FUEL – FUEL SYSTEM (1AZ–FSE) When not using the hand–held tester Connect the positive (+) lead form the battery to ter- minal 4 of the connector and connect the negative (–) lead to terminal 5. Check that the pump operates. Battery CHECK FUEL PUMP OPERATION (HIGH PRESSURE) Remove the No.
• Page 366
  11–30 FUEL – FUEL SYSTEM (1AZ–FSE) FUEL SYSTEM (1AZ–FSE) 110UZ–01 PRECAUTION PRECAUTION Before working on fuel system, disconnect negative (–) battery cable. Do not smoke or work near fire when handling the fuel system. Keep gasoline away from rubber or leather parts. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: Do not disconnect any part of the fuel system until…
• Page 367
  11–31 FUEL – FUEL SYSTEM (1AZ–FSE) Observe the following precautions when removing and installing fuel injectors. NOTICE: Never reuse the O–ring. When installing a new O–ring to the injector, be careful not to damage the injector. Coat the new O–ring with grease or gasoline before installing.
• Page 368
  11–32 FUEL – FUEL SYSTEM (1AZ–FSE) Observe these precautions when connecting the fuel tube connectors (Quick Type): Check that there is no damage or foreign objects in the connected part of the pipe. Match the axis of the connector with the axis of the pipe, and push into the connector until the connec- tor makes a ”click”…
• Page 369
  11–101 FUEL – FUEL TANK ASSY (DIESEL) FUEL TANK ASSY (DIESEL) 110UE–01 COMPONENTS Rear Seat Cushion Assy Rear Floor Service Hole Cover Fuel Pump Gauge Retainer Fuel and Evaporation Vent Tube Sub–assy Y Fuel Suction Tube Set Gasket Exhaust Pipe Assy Front 43 (440, 32) Compression Spring Y Gasket…
• Page 370
  11–102 FUEL – FUEL TANK ASSY (DIESEL) Fuel Tank to Filler Pipe Hose Breather Tube Fuel Hose Fuel Tank Band Fuel Tank Protector No. 1 Fuel Tank Band 40 (400, 29) 5.4 (55, 48 in. lbf) Parking Brake Cable Assy No. 2 5.4 (55, 48 in.
• Page 371
  11–103 FUEL – FUEL TANK ASSY (DIESEL) Fuel Evaporation Tube Sub–assy No. 2 Fuel Tank Return Tube Fuel Tank Main Tube Sub–assy Fuel Tank Assy A78269 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 372
  11–104 FUEL – FUEL TANK ASSY (DIESEL) 110UF–01 Removal & Installation and Disassembly & Reassembly REMOVE REAR SEAT CUSHION ASSY (See page 72–27) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the 4 screws and the rear floor service hole cover. Disconnect the connector.
• Page 373
  11–105 FUEL – FUEL TANK ASSY (DIESEL) DISCONNECT FUEL EVAPORATION TUBE SUB–ASSY NO.2 Pinch the quick connector then pull out the fuel evapora- tion tube sub–assy No. 2. NOTICE: Check if there is any dirt or mud around the connector before this operation and remove the dirt as neces- sary.
• Page 374
  11–106 FUEL – FUEL TANK ASSY (DIESEL) REMOVE PARKING BRAKE CABLE ASSY NO.2 Remove the 2 set bolts of the parking brake cable. A77884 REMOVE PARKING BRAKE CABLE ASSY NO.3 Remove the 2 set bolts of the parking brake cable. A77885 DISCONNECT BREATHER TUBE FUEL HOSE Loosen the hose clamp and disconnect the fuel tank…
• Page 375
  11–107 FUEL – FUEL TANK ASSY (DIESEL) DISCONNECT FUEL TANK MAIN TUBE SUB–ASSY Pinch the tab of the retainer to remove the lock claws and pull down it as shown in the illustration. Pull out the fuel tank main tube. NOTICE: Check if there is any dirt or mud around the connector before this operation and remove the dirt as neces-…
• Page 376
  11–108 FUEL – FUEL TANK ASSY (DIESEL) REMOVE FUEL TANK MAIN TUBE SUB–ASSY Unfasten the 4 claws, and remove the fuel tank main tube from the fuel tank. INSTALL FUEL TANK MAIN TUBE SUB–ASSY A77892 INSTALL FUEL EVAPORATION TUBE SUB–ASSY Upper NO.2 Install the hose clamp as shown in the illustration.
• Page 377
  11–109 FUEL – FUEL TANK ASSY (DIESEL) INSTALL FUEL AND EVAPORATION VENT TUBE SUB–ASSY Align the arrow marks of the fuel pump bracket and the fuel tank. Temporarily install the retainer. Mark A63379 Mount SST to the retainer. 09808–14010 A62989 Tighten the retainer until the arrow mark located on the re- tainer is positioned within the area shown in the illustra- tion.
• Page 378
  11–110 FUEL – FUEL TANK ASSY (DIESEL) CONNECT FUEL TANK RETURN TUBE Connect the fuel tank return tube with the tube joint clip. NOTICE: Check that there is no scratch or foreign objects on the connecting parts. Check that the connector is inserted securely. Check that the clip of the tube joint is on the collar of the connector.
• Page 379
  11–89 FUEL – FUEL TANK ASSY (GASOLINE) FUEL TANK ASSY (GASOLINE) 110U6–01 COMPONENTS Seat Fixed Type: Rear Seat Cushion Assembly Rear Floor Service Hole Cover 1AZ–FSE: Fuel Pump Connector Fuel Tank Return Tube Fuel Tank Main Tube Sub–assy Y Fuel Pump Gauge Retainer Fuel Evaporation Tube Sub–assy No.
• Page 380
  11–90 FUEL – FUEL TANK ASSY (GASOLINE) 1ZZ–FE/3ZZ–FE: w/o HID Sensor: RHD: Y Exhaust Pipe Clip Front Floor Footrest Gasket Floor Carpet Assy Front Y Exhaust Pipe Gasket 43 (440, 32) Compression Spring Exhaust Pipe Assy Front Floor Panel Brace Front Y Exhaust Pipe Gasket 30 (302, 22)
• Page 381
  11–91 FUEL – FUEL TANK ASSY (GASOLINE) Fuel Tank to Filler Pipe Hose Fuel Hose No. 1 Fuel Tank Assy Fuel Tank Band Sub–assy No. 1 40 (400, 29) 40 (400, 29) Fuel Tank Band Sub–assy No. 1 LH Fuel Tank Protector No.
• Page 382
  11–92 FUEL – FUEL TANK ASSY (GASOLINE) 1AZ–FSE: Fuel Evaporation Tube Sub–assy Fuel Tank Return Tube No. 2 Fuel Tank Main Tube Sub–assy Fuel Tank Assy A77882 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 383
  11–93 FUEL – FUEL TANK ASSY (GASOLINE) 110U5–01 Removal & Installation and Disassembly & Reassembly DISCHARGE FUEL SYSTEM PRESSURE HINT: 1ZZ–FE/3ZZ–FE: 11–1 1AZ–FE: 11–15 1AZ–FSE: 11–30 REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72–32) REMOVE COVER, RR FLOOR SERVICE HOLE (See page 11–85) DISCONNECT FUEL TANK RETURN TUBE (1AZ–FSE ENGINE TYPE)
• Page 384
  11–94 FUEL – FUEL TANK ASSY (GASOLINE) Remove the 4 bolts and 4 compression springs. Remove the exhaust pipe front from the 2 exhaust pipe supports. Remove each gasket from the exhaust manifold and the exhaust pipe front. A78518 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 385
  11–95 FUEL – FUEL TANK ASSY (GASOLINE) REMOVE EXHAUST PIPE ASSY CENTER (1AZ–FE/1AZ–FSE ENGINE TYPE) Remove the 4 bolts and 2 compression springs. Remove the exhaust pipe center and the gasket from the 2 exhaust pipe supports. Remove the gasket from the exhaust pipe center. A78519 REMOVE FUEL TANK PROTECTOR NO.1 Remove the 4 bolts, and then remove the fuel tank pro-…
• Page 386
  11–96 FUEL – FUEL TANK ASSY (GASOLINE) REMOVE PARKING BRAKE CABLE ASSY NO.3 Remove the 2 set bolts of the parking brake cable. A77885 DISCONNECT BREATHER TUBE FUEL HOSE Loosen the hose clamp and disconnect the fuel tank breather hose. A77886 DISCONNECT FUEL TANK TO FILLER PIPE HOSE Loosen the hose clamp and disconnect the fuel tank to fill-…
• Page 387
  11–97 FUEL – FUEL TANK ASSY (GASOLINE) DISCONNECT FUEL TANK MAIN TUBE SUB–ASSY Pinch the tab of the retainer to remove the lock claws and Pinch pull down it as shown in the illustration. Pull out the fuel tank main tube. NOTICE: Check if there is any dirt or mud around the connector Pinch…
• Page 388
  11–98 FUEL – FUEL TANK ASSY (GASOLINE) REMOVE FUEL TANK RETURN TUBE (1AZ–FSE ENGINE TYPE) Unfasten the 5 claws and remove the fuel tank return tube from the fuel tank. A77894 REMOVE FUEL EVAPORATION TUBE SUB–ASSY NO.2 Unfasten the 4 claws and remove the fuel evaporation tube from the fuel tank.
• Page 389
  11–99 FUEL – FUEL TANK ASSY (GASOLINE) CONNECT FUEL TANK MAIN TUBE SUB–ASSY Push in the fuel tube connector to the pipe until it makes ”click” sound, and then push up the retainer to the claws Push lock. NOTICE: Check if there is any damage or foreign objects on the connected part.
• Page 390
  11–100 FUEL – FUEL TANK ASSY (GASOLINE) Install a new gasket to the the exhaust pipe center (ex- New Gasket haust pipe tail side) as shown in the illustration. Install a new gasket (exhaust pipe front side) and the ex- haust pipe center to the 2 exhaust pipe supports.
• Page 391
  11–66 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) 110U9–01 COMPONENTS Clip Engine Room Cover Side 8.0 (82, 71 in. lbf) 5.0 (51, 44 in. lbf) Clip Retainer Injector Driver V (Cooler Compressor Radiator Support to Crankshaft Pulley) Opening Cover Belt No.
• Page 392
  11–67 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) * Gasket Timing Chain Cover Plate Timing Belt No. 2 Cover Timing Belt Seal Washer 7.4 (76, 66 in.·lbf) 9.0 (92, 80 in.·lbf) Transverse Engine Engine Mounting Bracket 37 (375, 27) 21 (214, 15) Timing Belt Tensioner…
• Page 393
  11–68 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) * 42 (428, 31) 46 (469, 34) 5.0 (51, 44 in. lbf) Injection Pipe Clamp No. 2 Injection Pipe Sub–assy * 31 (316, 23) 34 (347, 25) * 42 (428, 31) 46 (469, 34) * 31 (316, 23) 34 (347, 25)
• Page 394
  11–69 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) 110UA–01 REPLACEMENT REMOVE FRONT WHEEL RH DRAIN ENGINE COOLANT (See page 16–44) REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE UNDER COVER RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE AIR CLEANER ASSY (See page 11–60)
• Page 395
  11–70 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) REMOVE FUEL INLET PIPE SUB–ASSY NOTICE: After removing the fuel inlet pipe, cover the common rail and injection pump with vinyl tape to prevent dust from be- ing introduced. Remove the wire bracket and slide the engine wire. Using SST, remove the fuel inlet pipe from the common rail.
• Page 396
  11–71 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) REMOVE INTAKE MANIFOLD INSULATOR NO.1 Remove the 2 bolts and the intake manifold insulator. A79150 REMOVE OIL LEVEL GAGE SUB–ASSY REMOVE OIL LEVEL GAGE GUIDE (See page 17–22) REMOVE WATER INLET (See page 16–50) DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL…
• Page 397
  11–72 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) Using SST, remove the injection pump drive pulley. 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05021) A62779 REMOVE INJECTION OR SUPPLY PUMP ASSY Remove the 2 nuts and the injection pump. A79153 INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N m (210 kgf cm, 15 ft lbf) INSTALL INJECTION PUMP DRIVE PULLEY Using SST, install the pulley nut.
• Page 398
  11–73 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) Using SST, tighten the nut of the injection pipe to the com- Fulcrum mon rail side. Length 09023–12700 30 cm Torque: 42 N m (428 kgf cm, 31 ft lbf) for a used pipe using SST 46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using 31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST 34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using…
• Page 399
  11–74 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) INSTALL FUEL INLET PIPE SUB–ASSY NOTICE: 30 cm In case of having the injection pump replaced, must (11.81 in.) replace the fuel inlet pipe, too. When assembling the pipe, perform the operation with the engine cold under room temperature.
• Page 400
  11–75 FUEL – INJECTION OR SUPPLY PUMP ASSY (1CD–FTV) INSTALL TIMING BELT GUIDE (See page 14–307) INSTALL TIMING BELT NO.1 COVER (See page 14–307) INSTALL TIMING BELT NO.2 COVER (See page 14–307) INSTALL IDLER PULLEY SUB–ASSY Torque: 40 N m (408 kgf cm, 30 ft lbf) INSTALL CRANKSHAFT PULLEY (See page 14–307)
• Page 401
  11–58 FUEL – INJECTOR ASSY (1CD–FTV) INJECTOR ASSY (1CD–FTV) 110U7–01 COMPONENTS Radiator Support Opening Cover Clip Retainer 8.0 (82, 71 in. lbf) Engine Cover No. 1 Vacuum Reservoir Sub–assy 8.3 (85, 73 in. lbf) Union To Connector Tube Hose Air Cleaner Cap w/ Hose Air Cleaner Element 25 (255, 18) 7.0 (71, 62 in.
• Page 402
  11–59 FUEL – INJECTOR ASSY (1CD–FTV) 13 (135, 9.7) Y Nozzle Holder Seal Cylinder Head Cover Sub–assy Gasket 5.0 (51, 44 in.·lbf) 22 (224, 16) Nozzle Leakage Y Gasket Pipe Assy Y Gasket 18 (184, 13) Injection Pipe Clamp No. 2 31 (316, 23) 34 (347, 25) 27 (270, 20)
• Page 403
  11–60 FUEL – INJECTOR ASSY (1CD–FTV) 110U8–01 REPLACEMENT HINT: Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes which are used to optimize fuel injection for the injectors. When replacing the injector assembly, a compensa- tion code for the new injector assembly must be set to the ECM.
• Page 404
  11–61 FUEL – INJECTOR ASSY (1CD–FTV) REMOVE NOZZLE HOLDER SEAL Using a screwdriver, pry out the 4 nozzle holder seals. A09656 REMOVE CYLINDER HEAD COVER SUB–ASSY Remove the 10 bolts and the cylinder head cover. A79144 REMOVE NOZZLE LEAKAGE PIPE ASSY Remove the union bolt and the 4 hollow screws, then re- move the nozzle leakage pipe and the 5 gaskets.
• Page 405
  11–62 FUEL – INJECTOR ASSY (1CD–FTV) Install new back–up rings and O–rings to each injector. Apply a light coat of engine oil onto the O–rings on each Back–up ring injector. Install the injector to the cylinder head. NOTICE: Fit the injectors to the nozzle seat. O–ring A79187 Install the nozzle holder clamp as shown in the illustration.
• Page 406
  11–63 FUEL – INJECTOR ASSY (1CD–FTV) Install the bolt, the nozzle leakage No. 2 pipe and the gasket to the cylinder head with SST. 09280–00010 Torque: 8.8 N m (90 kgf cm, 79 in. lbf) for bolt 21 N m (214 kgf cm, 15 ft lbf) for SST Apply a light coat of soapy water (any fluid to detect fuel leakage) on the nozzle leakage pipe No.
• Page 407
  11–64 FUEL – INJECTOR ASSY (1CD–FTV) INSTALL NOZZLE HOLDER SEAL Install new 4 nozzle holder seals. INSTALL TIMING BELT NO.2 COVER (See page 14–307) INSTALL INJECTION PIPE SUB–ASSY NO.1 NOTICE: 30 cm In case of having the injectors replaced, must replace (11.81 in.) the injection pipes, too.
• Page 408
  11–65 FUEL – INJECTOR ASSY (1CD–FTV) INSTALL INJECTION PIPE SUB–ASSY NO.2 09023–12700 HINT: Perform the same procedures as injection pipe No. 1. INSTALL INJECTION PIPE SUB–ASSY NO.3 09023–12700 HINT: Perform the same procedures as injection pipe No. 1. INSTALL INJECTION PIPE SUB–ASSY NO.4 09023–12700 HINT: Perform the same procedures as injection pipe No.
• Page 409
  12–18 EMISSION CONTROL – EGR SYSTEM (1CD–FTV) 1209J–02 INSPECTION INSPECT VACUUM REGULATING VALVE ASSY Inspect E–VRV for open circuit Ohmmeter Using an ohmmeter, measure resistance between the terminals. Resistance: 10 to 14 f at 20®C (68®F) Resistance A77127 Inspect E–VRV for ground Using an ohmmeter, check that there is no continu- Ohmmeter ity between each terminal and the body.
• Page 410
  12–19 EMISSION CONTROL – EGR SYSTEM (1CD–FTV) INSPECT EGR VALVE ASSY EGR3 EGR4 Using an ohmmeter, measure the resistance between the terminals. EGR2 EGR1 Resistance at 20 -C (68 -F) Terminal 19.6 ( 1.4 f +B1 – EGR1 19.6 ( 1.4 f +B1 –…
• Page 411
  12–17 EMISSION CONTROL – EGR SYSTEM (1CD–FTV) EGR SYSTEM (1CD–FTV) 1209I–02 ON–VEHICLE INSPECTION HINT: In a malfunction where the EGR system is always on, black smoke or white smoke may be emitted from the exhaust pipe. If this occurs, inspect the EGR system as well. INSPECT SEATING OF EGR VALVE Start the engine and check that it starts and runs at idle.
• Page 412
  12–8 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FE) 1209F–02 INSPECTION INSPECT CHARCOAL CANISTER ASSY Inspect charcoal canister operation. Port C Check the charcoal canister operation according to Port A the table below. 09992–00242 Inspection: Checking method Result Close ports B and C, then apply vacuum Port B No leaks to port A…
• Page 413
  12–9 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FE) INSPECT VACUUM SWITCHING VALVE ASSY NO.1 Ohmmeter Inspect VSV for open circuit. Using an ohmmeter, measure resistance between the terminals. Resistance: 26 to 30 f at 20YC (68YF) If the resistance is not as specified, replace the VSV. Resistance A77115 Inspect the VSV for ground.
• Page 414
  12–10 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FE) Bank 2 Sensor 1: Bank 2 Sensor 1: Using an ohmmeter, measure the resistance be- tween the terminals. Resistance: Terminal No. Resistance 1.8 to 3.4 f at 20 YC (68 YF) 1 (HT) – 2 (+B) 5.0 to 7.5 f at 500 YC (932 YF) 1 (HT) –…
• Page 415
  12–6 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FE) EMISSION CONTROL SYSTEM (1AZ–FE) 1209E–02 ON–VEHICLE INSPECTION INSPECT AIR–FUEL RATIO COMPENSATION SYS- HINT: You can also check the system by choosing ”DATA MONITOR/ SENSOR OUTPUT VOLTAGE” on the monitor of the hand– held tester.
• Page 416
  12–7 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FE) VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. B11449 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 417
  12–13 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FSE) 1209H–02 INSPECTION INSPECT CHARCOAL CANISTER ASSY Inspect charcoal canister operation. Port C Check the charcoal canister operation according to Port A the table below. 09992–00242 Checking method Result Close ports B and C, then apply vacuum No leaks to port A Port B…
• Page 418
  12–14 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FSE) INSPECT VACUUM SWITCHING VALVE ASSY NO.1 Ohmmeter Inspect VSV for open circuit. Using an ohmmeter, measure resistance between the terminals. Resistance: 26 to 30 f at 20YC (68YF) If the resistance is not as specified, replace the VSV. Resistance A77115 Inspect the VSV for ground.
• Page 419
  12–15 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FSE) Bank 2 Sensor 2: Bank 2 Sensor 2: Using an ohmmeter, measure the resistance be- tween the terminals. Resistance: Terminal No. Resistance 11 to 16 f at 20 YC (68 YF) 1 (HT) – 2 (+B) 1 (HT) –…
• Page 420
  12–11 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FSE) EMISSION CONTROL SYSTEM (1AZ–FSE) 1209G–02 ON–VEHICLE INSPECTION INSPECT AIR–FUEL RATIO COMPENSATION SYS- HINT: You can also check the system by choosing ”DATA MONITOR/ SENSOR OUTPUT VOLTAGE” on the monitor of the hand– held tester.
• Page 421
  12–12 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1AZ–FSE) VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. B11449 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 422
  12–16 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1CD–FTV) EMISSION CONTROL SYSTEM (1CD–FTV) 1203V–03 ON–VEHICLE INSPECTION VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leak or damage. HINT: Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system be- tween the throttle body and cylinder head will allow air suction and cause the engine to run improperly.
• Page 423
  12–3 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1ZZ–FE/3ZZ–FE) 1209D–02 INSPECTION INSPECT CHARCOAL CANISTER ASSY Inspect charcoal canister operation. Port C Check the charcoal canister operation according to Port A the table below. 09992–00242 Inspection: Checking method Result Close ports B and C, then apply vacuum Port B No leaks to port A…
• Page 424
  12–4 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1ZZ–FE/3ZZ–FE) Apply battery voltage across the terminals. Check that air flows from port E to port F. If operation is not as specified, replace the VSV. Battery A77118 INSPECT VENTILATION VALVE SUB–ASSY Cylinder Head Side Blow air into the cylinder head side, and check that air passes through easily.
• Page 425
  12–5 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1ZZ–FE/3ZZ–FE) INSPECT FUEL TANK CAP ASSY Visually check if the cap or gasket is deformed or dam- aged. Gasket B04812 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 426
  12–1 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1ZZ–FE/3ZZ–FE) EMISSION CONTROL SYSTEM (1ZZ–FE/3ZZ–FE) 1209C–02 ON–VEHICLE INSPECTION INSPECT AIR–FUEL RATIO COMPENSATION SYS- HINT: You can also check the system by choosing ”DATA MONITOR/ SENSOR OUTPUT VOLTAGE” on the monitor of the hand– held tester.
• Page 427
  12–2 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1ZZ–FE/3ZZ–FE) VISUALLY INSPECT HOSES, CONNECTIONS AND 1ZZ–FE GASKETS Check for cracks, leaks or damage. HINT: Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system be- 3ZZ–FE tween the throttle body and cylinder head will allow air suction…
• Page 428
  13–2 INTAKE – INTAKE AIR CONTROL SYSTEM (1AZ–FSE) 1306S–02 INSPECTION INSPECT INTAKE AIR CONTROL VALVE ASSY With 34.7 kPa (260 mm Hg, 10.2 in. Hg) of vacuum ap- plied to the actuator, check that the actuator rod moves. One minute after applying the vacuum, check that the ac- tuator rod does not return.
• Page 429
  13–1 INTAKE – INTAKE AIR CONTROL SYSTEM (1AZ–FSE) INTAKE AIR CONTROL SYSTEM (1AZ–FSE) 1302G–03 ON–VEHICLE INSPECTION INSPECT INTAKE AIR CONTROL SYSTEM Using a 3–way connector, connect vacuum gauge to the Vacuum Gage actuator hose. Connect the hand–held tester to the DLC 3. Start the engine.
• Page 430
  13–18 INTAKE – INTERCOOLER ASSY (1CD–FTV) INTERCOOLER ASSY (1CD–FTV) 13070–01 REPLACEMENT REMOVE FRONT BUMPER COVER (See page 76–3) REMOVE INTERCOOLER COOLING AIR DUCT SUB–ASSY Remove the 2 bolts and the cooling air duct. A79168 REMOVE INTERCOOLER ASSY Disconnect the vacuum hose, the air hose No. 2 and No. 3 from the intercooler.
• Page 431
  13–19 INTAKE – INTERCOOLER ASSY (1CD–FTV) Tighten the hose clamps as shown in the illustration. Torque: 6.0 N m (61 kgf cm, 53 in. lbf) Clamp Front Bolt A64007 INSTALL INTERCOOLER COOLING AIR DUCT SUB–ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf) INSTALL FRONT BUMPER COVER (See page 76–3)
• Page 432
  13–7 INTAKE – TURBO CHARGER SYSTEM (1CD–FTV) 13030–02 INSPECTION VACUUM SWITCHING VALVE ASSY NO.1 Inspect VSV for open circuit. Using an ohmmeter, check that the there is continu- ity between the terminals. Resistance: 37 – 44 f at 20YC (68YF) A60591 Inspect VSV for ground.
• Page 433
  13–5 INTAKE – TURBO CHARGER SYSTEM (1CD–FTV) 1302Z–03 ON–VEHICLE INSPECTION INSPECT INTAKE AIR SYSTEM Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between the turbo- charger outlet and cylinder head. Clogged air cleaner…Clean or replace element Hoses collapsed or deformed…Repair or replace Leakage from connections…Check each connec- tion and repair…
• Page 434
  13–6 INTAKE – TURBO CHARGER SYSTEM (1CD–FTV) Inspect supply power Turn the ignition switch ON. Disconnect the vacuum hose from the turbo pres- sure sensor. Connect a voltmeter to terminals 35 (PIM) and 28 (E2) of the ECM and measure the output voltage under atmospheric pressure.
• Page 435
  If necessary, replace the oil pipe too. Thoroughly remove old gasket sticking to the lubrication oil pipe flange and the turbocharger oil flange. If replacing the bolt(s) or nut(s), must use Toyota genuine parts to prevent breakage or deformation. A77120 If replacing the turbocharger, put 20 cm (1.2 cu in.) of…
• Page 436
  13–4 INTAKE – TURBO CHARGER SYSTEM (1CD–FTV) Since the turbine wheels runs at an extremely high speed, if the engine is running without the air cleaner, case cover and hose, damage to the turbine wheel will result by introduced foreign particle. A77122 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 437
  13–8 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) TURBOCHARGER SUB–ASSY (1CD–FTV) 1306Y–01 COMPONENTS Clip Retainer 8.0 (82, 71 in. lbf) Radiator Support Opening Cover Engine Cover No. 1 Air Cleaner Cap w/ Hose Air Cleaner Element 7.0 (71, 62 in. lbf) Air Cleaner Case Engine Under Cover Sub–assy No.
• Page 438
  13–9 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) Union To Connector Tube Hose Vacuum Reservoir Sub–assy 7.5 (76, 66 in. lbf) w/ Cold Area: 8.3 (85, 73 in. lbf) Heater Bracket w/ Cold Area: 25 (255, 18) Heater Pump Assy 18 (178, 13) Fuel Filter Assy 7.5 (76, 66 in.
• Page 439
  13–10 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) Turbo Insulator No. 1 20 (204, 15) 20 (204, 15) Exhaust Manifold Heat Insulator No. 2 12 (122, 8.9) 12 (122, 8.9) 20 (204, 15) Turbo Insulator No. 2 Turbocharger Stay 53 (540, 39) 56 (571, 41) Y Gasket Turbocharger Sub–assy…
• Page 440
  13–11 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) 1306Z–01 REPLACEMENT REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 DRAIN ENGINE COOLANT (See page 16–44) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE VACUUM RESERVOIR SUB–ASSY Disconnect the 2 vacuum hoses and the connector.
• Page 441
  13–12 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) REMOVE HEATER BRACKET (W/ COLD AREA) Remove the bolt and the heater bracket. A79159 REMOVE FLOOR PANEL BRACE FRONT (See page 15–10) REMOVE EXHAUST PIPE ASSY FRONT (See page 15–10) REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) Remove the 2 nuts.
• Page 442
  13–13 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) REMOVE TURBO INSULATOR NO.1 Remove the 2 bolts and nut, and then remove the turbo insulator. A79161 REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 Remove the 2 bolts and the exhaust manifold heat insula- tor. A79162 REMOVE MANIFOLD STAY NO.2 Remove the bolt and nut and then remove the manifold…
• Page 443
  13–14 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) REMOVE TURBOCHARGER STAY Remove the 2 bolts and 2 nuts, and then remove the turbocharger stay. A79165 DISCONNECT TURBO WATER HOSE NO.1 A79166 DISCONNECT TURBO WATER HOSE NO.2 A79167 SEPARATE TURBO OIL INLET PIPE SUB–ASSY Remove the 2 nuts, the turbo oil pipe and the gasket.
• Page 444
  13–15 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) REMOVE TURBO WATER PIPE SUB–ASSY NO.1 Remove the 2 nuts, the turbo water pipe and the gasket. B13096 INSTALL TURBO WATER PIPE SUB–ASSY NO.1 Install a new gasket and the turbo water pipe with the 2 nuts. Torque: 13 N m (135 kgf cm, 9.7 ft lbf) INSTALL TURBOCHARGER SUB–ASSY Install a new gasket and the turbocharger with the 3 nuts.
• Page 445
  13–16 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) Install a new gasket and the manifold converter, and tem- porarily tighten bolts A and bolts B while pushing the up- per portion of the converter toward the turbocharger. Torque: 8.0 N m (82 kgf cm, 71 in. lbf) Tighten the 3 nuts.
• Page 446
  13–17 INTAKE – TURBOCHARGER SUB–ASSY (1CD–FTV) INSTALL INTERCOOLER AIR HOSE Install the air hose and hose clamps as shown in the il- lustration. 2 to 7 mm 0 to 2 mm A64328 Tighten the hose clamps as shown in the illustration. Torque: 6.0 N m (61 kgf cm, 53 in.
• Page 447
  14–168 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) CAMSHAFT (1AZ–FE) 141BG–01 COMPONENTS Engine Room Cover Side 7.0 (71.62, in. lbf) 7.0 (71.62, in. lbf) Engine Cover Sub–assy No. 1 Radiator Support Opening Cover Engine Under Cover RH N·m (kgf·cm, ft·lbf) : Specified torque A77322 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 448
  14–169 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) 9.0 (90, 80 in. lbf) Ignition Coil Assy 14 (143, 10) 11 (115, 8.0) Ventilation Hose No. 2 Ventilation Hose No. 2 11 (115, 8.0) Cylinder Head Cover Sub–assy Y Gasket N·m (kgf·cm, ft·lbf) : Specified torque Y Non–reusable part A77320 AVENSIS REPAIR MANUAL (RM1018E)
• Page 449
  14–170 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) Leaded Gasoline type: 54 (551, 40) Crankshaft Timing Geaer or Sprocket 30 (301, 22) 30 (301, 22) 9.0 (92, 80 in. lbf) Bearing Cap No. 3 Bearing Cap No. 1 Bearing Cap No. 2 Camshaft Unleaded Gasoline type: No.
• Page 450
  14–171 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) 141BK–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts and the engine cover No. 1. A77281 REMOVE IGNITION COIL ASSY Remove 4 bolts and the ignition coils.
• Page 451
  14–172 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) Check that each timing mark of the camshaft timing gears Unleaded Gasoline is aligned with each timing mark located on the No. 1 and Timing No. 2 bearing caps as shown in the illustration. Marks If not, turn the crankshaft 1 revolution (360Y) and align the marks as above.
• Page 452
  14–173 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) Raising the No. 2 camshaft, remove the set bolt. Remove the camshaft timing gear from the No. 2 cam- shaft with the timing chain wrapped. Remove the camshaft timing gear from the timing chain. A52473 REMOVE CAMSHAFT Using several steps, loosen and remove the 10 camshaft…
• Page 453
  14–174 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) Put air pressure into the oil port with 150 kpa (1.5 kgf/cm 21 psi), and turn the camshaft timing gear to the advance direction (counterclockwise) by hand. CAUTION: Cover the paths with shop rag to avoid oil splashing. HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand.
• Page 454
  14–175 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) INSTALL CAMSHAFT Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing gear.
• Page 455
  14–176 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) Check that the match marks on the timing chain and the Unleaded Gasoline camshaft timing gears are positioned as shown in the il- Timing lustration. Marks Timing Marks Leaded Gasoline Timing Marks Timing Marks A77285 INSTALL CHAIN TENSIONER ASSY NO.1 Release the ratchet pawl, fully push in the plunger and ap-…
• Page 456
  14–177 ENGINE MECHANICAL – CAMSHAFT (1AZ–FE) Turn the crankshaft counterclockwise, and check that the pin is disengaged from the hook. Disconnect Hook Turn A77396 Turn the crankshaft clockwise, and check the plunger is extended. INSTALL CYLINDER HEAD COVER SUB–ASSY Remove any old seal packing (FIPG) material. Plunger Push Turn…
• Page 457
  14–237 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) CAMSHAFT (1AZ–FSE) 141BP–01 COMPONENTS Engine Room Cover Side 7.0 (71, 62 in. lbf) 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Radiator Support Opening Cover Engine Under Cover RH N·m (kgf·cm, ft·lbf) : Specified torque A77322 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 458
  14–238 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) Fuel Pipe Sub–assy No. 1 Fuel Pressure 25 (255, 18) Pulsation Damper 9.0 (90, 80 in. lbf) Y Gasket Assy 33 (331, 24) Y Gasket Ignition Control Fuel Tube Sub–assy Fuel Pump Assy 9.0 (90, 80 in. lbf) 30 (306, 22) Y Gasket 14 (143, 10)
• Page 459
  14–239 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) 30 (301, 22) 30 (301, 22) 9.0 (92, 80 in. lbf) Bearing Cap No. 3 Bearing Cap No. 1 Bearing Cap No. 2 Camshaft Unleaded Gasoline type: No. 2 Camshaft Camshaft Timing Gear Assy 54 (551, 40) 54 (551, 40) Camshaft Timing Gear…
• Page 460
  14–240 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) 141BQ–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–30) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts and the engine cover No. 1. A77339 REMOVE IGNITION COIL ASSY Remove the 4 bolts and the ignition coils.
• Page 461
  14–241 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) Check that each timing mark of the camshaft timing gears Timing is aligned with each timing mark located on the No. 1 and Marks No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft 1 revolution (360Y) and align the marks as above.
• Page 462
  14–242 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) REMOVE CAMSHAFT Using several steps, loosen and remove the 10 camshaft bearing cap bolts uniformly in the sequence shown in the illustration. Remove 5 camshaft bearings. Remove the camshaft. A77309 Tie the timing chain as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover.
• Page 463
  14–243 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) Remove a fringe bolt of camshaft timing gear. NOTICE: Be sure not to remove the other 4 bolts. If reusing the camshaft timing gear, release the straight pin lock first, and then install the gear. A32639 INSTALL CAMSHAFT TIMING GEAR ASSY Straight…
• Page 464
  14–244 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) Raising the No. 2 camshaft, tighten the set bolt temporari- A52473 Examine the from marks and numbers and tighten the Bearing Cap No. 2 Bearing Cap No. 3 bolts in the sequence shown in the illustration. Torque: Bearing cap No.
• Page 465
  14–245 ENGINE MECHANICAL – CAMSHAFT (1AZ–FSE) Install a new gasket chain tensioner No. 1 with 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) NOTICE: If the hook is disengaged while installing, apply the hook again, and then resume the installation. Engine Front A77395…
• Page 466
  14–314 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) CAMSHAFT (1CD–FTV) 141C7–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer V (Cooler 8.0 (82, 71 in. lbf) Radiator Support Opening Cover Compressor to Crankshaft Pulley) Belt No. 1 72 (734, 53) Engine Cover No. 1 39 (398, 29) Power Steering Idle Pulley Bracket…
• Page 467
  14–315 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) Engine Mounting Insulator Sub–assy RH 52 (530, 38) 52 (530, 38) 5.0 (51, 44 in.·lbf) 8.3 (85, 73 in.·lbf) Vacuum Reservoir Sub–assy Injector Driver Union To Connector Tube Hose 52 (530, 38) 25 (255, 18) Air Tube No.
• Page 468
  14–316 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) * Gasket Timing Chain Cover Plate Timing Belt No. 2 Cover Timing Belt Seal Washer 7.4 (76, 66 in.·lbf) 9.0 (92, 80 in.·lbf) Transverse Engine Engine Mounting Bracket 37 (375, 27) 21 (214, 15) Timing Belt Tensioner Generator V belt…
• Page 469
  14–317 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) 13 (135, 9.7) 22 (224, 16) Y Nozzle Holder Seal 27 (270, 20) Y Gasket 18 (184, 13) Y Gasket Cylinder Head Cover Sub–assy Nozzle Leakage Vacuum Pump Assy Pipe Assy Washer Gasket Injector Assy 21 (214, 15) Fuel Injector Nozzle Holder Clamp…
• Page 470
  14–318 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) 141C8–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 ENGINE UNDER COVER RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE AIR CLEANER ASSY (See page 11–60)
• Page 471
  14–319 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) REMOVE INJECTION PIPE SUB–ASSY NO.1 (See page 11–60) Remove the 2 nuts and 2 upper infection pipe clamps from the intake manifold. Using SST, remove the injection pipe from the common rail side. 09023–12700 Using SST, remove the injection pipe from the injector side.
• Page 472
  14–320 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11–60) REMOVE INJECTOR ASSY (See page 11–60) HINT: Since each injector assembly has a characteristic fuel injecting behavior, store them in correct order so that they can be returned to the original locations when re–assembling. REMOVE CAMSHAFT OIL SEAL RETAINER Remove the 4 bolts.
• Page 473
  14–321 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) SET NO. 1 CYLINDER TO TDC/COMPRESSION TDC Mark Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing pulley at the position of 90Y BTDC. NOTICE: If the timing belt is disengaged, having the crankshaft tim- Dot Mark ing pulley at wrong angle can cause the piston head and valve head to come into contact with each other.
• Page 474
  14–322 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) Install the camshaft bearing caps. Seal Packing Remove any oil packing (FIPG) material from the No. 5 camshaft bearing cap. Apply seal packing to the No. 5 camshaft bearing cap as shown in the illustration. Seal packing: Part No.
• Page 475
  14–323 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) Install the oil seal retainer with the 4 bolts. Tighten the 4 bolts uniformly in several steps. Torque: 8.8 N m (90 kgf cm, 78 in. lbf) INSTALL CAMSHAFT TIMING PULLEY Install the pulley set key to the groove of the camshaft. Align the keyway of the timing pulley with the key located on the camshaft, slide the pulley into place.
• Page 476
  14–324 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) Using SST, tighten the nut of the injection pipe to the com- Fulcrum mon rail side. Length 09023–12700 30 cm Torque: 42 N m (428 kgf cm, 31 ft lbf) for a used pipe using SST 46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using 31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST 34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using…
• Page 477
  14–325 ENGINE MECHANICAL – CAMSHAFT (1CD–FTV) INSTALL TIMING CHAIN COVER PLATE (See page 14–307) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14–307) INSTALL TIMING BELT GUIDE (See page 14–307) INSTALL TIMING BELT NO.1 COVER (See page 14–307) INSTALL TIMING BELT NO.2 COVER (See page 14–307) INSTALL IDLER PULLEY SUB–ASSY…
• Page 478
  14–60 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) CAMSHAFT (1ZZ–FE/3ZZ–FE) 141CJ–01 COMPONENTS Clip Engine Room Side Cover RH Clip Retainer Radiator Cover Assy Clip Engine Under Cover RH Engine Under Cover No. 1 Clip A79321 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 479
  14–61 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Fan and Generator V Belt 52 (530, 38) Clip 7.0 (71, 62 in. lbf) Engine Mounting Insulator RH 52 (530, 38) Cylinder Head Cover No. 2 N·m (kgf·cm, ft·lbf) : Specified torque A76710 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 480
  14–62 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) 9.0 (92, 80 in. lbf) 9.0 (92, 80 in. lbf) Engine Wire 9.0 (92, 80 in. lbf) Ignition Coil Assy Ventilation Hose No. 2 9.0 (92, 80 in. lbf) 11 (112, Seal Washer 11 (112, 11 (112, Clamp Bracket…
• Page 481
  14–63 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Camshaft Bearing Cap No. 3 13 (133, 10) 23 (235, 17) Camshaft Bearing Cap No. 1 Camshaft No. 2 Camshaft Timing Gear Camshaft or Sprocket 54 (551, 40) Camshaft Timing Gear Assy 54 (551, 40) 9.0 (92, 80 in.
• Page 482
  14–64 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) 141CK–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) REMOVE ENGINE UNDER COVER RH (See page 14–27) REMOVE CYLINDER HEAD COVER NO.2 Remove and the 2 screw and 2 clips and detach the en- gine under cover No.2.
• Page 483
  14–65 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) DISCONNECT VENTILATION HOSE NO.2 Disconnect the ventilation hose from the cylinder head cover. A64058 REMOVE CYLINDER HEAD COVER SUB–ASSY Remove the 9 bolts, 2 seal washers, 2 nuts, and 3 clamp brackets. Remove the cylinder head cover. REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27)
• Page 484
  14–66 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley to align the timing notch with Mark Mark timing mark ”0” of the timing chain cover. Check that the point marks of the camshaft timing sprock- et and VVT timing sprocket are in straight line on the tim- ing chain cover surface as shown in the illustration.
• Page 485
  14–67 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Hold the camshaft with a wrench, loosen the camshaft Hold timing gear set bolt. Tighten NOTICE: Be careful not to damage the valve lifter. A62187 Using several steps, loosen the camshaft bearing cap bolts on No. 2 camshaft in the sequence shown in the il- lustration.
• Page 486
  14–68 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Tie the timing chain with a string as shown in the illustra- tion. NOTICE: Be careful not to drop anything inside the timing chain cov- A32556 INSPECT CAMSHAFT TIMING GEAR ASSY Retard Side Check the lock of camshaft timing gear. Path Clamp the camshaft in a vice, and confirm the cam- shaft timing gear is locked.
• Page 487
  14–69 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Confirm if the camshaft timing gear assembly re- Retard Advanced volves in the timing advance direction when weak- Side Path Side Path ening the air pressure of the timing retard path. HINT: When the lock pin is released, the camshaft timing gear re- volves in the advance direction.
• Page 488
  14–70 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Put air pressure into two broken paths (the advance side Retard Advanced path and the retard side path) with about 150 kPa {1.5 Side Path Side Path kgf cm}. CAUTION: Cover the paths with shop rag to avoid oil splashing. A62191 Confirm if the camshaft timing gear assembly revolves in Retard…
• Page 489
  14–71 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Check that there is no clearance between the gear’s fringe and the camshaft. Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N m (551 kgf cm 40 ft lbf) Check that the camshaft timing gear assembly can move to the retard angle side (the right angle) and is locked at the most retarded position.
• Page 490
  14–72 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration. Torque: 13 N m (133 kgf cm, 10 ft lbf) Install the bearing cap No. 1. Torque: 23 N m (235 kgf cm, 17 ft lbf) A62198 Hold the camshaft with a wrench, tighten the camshaft Hold…
• Page 491
  14–73 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) 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– Push hook the plunger by the hook to fix it.
• Page 492
  14–74 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) INSTALL CYLINDER HEAD COVER SUB–ASSY Seal Packing Remove any old packing (FIPG) material. 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.
• Page 493
  14–75 ENGINE MECHANICAL – CAMSHAFT (1ZZ–FE/3ZZ–FE) Install the engine wire with the 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) A76713 INSTALL CYLINDER HEAD COVER NO.2 Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N m (71 kgf cm, 62 in.
• Page 494
  14–135 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) CHAIN SUB–ASSY (1AZ–FE) 141B7–01 COMPONENTS Engine Room Cover Side 7.0 (71, 62 in. lbf) 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Radiator Support Opening Cover Fan and Generator V Belt Engine Under Cover RH Engine Under Cover LH N·m (kgf·cm, ft·lbf) : Specified torque…
• Page 495
  14–136 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Cooler Refrigerant Suction Hose No. 1 (LHD (w/ Air Conditioner) 5.0 (51, 44 in. lbf) Cooler Bracket Steering Position Type) (LHD (w/ Air Conditioner) 7.0 (71, 62 in. lbf) Steering Position Type) 5.0 (51, 44 in. lbf) 7.0 (71, 62 in.
• Page 496
  14–137 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) 9.0 (90, 80 in. lbf) Ignition Coil Assy 14 (143, 10) 11 (115, 8.0) Ventilation Hose No. 2 Ventilation Hose 11 (115, 8.0) Cylinder Head Cover Sub–assy Y Gasket N·m (kgf·cm, ft·lbf) : Specified torque Y Non–reusable part A77320 AVENSIS REPAIR MANUAL (RM1018E)
• Page 497
  14–138 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) 9.0 (90, 80 in. lbf) 43 (440, 32) Y Gasket Chain Tensioner Assy No. 1 V–ribbed Belt Tensioner Assy Timing Chain or Belt Cover 43 (440, 32) Sub–assy 60 (610, 44) 60 (610, 44) Crankshaft Position 43 (440, 32) Sensor…
• Page 498
  14–139 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) 141B8–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN ENGINE OIL Install a new gasket and the drain plug after draining the engine oil. Torque: 25 N m (255 kgf cm, 18 ft lbf) REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts and the engine cover No.
• Page 499
  14–140 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Remove the 2 nuts and separate the suction hose. A77303 SEPARATE VANE PUMP OIL RESERVOIR ASSY NOTICE: Do not disconnect the 2 hoses. REMOVE OIL RESERVOIR BRACKET NO.1 Remove the 2 bolts and the oil pump reservoir bracket No.
• Page 500
  14–141 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Remove the bolt and the engine service cover bracket RH. REMOVE IGNITION COIL ASSY Remove the 4 bolts and 4 ignition coils. REMOVE CYLINDER HEAD COVER SUB–ASSY Disconnect the 2 PCV hoses from the cylinder head cov- Remove the 8 bolts and 2 nuts, and then remove the cylin-…
• Page 501
  14–142 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE ENGINE MOUNTING BRACKET NO.2 RH Place the jack underneath the engine, and put a wooden block on the jack. A61184 Remove the 2 bolts and 2 nuts, and then detach the mounting bracket No. 2 RH. A66202 REMOVE TRANSVERSE…
• Page 502
  14–143 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE CHAIN TENSIONER ASSY NO.1 Remove the 2 nuts, the chain tensioner No. 1 and gasket. NOTICE: Do not turn the crankshaft. Push A77286 REMOVE CRANKSHAFT POSITION SENSOR REMOVE OIL PAN SUB–ASSY Remove the 12 bolts and 2 nuts. A64641 Insert the blade of SST between the crank case, timing chain cover and oil pan, cut off applied sealer and remove…
• Page 503
  14–144 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE TIMING CHAIN OR BELT COVER SUB–ASSY Remove the 14 bolts and 2 nuts. Using a screwdriver, pry between the timing chain cover and cylinder head or cylinder block. Remove the timing chain cover. NOTICE: Be careful not to damage the contact surface of the timing chain cover, cylinder head and cylinder block.
• Page 504
  14–145 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE NO.2 CHAIN SUB–ASSY Turn the crankshaft counterclockwise 90Y, and align an adjusting hole of the oil pump drive shaft gear with the Groove groove of the oil pump. A77382 Put a 4 mm diameter bar in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove the nut.
• Page 505
  14–146 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Align the mark links (yellow colored links) with the timing Mark Link marks of each gear as shown in the illustration. Timing Mark Install the gears to the crankshaft and oil pump shaft with the chain wrapped.
• Page 506
  14–147 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET SET NO. 1 CYLINDER TO TDC/COMPRESSION Unleaded Gasoline Turn the camshafts with a wrench on the hexagonal lobe, Timing and align the timing marks of the camshaft timing gear Marks with each timing mark located on the No.
• Page 507
  14–148 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Align the mark links (gold or yellow colored links) with Mark Links Timing Mark Timing Marks each timing mark located on the camshaft timing gears, and install the chain. A77389 INSTALL TIMING CHAIN GUIDE Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 508
  14–149 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to Seal Packing 0.157 in.)) of seal packing as shown in the illustration. Seal packing: Part No. 08826 – 00080 or equivalent 2.5 mm f 3 to 4 mm A77391 Install the timing chain cover with the 14 bolts and 2 nuts.
• Page 509
  14–150 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) INSTALL OIL PAN SUB–ASSY NOTICE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine within 2 hours after installing. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan.
• Page 510
  14–151 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Install a new gasket chain tensioner with the 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) NOTICE: If the hook is released wile inserting, apply the hook again, and insert the chain tensioner. Engine Front A77395…
• Page 511
  14–152 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Apply seal packing to the 2 locations as shown in the il- Seal Packing lustration. Seal Packing: Part No. 08826–00080 or equivalent NOTICE: Remove any oil from the contact surface. Install the cylinder head cover within 5 minutes after applying seal packing.
• Page 512
  14–139 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) 141B8–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN ENGINE OIL Install a new gasket and the drain plug after draining the engine oil. Torque: 25 N m (255 kgf cm, 18 ft lbf) REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts and the engine cover No.
• Page 513
  14–140 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Remove the 2 nuts and separate the suction hose. A77303 SEPARATE VANE PUMP OIL RESERVOIR ASSY NOTICE: Do not disconnect the 2 hoses. REMOVE OIL RESERVOIR BRACKET NO.1 Remove the 2 bolts and the oil pump reservoir bracket No.
• Page 514
  14–141 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Remove the bolt and the engine service cover bracket RH. REMOVE IGNITION COIL ASSY Remove the 4 bolts and 4 ignition coils. REMOVE CYLINDER HEAD COVER SUB–ASSY Disconnect the 2 PCV hoses from the cylinder head cov- Remove the 8 bolts and 2 nuts, and then remove the cylin-…
• Page 515
  14–142 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE ENGINE MOUNTING BRACKET NO.2 RH Place the jack underneath the engine, and put a wooden block on the jack. A61184 Remove the 2 bolts and 2 nuts, and then detach the mounting bracket No. 2 RH. A66202 REMOVE TRANSVERSE…
• Page 516
  14–143 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE CHAIN TENSIONER ASSY NO.1 Remove the 2 nuts, the chain tensioner No. 1 and gasket. NOTICE: Do not turn the crankshaft. Push A77286 REMOVE CRANKSHAFT POSITION SENSOR REMOVE OIL PAN SUB–ASSY Remove the 12 bolts and 2 nuts. A64641 Insert the blade of SST between the crank case, timing chain cover and oil pan, cut off applied sealer and remove…
• Page 517
  14–144 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE TIMING CHAIN OR BELT COVER SUB–ASSY Remove the 14 bolts and 2 nuts. Using a screwdriver, pry between the timing chain cover and cylinder head or cylinder block. Remove the timing chain cover. NOTICE: Be careful not to damage the contact surface of the timing chain cover, cylinder head and cylinder block.
• Page 518
  14–145 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) REMOVE NO.2 CHAIN SUB–ASSY Turn the crankshaft counterclockwise 90Y, and align an adjusting hole of the oil pump drive shaft gear with the Groove groove of the oil pump. A77382 Put a 4 mm diameter bar in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove the nut.
• Page 519
  14–146 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Align the mark links (yellow colored links) with the timing Mark Link marks of each gear as shown in the illustration. Timing Mark Install the gears to the crankshaft and oil pump shaft with the chain wrapped.
• Page 520
  14–147 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET SET NO. 1 CYLINDER TO TDC/COMPRESSION Unleaded Gasoline Turn the camshafts with a wrench on the hexagonal lobe, Timing and align the timing marks of the camshaft timing gear Marks with each timing mark located on the No.
• Page 521
  14–148 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Align the mark links (gold or yellow colored links) with Mark Links Timing Mark Timing Marks each timing mark located on the camshaft timing gears, and install the chain. A77389 INSTALL TIMING CHAIN GUIDE Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 522
  14–149 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to Seal Packing 0.157 in.)) of seal packing as shown in the illustration. Seal packing: Part No. 08826 – 00080 or equivalent 2.5 mm f 3 to 4 mm A77391 Install the timing chain cover with the 14 bolts and 2 nuts.
• Page 523
  14–150 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) INSTALL OIL PAN SUB–ASSY NOTICE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine within 2 hours after installing. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan.
• Page 524
  14–151 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Install a new gasket chain tensioner with the 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) NOTICE: If the hook is released wile inserting, apply the hook again, and insert the chain tensioner. Engine Front A77395…
• Page 525
  14–152 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FE) Apply seal packing to the 2 locations as shown in the il- Seal Packing lustration. Seal Packing: Part No. 08826–00080 or equivalent NOTICE: Remove any oil from the contact surface. Install the cylinder head cover within 5 minutes after applying seal packing.
• Page 526
  14–218 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FSE) CHAIN SUB–ASSY (1AZ–FSE) 141BC–01 COMPONENTS Engine Room Cover Side 7.0 (71, 62 in. lbf) 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Radiator Support Opening Cover Fan and Generator V Belt Engine Under Cover RH Engine Under Cover LH N·m (kgf·cm, ft·lbf) : Specified torque…
• Page 527
  14–219 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FSE) Cooler Bracket (LHD Steering Position Type) Cooler Refrigerant Suction Hose No. 1 (LHD Steering Position Type) 5.0 (51, 44 in. lbf) 7.0 (71, 62 in. lbf) 5.0 (51, 44 in. lbf) 7.0 (71, 62 in. lbf) 7.0 (71, 62 in.
• Page 528
  14–220 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FSE) Fuel Pipe Sub–assy No. 1 Fuel Pressure 25 (255, 18) Pulsation Damper 9.0 (90, 80 in. lbf) Y Gasket Assy 33 (331, 24) Y Gasket Ignition Control Fuel Tube Sub–assy Fuel Pump Assy 9.0 (90, 80 in.
• Page 529
  14–221 ENGINE MECHANICAL – CHAIN SUB–ASSY (1AZ–FSE) 9.0 (90, 80 in. lbf) 43 (440, 32) Y Gasket Chain Tensioner Assy No. 1 V–ribbed Belt Tensioner Assy Timing Chain or Belt Cover 43 (440, 32) Sub–assy 60 (610, 44) 60 (610, 44) Crankshaft Position 43 (440, 32) Sensor…
• Page 530
  14–45 ENGINE MECHANICAL – CHAIN SUB–ASSY (1ZZ–FE/3ZZ–FE) CHAIN SUB–ASSY (1ZZ–FE/3ZZ–FE) 141CH–01 COMPONENTS Clip Engine Room Side Cover RH Clip Retainer Radiator Cover Assy Clip Engine Under Cover RH Engine Under Cover No. 1 Clip A79321 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 531
  14–46 ENGINE MECHANICAL – CHAIN SUB–ASSY (1ZZ–FE/3ZZ–FE) Fan and Generator V Belt 25 (255, 18) 39.2 (400, 29) V–Ribbed Idler Assy No. 1 Terminal Cap Tube No. 1 Generator Assy 9.8 (100, 7) Clip 54 (551, 40) 7.0 (71, 62 in. lbf) 52 (530, 38) Cylinder Head Cover No.
• Page 532
  14–47 ENGINE MECHANICAL – CHAIN SUB–ASSY (1ZZ–FE/3ZZ–FE) 9.0 (92, 80 in. lbf) 9.0 (92, 80 in. lbf) Engine Wire 9.0 (92, 80 in. lbf) Ignition Coil Assy Ventilation Hose No. 2 Seal Washer 9.0 (92, 80 in. lbf) 11 (112, 11 (112, 11 (112, Clamp Bracket…
• Page 533
  14–48 ENGINE MECHANICAL – CHAIN SUB–ASSY (1ZZ–FE/3ZZ–FE) Transverse Engine Engine Mounting Bracket 47 (479, 35) Chain Tensioner Assy No. 1 29 (296, 21) 9.0 (92, 80 in. lbf) Timing Chain or V–ribbed Belt Belt Cover Sub–assy Tensioner Assy 13 (133, 10) 69 (704, 51) 13 (133, 10) (M6) 19 (194, 14) (M8)
• Page 534
  14–342 ENGINE MECHANICAL – CRANKSHAFT SEAL (1CD–FTV) CRANKSHAFT SEAL (1CD–FTV) 141CB–01 REPLACEMENT DRAIN ENGINE OIL Install a new gasket and the drain plug after draining engine oil. Torque: 34 N m (350 kgf cm, 25 ft lbf) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE…
• Page 535
  14–343 ENGINE MECHANICAL – CRANKSHAFT SEAL (1CD–FTV) REMOVE TIMING BELT (See page 14–307) REMOVE CRANKSHAFT TIMING PULLEY If the timing pulley cannot be removed by hand, use SST to remove the pulley. 09950–50013 (09951–05010, 09952–05010, 09953–05010, 09953–05020, 09954–05021) A09582 REMOVE CRANKSHAFT SEAL Using a knife, cut off the oil seal lip.
• Page 536
  14–344 ENGINE MECHANICAL – CRANKSHAFT SEAL (1CD–FTV) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14–307) INSTALL TIMING BELT GUIDE (See page 14–307) INSTALL TIMING BELT NO.1 COVER (See page 14–307) INSTALL TIMING BELT NO.2 COVER (See page 14–307) INSTALL IDLER PULLEY SUB–ASSY (See page 14–307) INSTALL CRANKSHAFT PULLEY…
• Page 537
  14–153 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) CYLINDER HEAD GASKET (1AZ–FE) 141BA–01 COMPONENTS Engine Room Cover Side 7.0 (71, 62 in. lbf) 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Radiator Support Opening Cover Fan and Generator V Belt Engine Under Cover RH Engine Under Cover LH N·m (kgf·cm, ft·lbf) : Specified torque…
• Page 538
  14–154 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) Cooler Refrigerant Suction Hose No. 1 (LHD (w/ Air Conditioner) 5.0 (51, 44 in. lbf) Cooler Bracket Steering Position Type) (LHD (w/ Air Conditioner) 7.0 (71, 62 in. lbf) Steering Position Type) 5.0 (51, 44 in.
• Page 539
  14–155 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) Accelerator Control Cable Sub–assy 30 (305, 22) 30 (305, 22) 30 (305, 22) Throttle Body Assy Y Gasket Heater Inlet Water Hose Union To Connector Tube Hose Fuel Tube Sub–assy Fuel Pipe Clamp Radiator Hose Inlet 5.0 (51, 44 in.
• Page 540
  14–156 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) 9.0 (90, 80 in. lbf) Ignition Coil Assy 14 (143, 10) 11 (115, 8.0) Ventilation Hose No. 2 Ventilation Hose 11 (115, 8.0) Cylinder Head Cover Sub–assy Y Gasket N·m (kgf·cm, ft·lbf) : Specified torque Y Non–reusable part A77320 AVENSIS REPAIR MANUAL (RM1018E)
• Page 541
  14–157 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) 43 (440, 32) Y Gasket 9.0 (90, 80 in. lbf) Chain Tensioner Assy No. 1 Timing Chain or Belt Cover Sub–assy V–ribbed Belt Tensioner 43 (440, 32) Sub–assy 60 (610, 44) 60 (610, 44) 43 (440, 32) Crank Position Sensor Y Oil Seal…
• Page 542
  14–158 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) 30 (306, 22) Intake Manifold 30 (306, 22) Y Gasket 12 (122, 9.0) Intake Manifold Insulator No. 1 12 (122, 9.0) 12 (122, 9.0) Unleaded type: Manifold Converter Insulator No. 1 Y Gasket 37 (378, 27) Leaded Gasoline type: 44 (449, 32)
• Page 543
  14–159 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) 30 (301, 22) 30 (301, 22) 9.0 (92, 80 in. lbf) Bearing Cap No. 1 Bearing Cap No. 3 Bearing Cap No. 2 Camshaft No. 2 Camshaft 1st: 79 (800, 58) Camshaft Timing 2nd: Turn 90®…
• Page 544
  14–160 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) 141BB–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN COOLANT (See page 16–19)
• Page 545
  14–161 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Remove the 2 nuts and separate the suction hose. A77303 SEPARATE VANE PUMP OIL RESERVOIR ASSY NOTICE: Do not disconnect the 2 hoses. REMOVE OIL RESERVOIR BRACKET NO.1 Remove the 2 bolts and the oil reservoir bracket No.
• Page 546
  14–162 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Remove the bolt and the engine service cover bracket RH. REMOVE CYLINDER HEAD COVER SUB–ASSY (See page 14–139) SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14–139) REMOVE ENGINE MOUNTING BRACKET NO.2 RH…
• Page 547
  14–163 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) REMOVE THROTTLE BODY ASSY (See page 10–26) REMOVE INTAKE MANIFOLD Remove the 5 bolts and 2 nuts, then remove the intake manifold and gasket. A56446 REMOVE INTAKE MANIFOLD INSULATOR NO.1 REMOVE MANIFOLD CONVERTER INSULATOR NO.1 Disconnect the oxygen sensor connector.
• Page 548
  14–164 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) REMOVE CAMSHAFT BEARING NO.2 A32664 SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE Install the oil pan sub–assy. Set the jack under the engine assembly w/ transaxle, and place a wooden block on the jack. Remove the chain block and sling devise.
• Page 549
  14–165 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) INSTALL CYLINDER HEAD GASKET Place a new cylinder head gasket on the cylinder block Lot No. surface with the Lot No. stamp upward. NOTICE: Remove any oil from contact surface. Be careful of the installation direction. Place the cylinder head gently in order not to damage the gasket with the bottom part of the head.
• Page 550
  14–166 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT–i) Install a light coat of the engine oil to the new O–ring and install it to the oil control valve. Install the oil control valve with the bolt. Torque: 9.0 N m (92 kgf cm, 79 in.
• Page 551
  14–167 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FE) INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL CHAIN SUB–ASSY (See page 14–139) INSTALL TIMING CHAIN GUIDE Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N m (195 kgf cm, 15 ft lbf) INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1…
• Page 552
  14–254 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) 141BO–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN COOLANT (See page 16–19)
• Page 553
  14–255 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) SEPARATE RETURN TUBE SUB–ASSY Remove the 3 bolts and separate the return tube shown in the illustration. A77299 SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) Remove the 2 nuts and separate the suction hose. A77303 SEPARATE VANE PUMP OIL RESERVOIR ASSY REMOVE OIL RESERVOIR BRACKET NO.1…
• Page 554
  14–256 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) Remove the bolt and the cooler bracket. A77340 REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Remove the bolt and the engine service cover bracket RH. REMOVE CYLINDER HEAD COVER SUB–ASSY (See page 14–222)
• Page 555
  14–257 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) Raise a clamp up, and slide it toward the air cleaner cap, then remove the air cleaner cap from its case. Remove the air cleaner element. Remove the 4 bolts and the air cleaner case. A77302 DISCONNECT RADIATOR HOSE INLET DISCONNECT UNION TO CONNECTOR TUBE HOSE…
• Page 556
  14–258 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) REMOVE EXHAUST MANIFOLD CONVERTER SUB–ASSY Remove the 2 bolts and 2 nuts, and then detach the No. 1 and No. 2 exhaust manifold stay. Disconnect the 3 oxygen sensor connectors. A77350 Remove the 5 nuts, the exhaust manifold and gasket. A52497 REMOVE NO.2 CAMSHAFT (See page…
• Page 557
  14–259 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) REMOVE CYLINDER HEAD SUB–ASSY Using several steps, loosen the 10 cylinder head bolts, with 10 mm bi–hexagon wrench uniformly in the se- quence shown in the illustration. Remove 10 cylinder head bolts and plate washers. NOTICE: Be careful not to drop washers into the cylinder head.
• Page 558
  14–260 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) of seal packing as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent NOTICE: Cylinder Head Remove any oil from contact surface. Install the cylinder head within 3 minutes after apply- f 2.5 to 3 mm Cylinder…
• Page 559
  14–261 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) INSTALL EXHAUST MANIFOLD CONVERTER SUB–ASSY Install a new gasket and the exhaust manifold with the 5 nuts. Torque: 37 N m (378 kgf cm, 27 ft lbf) A77332 Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
• Page 560
  14–262 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1AZ–FSE) INSTALL CYLINDER HEAD COVER SUB–ASSY (See page 14–222) INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 561
  14–326 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) CYLINDER HEAD GASKET (1CD–FTV) 141C9–01 COMPONENTS Clip Engine Room Cover Side Clip V (Cooler Retainer Compressor to 8.0 (82, 71 in. lbf) Radiator Support Opening Cover Crankshaft Pulley) Belt No. 1 72 (734, 53) Engine Cover No.
• Page 562
  14–327 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) Engine Mounting Insulator 52 (530, 38) 8.3 (85, 73 in. lbf) Sub–assy RH Union To Connector Tube Hose 52 (530, 38) Vacuum Reservoir Sub–assy 5.0 (51, 44 in. lbf) 7.5 (76, 66 in. lbf) Injector Driver w/ Cold Area: Heater Bracket…
• Page 563
  14–328 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) Turbo Insulator No. 1 20 (204, 15) 20 (204, 15) Exhaust Manifold Heat Insulator No. 2 12 (122, 8.9) 12 (122, 8.9) 20 (204, 15) Turbo Insulator No. 2 Turbocharger Stay 53 (540, 39) 56 (571, 41) Y Gasket Turbocharger Sub–assy…
• Page 564
  14–329 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) * Gasket Timing Chain Cover Plate Timing Belt No. 2 Cover Timing Belt Seal Washer 7.4 (76, 66 in.·lbf) 9.0 (92, 80 in.·lbf) Transverse Engine Engine Mounting Bracket 37 (375, 27) 21 (214, 15) Timing Belt Tensioner Generator V belt…
• Page 565
  14–330 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) * 42 (428, 31) 46 (469, 34) 5.0 (51, 44 in. lbf) Injection Pipe Clamp No. 2 Injection Pipe Sub–assy * 31 (316, 23) 34 (347, 25) * 42 (428, 31) 46 (469, 34) Common Rail Assy * 31 (316, 23) 34 (347, 25)
• Page 566
  14–331 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) 13 (135, 9.7) 22 (224, 16) 27 (270, 20) z Nozzle Holder Seal z Gasket 18 (184, 13) z Gasket Cylinder Head Cover Sub–assy Nozzle Leakage Pipe Assy Washer Gasket Injector Assy Fuel Injector Nozzle Holder Clamp Back–up Ring No.
• Page 567
  14–332 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) 141CA–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE UNDER COVER RH DRAIN ENGINE COOLANT (See page 16–44) DRAIN ENGINE OIL (See page 14–342) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE…
• Page 568
  14–333 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13–11) REMOVE MANIFOLD STAY NO.2 (See page 13–11) REMOVE MANIFOLD STAY (See page 13–11) REMOVE EXHAUST MANIFOLD CONVERTER SUB–ASSY (See page 13–11) REMOVE TURBOCHARGER STAY (See page 13–11) REMOVE TURBO WATER HOSE NO.1…
• Page 569
  14–334 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) REMOVE INJECTION PIPE SUB–ASSY NO.4 09023–12700 HINT: Perform the same procedures as injection pipe No. 1. REMOVE VACUUM PUMP ASSY (See page 14–318) REMOVE NOZZLE HOLDER SEAL Using a screwdriver, pry out the 4 nozzle holder seals. A09656 REMOVE CYLINDER HEAD COVER SUB–ASSY Remove the 10 bolts, the cylinder head cover and the…
• Page 570
  14–335 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a work bench. NOTICE: Be careful not to damage the contact surfaces of the cylin- der head and cylinder block.
• Page 571
  14–336 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) Measure a protrusion height of the piston head for Front each cylinder at 2 places as shown in the illustra- tion. (Total of 8 measurements.) Record the highest protrusion height from the 2 measurements at each cylinder.
• Page 572
  14–337 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) INSTALL CYLINDER HEAD SUB–ASSY HINT: The cylinder head bolts are tightened in 4 successive steps (steps (c), (e), (f) and (g)). If the cylinder head bolt is broken or deformed, replace it with a new bolt.
• Page 573
  14–338 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) INSTALL CAMSHAFT OIL SEAL RETAINER (See page 14–318) INSTALL CAMSHAFT TIMING PULLEY (See page 14–318) 09960–10010 (09962–01000, 09963–01000) INSTALL CAMSHAFT POSITION SENSOR (See page 10–64) INSTALL INJECTOR ASSY (See page 11–60) INSTALL NOZZLE LEAKAGE PIPE ASSY (See page 11–60) 09992–00242…
• Page 574
  14–339 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) Using SST, tighten the nut of the injection pipe to the com- Fulcrum mon rail side. Length 09023–12700 30 cm Torque: 42 N m (428 kgf cm, 31 ft lbf) for a used pipe using SST 46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using 31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST 34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using…
• Page 575
  14–340 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) INSTALL FUEL INLET PIPE SUB–ASSY NOTICE: In case of having the cylinder head gasket replaced, must replace fuel inlet pipe, too. When assembling the pipe, perform the operation with the engine cold under room temperature. Temporarily install the new fuel inlet pipe.
• Page 576
  14–341 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1CD–FTV) INSTALL TURBO INSULATOR NO.1 (See page 13–11) INSTALL TURBO INSULATOR NO.2 (See page 13–11) INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13–11) INSTALL EXHAUST PIPE ASSY FRONT (See page 15–10) INSTALL FLOOR PANEL BRACE FRONT (See page 15–10)
• Page 577
  14–76 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) 141CL–01 COMPONENTS Clip Engine Room Side Cover RH Clip Retainer Radiator Cover Assy Clip Engine Under Cover RH Engine Under Cover No. 1 Clip A79321 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 578
  14–77 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) Fan and Generator V Belt 25 (255, 18) 39 (400, 29) V–ribbed idler Assy No. 1 Terminal Cap Tube No. 1 Generator Assy 9.8 (100, 7) Clip 54 (551, 40) 7.0 (71, 62 in. lbf) 52 (530, 38) Engine Mounting…
• Page 579
  14–78 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) 9.0 (92, 80 in. lbf) 9.0 (92, 80 in. lbf) Engine Wire 9.0 (92, 80 in. lbf) Ignition Coil Assy Ventilation Hose No. 2 9.0 (92, 80 in. lbf) 11 (112, Seal Washer 11 (112, 11 (112,
• Page 580
  14–79 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) Transverse Engine Engine Mounting Bracket 47 (479, 35) Chain Tensioner Assy No. 1 29 (296, 21) 9.0 (92, 80 in. lbf) Timing Chain or V–ribbed Belt Belt Cover Sub–assy Tensioner Assy 13 (133, 10) 69 (704, 51) 13 (133, 10) (M6) 19 (194, 14) (M8)
• Page 581
  14–80 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) Camshaft Bearing Cap No. 1 13 (133, 10) 23 (235, 17) Camshaft Bearing Cap No. 3 Camshaft No. 2 Camshaft See page 14–81 1st 49 (500, 36) 2nd Turn 90_ Cylinder Head Sub–assy Plate Washer z O–ring Camshaft Timing…
• Page 582
  14–81 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) 141CM–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–1) REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) REMOVE ENGINE ROOM COVER SIDE (See page 14–27) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27) REMOVE ENGINE UNDER COVER RH…
• Page 583
  14–82 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) DISCONNECT FUEL TUBE SUB–ASSY (See page 11–11) 09268–21010 DISCONNECT UNION TO CONNECTOR TUBE HOSE Disconnect the union to connector tube hose from the hose to hose tube. DISCONNECT RADIATOR HOSE INLET Disconnect radiator hose inlet from the cylinder head. DISCONNECT HEATER INLET WATER HOSE Disconnect the heater inlet water hose from the cylinder head.
• Page 584
  14–83 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) DISCONNECT VENTILATION HOSE Disconnect the ventilation hose from the cylinder head cover. A65078 DISCONNECT VENTILATION HOSE NO.2 Disconnect the ventilation hose from the cylinder head cover. A64058 REMOVE INTAKE MANIFOLD Disconnect the 2 water hoses from the throttle body. Disconnect the ventilation hose and ventilation hose No.
• Page 585
  14–84 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY Remove the bolt and the camshaft timing oil control valve. SEPARATE EXHAUST PIPE ASSY FRONT Remove the 2 bolts and 2 compression springs which are used to secure the front side of exhaust pipe.
• Page 586
  14–85 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) REMOVE CYLINDER HEAD COVER SUB–ASSY Remove the 9 bolts, 2 seal washers, 2 nuts and 3 clamp brackets. Remove the cylinder head cover. A64856 SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley to align the timing notch with Mark Mark the timing mark ”0”…
• Page 587
  14–86 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 3 bolts and the transverse engine engine mounting bracket. A12816 REMOVE CRANKSHAFT POSITION SENSOR Remove the 2 bolts which are used to secure the crank- shaft position sensor.
• Page 588
  14–87 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) REMOVE CHAIN SUB–ASSY 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.
• Page 589
  14–88 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) INSTALL CYLINDER HEAD SUB–ASSY HINT: The cylinder head bolts are tightened in 2 successive steps. Apply a light coat of engine oil on the threads of the cylin- der head bolts. 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.
• Page 590
  14–89 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) Using a crankshaft pulley bolt, turn the crankshaft Set Key Upward and set the set key on the crankshaft upward. A62170 Install the timing chain on the crankshaft timing sprocket Yellow with the yellow color link and the timing mark on the crank- Color Link shaft timing sprocket aligned.
• Page 591
  14–90 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) INSTALL TIMING GEAR COVER OIL SEAL Apply MP grease to a new oil seal lip. Using SST, tap in the oil seal until its surface is flush with the timing chain cover edge. 09223–22010 NOTICE: Keep the lip free of foreign objects.
• Page 592
  14–91 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) Install the timing chain cover with the 11 bolts and nut. Torque: 13 N m (133 kgf cm, 10 ft lbf) for A 19 N m (194 kgf cm, 14 ft lbf) for B Using a torx wrench socket (E8), install the stud bolt.
• Page 593
  14–92 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the transverse engine engine mounting bracket with the 3 bolts. Torque: 47 N m (479 kgf cm, 35 ft lbf) INSTALL WATER PUMP ASSY (See page 16–9) A12816 INSTALL V–RIBBED BELT TENSIONER ASSY…
• Page 594
  14–93 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) INSTALL CYLINDER HEAD COVER SUB–ASSY Seal Packing Remove any old packing (FIPG) material. 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.
• Page 595
  14–94 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) INSTALL MANIFOLD STAY 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 A76720 INSTALL MANIFOLD STAY NO.2 Install the manifold stay with the 3 bolts.
• Page 596
  14–95 ENGINE MECHANICAL – CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE) INSTALL IGNITION COIL ASSY Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) A64023 Install the engine wire with the 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 597
  14–269 ENGINE MECHANICAL – DRIVE BELT (1CD–FTV) DRIVE BELT (1CD–FTV) 141C1–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE (COOLER COMPRESSOR CRANKSHAFT PULLEY) BELT NO.1 Loosen nut A and bolt B. Remove the V–ribbed belt.
• Page 598
  14–101 ENGINE MECHANICAL – ENGINE (1AZ–FE) ENGINE (1AZ–FE) 140D1–02 INSPECTION INSPECT COOLANT (See page 16–13) INSPECT ENGINE OIL (See page 17–6) INSPECT BATTERY Standard specific gravity: 1.25 to 1.29 at 20_C (68_F) INSPECT AIR CLEANER FILTER ELEMENT SUB–ASSY INSPECT SPARK PLUG (See page 18–9) INSPECT V–RIBBED BELT…
• Page 599
  14–102 ENGINE MECHANICAL – ENGINE (1AZ–FE) Disconnect terminals 13 (TC) and 4 (CG) of DLC3. Inspect ignition timing at idle. Ignition timing: 5 to 15_ BTDC Confirm that ignition timing to go advanced angle side when the engine rpm is increased. Remove the timing light.
• Page 600
  14–103 ENGINE MECHANICAL – ENGINE (1AZ–FE) While cranking the engine, measure the compres- sion pressure. Compression pressure: 1,300 kPa (13.3 kgf/cm , 189 psi) Minimum pressure: 1000 kPa (10.2 kgf/cm , 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm , 14 psi) NOTICE: Always use a fully charged battery to obtain engine…
• Page 601
  14–104 ENGINE MECHANICAL – ENGINE (1AZ–FE) Problems Causes 1. Faulty ignitions: Y Incorrect timing Y Fouled, shorted or improperly gapped plugs Normal High Rough idle 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders 1.
• Page 602
  14–181 ENGINE MECHANICAL – ENGINE (1AZ–FSE) ENGINE (1AZ–FSE) 141CP–01 INSPECTION INSPECT COOLANT (See page 16–25) INSPECT ENGINE OIL(See page 17–13) INSPECT BATTERY Standard specific gravity: 1.25 to 1.29 at 20_C (68_F) INSPECT AIR CLEANER FILTER ELEMENT SUB–ASSY INSPECT SPARK PLUG (See page 18–14) INSPECT V–RIBBED BELT…
• Page 603
  14–182 ENGINE MECHANICAL – ENGINE (1AZ–FSE) Inspect ignition timing at idle. Ignition timing: 5 to 23_ BTDC Confirm that ignition timing to go advanced angle side when the engine rpm is increased. Remove the timing light. INSPECT ENGINE IDLE SPEED Warm up engine.
• Page 604
  14–183 ENGINE MECHANICAL – ENGINE (1AZ–FSE) Inspect cylinder compression pressure. 09992–00500 Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compres- sion pressure. Compression pressure: 1,300 kPa (13.3 kgf/cm , 189 psi) A79033 Minimum pressure: 1000 kPa (10.2 kgf/cm…
• Page 605
  14–184 ENGINE MECHANICAL – ENGINE (1AZ–FSE) Problems Causes 1. Faulty ignitions: Y Incorrect timing Y Fouled, shorted or improperly gapped plugs Normal High Rough idle 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders 1.
• Page 606
  14–266 ENGINE MECHANICAL – ENGINE (1CD–FTV) ENGINE (1CD–FTV) 140DD–03 INSPECTION INSPECT COOLANT (See page 16–37) INSPECT ENGINE OIL (See page 17–20) INSPECT BATTERY (See page 19–26) INSPECT AIR CLEANER FILTER ELEMENT SUB–ASSY INSPECT DRIVE BELT Inspect vane pump V belt. Measure the belt deflection A/C equipped Pressing force: 98 N m (10 kgf 22 lbf)
• Page 607
  14–267 ENGINE MECHANICAL – ENGINE (1CD–FTV) INSPECT ENGINE IDLE SPEED Using SST, connect a tachometer test prove to terminal 9 (TAC) of DLC3. 09843–18040 Check the idle speed. Idle speed: 750 to 850 rpm NOTICE: Check the idle speed with the cooling fan OFF. Switch off all accessories and air conditioning before A52006 connecting the test prove to the terminal.
• Page 608
  14–268 ENGINE MECHANICAL – ENGINE (1CD–FTV) Connect SST (compression gauge) to the SST (at- tachment). Compression Gauge 09992–00025 (09992–00211) Fully open the throttle valve, and start the engine. While cranking the engine, measure the compres- sion pressure. NOTICE: Always use a fully charged battery to obtain engine speed of 250 rpm or more.
• Page 609
  14–1 ENGINE MECHANICAL – ENGINE (1ZZ–FE/3ZZ–FE) ENGINE (1ZZ–FE/3ZZ–FE) 140KR–02 INSPECTION INSPECT COOLANT (See page 16–1) INSPECT ENGINE OIL (See page 17–1) INSPECT BATTERY (See page 19–5) INSPECT AIR CLEANER FILTER ELEMENT SUB–ASSY INSPECT SPARK PLUG (See page 18–3) INSPECT FAN AND GENERATOR V BELT HINT: You don’t need to check the belt deflection because auto tensioner is adopted.
• Page 610
  14–2 ENGINE MECHANICAL – ENGINE (1ZZ–FE/3ZZ–FE) Inspect ignition timing at idle. Ignition timing: 8 to 12_BTDC NOTICE: When checking the ignition timing, shift the transmission to the neutral position. HINT: Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that the engine rpm returns to the idle speed.
• Page 611
  14–3 ENGINE MECHANICAL – ENGINE (1ZZ–FE/3ZZ–FE) While cranking the engine, measure the compres- sion pressure. Compression pressure 1,300 kPa (13.3 kgf cm , 189 psi) Minimum pressure: 1,000 kPa (10.2 kgf cm , 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf cm , 14 psi) NOTICE: Always use a fully charged battery to obtain engine…
• Page 612
  14–4 ENGINE MECHANICAL – ENGINE (1ZZ–FE/3ZZ–FE) Problems Causes 1. Faulty ignitions: Y Incorrect timing Y Fouled, shorted or improperly gapped plugs Normal High Rough idle 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders 1.
• Page 613
  14–180 ENGINE MECHANICAL – ENGINE REAR OIL SEAL (1AZ–FE) ENGINE REAR OIL SEAL (1AZ–FE) 141BI–01 REPLACEMENT REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41–24) REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40–25) REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42–26) REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL…
• Page 614
  14–265 ENGINE MECHANICAL – ENGINE REAR OIL SEAL (1AZ–FSE) ENGINE REAR OIL SEAL (1AZ–FSE) 141BS–01 REPLACEMENT REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41–24) REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40–25) REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42–26) REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL…
• Page 615
  14–345 ENGINE MECHANICAL – ENGINE REAR OIL SEAL (1CD–FTV) ENGINE REAR OIL SEAL (1CD–FTV) 141CC–01 REPLACEMENT REMOVE MANUAL TRANSAXLE ASSY (See page 41–33) 09930–00010, 09628–62011, 09520–01010, 09520–24010 (09520–32040) REMOVE CLUTCH COVER ASSY (See page 42–26) REMOVE CLUTCH DISC ASSY (See page 42–26) REMOVE FLYWHEEL SUB–ASSY Hold the crankshaft with SST.
• Page 616
  14–346 ENGINE MECHANICAL – ENGINE REAR OIL SEAL (1CD–FTV) INSTALL FLYWHEEL SUB–ASSY Hold the crankshaft with SST. 09213–54015 (90105–08076), 09330–00021 Clean the bolt and the bolt hole. Apply Adhesive to the bolts. Adhesive: Part No. 08833–00070, THREE BOND or equivalent A61186 Using several steps, install and tighten the 8 screws with a torx socket wrench (T55) uniformly in the sequence…
• Page 617
  14–98 ENGINE MECHANICAL – ENGINE REAR OIL SEAL (1ZZ–FE/3ZZ–FE) ENGINE REAR OIL SEAL (1ZZ–FE/3ZZ–FE) 141CO–01 REPLACEMENT REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41–15) REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40–11) REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42–26) REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE)
• Page 618
  14–99 ENGINE MECHANICAL – ENGINE REAR OIL SEAL (1ZZ–FE/3ZZ–FE) INSTALL FLYWHEEL SUB–ASSY (M/T TRANSAXLE) Fix the crankshaft with SST. 09960–10010 (09962–01000, 09963–01000) A62838 Clean the bolt and bolt hole. Apply adhesive to the bolts. Adhesive: Part No. 09330–00070, THREE BOND or equivalent. Using several steps, Install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
• Page 619
  14–100 ENGINE MECHANICAL – ENGINE REAR OIL SEAL (1ZZ–FE/3ZZ–FE) INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41–15) INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40–11) AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 620
  14–105 ENGINE MECHANICAL – FAN AND GENERATOR V BELT (1AZ–FE) FAN AND GENERATOR V BELT (1AZ–FE) 141B5–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE FAN AND GENERATOR V BELT Using SST, loosen the V–ribbed belt tensioner arm clock- wise, and remove the fan and generator V belt.
• Page 621
  14–185 ENGINE MECHANICAL – FAN AND GENERATOR V BELT (1AZ–FSE) FAN AND GENERATOR V BELT (1AZ–FSE) 141BJ–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE FAN AND GENERATOR V BELT Using SST, loosen the V–ribbed belt tensioner arm clock- wise, and remove the fan and generator V belt.
• Page 622
  14–5 ENGINE MECHANICAL – FAN AND GENERATOR V BELT (1ZZ–FE/3ZZ–FE) FAN AND GENERATOR V BELT (1ZZ–FE/3ZZ–FE) 141CD–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) REMOVE ENGINE ROOM COVER SIDE (See page 14–27) REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27) REMOVE FAN AND GENERATOR V BELT…
• Page 623
  14–111 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) PARTIAL ENGINE ASSY (1AZ–FE) 141B9–01 COMPONENTSCOMPONENTS Engine Room Cover Side 7.0 (71, 62 in. lbf) 7.0 (71, 62 in. lbf) Engine Cover Sub–assy No. 1 Radiator Support Opening Cover Fan and Generator V Belt Engine Under Cover RH Engine Under Cover LH A77310…
• Page 624
  14–112 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 52 (530, 38) 21 (214, 16) Cooler Refrigerant Suction Hose No. 1 (RHD (w/ Air Conditioning) 19 (194, 14) Generator ASSY Steering Position Type) 9.8 (100, 7.2) Radiator Hose Inlet 19 (194, 14) Radiator ASSY Radiator Hose Outlet 7.0 (71, 62 in.
• Page 625
  14–113 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 5.0 (51, 44 in. lbf) Radiator Reserve Tank Sub–assy 5.0 (51, 44 in. lbf) Vane Pump Oil Reservoir Assy 8.0 (82, 44 in. lbf) Fuel Tube Sub–assy Fuel Pipe Clamp 8.0 (82, 44 in. lbf) Return Tube Accelerator Control Sub–assy…
• Page 626
  14–114 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) Cooler Bracket (LHD (w/ Air Conditioner) Steering Position Type) 5.0 (51, 44 in. lbf) Heater Outlet Water Hose 7.0 (71, 62 in. lbf) Oil Reservoir Heater Inlet Water Hose Bracket No. 1 Steering Intermediate 5.0 (51, 44 in.
• Page 627
  14–115 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) A/T: Clip Transmission Control Cable Assy 12 (122, 8.9) M/T: M/T: Transmission Control Clutch Release Cable Assy Cylinder Assy 5.0 (51, 44 in. lbf) 5.0 (51, 44 in. lbf) 12 (120, 9.0) Clip 9.0 (92, 80 in.
• Page 628
  14–116 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 113 (1,152, 83) 52 (530, 38) 52 (530, 38) Engine Mounting Bracket No. 2 RH Transverse Engine Engine Mounting Insulator 87 (887, 64) 52 (530, 38) 52 (530, 38) 52 (530, 38) 52 (530, 38) Front Suspension Brace RH Front Suspension…
• Page 629
  14–117 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) M/T: Engine Assy 34 (347, 25) Drive Shaft Bearing Bracket 44 (440, 32) 130 (1327, 96) 19 (194, 14) Wire Clamp Bracket Flywheel Sub–Assy Clutch Disc Assy Clutch Cover Assy 64 (650, 47) 46 (470, 34) Manual Transaxle Assy 46 (470, 34)
• Page 630
  14–118 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) A/T: Engine Assy 34 (347, 25) 41 (420, 32) Drive Shaft Bearing Bracket Hole Plug 98 (1,000, 72) 41 (418, 30) Drive Plate & Ring Gear Automatic Transaxle Sub–Assy Wire Clamp Bracket 46 (469, 34) 64 (653, 47) 46 (469, 34)
• Page 631
  14–119 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 9.0 (92, 80 in. lbf) 30 (306, 22) 30 (306, 22) Intake Manifold Ignition Coil 30 (306, 22) Y Gasket Intake Manifold Insulator No. 1 Ventilation Hose No. 2 Ventilation Hose 12 (122, 9.0) V–ribbed Belt Tensioner ASSY 12 (122, 9.0)
• Page 632
  14–120 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 19 (194, 14) 19 (194, 14) Fuel Delivery Pipe w/ Injector Y Gasket Spacer Engine Oil Pressure Switch Assy 9.0 (92, 79 in. lbf) 15 (153, 11) 20 (204, 15) Oil Control Valve Knock Control Sensor Water Temperature Sensor 20 (204, 15)
• Page 633
  14–121 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 141BF–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–19) REMOVE FRONT WHEELS REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN COOLANT (See page 16–19)
• Page 634
  14–122 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY WITH HOSE Disconnect 2 connectors. Disconnect the air cleaner hose from the throttle body. Raise a clamp up, and slide it toward the air cleaner cap, then remove the air cleaner cap from its case.
• Page 635
  14–123 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) REMOVE OIL RESERVOIR BRACKET NO.1 Remove 2 bolts and the oil reservoir bracket No. 1. A77308 SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Remove 2 nuts and separate the suction hose. A77303 REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Remove a bolt and the service cover bracket RH.
• Page 636
  14–124 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) REMOVE FRONT AXLE HUB RH NUT 09330–00030 HINT: Perform the same procedure as above on the opposite side. SEPARATE TIE ROD END SUB–ASSY LH (See page 51–36) SEPARATE TIE ROD END SUB–ASSY RH HINT: Perform the same procedure as above on the opposite side.
• Page 637
  14–125 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) SEPARATE ENGINE ROOM RELAY BLOCK NO.2 Remove the nut and disconnect the connector as shown in the illustration. A77338 SEPARATE ENGINE WIRE Remove the bolt and separate the grand terminal. A77337 Separate the grand terminal connector. Remove the glove compartment door panel.
• Page 638
  14–126 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) REMOVE ENGINE MOUNTING BRACKET NO.2 RH Set the engine lifter. Remove 2 bolts and 2 nuts, and then remove the mount- ing bracket No. 2. A77401 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Remove 3 bolts and the engine mounting insulator.
• Page 639
  14–127 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) SEPARATE VANE PUMP ASSY Disconnect the PS oil pressure switch connector. Remove the 2 bolts and separate the vane pump from the engine. REMOVE STARTER ASSY (See page 19–12) REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER Remove the through bolt and nut from the engine mounting insulator FR.
• Page 640
  14–128 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) REMOVE EXHAUST MANIFOLD CONVERTER SUB–ASSY Remove the 3 bolts and 2 nuts, and then detach the No. 1 and No. 2 exhaust manifold stays. A60067 Remove the 5 nuts, and then remove the exhaust man- ifold converter and gasket.
• Page 641
  14–129 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) REMOVE KNOCK SENSOR Remove the nut and the knock sensor. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Using SST, remove the engine coolant temperature sensor. 09817–33190 REPLACE PARTIAL ENGINE ASSY INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket to the engine coolant temperature sensor.
• Page 642
  14–130 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts. Torque: 44 N m (449 kgf cm, 32 ft lbf) A52499 105. INSTALL MANIFOLD CONVERTER INSULATOR NO.1 Torque: 12 N m (122 kgf cm, 9.0 ft lbf) 106.
• Page 643
  14–131 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) Install the drive plate. (A/T) Clean the bolt and bolt hole. Apply adhesive to the bolts. Using several steps, install and tighten the 8 bolts uniformly in the sequence shown in the illustration. Torque: 98 N m (1,000 kgf cm, 72 ft lbf) Install the flywheel.
• Page 644
  14–132 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 120. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 87 N m (887 kgf cm, 64 ft lbf) A77304 121. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N m (530 kgf cm, 38 ft lbf) A77305 122.
• Page 645
  14–133 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 128. INSTALL FRONT AXLE ASSY LH Torque: 294 N m (3,000 kgf cm, 217 ft lbf) 129. INSTALL FRONT AXLE ASSY RH Torque: 294 N m (3,000 kgf cm, 217 ft lbf) 130.
• Page 646
  14–134 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1AZ–FE) 155. INSTALL RADIATOR ASSY (See page 16–24) 156. INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N m (51 kgf cm, 44 in. lbf) 157. INSTALL ENGINE COVER SUB–ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in. lbf) 158.
• Page 647
  14–277 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) PARTIAL ENGINE ASSY (1CD–FTV) 141C3–01 COMPONENTS Clip Engine Room Relay Block No. 3 Engine Room Cover Side Clip Radiator Support Opening Cover 8.0 (82, 71 in. lbf) 5.3 (54, 47in. lbf) Retainer 19 (194, 14) Radiator Support Upper Engine Cover No.
• Page 648
  14–278 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Vacuum Reservoir Sub–assy Heater Outlet Water Hose Heater Inlet Water Hose 5.0 (51, 44 in. lbf) Union To Connector Tube Hose Injector Driver 8.3 (85, 73 in. lbf) 18 (178, 13) 25 (255, 18) Air Tube No.
• Page 649
  14–279 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Glove Compartment Door Assy V (Cooler Compressor to Crankshaft pulley) Belt No. 1 Steering Intermediate Transmission Control Shaft Assy No. 2 Cable Assy Clip Clutch Accumulator Assy 35 (357, 26) Clip Clip Column Hole Cover Silencer Sheet Front Stabilizer Link Assy LH 74 (755, 55)
• Page 650
  14–280 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 25 (255, 18) 52 (530, 38) Air Tube No. 1 52 (530, 38) 25 (255, 18) Engine Mounting Insulator Sub–assy RH 52 (530, 38) 87 (887, 64) 80 (816, 59) 52 (530, 38) 72 (734, 53) Front Suspension Crossmember Sub–assy…
• Page 651
  14–281 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 64 (653, 47) Drive Shaft Bearing Bracket 88 (897, 65) 64 (653, 47) 19 (195, 14) Flywheel Sub–assy Clutch Disc Assy Clutch Cover Assy Starter Assy Manual Transaxle 37 (377, 27) N·m (kgf·cm, ft·lbf) : Specified torque A79421 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 652
  14–282 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Turbo Insulator No. 1 20 (204, 15) 20 (204, 15) Exhaust Manifold Heat Insulator No. 2 12 (122, 8.9) 12 (122, 8.9) 20 (204, 15) Turbo Insulator No. 2 Turbocharger Stay 53 (540, 39) 56 (571, 41) Y Gasket Turbocharger Sub–assy…
• Page 653
  14–283 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) * Gasket Timing Chain Cover Plate Timing Belt No. 2 Cover Timing Belt Seal Washer 7.4 (76, 66 in.·lbf) 9.0 (92, 80 in.·lbf) Transverse Engine Engine Mounting Bracket 21 (214, 15) 37 (375, 27) Timing Belt Tensioner Generator V belt…
• Page 654
  14–284 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) * 31 (316, 23) 34 (347, 25) 5.0 (51, 44 in. lbf) Injection Pipe Clamp No. 2 Y Injection Pipe Sub–assy * 31 (316, 23) 34 (347, 25) * 31 (316, 23) 34 (347, 25) Fuel Inlet Pipe Sub–assy Common Rail Assy…
• Page 655
  14–285 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Vacuum Pump Oil Pipe Fuel Filter To Injection Pump Union Bolt 45 (454, 33) Fuel Pipe Y O–ring 21 (214, 15) Oil Cooler Assy 8.8 (90, 65 in. lbf) Y O–ring Turbo Oil Outlet Pipe No. 2 59 (600, 43) Generator Assy 8.8 (90, 6.5 in.
• Page 656
  14–286 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 141C4–01 REPLACEMENT REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE UNDER COVER RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE DRAIN ENGINE COOLANT (See page 16–44) DRAIN ENGINE OIL…
• Page 657
  14–287 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) SEPARATE TRANSMISSION CONTROL CABLE ASSY Remove the 2 clips and 2 washers, separate the control cable assy. REMOVE INJECTOR DRIVER Remove the 2 nuts which is used to secure the injector driver. Disconnect the injector driver connector and the harness clamp.
• Page 658
  14–288 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) SEPARATE RETURN TUBE SUB–ASSY Remove the 2 clamp bolts and separate the return tube sub–assy. A79140 SEPARATE VANE PUMP OIL RESERVOIR ASSY REMOVE FRONT AXLE HUB LH NUT (See page 30–6) 09930–00010 HINT: Perform the same procedure as above on the opposite side.
• Page 659
  14–289 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Set the engine lifter. Remove the 3 bolts, 3 nuts and the engine mounting insu- lator sub–assy RH. A79179 Remove the through bolt and nut, detach the engine mounting insulator LH from the vehicle. A61177 Remove the 8 bolts and the front suspension member brace rear RH and LH.
• Page 660
  14–290 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Attach the engine sling and hang the engine with the chain block. REMOVE FRONT SUSPENSION CROSSMEMBER SUB–ASSY Remove the through bolt and nut, detach the engine mounting insulator FR from the engine mounting bracket. A62711 Remove the through bolt, detach the engine mounting in- sulator RR from the suspension crossmember.
• Page 661
  14–291 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) REMOVE IDLER PULLEY SUB–ASSY (See page 14–307) REMOVE TIMING BELT NO.2 COVER (See page 14–307) REMOVE TIMING BELT NO.1 COVER (See page 14–307) REMOVE TIMING BELT GUIDE REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14–307) SET NO.
• Page 662
  14–292 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) REMOVE EGR PIPE SUB–ASSY NO.1 Remove the bolt and 4 nut, and then detach the EGR pipe and the 2 gaskets. REMOVE EXHAUST MANIFOLD Remove the 8 nuts, the exhaust manifold and the gasket. A80118 REMOVE OIL COOLER ASSY (See page…
• Page 663
  14–293 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) REMOVE NOZZLE LEAKAGE PIPE NO.2 Remove the check valve and bolt, and then detach the leakage pipe and the gasket. A79194 REMOVE FUEL INLET PIPE SUB–ASSY Using SST, remove the fuel inlet pipe from the common rail side.
• Page 664
  14–294 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) REMOVE INTAKE MANIFOLD INSULATOR NO.1 Remove the 2 bolts and the intake manifold insulator. A79150 REMOVE COMMON RAIL ASSY (See page 11–78) REMOVE POWER STEERING IDLE PULLEY BRACKET Remove the 3 bolts and the idle pulley bracket. A61175 REMOVE INTAKE MANIFOLD Remove the 2 bolts and the wiring harness clamp bracket.
• Page 665
  14–295 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 106. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and the crankshaft position sensor. 107. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt and the camshaft position sensor. 108. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 109.
• Page 666
  14–296 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 123. INSTALL POWER STEERING IDLE PULLEY BRACKET Install the idle w/ bracket pulley with the 3 bolts. Torque: 72 N m (734 kgf cm, 53 ft lbf) for bolt A 39 N m (398 kgf cm, 29 ft lbf) for bolt B A61175 124.
• Page 667
  14–297 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Using SST, tighten the nut of the injection pipe to the injec- tor side. 09023–12700 Torque: 42 N m (428 kgf cm, 31 ft lbf) for a used pipe using SST 46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using 31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST 34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using HINT:…
• Page 668
  14–298 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Using SST, tighten the nut of the fuel inlet pipe to the com- Fulcrum mon rail side. Length 09023–12700 30 cm Torque: 42 N m (428 kgf cm, 31 ft lbf) for a used pipe using SST 46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using 31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST 34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using…
• Page 669
  14–299 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 132. INSTALL VACUUM PUMP ASSY New O–Ring Install 2 new O–rings to the vacuum pump. Align the key of the vacuum pump with the keyway of the exhaust camshaft, insert the vacuum pump into place. Secure the pump with the 2 bolts.
• Page 670
  14–300 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 147. INSTALL OIL FILTER BRACKET SUB–ASSY Install a new gasket and oil filter bracket with the bolt and 2 nuts. Torque: 34 N m (347 kgf cm, 25 ft lbf) 148. INSTALL V–RIBBED BELT TENSIONER ASSY Torque: 31 N m (316 kgf cm, 23 ft lbf) 149.
• Page 671
  14–301 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Using several steps, install and tighten the 8 screws with a torx socket wrench (T55) uniformly in the sequence shown in the illustration. Torque: 71 N m (720 kgf cm, 52 ft lbf) A79183 166.
• Page 672
  14–302 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) Install the front suspension crossmember with the 2 bolts and 2 nuts. Torque: 45 N m (459 kgf cm, 33 ft lbf) for bolt A 133 N m (1,356 kgf cm, 98 ft lbf) for nut B A59792 Install the front suspension member brace LH and RH with the 8 bolts.
• Page 673
  14–303 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 184. INSTALL AIR TUBE NO.1 Install the new air hose No. 1 and new hose clamp as shown in the illustration. 0 to 2 mm 2 to 7 mm A64328 Tighten the hose clamp as shown in the illustration. Torque: 6.0 N m (61 kgf cm, 53 in.
• Page 674
  14–304 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV) 191. INSTALL AIR CLEANER ASSY Torque: 7.0 N m (71 kgf cm, 62 in. lbf) 192. INSTALL ENGINE COVER NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf) 193. BLEED CLUTCH PIPE LINE (See page 42–17) 194.
• Page 675
  14–19 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 141CF–01 COMPONENTS Clip Engine Room Cover Side Clip Retainer Radiator Support Upper 19 (194, 14) Radiator Suport Opening Cover Oil Cooler Clip Outlet Tube No.1 7.0 (71, 62 in. lbf) Oil Cooler Inlet Tube No.1 5.0 (51, 44) 19 (194, 14)
• Page 676
  14–20 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Union to Connector Tube Hose Heater Inlet Water Hose Heater Outlet Water Hose Fuel Tube Sub–assy Fuel Pipe Clamp Accelerator Control Cable Assy Oil Cooler Inlet Hose Oil Cooler Outlet Hose VSV Connector 5.0 (51, 44 in.
• Page 677
  14–21 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Fan and Generator V Belt A/T: Clip Floor Shift Transmission Control Cable Assy 25 (255, 18) 12 (122, 9) Terminal Cap No. 1 Generator Assy 9.8 (100, 7) 54 (551, 40) 29 (296, 21) Cooler Compressor Assy 25 (255, 18) 25 (255, 18)
• Page 678
  14–22 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Front Door Scuff Plate RH Cowl Side Trim Board RH Clip Grove Compartment Door Assy Instrument Panel Under Cover Sub–assy No. 2 Front Floor Footrest (RHD) Steering Intermediate Shaft 35 (357, 26) Clip Column Hole Cover Silencer Sheet Front Stabilizer Link Assy LH…
• Page 679
  14–23 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 52 (530, 38) Engine Mounting Insulator RH Engine Assembly with Transaxle 80 (816, 59) 52 (530, 38) Front Suspension Member Brace RH Front Suspension Member Brace RH 80 (816, 59) 133 (1,356, 98) 45 (459, 33) 133 (1,356, 98) 80 (816, 59)
• Page 680
  14–24 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Flywheel Sub–assy 47 (479, 35) Clutch Disk Assy Clutch Cover Assy 64 (653, 47) Starter Assy See page 14–27 9.8 (100, 7) 1st 49 (500, 36) 37 (377, 27) 2nd Turn 90_ 37 (377, 27) 19 (194, 14) A/T:…
• Page 681
  14–25 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 9.0 (92, 80 in. lbf) 19 (194, 14) Fuel Delivery Pipe Sub–assy No. 1 Spacer Water By–pass Pipe No. 1 9.0 (92, 80 in. lbf) Ignition Coil Assy 9.0 (92, 80 in. lbf) 29 (296, 21) Y Gasket Camshaft Position Sensor…
• Page 682
  14–26 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Clamp Bracket V–Ribbed Idler Assy No. 1 9.0 (92, 80 in. lbf) Water By–pass Hose No. 2 Radiator Hose Inlet 39.2 (400, 29) Y Gasket Engine Coolant Temperature Sensor 20 (204, 15) Tube 10 (102, 7) Radio Setting Condenser…
• Page 683
  14–27 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 141CG–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–1) REMOVE RADIATOR SUPPORT OPENING COVER Remove the retainer and the 4 clips. Unfasten the 5 claws, and remove the radiator support opening cover. 5 Claws A78457 REMOVE ENGINE ROOM COVER SIDE…
• Page 684
  14–28 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE ENGINE UNDER COVER RH Remove the 6 screws and 3 clips, then detach the engine under cover. A78516 DRAIN ENGINE COOLANT (See page 16–7) DRAIN ENGINE OIL Install a new gasket and the drain plug after draining engine oil. Torque: 37 N m (377 kgf cm, 27 ft lbf) DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (See page…
• Page 685
  14–29 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE RADIATOR ASSY Remove the 2 bolts and the relay block. Disconnect the connector and the 2 harness clamps. Remove the 2 bolts, the 2 radiator support upper and the radiator. REMOVE BATTERY REMOVE BATTERY TRAY A76724 REMOVE BATTERY CARRIER…
• Page 686
  14–30 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE) (See page 41–15) SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE) (See page 41–15) SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40–11) SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
• Page 687
  14–31 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE GENERATOR ASSY (See page 19–7) 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 page 55–74) 3ZZ–FE (See page…
• Page 688
  14–32 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Remove the through bolt and nut, detach the engine mounting insulator from the vehicle. A76715 Remove the 2 bolts and 2 nuts as shown in the illustration. A76717 Remove the 8 bolts and the front suspension member brace rear RH and LH.
• Page 689
  14–33 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER Remove the through bolt and nut, detach the engine mounting insulator FR from the engine mounting bracket. A76718 Remove the through bolt, detach the engine mounting in- sulator RR from the suspension crossmember.
• Page 690
  14–34 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Remove the 2 nuts which are used to secure the engine wire. A76713 Remove the 4 bolts and the 4 ignition coils. REMOVE FUEL DELIVERY PIPE SUB–ASSY (See page 11–11) A64023 REMOVE INTAKE MANIFOLD Disconnect the 2 water hoses from the throttle body.
• Page 691
  14–35 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE WATER BY–PASS PIPE NO.1 Disconnect the knock sensor cramp. Remove the 2 bolts and 2 nuts, then detach the water by– pass pipe and the gasket. A64027 REMOVE WATER INLET Remove the 2 nuts and the water inlet. REMOVE THERMOSTAT REMOVE ENGINE OIL PRESSURE SWITCH ASSY (See page…
• Page 692
  14–36 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE V–RIBBED IDLER ASSY NO.1 Remove the nut, bolt, tube and the idler. A79324 REMOVE V–RIBBED BELT TENSIONER ASSY Remove the bolts, nut and the V–ribbed belt tensioner. A64059 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 3 bolts and the transverse engine mounting…
• Page 693
  14–37 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 Disconnect the heated oxygen sensor connector. Remove the 3 bolts and the nut, and then remove the ex- haust manifold heat insulator. A76722 REMOVE EXHAUST MANIFOLD Remove the 5 nuts, then remove the exhaust manifold and the gasket.
• Page 694
  14–38 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket to the engine coolant temperature sensor. Using SST, install the engine coolant temperature sensor. 09817–33190 Torque: 20 N m (204 kgf cm, 15 ft lbf) A64033 INSTALL EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the 5…
• Page 695
  14–39 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the transverse engine mounting bracket with the bolts. Torque: 47 N m (479 kgf cm, 35 ft lbf) A64060 100. INSTALL V–RIBBED BELT TENSIONER ASSY Install the V–ribbed belt tensioner with the bolt and nut.
• Page 696
  14–40 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 107. INSTALL WATER INLET Install the water inlet with the 2 nuts. Torque: 11 N m (112 kgf cm, 8 ft lbf) A64028 108. INSTALL WATER BY–PASS PIPE NO.1 Install a new gasket and water by–pass pipe with the 2 nuts and 2 bolts.
• Page 697
  14–41 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Install the engine wire with the 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) A76713 113. INSTALL FLYWHEEL SUB–ASSY (M/T TRANSAXLE) Hold the crankshaft with SST. 09960–10010 (09962–01000, 09963–01000) A62838 Clean the bolt and bolt hole.
• Page 698
  14–42 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Clean the bolt and bolt hole. Apply adhesive to the bolts. Adhesive: Part No. 09330–00070, THREE BOND or equivalent. Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration. Torque: 88 N m (897 kgf cm, 65 ft lbf) A62204 115.
• Page 699
  14–43 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Tighten the 2 bolts and 2 nuts. Torque: 45 N m (459 kgf cm, 33 ft lbf) for Bolt A 133 N m (1,356 kgf cm, 98 ft lbf) for Nut B A76717 Install the front suspension member brace LH and RH with the 8 bolts.
• Page 700
  14–44 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 137. INSTALL BATTERY CARRIER Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N m (131 kgf cm, 9 ft lbf) A76714 138. INSTALL BATTERY Torque: 5.0 N m (51 kgf cm, 44 in. lbf) 139.
• Page 701
  14–305 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) TIMING BELT (1CD–FTV) 141C5–01 COMPONENTS Clip Engine Room Cover Side 8.0 (82, 71 in. lbf) Clip Retainer 5.0 (51, 44 in. lbf) Radiator Support V (Cooler Injector Driver Opening Cover Compressor to Crankshaft Pulley) Belt No.
• Page 702
  14–306 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) * Gasket Timing Chain Cover Plate Timing Belt No. 2 Cover Timing Belt Seal Washer 7.4 (76, 66 in.·lbf) 9.0 (92, 80 in.·lbf) Transverse Engine Engine Mounting Bracket 37 (375, 27) 21 (214, 15) Timing Belt Tensioner Generator V belt…
• Page 703
  14–307 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) 141C6–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE UNDER COVER RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE INJECTOR DRIVER (See page 14–286)
• Page 704
  14–308 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) Using SST, remove the pulley. 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05031) A61183 REMOVE IDLER PULLEY SUB–ASSY Remove the bolt and washer, and then remove the pulley. REMOVE TIMING BELT NO.2 COVER Remove the 7 bolts and 7 seal washers, and then remove the timing belt cover. REMOVE TIMING BELT NO.1 COVER Remove the 5 bolts and 5 seal washers, and then remove the timing belt cover.
• Page 705
  14–309 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) REMOVE TIMING BELT HINT: If re–use the timing belt, draw an arrow on the belt which indi- cates the engine revolution direction and put match marks on the pulleys and the belt before removing. This operation will be very helpful when re–installing the timing belt.
• Page 706
  14–310 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) Install the timing belt in the following order: 1. Camshaft timing pulley 2. Supply pump drive pulley 3. Water pump pulley 4. Crankshaft timing pulley 5. No. 2 idler pulley 6. Oil pump pulley 7.
• Page 707
  14–311 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) Check that each timing mark of the pulleys is aligning with the timing marks of the engine assembly as shown in the illustration. If the timing marks are not aligned, remove the timing belt and reinstall it.
• Page 708
  14–312 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) Install the No. 1 timing belt cover and the gasket with the 5 bolts and 5 seal washers. Torque: 7.4 N m (75 kgf cm, 65 in. lbf) After installing the belt cover, check that there is no peel- ings of the gasket.
• Page 709
  14–313 ENGINE MECHANICAL – TIMING BELT (1CD–FTV) INSTALL INJECTOR DRIVER (See page 14–286) INSTALL ENGINE COVER NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf) INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf) AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 710
  14–96 ENGINE MECHANICAL – TIMING CHAIN OR BELT COVER OIL SEAL (1ZZ–FE/3ZZ–FE) TIMING GEAR COVER OIL SEAL (1ZZ–FE/3ZZ–FE) 141CN–01 REPLACEMENT REMOVE FRONT WHEEL RH (See page 14–27) REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27) REMOVE ENGINE UNDER COVER RH (See page 14–27) REMOVE RADIATOR SUPPORT OPENING COVER…
• Page 711
  14–97 ENGINE MECHANICAL – TIMING CHAIN OR BELT COVER OIL SEAL (1ZZ–FE/3ZZ–FE) REMOVE TIMING GEAR COVER OIL SEAL Using a knife, cut off the oil seal lip. Cut Position Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
• Page 712
  14–178 ENGINE MECHANICAL – TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (1AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (1AZ–FE) 141BH–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts and the engine cover No.
• Page 713
  14–179 ENGINE MECHANICAL – TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (1AZ–FE) REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 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.
• Page 714
  14–263 ENGINE MECHANICAL – TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (1AZ–FSE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (1AZ–FSE) 141BR–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts and the engine cover No.
• Page 715
  14–264 ENGINE MECHANICAL – TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (1AZ–FSE) REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 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.
• Page 716
  14–106 ENGINE MECHANICAL – VALVE CLEARANCE (1AZ–FE) VALVE CLEARANCE (1AZ–FE) 141B6–01 ADJUSTMENT REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE COVER SUB–ASSY NO.1 Remove 2 nuts and the engine cover No. 1. A77281 REMOVE IGNITION COIL ASSY Remove 4 bolts and the ignition coils.
• Page 717
  14–107 ENGINE MECHANICAL – VALVE CLEARANCE (1AZ–FE) ADJUST VALVE CLEARANCE NOTICE: Be sure not to turn the crankshaft without the chain ten- sioner. Set the No. 1 cylinder to TDC/compression. (See page 14–171) Remove the chain tensioner. (See page 14–171) Remove the camshafts.
• Page 718
  14–108 ENGINE MECHANICAL – VALVE CLEARANCE (1AZ–FE) A77296 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 719
  14–109 ENGINE MECHANICAL – VALVE CLEARANCE (1AZ–FE) A77297 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 720
  14–110 ENGINE MECHANICAL – VALVE CLEARANCE (1AZ–FE) Install the camshafts. (See page 14–171) Install the chain tensioner. (See page 14–171) INSTALL CYLINDER HEAD COVER SUB–ASSY (See page 14–171) INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgf cm, 80 in. lbf) CHECK FOR ENGINE OIL LEAKS INSTALL ENGINE COVER SUB–ASSY NO.1 Torque: 7.0 N m (71 kgf cm, 62 in.
• Page 721
  14–6 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) 141CE–01 ADJUSTMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) REMOVE ENGINE ROOM COVER SIDE (See page 14–27) REMOVE CYLINDER HEAD COVER NO.2 Remove the 2 nuts and 2 clips and detach cylinder head cover No.2.
• Page 722
  14–7 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) DISCONNECT VENTILATION HOSE NO.2 Disconnect the ventilation hose from the cylinder head cover. A64058 REMOVE CYLINDER HEAD COVER SUB–ASSY Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp brackets and cylinder head cover. REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE UNDER COVER RH A64856…
• Page 723
  14–8 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) Turn the crankshaft 1 revolution (360 Y) and set No. 4 cyl- inder to TDC/compression. Check the valves indicated in the illustration. Using a feeler gauge, measure the clearance be- tween the valve lifter and camshaft. Record the out–of specification valve clearance measurements.
• Page 724
  14–9 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) REMOVE V–RIBBED BELT TENSIONER ASSY Remove the bolt and nut, then remove the V–ribbed belt tensioner. HINT: Jack up and down to remove the bolt. A11858 ADJUST VALVE CLEARANCE Paint Mark NOTICE: Be sure not to revolve the crankshaft without the chain ten- sioner.
• Page 725
  14–10 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) Using several steps, loosen the camshaft bearing cap bolts on the No. 2 camshaft in the sequence shown in the illustration and remove the bearing caps. A62188 Remove the camshaft timing gear as shown in the illustra- tion.
• Page 726
  14–11 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) Remove the valve lifters. Using a micrometer, measure the thickness of the re- moved lifter. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. Thickness of new lifter Thickness of used lifter Measured valve clearance Valve clearance:…
• Page 727
  14–12 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) A79322 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 728
  14–13 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) A79323 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 729
  14–14 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) Install the timing chain on the camshaft timing gear with Painted Link the painted links aligned with the timing marks on the camshaft timing sprocket as shown in the illustration. Timing Mark A62195 Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
• Page 730
  14–15 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) Hold the camshaft with a wrench, tighten the camshaft Hold timing gear set bolt. Tighten Torque: 54 N m (551 kgf cm, 40 ft lbf) NOTICE: Be careful not damage the valve lifter. A62187 Check the match marks on the 2 camshaft sprockets are aligned with each other and aligned with the painted links…
• Page 731
  14–16 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) Turn the crankshaft counterclockwise, and take the hook off the knock pin to release the plunger. Disconnect Hook Turn A62180 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 732
  14–17 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) INSTALL CYLINDER HEAD COVER SUB–ASSY Seal Packing Remove any old packing (FIPG) material. 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.
• Page 733
  14–18 ENGINE MECHANICAL – VALVE CLEARANCE (1ZZ–FE/3ZZ–FE) Install the engine wire with the 2 nuts. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) A76713 INSTALL CYLINDER HEAD COVER NO.2 Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N m (71 kgf cm, 62 in.
• Page 734
  15–6 EXHAUST – EXHAUST PIPE ASSY (1AZ–FE/1AZ–FSE) EXHAUST PIPE ASSY (1AZ–FE/1AZ–FSE) 1509U–01 COMPONENTS 1AZ–FE (Leaded Gasoline) 1AZ–FSE: Exhaust Pipe Assy Center Y Exhaust Pipe Gasket Exhaust Pipe Assy Center Exhaust Pipe Assy Front Y Exhaust Pipe Gasket Y Exhaust Pipe Gasket Floor Panel Brace Front 43 (440, 32) 30 (302, 22)
• Page 735
  15–7 EXHAUST – EXHAUST PIPE ASSY (1AZ–FE/1AZ–FSE) 1509V–01 Removal & Installation and Disassembly & Reassembly REMOVE FLOOR PANEL BRACE FRONT (See page 15–2) REMOVE EXHAUST PIPE ASSY TAIL (See page 15–2) REMOVE EXHAUST PIPE ASSY CENTER Remove the 2 bolts. Remove the exhaust pipe center and the gasket from the 2 exhaust pipe supports.
• Page 736
  15–8 EXHAUST – EXHAUST PIPE ASSY (1AZ–FE/1AZ–FSE) INSTALL EXHAUST PIPE ASSY FRONT Compression spring inspection Using vernier calipers, measure the free length of the compression spring. Minimum length: 41.5 mm (1.634 in.) If the free length is less than minimum, replace the compression spring.
• Page 737
  15–9 EXHAUST – EXHAUST PIPE ASSY (1CD–FTV) EXHAUST PIPE ASSY (1CD–FTV) 1509W–01 COMPONENTS Y Gasket Exhaust Pipe Assy Front Floor Panel Brace Front Y Gasket 43 (440, 32) 30 (302, 22) Compression Spring Exhaust Pipe Assy Tail Compression Spring 43 (440, 32) N·m (kgf·cm, ft·lbf) : Specified torque Y Non–reusable part A79443…
• Page 738
  15–10 EXHAUST – EXHAUST PIPE ASSY (1CD–FTV) 1509X–01 Removal & Installation and Disassembly & Reassembly REMOVE FLOOR PANEL BRACE FRONT Remove the 2 nuts and the floor panel brace front. REMOVE EXHAUST PIPE ASSY TAIL Remove the 2 bolts and 2 compression springs. Disconnect the 3 exhaust pipe supports and remove the exhaust pipe tail.
• Page 739
  15–11 EXHAUST – EXHAUST PIPE ASSY (1CD–FTV) REMOVE EXHAUST PIPE ASSY FRONT Remove the 2 bolts and 2 compression springs. Disconnect the 2 exhaust pipe supports and remove the exhaust pipe front. Remove the gasket from the manifold converter. A78272 INSTALL EXHAUST PIPE ASSY FRONT Using vernier calipers, measure the free length of the compression spring.
• Page 740
  15–12 EXHAUST – EXHAUST PIPE ASSY (1CD–FTV) INSTALL EXHAUST PIPE ASSY TAIL Using vernier calipers, measure the free length of the compression spring. Minimum Length: 38.5 mm (1.515 in.) If the minimum length is less than minimum, replace the com- pression spring.
• Page 741
  15–1 EXHAUST – EXHAUST PIPE ASSY (1ZZ–FE/3ZZ–FE) EXHAUST PIPE ASSY (1ZZ–FE/3ZZ–FE) 1509S–01 COMPONENTS w/o HID Sensor: RHD: Clip Front Floor Footrest Y Exhaust Pipe Gasket Floor Carpet Assy Front w/ HID Sensor: Heated Oxygen Sensor Heated Oxygen Sensor 44 (449, 33) 44 (449, 33) Exhaust Pipe Assy Front Floor Panel Brace Front…
• Page 742
  15–2 EXHAUST – EXHAUST PIPE ASSY (1ZZ–FE/3ZZ–FE) 1509T–01 Removal & Installation and Disassembly & Reassembly REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR) (See page 76–32) REMOVE HEATED OXYGEN SENSOR (W/O HID SENSOR) Using a clip remover, remove the 2 clips. Open the floor carpet.
• Page 743
  15–3 EXHAUST – EXHAUST PIPE ASSY (1ZZ–FE/3ZZ–FE) REMOVE FLOOR PANEL BRACE FRONT Remove the 2 nuts, and then remove the floor panel brace front. A77865 REMOVE EXHAUST PIPE ASSY TAIL Remove the 2 bolts and 2 compression springs. Remove the exhaust pipe tail from the 3 exhaust pipe supports.
• Page 744
  15–4 EXHAUST – EXHAUST PIPE ASSY (1ZZ–FE/3ZZ–FE) REMOVE EXHAUST PIPE ASSY FRONT Remove the 2 bolts and 2 compression springs. Remove the exhaust pipe front from the 2 exhaust pipe supports. Remove the gasket from the exhaust manifold. A78492 INSTALL EXHAUST PIPE ASSY FRONT Compression spring inspection Using vernier calipers, measure the free length of the compression spring.
• Page 745
  15–5 EXHAUST – EXHAUST PIPE ASSY (1ZZ–FE/3ZZ–FE) INSTALL EXHAUST PIPE ASSY TAIL Compression spring inspection Using vernier calipers, measure the free length of the compression spring. Minimum length: 38.5 mm (1.516 in.) If the free length is less than minimum, replace the compression spring.
• Page 746
  16–1 COOLING – WATER PUMP ASSY (1ZZ–FE/3ZZ–FE) WATER PUMP ASSY (1ZZ–FE/3ZZ–FE) 160AO–01 INSPECTION INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage. Hole B10233 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) http://vnx.su…
• Page 747
  14–38 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 140KO–01 COMPONENTS Compression Ring No.1 Compression Ring No.2 Oil Ring (Side Rail) Oil Ring (Expander) _ Snap Ring Piston _ Snap Ring Piston Pin _ Bush Connecting Rod Connecting Rod Bearing 5.0 (51, 44 in.
• Page 748
  14–39 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) 140KP–01 OVERHAUL INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 – 0.342 mm (0.063 – 0.0135 in.) Maximum thrust clearance: 0.342 mm (0.0135 in.) A01155 INSPECT CONNECTING ROD BEARING OIL…
• Page 749
  14–40 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using SST, tighten the bolts in several passes by the spe- cified torque. 09205–16010 Torque: 20 N m (204 kgf cm, 15 ft lbf) A01163…
• Page 750
  14–41 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) REMOVE CONNECTING ROD BEARING Remove the connecting rod bearing from the connecting rod and crankshaft. REMOVE PISTON RING SET HINT: Take care not to misplace the piston rings on both the match with the piston and the direction of the rings. Using a piston ring expander, remove the 2 compression rings.
• Page 751
  14–42 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) REMOVE CRANKSHAFT BEARING CAP SUB ASSY Remove the 10 bearing cap bolts. Uniformly loosen the 10 bearing cap sub–assy bolts, in several passes, in the sequence shown in the illustration. 09011–38121 A62801 Using a screwdriver, remove the bearing cap sub–assem- bly by prying the indicated portions between the cylinder block and bearing cap sub–assembly.
• Page 752
  14–43 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, mea- sure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) A01169 INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diame- ter at positions A, B and C in the thrust and axial direc- tions.
• Page 753
  14–44 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) INSPECT PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 1ZZ–FE 0.065 – 0.088 mm (0.0026 – 0.0035 in.) 3ZZ–FE 0.035 – 0.058 mm (0.0014 – 0.0023 in.) Maximum oil clearance: 1ZZ–FE 0.088 mm (0.0035 in.) 3ZZ–FE 0.058 mm (0.0023 in.)
• Page 754
  14–45 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.25 – 0.35 mm (0.0098 – 0.0138 in.) No. 2 0.35 – 0.50 mm (0.0138 – 0.0197 in.) Maximum end gap: No.
• Page 755
  14–46 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration. Diameter: 43.992 – 44.000 mm (1.7320 – 1.7323 in.) Check each crank pin for taper and out–of–round as shown.
• Page 756
  14–47 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Measure the Plastigage at its widest point. Standard oil clearance: 0.013 – 0.030 mm (0.0005 – 0.0012 in.) Minimum oil clearance: 0.05 mm (0.0020 in.) NOTICE: Completely remove the plastigage A11781 If replacing a bearing, select a new one having the same No.
• Page 757
  14–48 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) INSTALL STUD BOLT Install the 9 stud bolt to the cylinder block. Torque: Stud bolt A, B and C 5.0 N m (51 kgf cm, 44 in. lbf) Stud bolt D 11 N m (112 kgf cm, 8 ft lbf) Upper side: Lower side: Intake side:…
• Page 758
  14–49 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) INSTALL STRAIGHT PIN Using a plastic hammer, install the 9 straight pins to the cylinder block. Standard protrusion: Straight pin A 5 mm (0.20 in.) Straight pin B 7.5 mm (0.30 in.) Straight pin C 8 mm (0.31 in.) Straight pin D 12 mm (0.47 in.) Lower side: Front side:…
• Page 759
  14–50 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Using SST and a press, press into the small end bushing. 09222–30010 After installing the bushing, check that the oil hole of the connecting rod is aligned with the hole of the small end bushing and that the oil clearance measured on both sides of connecting rod are equal.
• Page 760
  14–51 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) INSTALL PISTON RING SET Cord Mark HINT: In case of reusing the piston rings, install them to the matched pistons with the surfaces faced correctly. Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
• Page 761
  14–52 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Install the 2 thrust washers under the No. 3 journal posi- tion of the cylinder block with the oil grooves facing out- ward. Apply engine oil to upper bearing and install the crank- shaft on the cylinder block.
• Page 762
  14–53 ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) INSTALL CONNECTING ROD SUB–ASSY Front Mark Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. Check the position of the piston ring ends. Using a piston ring compressor, push the correctly num- bered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
• Page 763
  14–27 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 140KM–01 COMPONENTS Valve Lifter Valve Spring Retainer Lock Valve Lifter Valve Spring Retainer Valve Spring Retainer Lock Inner Compression Spring Valve Spring Retainer Y Valve Stem Oil O Seal or Ring Valve Spring Seat Inner Compression Spring Y Valve Stem Oil O Seal or Ring…
• Page 764
  14–28 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) 140KN–01 OVERHAUL REMOVE W/HEAD TAPER SCREW PLUG NO.2 Using a socket hexagon wench 10, remove the taper screw plug and gasket. REMOVE VALVE LIFTER Remove the 16 valve lifters from the cylinder head. REMOVE INNER COMPRESSION SPRING Using SST, compress the valve spring and remove the 2 keepers, the retainer, and the spring seat.
• Page 765
  14–29 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and a feeler gauge, mea- sure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.10 mm (0.0040 in.)
• Page 766
  14–30 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.01 mm (0.0039 in.)
• Page 767
  14–31 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) INSPECT INTAKE VALVE Using a vernier calipers, check the valve overall length. Standard overall length: 88.65 mm (3.4902 in.) Minimum overall length: 88.35 mm (3.4784 in.) EM2534 Using a vernier calipers, check the valve head margin thickness.
• Page 768
  14–32 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) If blue appears 360Y around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with the width between 1.0 – 1.4 mm (0.039 –…
• Page 769
  14–33 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) INSPECT CAMSHAFT THRUST CLEARANCE Install the 2 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 – 0.095 mm (0.0016 – 0.0037 in.) Maximum thrust clearance: 0.110 mm (0.0043 in.) If the thrust clearance is greater than maximum, replace the cylinder head.
• Page 770
  14–34 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) INSTALL STUD BOLT AND RING PIN Install the 11 stud bolts to cylinder head, Torque: Stud bolt A, D and E 9.5 N m (97, 84 in. lbf) Stud bolt B and C 5.0 N m (51, 44 in. lbf) Using a plastic hammer, install the new 2 ring pins to the cylinder head.
• Page 771
  14–35 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) INSTALL UNION 14 mm Mark the standard position away from the edge, onto the water hose union as shown in the illustration. 25 mm 9 mm A62791 Apply adhesive to the water hose union hole of the cylin- Adhesive der head.
• Page 772
  14–36 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) INSTALL VALVE STEM OIL O SEAL OR RING Mark Intake Exhaust ”NOK” Apply a light coat of engine oil on the valve stem oil seals. NOTICE: Be very careful to assemble the oil seal for intake and ex- haust.
• Page 773
  14–37 ENGINE MECHANICAL – CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) INSTALL W/HEAD TAPER SCREW PLUG NO.2 Using a socket hexagon wrench 10, install the taper screw plug with a new gasket. Torque: 44 N m (449 kgf cm, 33 ft lbf) 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) http://vnx.su…
• Page 774
  14–1 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 140KJ–01 COMPONENTS Oil Filler Cap Sub–assy Gasket 11 (112, 9.0 (92, 80 in. lbf) Ventilation Valve Seal Washer Sub–assy 9.0 (92, 80 in. lbf) 9.0 (92, 80 in. lbf) Cylinder Head Cover Sub–assy Gasket…
• Page 775
  14–2 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 13 (133, 10) 23 (235, 17) Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 1 Camshaft No.2 Camshaft Timing Gear or Sprocket Camshaft 54 (551, 40) 54 (551, 40) Camshaft Timing Gear Assy Chain Sub–assy Chain Tensioner Slipper…
• Page 776
  14–3 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) See page 14–4 1st 49 (500, 36) 2nd Turn 90_ Plate Washer Cylinder Head Sub–assy z O–ring Oil Control Valve Filter z Gasket Camshaft Timing Oil Control Valve Assy 30 (306, 22) 9.0 (92, 80 in.
• Page 777
  14–4 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 140KL–01 OVERHAUL REMOVE OIL FILLER CAP SUB–ASSY Remove the oil filler cap from the cylinder head cover. REMOVE OIL FILLER CAP GASKET Remove the gasket from the oil filler cap. REMOVE VENTILATION VALVE SUB–ASSY Remove the ventilation valve from the cylinder head cover.
• Page 778
  14–5 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Using SST, remove the pulley bolt. 09960–10010 (09962–01000, 09963–01000) Remove the crankshaft pulley from the crankshaft. A62837 REMOVE CHAIN TENSIONER ASSY NO.1 Remove the 2 nuts and chain tensioner. NOTICE: Be sure not to revolve the crank shaft without the chain tensioner. REMOVE TIMING CHAIN OR BELT COVER SUB–ASSY Remove the 11 bolts and nuts.
• Page 779
  14–6 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE CHAIN SUB–ASSY Using screwdrivers, ply out the timing chain with the crankshaft timing gear 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 for valves not to touch the pistons.
• Page 780
  14–7 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Put air pressure into two broken paths (the advance Retard Advanced side path and the retard side path) with about 150 Side Path Side Path kPa {1.5 kgf cm}. CAUTION: Cover the pathes with shop rag to avoid oil splashing. A62191 Confirm if the camshaft timing gear assembly re- Retard…
• Page 781
  14–8 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE CAMSHAFT TIMING GEAR ASSY Retard Side Path Grip the camshaft with a vice, and confirm that the gear is locked. CAUTION: Advance Be careful not to damage the camshaft. Side Path Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.
• Page 782
  14–9 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Remove the fringe bolt of camshaft timing gear assembly. NOTICE: Be sure not to remove the other 4 bolts. Fringe Bolt In case of reusing the camshaft timing gear, release the strait pin locking first, and then install the gear. Straight Pin A62193 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY…
• Page 783
  14–10 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE OIL FILTER SUB–ASSY Using SST, remove the oil filter. 09228–06501 A62817 REMOVE OIL FILTER UNION Using a socket hexagon wrench 12, remove the oil filter union. REMOVE ENGINE REAR OIL SEAL Cut Position Using a knife, cut off the oil seal lip.
• Page 784
  14–11 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) REMOVE OIL STRAINER SUB–ASSY Remove the bolt, 2 nuts, oil strainer and gasket. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB–ASSY Remove the cylinder block water drain cock from the cylinder block. INSPECT CHAIN TENSIONER ASSY NO.1 Raise Check that the plunger moves smoothly when the ratchet Move…
• Page 785
  14–12 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing sprocket. Using a vernier calipers, measure the timing sprocket di- ameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for the mea- suring.
• Page 786
  14–13 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSPECT CAMSHAFT Inspect camshaft for runout. Place the camshaft on V–blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) EM1628 Inspect cam lobes. Using a micrometer, measure the cam lobe height.
• Page 787
  14–14 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSTALL OIL PAN SUB–ASSY Seal Packing Remove any old packing material from the contact sur- face. Apply seal packing in the shape of bead (Diameter 3.5 mm – 4.5 mm(0.1379–0.177in)) consequently as shown in the illustration.
• Page 788
  14–15 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSTALL OIL PUMP ASSY Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, and side the oil pump. Install the oil pump with the 5 bolts. Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 789
  14–16 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Install a new O–ring to the camshaft timing oil control valve. Install the camshaft timing oil control valve with the bolt. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL CAMSHAFT TIMING GEAR ASSY Straight Pin Put the camshaft timing gear assembly and the camshaft…
• Page 790
  14–17 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Examine the front marks and numbers and tighten the bolts in the order shown in the illustration. Torque: Bearing cap No. 1 23 N m (235 kgf cm, 17 ft lbf) Bearing cap No. 3 13 N m (133 kgf cm, 10 ft lbf) A62825 INSTALL CHAIN SUB–ASSY Set No.
• Page 791
  14–18 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Install the timing chain on the camshaft timing sprockets Yellow Color Mark with the yellow color links aligned with the timing marks on the camshaft timing sprockets. Timing Mark A62173 INSTALL CHAIN VIBRATION DAMPER NO.1 Install the chain vibration damper with the 2 bolts.
• Page 792
  14–19 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Apply seal packing in the shape of bead (Diameter 3.5 Chain Cover mm – 4.5 mm(0.1379–0.177in)) consequently as shown Groove in the illustration. Seal packing: Water pump part part No. 08826–00100 or equivalent Other part part No.
• Page 793
  14–20 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. 09960–10010 (09962–01000, 09963–01000) Torque: 138 N m (1,407 kgf cm, 102 ft lbf) A62837 Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
• Page 794
  14–21 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) INSPECT VALVE CLEARANCE Set No. 1 cylinder to TDC/compression. Mark Mark Turn the crankshaft pulley, and align its groove with timing mark ”0” of the timing chain cover. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.
• Page 795
  14–22 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) ADJUST VALVE CLEARANCE NOTICE: Be sure not to revolve the crankshaft without the chain ten- sioner. Set the No. 1 cylinder to the TDC/compression. Place match marks on the timing chain and camshaft tim- Paint Mark ing sprockets.
• Page 796
  14–23 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Remove the camshaft with holding the timing chain. A32125 Tie the timing chain with a string as shown in the illustra- tion. NOTICE: Be careful not to drop anything inside the timing chain cov- Remove the valve lifters.
• Page 797
  14–24 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Examine the front marks and numbers and tighten the bolts in the order shown in the illustration. Torque: 13 N m (133 kgf cm, 10 ft lbf) A62196 Put the camshaft No.2 on the cylinder head with the Painted Link painted links of the chain aligned with the timing mark on the camshaft timing sprockets.
• Page 798
  14–25 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Check the match marks on the timing chain and camshaft timing sprockets, and then the alignment of the pulley Mark Mark groove with timing mark of the chain cover as shown in the illustration.
• Page 799
  14–26 ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. Plunger Push Turn A62181 HINT: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out.
• Page 800
  01–7 INTRODUCTION – TERMS (1ZZ–FE/3ZZ–FE) TERMS (1ZZ–FE/3ZZ–FE) 010BJ–01 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti–Lock Brake System Air Conditioner Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air–Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier…
• Page 801
  01–8 INTRODUCTION – TERMS (1ZZ–FE/3ZZ–FE) Abbreviations Meaning DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Cam Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code ECAM Engine Control And Measurement System Electronic Controlled Diesel ECDY Eddy Current Dynamometer…
• Page 802
  01–9 INTRODUCTION – TERMS (1ZZ–FE/3ZZ–FE) Abbreviations Meaning Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Idle Speed Control Junction Block Junction Connector Kick–Down Local Area Network Liftback Liquid Crystal Display Light Emitting Diode Left–Hand…
• Page 803
  TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension Toyota Free–Tronic Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. Traction Control System TURBO Turbocharge Three–Way Catalyst Underdrive Undersize 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) http://vnx.su…
• Page 804
  01–11 INTRODUCTION – TERMS (1ZZ–FE/3ZZ–FE) Abbreviations Meaning Vacuum Control Valve VENT Ventilator Vehicle Identification Number Variable Power Steering Vehicle Skid Control Vacuum Switching Valve Vacuum Transmitting Valve VVT–i Variable Valve Timing–intelligent With Wagon Wire Harness Without First Second Two Wheel Drive Vehicle (4 x 2) Third Fourth Four Wheel Drive Vehicle (4 x 4)
• Page 805
  01–1 INTRODUCTION – HOW TO USE THIS MANUAL (1ZZ–FE/3ZZ–FE) HOW TO USE THIS MANUAL (1ZZ–FE/3ZZ–FE) 010BH–01 GENERAL INFORMATION GENERAL DESCRIPTION This manual is made in accordance with SAE J2008. Generally repair operations can be separated in the following 3 main processes: 1.
• Page 806
  01–2 INTRODUCTION – HOW TO USE THIS MANUAL (1ZZ–FE/3ZZ–FE) Tightening torque, oil applying position, and non–reusable parts are described as important points in the procedure. NOTICE: There are cases where such information can only be indicated by an illustration. In that case, all the information such as torque, oil, etc.
• Page 807
  01–3 INTRODUCTION – HOW TO USE THIS MANUAL (1ZZ–FE/3ZZ–FE) SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys- tem of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf) 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL…
• Page 808
  TERMS (1ZZ–FE/3ZZ–FE) 010BK–01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS…
• Page 809
  01–13 INTRODUCTION – TERMS (1ZZ–FE/3ZZ–FE) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel–Shutoff –…
• Page 810
  01–14 INTRODUCTION – TERMS (1ZZ–FE/3ZZ–FE) Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range – Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalytic (TWC) Three–Way Catalytic Converter Manifold Converter TWC+OC Three–Way + Oxidation Catalytic Converter + CCo…
• Page 811
  01–4 INTRODUCTION – REPAIR INSTRUCTION (1NZ–FE/2NZ–FE) REPAIR INSTRUCTION (1NZ–FE/2NZ–FE) 010BI–01 PRECAUTION TO PREVENT FROM ENTERING FOREIGN SUBSTANCES. When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often causes functional failure of the engine. Precaution before disassembly.
• Page 812
  01–5 INTRODUCTION – REPAIR INSTRUCTION (1NZ–FE/2NZ–FE) NOTICE: Do the torque checking with the lower limit value of the torque tolerance. Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for a specified time until it hardens. Gaskets: When necessary, use a sealer on gaskets to prevent leaks.
• Page 813
  01–6 INTRODUCTION – REPAIR INSTRUCTION (1NZ–FE/2NZ–FE) Never use any electric equipment like an electric motor or a working light as they may cause spark or high temperature. Never use an iron hammer as it may cause spark. Dispose the shop lag separately from any fuel deposit. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS If any metal tip is mixed in the inlet pass, that may give a…
• Page 814
  17–1 LUBRICATION – OIL PUMP ASSY (1ZZ–FE/3ZZ–FE) OIL PUMP ASSY (1ZZ–FE/3ZZ–FE) 1706D–01 COMPONENTS Oil Pump relief Valve Plug 37 (377, 27) 10 (102, 7) Oil Pump Relief Valve Spring Oil Relief Valve Oil Pump Cover Oil Pump Drive Rotor Oil Pump Driven Rotor Oil Pump Body N·m (kgf·cm, ft·lbf) : Specified torque A62218…
• Page 815
  17–2 LUBRICATION – OIL PUMP ASSY (1ZZ–FE/3ZZ–FE) 1700D–03 OVERHAUL REMOVE OIL PUMP DRIVE AND DRIVEN ROTORS Remove the 3 screws and oil pump cover. Remove the oil pump drive and driven rotors from the oil pump. REMOVE VALVE, OIL PUMP RELIEF Remove the plug, spring and valve from the oil pump.
• Page 816
  17–3 LUBRICATION – OIL PUMP ASSY (1ZZ–FE/3ZZ–FE) INSPECT BODY CLEARANCE Using a feeler gauge, measure the clearance between the driven rotor and oil pump body. Standard body clearance: 0.260 – 0.325 mm (0.0102 – 0.0128 in.) Maximum body clearance: 0.325 mm (0.0128 in.) A32177 INSTALL OIL PUMP RELIEF VALVE Coat the oil pump relief valve with engine oil, and insert oil pump relief valve and spring to the valve…
• Page 817
  02–1 PREPARATION – ENGINE MECHANICAL ENGINE MECHANICAL 0214A–01 PREPARATION 09011–38121 12 mm Socket Wrench for 12 CYLINDER BLOCK Pointed Head (1ZZ–FE/3ZZ–FE) 09032–00100 Oil Pan Seal Cutter PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 09201–01055 Valve Guide Bushing Remover & CYLINDER HEAD ASSY Replacer 5.5 (1ZZ–FE/3ZZ–FE) Valve Guide Bushing Remover &…
• Page 818
  02–2 PREPARATION – ENGINE MECHANICAL 09950–70010 Handle Set PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) Handle 100 PARTIAL ENGINE ASSY (09951–07100) (1ZZ–FE/3ZZ–FE) CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) Variable Pin Wrench Set PARTIAL ENGINE ASSY 09960–10010 (1ZZ–FE/3ZZ–FE) (09962–01000) Variable Pin Wrench Arm Assy PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) (09963–01000)
• Page 819
  02–3 PREPARATION – ENGINE MECHANICAL 08833–00070 ”Adhesive 1324,” CYLINDER HEAD ASSY THREE BOND 1324 or equivalent (1ZZ–FE/3ZZ–FE) CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Equipment Wooden block Spring tension gauge Vernier calipers V–block Dial indicator Micrometer Torque wrench Heater Precision straight edge Feeler gauge Caliper gauge Steel square Plastigage…
• Page 820
  02–4 PREPARATION – LUBRICATION LUBRICATION 02149–01 PREPARATION Equipment Feeler gauge Precision straight edge Torque wrench 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) http://vnx.su…
• Page 821
  02–1 PREPARATION – ENGINE MECHANICAL ENGINE MECHANICAL 0214A–01 PREPARATION 09011–38121 12 mm Socket Wrench for 12 CYLINDER BLOCK Pointed Head (1ZZ–FE/3ZZ–FE) 09032–00100 Oil Pan Seal Cutter PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) 09201–01055 Valve Guide Bushing Remover & CYLINDER HEAD ASSY Replacer 5.5 (1ZZ–FE/3ZZ–FE) Valve Guide Bushing Remover &…
• Page 822
  02–2 PREPARATION – ENGINE MECHANICAL 09950–70010 Handle Set PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) Handle 100 PARTIAL ENGINE ASSY (09951–07100) (1ZZ–FE/3ZZ–FE) CYLINDER HEAD ASSY (1ZZ–FE/3ZZ–FE) Variable Pin Wrench Set PARTIAL ENGINE ASSY 09960–10010 (1ZZ–FE/3ZZ–FE) (09962–01000) Variable Pin Wrench Arm Assy PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE) (09963–01000)
• Page 823
  02–3 PREPARATION – ENGINE MECHANICAL 08833–00070 ”Adhesive 1324,” CYLINDER HEAD ASSY THREE BOND 1324 or equivalent (1ZZ–FE/3ZZ–FE) CYLINDER BLOCK (1ZZ–FE/3ZZ–FE) Equipment Wooden block Spring tension gauge Vernier calipers V–block Dial indicator Micrometer Torque wrench Heater Precision straight edge Feeler gauge Caliper gauge Steel square Plastigage…
• Page 824
  Alternator Pulley Set Nut 22 mm GENERATOR ASSY (09820–06020) Wrench (1ZZ–FE/3ZZ–FE) Recomended Tools Socket Wrench for 29 mm . GENERATOR ASSY 09011–12291 (1ZZ–FE/3ZZ–FE) 09082–00040 TOYOTA Electrical Tester STARTER ASSY (1ZZ–FE/3ZZ–FE) GENERATOR ASSY (1ZZ–FE/3ZZ–FE) (09083–00150) Test Lead Set STARTER ASSY (1ZZ–FE/3ZZ–FE) GENERATOR ASSY (1ZZ–FE/3ZZ–FE)
• Page 825
  03–4 SERVICE SPECIFICATIONS – ENGINE MECHANICAL ENGINE MECHANICAL 0300O–02 SERVICE DATA Chain sub–assy Length at 16 links Maximum 112.6 mm (4.433 in.) Camshaft timing gear or sprocket Diameter (w/ chain) Minimum 97.3 mm (3.831 in.) Crankshaft timing gear or sprocket Diameter (w/ chain) Minimum 51.6 mm (2.032 in.) Chain tensioner slipper…
• Page 826
  03–5 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Valve lifter Diameter 30.966 – 30.976 mm (1.2191 – 1.2195 in.) Bore diameter 31.000 – 31.025 mm (1.2205 – 1.2215 in.) Oil clearance Standard 0.024 – 0.059 mm (0.0016 – 0.0037 in.) Maximum 0.1 mm (0.0039 in.) Straight pin Protrusion height 5 mm (0.20 in.)
• Page 827
  03–6 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Straight pin Timing chain or belt cover sub–assy x cylinder block sub–assy length 15 mm (0.59 in.) 5 mm (0.20 in.) length 12 mm (0.47 in.) 6 mm (0.24 in.) Transaxle housing x Cylinder block sub–assy 12 mm (0.47 in.) Cylinder head sub–assy x Cylinder block sub–assy 7 mm (0.28 in.)
• Page 828
  03–7 SERVICE SPECIFICATIONS – ENGINE MECHANICAL 0300P–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Cylinder block water drain cock sub–assy x Cylinder block sub–assy Oil strainer sub–assy x Cylinder block sub–assy 80 in. lbf Oil pan sub–assy x Cylinder block sub–assy 80 in.
• Page 829
  03–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT 030K5–01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/ Washer w/ Washer B06431 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E)
• Page 830
  03–3 SERVICE SPECIFICATIONS – STANDARD BOLT 030K7–01 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class Hexagon Nut Cold Forging Nut Cutting Processed Nut No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 7N (5T) 10N (7T)
• Page 831
  03–8 SERVICE SPECIFICATIONS – LUBRICATION LUBRICATION 0300L–02 SERVICE DATA Rotor tip clearance Standard 0.040 – 0.160 mm (0.0016 – 0.0063 in.) Maximum 0.160 mm (0.0063 in.) Rotor side clearance Standard 0.025 – 0.071 mm (0.0010 – 0.0028 in.) Maximum 0.071 mm (0.0028 in.) Body clearance Standard 0.260 –…
• Page 832
  03–9 SERVICE SPECIFICATIONS – LUBRICATION 0300K–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Oil pump relief valve plug x Oil pump body Oil pump cover x Oil pump body 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) http://vnx.su…
• Page 833
  03–4 SERVICE SPECIFICATIONS – ENGINE MECHANICAL ENGINE MECHANICAL 0300O–02 SERVICE DATA Chain sub–assy Length at 16 links Maximum 112.6 mm (4.433 in.) Camshaft timing gear or sprocket Diameter (w/ chain) Minimum 97.3 mm (3.831 in.) Crankshaft timing gear or sprocket Diameter (w/ chain) Minimum 51.6 mm (2.032 in.) Chain tensioner slipper…
• Page 834
  03–5 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Valve lifter Diameter 30.966 – 30.976 mm (1.2191 – 1.2195 in.) Bore diameter 31.000 – 31.025 mm (1.2205 – 1.2215 in.) Oil clearance Standard 0.024 – 0.059 mm (0.0016 – 0.0037 in.) Maximum 0.1 mm (0.0039 in.) Straight pin Protrusion height 5 mm (0.20 in.)
• Page 835
  03–6 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Straight pin Timing chain or belt cover sub–assy x cylinder block sub–assy length 15 mm (0.59 in.) 5 mm (0.20 in.) length 12 mm (0.47 in.) 6 mm (0.24 in.) Transaxle housing x Cylinder block sub–assy 12 mm (0.47 in.) Cylinder head sub–assy x Cylinder block sub–assy 7 mm (0.28 in.)
• Page 836
  03–2 SERVICE SPECIFICATIONS – STANDARD BOLT 030K6–01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Class Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 48 in.·lbf 52 in.·lbf 1.25 12.5 1.25 1.25 1,150 – – –…
• Page 837
  03–10 SERVICE SPECIFICATIONS – STARTING & CHARGING STARTING & CHARGING 0300Q–02 SERVICE DATA Starter armature assy Circle runout Maximum 0.05 mm (0.0020 in.) Commutator diameter Standard 28 mm (1.102 in.) Minimum 27 mm (1.063 in.) Undercut depth Standard 0.6 mm (0.024 in.) Minimum 0.2 mm (0.008 in.) Starter yoke assy…
• Page 838
  03–11 SERVICE SPECIFICATIONS – STARTING & CHARGING 0300R–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Starter commutator end frame assy x Starter brush holder assy 13 in. lbf Starter yoke assy x Starter drive housing assy 52 in. lbf Magnet starter switch assy x Starter drive housing assy 73 in.
• Page 839
  03–7 SERVICE SPECIFICATIONS – ENGINE MECHANICAL 0300P–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Cylinder block water drain cock sub–assy x Cylinder block sub–assy Oil strainer sub–assy x Cylinder block sub–assy 80 in. lbf Oil pan sub–assy x Cylinder block sub–assy 80 in.
• Page 840
  19–9 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) GENERATOR ASSY (1ZZ–FE/3ZZ–FE) 190A9–01 COMPONENTS Washer Generator Drive End Frame Terminal Insulator Generator Rotor Assy 111 (1,132, 82) 2.9 (30, 26 in. lbf) Generator Pulley 4.4 (45, 39 in. lbf) Generator Brush Cover 3.9 (40, 35 in.
• Page 841
  19–10 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) 190AA–01 OVERHAUL REMOVE GENERATOR PULLEY 1 – A 1 – B 09820–63010 (09820–06010, 09820–06020) HINT: SST1 – A, B 09820–06010 SST2 09820–06020 Hold SST 1 – A with a torque wrench, and tighten SST 1 –…
• Page 842
  19–11 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) REMOVE GENERATOR BRUSH HOLDER ASSY Remove the nut and terminal insulator. Remove the screw, nut and terminal plate. Remove the 2 nuts and rear end cover. Remove the brush cover from the brush holder. Remove the 2 screw and brush holder.
• Page 843
  19–12 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) INSPECT GENERATOR ROTOR ASSY Slip Ring Using an ohmmeter, check that there is continuity be- tween the slip rings. Standard resistance: 2.1 – 2.5 f at 20YC (68YF) A62758 Using an ohmmeter, check that there is no continuity be- Rotor tween the slip ring and rotor.
• Page 844
  19–13 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) INSTALL GENERATOR ROTOR ASSY Install the rotor to the drive end frame. B00219 Using a socket wrench 29 and press, slowly press in the Socket Wrench rectifier end frame. B00211 Install the cord clip and 4 nuts. Torque: Nut A 4.5 N m (46 kgf cm, 40 in.
• Page 845
  19–14 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) Install the rear end cover with the 2 nuts. Torque: 4.4 N m (45 kgf cm, 39 in. lbf) Install the terminal plate with the screw and nut. Torque: Bolt 3.9 N m (40 kgf cm, 35 in. lbf) Nut 4.4 N m (45 kgf cm, 39 in.
• Page 846
  19–15 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) Turn SST 1 – B, and remove SST 1 – A, B. Turn the pulley, and check that the pulley moves smooth- 1 – A 1 – B A62756 1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E) http://vnx.su…
• Page 847
  19–1 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) STARTER ASSY (1ZZ–FE/3ZZ–FE) 190A8–01 COMPONENTS Starter Yoke Assy Starter Commutator End Frame Assy Starter Armature Assy 5.9 (60, 52 in. lbf) Starter Brush Holder Assy 1.5 (15, 13 in. lbf) Starter Drive Housing Assy 8.3 (85, 73 in.
• Page 848
  19–2 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) 1900P–02 OVERHAUL REMOVE MAGNET STARTER SWITCH ASSY Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Loosen the 2 nuts holding the magnetic switch to the starter housing. Pull the magnetic switch and while lifting the front part of the magnetic switch, release the plunger hook from the driver lever, then release the magnetic switch.
• Page 849
  19–3 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) REMOVE STARTER CLUTCH SUB–ASSY Remove drive lever and starter clutch with shock absorb- er from starter housing. ST0741 Using a screwdriver, tap in the stop collar towards the starter clutch. A33589 Using a screwdriver, pry off the snap ring. Remove the stop collar and starter clutch from the plane- tary shaft.
• Page 850
  19–4 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) Check the commutator for dirty and burn on surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. Place the commutator on V – blocks. Using a dial indicator, measure the circle runout.
• Page 851
  19–5 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) Using an ohmmeter, check that there is no continuity be- tween the field coil end and field frame. A62224 INSPECT BRUSH Using a vernier calipers, measure the brush length. Standard length: 14 mm (0.551 in.) Minimum length: 9 mm (0.354 in.) A37017 INSPECT STARTER BRUSH HOLDER ASSY…
• Page 852
  19–6 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) Using an ohmmeter, check that there is continuity be- Terminal C tween terminals 50 and C. Terminal 50 A62226 Using an ohmmeter, check that there is continuity be- Switch Body tween terminals 50 and the switch body. Terminal 50 A62227 INSTALL STARTER CLUTCH SUB–ASSY…
• Page 853
  19–7 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) Apply grease to the drive lever touching the starter pivot Grease part of the drive lever. Install the drive lever to the starter clutch. ST0741 Align the protrusion of the shock absorber with the cutout Cutout of the starter housing and install them.
• Page 854
  19–8 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) INSTALL STARTER YOKE ASSY Protrusion Cutout Align the cutout of the field frame with the protrusion of the shock absorber. A62229 Install the field frame and armature assembly with the 2 through bolts. Torque: 5.9 N m (60 kgf cm, 52 in.
• Page 855
  16–17 COOLING – COOLING FAN SYSTEM (1AZ–FE) COOLING FAN SYSTEM (1AZ–FE) 1600R–13 ON–VEHICLE INSPECTION HINT: It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 77YC (171YF)) Turn the ignition switch ON.
• Page 856
  16–18 COOLING – COOLING FAN SYSTEM (1AZ–FE) 160N3–01 INSPECTION INSPECT COOLING FAN RELAY Continuity inspection. Using an ohmmeter, check for continuity between each terminal. Specified condition: Terminal No. Specified condition 1 – 2 Continuity No continuity 3 – 5 Continuity E34090 (Apply battery voltage terminals 1 and 2) INSPECT COOLING FAN RELAY NO.2…
• Page 857
  16–29 COOLING – COOLING FAN SYSTEM (1AZ–FSE) COOLING FAN SYSTEM (1AZ–FSE) 1600R–12 ON–VEHICLE INSPECTION HINT: It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83YC (181YF)) Turn the ignition switch ON.
• Page 858
  16–30 COOLING – COOLING FAN SYSTEM (1AZ–FSE) 160N0–01 INSPECTION INSPECT COOLING FAN RELAY Continuity inspection. Using an ohmmeter, check for continuity between each terminal. Specified condition: Terminal No. Specified condition 1 – 2 Continuity No continuity 3 – 5 Continuity E34090 (Apply battery boltage terminals 1 and 2) INSPECT COOLING FAN RELAY NO.2…
• Page 859
  16–41 COOLING – COOLING FAN SYSTEM (1CD–FTV) COOLING FAN SYSTEM (1CD–FTV) 1606N–03 ON–VEHICLE INSPECTION CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83YC (181YF)) Turn the ignition switch ON. Check that the cooling fan stops. Disconnect the temperature detect switch connector. Connect the terminals on the temperature detect switch connector.
• Page 860
  16–42 COOLING – COOLING FAN SYSTEM (1CD–FTV) 160N8–01 INSPECTION INSPECT COOLING FAN RELAY Continuity inspection. Using an ohmmeter, check for continuity between each terminal. Specified condition: Terminal No. Specified condition 1 – 2 Continuity No continuity 3 – 5 Continuity A35654 (Apply battery voltage terminals 1 and 2) INSPECT COOLING FAN RELAY NO.2…
• Page 861
  16–43 COOLING – COOLING FAN SYSTEM (1CD–FTV) INSPECT TEMPERATURE DETECT SWITCH NO.2 Using an ohmmeter, check that there is continuity be- tween the terminals when the coolant temperature is above 93YC (199YF). Ohmmeter Specified condition: Continuity Using an ohmmeter, check that there is no continuity be- tween the terminals when the coolant temperature is be- low 83YC (181YF).
• Page 862
  16–5 COOLING – COOLING FAN SYSTEM (1ZZ–FE/3ZZ–FE) COOLING FAN SYSTEM (1ZZ–FE/3ZZ–FE) 1600R–14 ON–VEHICLE INSPECTION HINT: It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 94.5YC (202YF)) Turn the ignition switch ON.
• Page 863
  16–6 COOLING – COOLING FAN SYSTEM (1ZZ–FE/3ZZ–FE) 1600S–11 INSPECTION INSPECT COOLING FAN RELAY Continuity inspection. Using an ohmmeter, check for continuity between each terminal. Specified condition: Terminal No. Specified condition 1 – 2 Continuity No continuity 3 – 5 Continuity E34090 (Apply battery voltage terminals 1 and 2) INSPECT COOLING FAN RELAY NO.2…
• Page 864
  16–11 COOLING – RADIATOR ASSY (1ZZ–FE/3ZZ–FE) RADIATOR ASSY (1ZZ–FE/3ZZ–FE) 160MK–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) REMOVE ENGINE ROOM COVER SIDE (See page 14–27) ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27) DRAIN ENGINE COOLANT (See page 16–1) DISCONNECT RADIATOR HOSE INLET Disconnect the radiator hose inlet from the radiator.
• Page 865
  16–12 COOLING – RADIATOR ASSY (1ZZ–FE/3ZZ–FE) INSTALL RADIATOR ASSY Upper Hook Align the 2 keyways of the fan shroud with the 2 keys lo- cated on the lower bottom of the radiator and fit them. Install the fan should to the radiator with the 2 upper hooks.
• Page 866
  CHECK ENGINE COOLANT LEVEL AT RESERVOIR The engine coolant should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to the ”FULL” line. CHECK ENGINE COOLANT QUALITY Remove the radiator cap.
• Page 867
  16–14 COOLING – COOLING SYSTEM (1AZ–FE) INSPECT FINS BLOCKAGE If fins are clogged, wash them with water or a steam cleaner and dry with compressed air. NOTICE: If the distance between the steam cleaner and the core is too close, there is a possibility of damaging the fins, so keep the following injection distance.
• Page 868
  16–15 COOLING – COOLING SYSTEM (1AZ–FE) 160N2–01 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ture. P13560 Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature of the thermostat. Valve opening temperature: 80 to 84_C (176 to 183_F) If the valve opening temperature is not as specified, replace the…
• Page 869
  16–16 COOLING – COOLING SYSTEM (1AZ–FE) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Radiator Cap Tester Pump speed: 1 push / 3 seconds or more NOTICE: Push the pump at a constant speed. 30_ or more If air is not coming from the vacuum valve, replace the radiator cap.
• Page 870
  CHECK ENGINE COOLANT LEVEL AT RESERVOIR The engine coolant should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to the ”FULL” line. CHECK ENGINE COOLANT QUALITY Remove the radiator cap.
• Page 871
  16–26 COOLING – COOLING SYSTEM (1AZ–FSE) INSPECT FINS BLOCKAGE If fins are clogged, wash them with water or a steam cleaner and dry with compressed air. NOTICE: If the distance between the steam cleaner and the core is too close, there is a possibility of damaging the fins, so keep the following injection distance.
• Page 872
  16–27 COOLING – COOLING SYSTEM (1AZ–FSE) 160MZ–01 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ture. P35001 Immerse the thermostat in water an gradually heat the water. Check the valve opening temperature of the thermostat. Valve opening temperature: 86 to 90_C (187 to 198_F) If the valve opening temperature is not as specified, replace the…
• Page 873
  16–28 COOLING – COOLING SYSTEM (1AZ–FSE) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Radiator Cap Tester Pump speed: 1 push / 3 seconds or more NOTICE: Push the pump at a constant speed. 30_ or more If air is not coming from the vacuum valve, replace the radiator cap.
• Page 874
  CHECK ENGINE COOLANT LEVEL AT RESERVOIR The engine coolant should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to the ”FULL” line. CHECK ENGINE COOLANT QUALITY Remove the radiator cap.
• Page 875
  16–38 COOLING – COOLING SYSTEM (1CD–FTV) INSPECT FINS BLOCKAGE If fins are clogged, wash them with water or a steam cleaner and dry with compressed air. NOTICE: If the distance between the steam cleaner and the core is too close, there is a possibility of damaging the fins, so keep the following injection distance.
• Page 876
  16–39 COOLING – COOLING SYSTEM (1CD–FTV) 160N7–01 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ture. B08008 Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature of the thermostat. Valve opening temperature: 80 to 84_C (176 to 183_F) If the valve opening temperature is not as specified, replace the…
• Page 877
  16–40 COOLING – COOLING SYSTEM (1CD–FTV) Using a radiator cap tester, slowly pump the tester and Reserve tank Cap Radiator Cap Tester check that air is coming from the vacuum valve. Pump speed: 1 push / 3 seconds or more NOTICE: Push the pump at a constant speed.
• Page 878
  CHECK ENGINE COOLANT LEVEL AT RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to the ”FULL” line. CHECK ENGINE COOLANT QUALITY Remove the radiator cap.
• Page 879
  16–2 COOLING – COOLING SYSTEM (1ZZ–FE/3ZZ–FE) INSPECT FINS BLOCKAGE If fins are clogged, wash them with water or a steam cleaner and dry with compressed air. NOTICE: If the distance between the steam cleaner and the core is too close, there is a possibility of damaging the fins, so keep the following injection distance.
• Page 880
  16–3 COOLING – COOLING SYSTEM (1ZZ–FE/3ZZ–FE) 160N5–01 INSPECTION INSPECT THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat. P13560 Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 80 to 84_C (176 to 183_F) If the valve opening temperature is not as specified, replace the thermostat.
• Page 881
  16–4 COOLING – COOLING SYSTEM (1ZZ–FE/3ZZ–FE) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Radiator Cap Tester Pump speed: 1 push / 3 seconds or more NOTICE: Push the pump at a constant speed. 30_ or more If air is not coming from the vacuum valve, replace the radiator cap.
• Page 882
  16–19 COOLING – ENGINE COOLANT (1AZ–FE) ENGINE COOLANT (1AZ–FE) 160MV–01 REPLACEMENT DRAIN ENGINE COOLANT CAUTION: To avoid the danger of being burned, do not remove the ra- diator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. Remove the radiator cap.
• Page 883
  HINT: Use of improper coolants may damage engine cooling system. Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufactur- er’s directions. Using of coolant with includes more than 50 % (freezing protection down to –35_C (–31_F)) or 60 % (freezing protection down to –50_C (–58_F)) of ethylene–glycol is recommended but not more than…
• Page 884
  16–31 COOLING – ENGINE COOLANT (1AZ–FSE) ENGINE COOLANT (1AZ–FSE) 160MU–01 REPLACEMENT DRAIN ENGINE COOLANT CAUTION: To avoid the danger of being burned, do not remove the ra- diator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. Remove the radiator cap.
• Page 885
  HINT: Use of improper coolants may damage engine cooling system. Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufactur- er’s directions. Using of coolant with includes more than 50 % (freezing protection down to –35_C (–31_F)) or 60 % (freezing protection down to –50_C (–58_F)) of ethylene–glycol is recommended but not more than…
• Page 886
  HINT: Use of improper coolants may damage engine cooling system. A63951 Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufacturer’s instruc- tion. Using of coolant which includes more than 50 % (freezing protection down to –35_C (–31_F)) or 60 % (freezing…
• Page 887
  16–45 COOLING – ENGINE COOLANT (1CD–FTV) CHECK FOR ENGINE COOLANT LEAKS Fill the radiator with coolant and attach a radiator cap tester. Pump it to 137 kPa (1.4 kgf/cm 19.9 psi), and check that the pressure does not drop. AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 888
  HINT: Use of improper coolants may damage engine cooling system. Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufactur- er’s instruction. Using of coolant with includes more than 50 % (freezing protection down to –35_C (–31_F)) or 60 % (freezing protection down to –50_C (–58_F)) of ethylene–glycol is recommended but not more than…
• Page 889
  16–8 COOLING – ENGINE COOLANT (1ZZ–FE/3ZZ–FE) Warm up the engine until the thermostat valve begins to open. HINT: Press the radiator inlet and outlet hose several times by hand during the warming up. Stop the engine and wait until the coolant temperature gets cold. Then remove the radiator cap to check the coolant level.
• Page 890
  16–24 COOLING – RADIATOR ASSY (1AZ–FE) RADIATOR ASSY (1AZ–FE) 160MX–01 REPLACEMENT DRAIN COOLANT (See page 16–19) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET REMOVE RADIATOR SUPPORT UPPER Disconnect the fan w/ motor wire harness, connector and the horn connector.
• Page 891
  16–36 COOLING – RADIATOR ASSY (1AZ–FSE) RADIATOR ASSY (1AZ–FSE) 160MS–01 REPLACEMENT DRAIN COOLANT (See page 16–31) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET REMOVE RADIATOR SUPPORT UPPER Disconnect the fan w/ motor wire harness, connector and the horn connector.
• Page 892
  16–51 COOLING – RADIATOR ASSY (1CD–FTV) RADIATOR ASSY (1CD–FTV) 160MG–01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16–44) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE RADIATOR RESERVE TANK ASSY (See page 16–50) DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET REMOVE RADIATOR ASSY Remove the 2 bolts and separate the relay box.
• Page 893
  16–11 COOLING – RADIATOR ASSY (1ZZ–FE/3ZZ–FE) RADIATOR ASSY (1ZZ–FE/3ZZ–FE) 160MK–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) REMOVE ENGINE ROOM COVER SIDE (See page 14–27) ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27) DRAIN ENGINE COOLANT (See page 16–1) DISCONNECT RADIATOR HOSE INLET Disconnect the radiator hose inlet from the radiator.
• Page 894
  16–12 COOLING – RADIATOR ASSY (1ZZ–FE/3ZZ–FE) INSTALL RADIATOR ASSY Upper Hook Align the 2 keyways of the fan shroud with the 2 keys lo- cated on the lower bottom of the radiator and fit them. Install the fan should to the radiator with the 2 upper hooks.
• Page 895
  16–35 COOLING – THERMOSTAT (1AZ–FSE) THERMOSTAT (1AZ–FSE) 160MQ–01 REPLACEMENT DRAIN COOLANT (See page 16–31) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE FAN AND GENERATOR V BELT (See page 14–185) 09249–63010 REMOVE GENERATOR ASSY (See page 19–20) REMOVE WATER INLET…
• Page 896
  16–50 COOLING – THERMOSTAT (1CD–FTV) THERMOSTAT (1CD–FTV) 160MF–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE DRAIN ENGINE COOLANT (See page 16–44) REMOVE RADIATOR RESERVE TANK ASSY Disconnect the water by–pass hose No. 1 and water by–pass hose No. 2. Remove the 2 bolts and the reserve tank assembly.
• Page 897
  16–10 COOLING – THERMOSTAT (1ZZ–FE/3ZZ–FE) THERMOSTAT (1ZZ–FE/3ZZ–FE) 160MJ–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) ENGINE ROOM COVER SIDE (See page 14–27) REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27) DRAIN ENGINE COOLANT (See page 16–1) REMOVE FAN AND GENERATOR V BELT (See page 14–5) REMOVE GENERATOR ASSY…
• Page 898
  16–23 COOLING – THERMOSTAT (1AZ–FE) THERMOSTAT (1AZ–FE) 160MT–01 REPLACEMENT DRAIN COOLANT(See page 16–19) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE FAN AND GENERATOR V BELT (See page 14–105) 09249–63010 REMOVE GENERATOR ASSY (See page 19–20) REMOVE WATER INLET…
• Page 899
  16–21 COOLING – WATER PUMP ASSY (1AZ–FE) WATER PUMP ASSY (1AZ–FE) 160MW–01 REPLACEMENT DRAIN COOLANT (See page 16–19) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE FAN AND GENERATOR V BELT (See page 14–105) 09249–63010 REMOVE GENERATOR ASSY…
• Page 900
  16–22 COOLING – WATER PUMP ASSY (1AZ–FE) INSTALL WATER PUMP ASSY Remove any old packing (FIPG) material from the con- tact surface. Apply seal packing to the water pump as shown in the il- lustration. Seal packing: Part No. 08826 – 00100 or equivalent Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.09 to 0.10 in.) opening.
• Page 901
  16–33 COOLING – WATER PUMP ASSY (1AZ–FSE) WATER PUMP ASSY (1AZ–FSE) 160MR–01 REPLACEMENT DRAIN COOLANT (See page 16–31) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE FAN AND GENERATOR V BELT (See page 14–185) 09249–63010 REMOVE GENERATOR ASSY…
• Page 902
  16–34 COOLING – WATER PUMP ASSY (1AZ–FSE) INSTALL WATER PUMP ASSY Remove any old packing (FIPG) material from the contact surface. Apply seal packing to the water pump as shown in the il- lustration. Seal packing: Part No. 08826 – 00100 or equivalent Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.09 to 0.10 in.) opening.
• Page 903
  16–46 COOLING – WATER PUMP ASSY (1CD–FTV) WATER PUMP ASSY (1CD–FTV) 160ME–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE DRAIN ENGINE COOLANT (See page 16–44) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE UNDER COVER RH REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover.
• Page 904
  16–47 COOLING – WATER PUMP ASSY (1CD–FTV) REMOVE INJECTION PUMP DRIVE PULLEY (See page 11–69) 09960–10010 (09962–01000, 09963–01000), 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05021) REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11–69) REMOVE TIMING BELT IDLER SUB–ASSY NO.1 8 mm Using an 8 mm hexagon wrench, remove the idler pulley Hexagon shaft, the idler pulley and the plate washer.
• Page 905
  16–48 COOLING – WATER PUMP ASSY (1CD–FTV) INSTALL INTAKE MANIFOLD INSULATOR NO.1 (See page 11–69) INSTALL FUEL INLET PIPE SUB–ASSY NOTICE: In case of having the water pump replaced, must re- place fuel inlet pipe, too. When assembling the pipe, perform the operation with the engine cold under room temperature.
• Page 906
  16–49 COOLING – WATER PUMP ASSY (1CD–FTV) SET NO. 1 CYLINDER TO TDC/COMPRESSION 09960–10010 (09962–01000, 09963–01000) INSTALL TIMING BELT (See page 14–307) CHECK VALVE TIMING (See page 14–307) INSTALL TIMING CHAIN COVER PLATE (See page 14–307) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14–307) INSTALL TIMING BELT GUIDE…
• Page 907
  16–9 COOLING – WATER PUMP ASSY (1ZZ–FE/3ZZ–FE) WATER PUMP ASSY (1ZZ–FE/3ZZ–FE) 160MI–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–27) REMOVE ENGINE ROOM COVER SIDE (See page 14–27) REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–27) REMOVE ENGINE UNDER COVER RH (See page 14–27) DRAIN ENGINE COOLANT…
• Page 908
  17–6 LUBRICATION – LUBRICATION SYSTEM (1AZ–FE) LUBRICATION SYSTEM (1AZ–FE) 1700F–09 ON–VEHICLE INSPECTION CHECK ENGINE OIL LEVEL After warm up the engine and then 5 minutes after the engine stop, oil level should be between the low level and full level marks of the dipstick. If low, check for leakage and add oil up to the full level mark.
• Page 909
  17–7 LUBRICATION – LUBRICATION SYSTEM (1AZ–FE) CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm , 4.3 psi) or more At 3,000 rpm 245 to 539 kPa (2.5 to 5.5 kgf/cm , 36 to 78 psi) or more REMOVE OIL PRESSURE GAUGE INSTALL OIL PRESSURE SWITCH ASSY Apply adhesive to 2 or 3 threads of the oil pressure switch.
• Page 910
  17–13 LUBRICATION – LUBRICATION SYSTEM (1AZ–FSE) LUBRICATION SYSTEM (1AZ–FSE) 1700E–07 ON–VEHICLE INSPECTION CHECK ENGINE OIL LEVEL After warm up the engine and then 5 minutes after the engine stop, oil level should be between the low level and full level marks of the dipstick. If low, check for leakage and add oil up to the full level mark.
• Page 911
  17–14 LUBRICATION – LUBRICATION SYSTEM (1AZ–FSE) CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm , 4.3 psi) or more At 3,000 rpm 245 to 539 kPa (2.5 to 5.5 kgf/cm , 36 to 78 psi) or more REMOVE OIL PRESSURE GAUGE INSTALL OIL PRESSURE SWITCH ASSY Apply adhesive to 2 or 3 threads of the oil pressure switch.
• Page 912
  17–20 LUBRICATION – LUBRICATION SYSTEM (1CD–FTV) LUBRICATION SYSTEM (1CD–FTV) 17045–03 ON–VEHICLE INSPECTION CHECK ENGINE OIL LEVEL After warm up the engine and then 5 minutes after the engine stop, oil level should be between the low level and full level marks of the dipstick. If low, check for leakage and add oil up to the full level mark.
• Page 913
  17–21 LUBRICATION – LUBRICATION SYSTEM (1CD–FTV) CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm , 4.3 psi) or more At 4,500 rpm 245 to 588 kPa (2.5 to 6.0 kgf/cm , 36 to 85 psi) or more REMOVE OIL PRESSURE GAUGE INSTALL OIL PRESSURE SWITCH ASSY Adhesive…
• Page 914
  17–1 LUBRICATION – LUBRICATION SYSTEM (1ZZ–FE/3ZZ–FE) LUBRICATION SYSTEM (1ZZ–FE/3ZZ–FE) 1700F–10 ON–VEHICLE INSPECTION CHECK ENGINE OIL LEVEL After warm up the engine and then 5 minutes after the engine stop, oil level should be between the low level and full level marks of the dipstick. If low, check for leakage and add oil up to the full level mark.
• Page 915
  17–2 LUBRICATION – LUBRICATION SYSTEM (1ZZ–FE/3ZZ–FE) CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm , 4.3 psi) or more At 3,000 rpm 294 to 539 kPa (3.0 to 5.5 kgf/cm , 43 to 78 psi) or more REMOVE OIL PRESSURE GAUGE INSTALL OIL PRESSURE SWITCH ASSY Apply adhesive to 2 or 3 threads of the oil pressure switch.
• Page 916
  17–32 LUBRICATION – OIL COOLER ASSY (1CD–FTV) OIL COOLER ASSY (1CD–FTV) 170FQ–01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16–44) DRAIN ENGINE OIL (See page 17–30) REMOVE ENGINE UNDER COVER LH REMOVE OIL COOLER ASSY Disconnect the 2 cooler hoses from the oil cooler. Remove the union bolt and the oil cooler.
• Page 917
  17–12 LUBRICATION – OIL FILTER SUB–ASSY (1AZ–FE) OIL FILTER SUB–ASSY (1AZ–FE) 170FW–01 REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po- tentially harmful contaminants which may cause skin cancer.
• Page 918
  17–19 LUBRICATION – OIL FILTER SUB–ASSY (1AZ–FSE) OIL FILTER SUB–ASSY (1AZ–FSE) 170FV–01 REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po- tentially harmful contaminants which may cause skin cancer.
• Page 919
  17–30 LUBRICATION – OIL FILTER SUB–ASSY (1CD–FTV) OIL FILTER SUB–ASSY (1CD–FTV) 170FO–01 REPLACEMENT NOTICE: Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po- tentially harmful contaminants which may cause skin cancer.
• Page 920
  17–31 LUBRICATION – OIL FILTER SUB–ASSY (1CD–FTV) Fill with fresh engine oil. Capacity: With the oil filter replacement: 5.9 liters (6.2 US qts, 5.2 lmp. qts) Without the oil filter replacement: 5.3 liters (5.6 US qts, 4.7 lmp. qts) Dry fill: 6.7 liters (7.1 US qts, 5.9 lmp. qts) Install the oil filler cap.
• Page 921
  17–4 LUBRICATION – OIL FILTER SUB–ASSY (1ZZ–FE/3ZZ–FE) OIL FILTER SUB–ASSY (1ZZ–FE/3ZZ–FE) 170FS–01 REPLACEMENT CAUTION: Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po- tentially harmful contaminants which may cause skin cancer.
• Page 922
  17–5 LUBRICATION – OIL FILTER SUB–ASSY (1ZZ–FE/3ZZ–FE) INSTALL OIL PAN DRAIN PLUG Clean and install the oil pan drain plug with a new gasket. Torque: 37 N m (377 kgf cm, 27 in. lbf) ADD ENGINE OIL Capacity: With oil filler replacement: 3.7 liters (3.9 US qts, 3.3 lmp. qts) Without oil filler replacement: 3.5 liters (3.7 US qts, 3.1 lmp.
• Page 923
  17–8 LUBRICATION – OIL PUMP ASSY (1AZ–FE) OIL PUMP ASSY (1AZ–FE) 170FU–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN ENGINE OIL Install a new gasket and drain plug after draining engine oil.
• Page 924
  17–9 LUBRICATION – OIL PUMP ASSY (1AZ–FE) REMOVE CRANKSHAFT PULLEY (See page 14–139) 09213–54015 (91651–60855), 09330–00021, 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05021) REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14–139) REMOVE CRANKSHAFT POSITION SENSOR (See page 18–16) REMOVE OIL PAN SUB–ASSY Remove 12 bolts and 2 nuts.
• Page 925
  17–10 LUBRICATION – OIL PUMP ASSY (1AZ–FE) SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14–139) INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL CHAIN SUB–ASSY (See page 14–139) INSTALL TIMING CHAIN GUIDE Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 926
  17–11 LUBRICATION – OIL PUMP ASSY (1AZ–FE) INSTALL ENGINE WIRE Torque: 7.0 N m (71 kgf cm, 62 in. lbf) INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf) INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 927
  17–15 LUBRICATION – OIL PUMP ASSY (1AZ–FSE) OIL PUMP ASSY (1AZ–FSE) 170FX–01 REPLACEMENT DISCHARGE FUEL SYSTEM PRESSURE (See page 11–30) REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN ENGINE OIL Install a new gasket and drain plug after draining engine oil.
• Page 928
  17–16 LUBRICATION – OIL PUMP ASSY (1AZ–FSE) REMOVE CRANKSHAFT PULLEY (See page 14–222) 09213–54015 (91651–60855), 09330–00021, 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05021) REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14–139) REMOVE CRANKSHAFT POSITION SENSOR (See page 18–17) REMOVE OIL PAN SUB–ASSY Remove 12 bolts and 2 nuts.
• Page 929
  17–17 LUBRICATION – OIL PUMP ASSY (1AZ–FSE) SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14–139) INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL CHAIN SUB–ASSY (See page 14–139) INSTALL TIMING CHAIN GUIDE Torque: 9.0 N m (92 kgf cm, 80 in.
• Page 930
  17–18 LUBRICATION – OIL PUMP ASSY (1AZ–FSE) INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf) INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL RETURN TUBE SUB–ASSY Torque: 8.0 N m (82 kgf cm, 71 in.
• Page 931
  17–22 LUBRICATION – OIL PUMP ASSY (1CD–FTV) OIL PUMP ASSY (1CD–FTV) 170FP–01 REPLACEMENT DRAIN ENGINE OIL (See page 17–30) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover.
• Page 932
  17–23 LUBRICATION – OIL PUMP ASSY (1CD–FTV) REMOVE OIL LEVEL GAGE GUIDE Remove the bolt which is used to secure the oil level gage guide to the cylinder block. Pull out the oil level gage guide together with the oil level gage from the No.
• Page 933
  17–24 LUBRICATION – OIL PUMP ASSY (1CD–FTV) REMOVE OIL PAN INSULATOR Remove the bolt and the oil pan insulator. B08009 REMOVE OIL PAN SUB–ASSY Remove the 19 bolts and 3 nuts. A56697 Using a screwdriver, remove the oil pan by prying be- tween the cylinder block and the No.
• Page 934
  17–25 LUBRICATION – OIL PUMP ASSY (1CD–FTV) INSTALL CRANKSHAFT SEAL Using SST and a hammer, tap in a new oil seal until its sur- face is flush with the oil pump edge. 09316–60011 (09316–00011, 09316–00021) A56700 INSTALL OIL PUMP ASSY Remove any old packing (FIPG) and be careful not to drop any oil on the contact surfaces of the oil pump and the cylinder block.
• Page 935
  17–26 LUBRICATION – OIL PUMP ASSY (1CD–FTV) Install the oil pump with the 9 bolts. Torque: 31 N m (320 kgf cm, 23 ft lbf) A57099 Measure the oil pump rotating torque. Check that the pump rotates smoothly without noise. Using a torque wrench, check the pump rotating torque.
• Page 936
  17–27 LUBRICATION – OIL PUMP ASSY (1CD–FTV) Apply a seal packing to the No. 1 oil pan as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent Install a nozzle that has been cut to a 4 to 7 mm (0.16 to 0.28 in.) opening.
• Page 937
  17–28 LUBRICATION – OIL PUMP ASSY (1CD–FTV) Using a non–residue solvent, clean both the sealing surfaces. NOTICE: Do not use a solvent, which will affect the painted surfaces. Apply a seal packing to the oil pan as shown in the illustra- tion.
• Page 938
  17–29 LUBRICATION – OIL PUMP ASSY (1CD–FTV) INSTALL CRANKSHAFT TIMING PULLEY Align the keyway of the timing pulley with the key located Inward on the camshaft, slide the pulley into place. Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
• Page 939
  17–3 LUBRICATION – OIL PUMP ASSY (1ZZ–FE/3ZZ–FE) OIL PUMP ASSY (1ZZ–FE/3ZZ–FE) 170FR–01 REPLACEMENT DRAIN ENGINE OIL Remove the oil pan drain plug and drain engine oil. REMOVAL & INSTALLATION CHAIN SUB–ASSY (See page 14–49) REMOVE CHAIN VIBRATION DAMPER NO.1 Remove the 2 bolts and the chain vibration damper No. 1. REMOVE OIL PUMP ASSY Remove the 5 bolts.
• Page 940
  18–16 IGNITION – CAMSHAFT POSITION SENSOR (1AZ–FE/1AZ–FSE) CAMSHAFT POSITION SENSOR (1AZ–FE/1AZ–FSE) 1807K–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) REMOVE CAMSHAFT POSITION SENSOR Disconnect the camshaft position sensor connector. Remove the bolt, and then remove the camshaft position sensor.
• Page 941
  18–5 IGNITION – CAMSHAFT POSITION SENSOR (1ZZ–FE/3ZZ–FE) CAMSHAFT POSITION SENSOR (1ZZ–FE/3ZZ–FE) 1807I–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–9) REMOVE CYLINDER HEAD COVER NO.2 (See page 10–9) REMOVE CAMSHAFT POSITION SENSOR Disconnect the camshaft position sensor connector. Remove the bolt, and then remove the camshaft position sensor.
• Page 942
  18–17 IGNITION – CRANKSHAFT POSITION SENSOR (1AZ–FE/1AZ–FSE) CRANKSHAFT POSITION SENSOR (1AZ–FE/1AZ–FSE) 1807L–01 REPLACEMENT REMOVE ENGINE UNDER COVER LH (See page 19–20) REMOVE ENGINE UNDER COVER RH (See page 19–20) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) REMOVE ENGINE ROOM COVER SIDE (See page 10–26) REMOVE FAN AND GENERATOR V BELT…
• Page 943
  18–6 IGNITION – CRANKSHAFT POSITION SENSOR (1ZZ–FE/3ZZ–FE) CRANKSHAFT POSITION SENSOR (1ZZ–FE/3ZZ–FE) 1807J–01 REPLACEMENT REMOVE ENGINE UNDER COVER LH (See page 19–20) REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 10–17) REMOVE ENGINE UNDER COVER RH (See page 19–20) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–9) REMOVE ENGINE ROOM COVER SIDE…
• Page 944
  18–7 IGNITION – IGNITION SYSTEM (1AZ–FE) IGNITION SYSTEM (1AZ–FE) 1807M–01 ON–VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in this section mean the temperature of the coils themselves.”Cold” is from –10_C (14_F) to 50 _C (122 _F) and ”Hot” is from 50 _C (122 _F) to 100 _C (212 _F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check for DTCs.
• Page 945
  18–8 IGNITION – IGNITION SYSTEM (1AZ–FE) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 19 N m (194 kgf cm, 14 ft lbf) Install the ignition coil with igniter. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) Install the cylinder head cover No.
• Page 946
  18–9 IGNITION – IGNITION SYSTEM (1AZ–FE) 1807N–01 INSPECTION INSPECT SPARK PLUG (EXCEPT EUROPE) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner then dry it. Air pressure: Below 588 kPa (6kg/cm , 85 psi) Duration: 20 seconds or less A50033…
• Page 947
  18–10 IGNITION – IGNITION SYSTEM (1AZ–FE) Alternative inspection: Quickly accelerate the engine to 4,000 rpm 5 times. Remove the spark plug. Visually check the spark plug. If the electrode is dry…OK. If the electrode is wet…Proceed to step (C). Reinstall the spark plug. B01301 Check the spark plug for any damage on its thread and insulator.
• Page 948
  18–11 IGNITION – IGNITION SYSTEM (1AZ–FE) INSPECT CRANKSHAFT POSITION SENSOR Using an ohmmeter, measure the resistance between the terminals. RESISTANCE: 985 to 1,600 W at cold 1,265 to 1,890 W at hot NOTICE: ”Cold” and ”Hot” mean the temperature of the coils themselves.”Cold” is from – 10_C (14_F) to 50 _C (122 _F) and ”Hot”…
• Page 949
  18–12 IGNITION – IGNITION SYSTEM (1AZ–FSE) IGNITION SYSTEM (1AZ–FSE) 1807Q–01 ON–VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in this section mean the temperature of the coils themselves.”Cold” is from –10_C (14_F) to 50 _C (122 _F) and ”Hot” is from 50 _C (122 _F) to 100 _C (212 _F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check for DTCs.
• Page 950
  18–13 IGNITION – IGNITION SYSTEM (1AZ–FSE) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 19 N m (194 kgf cm, 14 ft lbf) Install the ignition coil with igniter. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) Install the cylinder head cover No.
• Page 951
  18–14 IGNITION – IGNITION SYSTEM (1AZ–FSE) 1807R–01 INSPECTION INSPECT SPARK PLUG NOTICE: Do not use a wire brush for cleaning. Do not attempt to adjust the electrode gap of a used spark plug. Spark plug should be replaced every 100,000 km (60,000 miles).
• Page 952
  18–15 IGNITION – IGNITION SYSTEM (1AZ–FSE) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) 1.0 to 1.1 mm A78640…
• Page 953
  18–1 IGNITION – IGNITION SYSTEM (1ZZ–FE/3ZZ–FE) IGNITION SYSTEM (1ZZ–FE/3ZZ–FE) 1807O–01 ON–VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in this section mean the temperature of the coils themselves.”Cold” is from –10_C (14_F) to 50 _C (122 _F) and ”Hot” is from 50 _C (122 _F) to 100 _C (212 _F). INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check for DTCs.
• Page 954
  18–2 IGNITION – IGNITION SYSTEM (1ZZ–FE/3ZZ–FE) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 18 N m (184 kgf cm, 13 ft lbf) Install the ignition coil with igniter. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) Install the cylinder head cover No.
• Page 955
  18–3 IGNITION – IGNITION SYSTEM (1ZZ–FE/3ZZ–FE) 1807P–01 INSPECTION INSPECT SPARK PLUG Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner then dry it. Air pressure: Below 588 kPa (6kg/cm , 85 psi) Duration: 20 seconds or less A50033…
• Page 956
  18–4 IGNITION – IGNITION SYSTEM (1ZZ–FE/3ZZ–FE) INSPECT CRANKSHAFT POSITION SENSOR Using an ohmmeter, measure the resistance between the terminals. RESISTANCE: 1,630 to 2,740 ( at cold 2,065 to 3,225 ( at hot NOTICE: ”Cold” and ”Hot” mean the temperature of the coils themselves.”Cold” is from – 10YC (14YF) to 50 YC (122 YF) and ”Hot”…
• Page 957
  19–14 STARTING & CHARGING – CHARGING SYSTEM (1AZ–FE) CHARGING SYSTEM (1AZ–FE) 190NV–01 PRECAUTION Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.
• Page 958
  19–15 STARTING & CHARGING – CHARGING SYSTEM (1AZ–FE) 190NW–01 ON–VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.
• Page 959
  19–16 STARTING & CHARGING – CHARGING SYSTEM (1AZ–FE) Check that it fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. B00540 VISUALLY CHECK GENERATOR WIRING Check that the wiring is in good condition.
• Page 960
  19–17 STARTING & CHARGING – CHARGING SYSTEM (1AZ–FSE) CHARGING SYSTEM (1AZ–FSE) 190NS–01 PRECAUTION Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.
• Page 961
  19–18 STARTING & CHARGING – CHARGING SYSTEM (1AZ–FSE) 190NT–01 ON–VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.
• Page 962
  19–19 STARTING & CHARGING – CHARGING SYSTEM (1AZ–FSE) Check that it fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. B00540 VISUALLY CHECK GENERATOR WIRING Check that the wiring is in good condition.
• Page 963
  19–25 STARTING & CHARGING – CHARGING SYSTEM (1CD–FTV) CHARGING SYSTEM (1CD–FTV) 190NM–01 PRECAUTION Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.
• Page 964
  19–26 STARTING & CHARGING – CHARGING SYSTEM (1CD–FTV) 190NN–01 ON–VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.
• Page 965
  19–27 STARTING & CHARGING – CHARGING SYSTEM (1CD–FTV) INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. HINT: If any defect found, replace the drive belt. Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
• Page 966
  19–28 STARTING & CHARGING – CHARGING SYSTEM (1CD–FTV) HINT: If the voltmeter reading is more than standard voltage, re- place the voltage regulator. If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows: INSPECT CHARGING CIRCUIT WITH LOAD Keep the engine speed at 2,000 rpm, turn on the high beam headlights and turn the heater blower switch to the ”HI”…
• Page 967
  19–4 STARTING & CHARGING – CHARGING SYSTEM (1ZZ–FE/3ZZ–FE) CHARGING SYSTEM (1ZZ–FE/3ZZ–FE) 190NP–01 PRECAUTION Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.
• Page 968
  19–5 STARTING & CHARGING – CHARGING SYSTEM (1ZZ–FE/3ZZ–FE) 190NQ–01 ON–VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.
• Page 969
  19–6 STARTING & CHARGING – CHARGING SYSTEM (1ZZ–FE/3ZZ–FE) Check that it fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. B00540 VISUALLY CHECK GENERATOR WIRING Check that the wiring is in good condition.
• Page 970
  19–20 STARTING & CHARGING – GENERATOR ASSY (1AZ–FE/1AZ–FSE) GENERATOR ASSY (1AZ–FE/1AZ–FSE) 190NK–01 REPLACEMENT REMOVE ENGINE UNDER COVER LH Remove the 6 screws and 5 clips, and then remove the engine under cover. A78515 REMOVE ENGINE UNDER COVER RH Remove the 6 screws and the 3 clips, and then remove the engine under cover.
• Page 971
  19–21 STARTING & CHARGING – GENERATOR ASSY (1AZ–FE/1AZ–FSE) Remove the 2 bolts, and then remove the generator. A77905 Remove the bolt, and then remove the wire harness clamp bracket. A77906 INSTALL GENERATOR ASSY Install the wire harness clamp bracket wire the bolt. Torque: 8.4 N m (86 kgf cm, 74 in.
• Page 972
  19–29 STARTING & CHARGING – GENERATOR ASSY (1CD–FTV) GENERATOR ASSY (1CD–FTV) 190O1–01 REPLACEMENT REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 REMOVE ENGINE UNDER COVER RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14–269) REMOVE GENERATOR V BELT…
• Page 973
  19–7 STARTING & CHARGING – GENERATOR ASSY (1ZZ–FE/3ZZ–FE) GENERATOR ASSY (1ZZ–FE/3ZZ–FE) 190NI–01 REPLACEMENT REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 10–17) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–9) REMOVE ENGINE ROOM COVER SIDE (See page 10–9) REMOVE FAN AND GENERATOR V BELT (See page 14–5) REMOVE GENERATOR ASSY…
• Page 974
  19–33 STARTING & CHARGING – GLOW PLUG ASSY (1CD–FTV) GLOW PLUG ASSY (1CD–FTV) 190O2–01 REPLACEMENT REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE GLOW PLUG ASSY Remove the 5 grommets. Remove the 5 nuts and the glow plug connector. Remove the 4 glow plugs.
• Page 975
  19–30 STARTING & CHARGING – PRE–HEATING SYSTEM (1CD–FTV) PRE–HEATING SYSTEM (1CD–FTV) 190JE–02 ON–VEHICLE INSPECTION NOTICE: Turn the ignition switch OFF for 60 seconds before performing the following inspections. INSPECT LIGHTING DURATION OF GLOW INDICA- (sec.) Light Lightning Time TOR LIGHT Turn the ignition switch ON, and measure the lighting duration.
• Page 976
  19–31 STARTING & CHARGING – PRE–HEATING SYSTEM (1CD–FTV) INSPECT GLOW PLUGS Ohmmeter Using an ohmmeter, check that there is continuity be- tween the glow plug terminal and ground. Standard resistance: Approx. 0.72 f at 20_C (68_F) NOTICE: Be careful not to damage the glow plug pipes as it Continuity could cause an open circuit or shorten life of the glow plugs.
• Page 977
  19–32 STARTING & CHARGING – PRE–HEATING SYSTEM (1CD–FTV) 190JF–02 INSPECTION INSPECT GLOW PLUG RELAY ASSY Using an ohmmeter, check for continuity between each terminal. Specified condition: No continuity 1 – 2 Continuity (Apply battery voltage terminals 3 and 4) A34838 AVENSIS REPAIR MANUAL (RM1018E) http://vnx.su…
• Page 978
  19–12 STARTING & CHARGING – STARTER ASSY (1AZ–FE/1AZ–FSE) STARTER ASSY (1AZ–FE/1AZ–FSE) 190NJ–01 REPLACEMENT REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) REMOVE BATTERY CLAMP SUB–ASSY REMOVE BATTERY REMOVE BATTERY TRAY REMOVE BATTERY CARRIER Remove the 4 bolts, and then remove the battery carrier. A77898 REMOVE STARTER ASSY Terminal Cap Cover…
• Page 979
  19–13 STARTING & CHARGING – STARTER ASSY (1AZ–FE/1AZ–FSE) INSTALL STARTER ASSY Install the wire harness clamp bracket with the bolt. Torque: 8.4 N m (86 kgf cm, 74 in. lbf) Install the starter with the 2 bolts. Torque: 37 N m (380 kgf cm, 28 ft lbf) Connect the starter connector.
• Page 980
  19–24 STARTING & CHARGING – STARTER ASSY (1CD–FTV) STARTER ASSY (1CD–FTV) 190O0–01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16–44) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE RADIATOR RESERVE TANK ASSY (See page 16–50) REMOVE AIR CLEANER ASSY (See page 14–286) REMOVE BATTERY REMOVE STARTER ASSY Remove the nut and disconnect terminal 30.
• Page 981
  19–3 STARTING & CHARGING – STARTER ASSY (1ZZ–FE/3ZZ–FE) STARTER ASSY (1ZZ–FE/3ZZ–FE) 190NH–01 REPLACEMENT REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 10–17) REMOVE STARTER ASSY Terminal Disconnect the starter connector. Cap Cover Open the terminal cap cover. Remove the nut and disconnect the starter wire. A78485 Remove the 2 bolts, and then remove the starter.
• Page 982
  19–8 STARTING & CHARGING – STARTING SYSTEM (1AZ–FE) STARTING SYSTEM (1AZ–FE) 190NU–01 INSPECTION INSPECT STARTER ASSY Terminal 50 NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Do pull–in test Disconnect the field coil lead wire from terminal C. Connect the battery to the magnetic switch as shown in the illustration on the left.
• Page 983
  19–9 STARTING & CHARGING – STARTING SYSTEM (1AZ–FE) Do no–load performance test Terminal 30 Connect the field coil lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 N m (60 kgf cm, 52 in lbf) Clamp the starter in a vise.
• Page 984
  19–10 STARTING & CHARGING – STARTING SYSTEM (1AZ–FSE) STARTING SYSTEM (1AZ–FSE) 190NR–01 INSPECTION INSPECT STARTER ASSY Terminal 50 NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Do pull–in test Disconnect the field coil lead wire from terminal C. Connect the battery to the magnetic switch as shown in the illustration on the left.
• Page 985
  19–11 STARTING & CHARGING – STARTING SYSTEM (1AZ–FSE) Do no–load performance test Terminal 30 Connect the field coil lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 N m (60 kgf cm, 52 in lbf) Clamp the starter in a vise.
• Page 986
  19–22 STARTING & CHARGING – STARTING SYSTEM (1CD–FTV) STARTING SYSTEM (1CD–FTV) 190NL–01 INSPECTION INSPECT STARTER ASSY NOTICE: Terminal 50 These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Do pull–in test Disconnect the field coil lead wire from terminal C. Connect the battery to the magnetic switch as shown in the illustration on the left.
• Page 987
  19–23 STARTING & CHARGING – STARTING SYSTEM (1CD–FTV) Do no–load performance test Terminal 30 Connect the field coil lead wire to terminal C. Make Terminal 50 sure that the lead is not grounded. Torque: 5.9 N m (60 kgf cm, 52 in lbf) Clamp the starter in a vise.
• Page 988
  19–1 STARTING & CHARGING – STARTING SYSTEM (1ZZ–FE/3ZZ–FE) STARTING SYSTEM (1ZZ–FE/3ZZ–FE) 190NO–01 INSPECTION INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Do pull–in test Disconnect the field coil lead wire from terminal C. Connect the battery to the magnetic switch as shown in the illustration on the left.
• Page 989
  19–2 STARTING & CHARGING – STARTING SYSTEM (1ZZ–FE/3ZZ–FE) Do no–load performance test Connect the field coil lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 N m (60 kgf cm, 52 in lbf) Clamp the starter in a vise. Connect the battery and an ammeter to the starter as shown in the illustration.
• Page 990
  26–10 FRONT SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING FRONT SHOCK ABSORBER WITH COIL SPRING 2600M–04 OVERHAUL HINT: COMPONENTS: See page 26–2 This procedure is provided for the overhaul on the LH side. Overhaul the other side by the same proce- dure as the LH side.
• Page 991
  26–11 FRONT SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING FIX FRONT SHOCK ABSORBER WITH COIL SPRING Install 2 nuts and a bolt to the bracket at the lower side of the shock absorber and secure it in a vise. 28mm F44963 REMOVE FRONT SUSPENSION SUPPORT DUST COVER LH…
• Page 992
  26–12 FRONT SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING INSPECT SHOCK ABSORBER ASSY FRONT LH Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation. If there is any abnormality, replace the shock absorber with a new one.
• Page 993
  26–13 FRONT SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING INSTALL FRONT SUSPENSION SUPPORT LH DUST SEAL Install a new dust seal. INSTALL FRONT SUSPENSION SUPPORT SUB–ASSY LH INSTALL FRONT SUPPORT TO FRONT SHOCK ABSORBER LH NUT Using SST to hold the suspension support, install a new nut.
• Page 994
  26–14 FRONT SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING Install the flexible hose and ABS speed sensor wire har- ness bracket with the bolt. Torque: 19 N m (192 kgf cm, 14 ft lbf) C80880 INSTALL FRONT STABILIZER LINK ASSY LH Install the stabilizer bar link with the nut.
• Page 995
  26–15 FRONT SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING 2600N–04 DISPOSAL HINT: Dispose the RH side by the same procedures as the LH side. DISPOSE OF SHOCK ABSORBER ASSY FRONT LH Fully extend the shock absorber rod. Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside.
• Page 996
  26–2 FRONT SUSPENSION – FRONT SUSPENSION FRONT SUSPENSION 260DP–01 COMPONENTS 39 (398, 29) Front Shock Absorber with Coil Spring Front Stabilizer Link Assy LH Front Suspension Support Dust Cover LH 74 (755, 55) 19 (194, 14) Front Suspension Support Sub–assy LH 47 (479, 35) Front Suspension 220 (2,240, 162)
• Page 997
  26–3 FRONT SUSPENSION – FRONT SUSPENSION 49 (500, 36) Rack & Pinion Power Steering Gear Assy Engine Mounting Member Sub–assy Center Tie Rod End Sub–assy LH Transverse Engine Engine Mounting Insulator Front Stabilizer Link Assy RH Front Stabilizer Link Assy LH Front Suspension Crossmember Sub–assy Front Suspension…
• Page 998
  26–4 FRONT SUSPENSION – FRONT SUSPENSION 220 (2,240, 162) Front Shock Absorber with Coil Spring Speed Sensor Front LH Front Drive Shaft Assy LH 8 (82, 71 in. lbf) Cotter Pin 49 (500, 36) 102 (1,040, 75) Tie Rod End Sub–assy LH Cotter Pin Front Disc…
• Page 999
  26–5 FRONT SUSPENSION – FRONT SUSPENSION 49 (500, 36) w/ HID: 49 (500, 36) 5.4 (55, 48 in. lbf) Rack & Pinion 19 (194, 14) Power Steering Gear Assy Tie Rod End HID Height Sub–assy LH Control Sensor 19 (194, 14) Front Stabilizer 19 (194, 14) Bracket No.1 LH…
• Page 1000
  26–16 FRONT SUSPENSION – FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH (ATM) FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH (ATM) 260DQ–01 REPLACEMENT HINT: COMPONENTS: See page 26–2 Replace the RH side (Engine: 1AZ) by the same procedures as the LH (ATM) side. Replace the RH side (Engine: 1ZZ) by the same procedures as the LH (MTM) side.
• Page 1001
  26–17 FRONT SUSPENSION – FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH (ATM) REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH Support the front suspension crossmember sub–assy with a transmission jack. Remove the 4 bolts and front suspension member brace rear LH. Remove the front suspension member body mounting stopper rear from the front suspension member brace rear LH.