TOYOTA AVENSIS 2005 Service Repair Manual

A12816
A76692
A62178
Push
A10076
A30848
14±52
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and the transverse engine engine
mounting bracket.
21. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts which are used to secure the crank-
shaft position sensor.
22. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and the chain tensioner.
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
23. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 11 bolts and nuts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying between the cyl-
inder head and the cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the timing chain cover, the cylin-
der head and the cylinder block.
24. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.
25. REMOVE CRANKSHAFT POSITION SENSOR PLATE
NO.1
26. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and the chain tensioner slipper.

A30857
A10079
A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
A62172
SST
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±53
AVENSIS REPAIR MANUAL (RM1018E)
27. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain with the crankshaft timing gear
by plying it 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 for valves not to touch the pistons.
28. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the camshafts with a wrench and align the
point marks of the camshaft timing sprockets.
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain to the crankshaft timing sprocket
with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
HINT:
Three yellow color links are on the chain.
(c) Using SST, install the crankshaft timing sprocket.
SST 09223±22010

A62173
Yellow Color Link
Timing Mark
A30867
A62174
SST
A62175
Seal Width
4 to 5 mm
Seal Packing
14±54
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Install the timing chain to the camshaft timing sprockets
with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
29. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
30. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing outward.
31. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to a new oil seal lip.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip free of foreign objects.
32. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing (FIPG) material from the contact
surface.

A65676
Timing Chain Cover side:
3 (0.118)3 (0.118)
A
ABB
C
C
7 (0.276)
4.5 (0.177)
12 (0.472)6 (0.236)
3 (0.118)
Width 4 (0.157)
A ± AB ± B
C ± C
08826±00100 or equivalent
08826±00080 or equivalent
(mm (in.))
A65677
A
A
AA
A
A
AAA B
B
B
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±55
AVENSIS REPAIR MANUAL (RM1018E)
(b) Apply a continuous bead of seal packing (Diameter 3.5
mm to 4.5 mm (0.1379 to 0.177 in.)) as shown in the il-
lustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent.
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal to engine oil within 2 hours af-
ter installing.
(c) 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
(d) Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.5 N
m (97 kgf
cm, 84 in.
lbf)

A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
A12816
A11858
14±56
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
33.INSTALL CHAIN TENSIONER ASSY NO.1
(a)Check that the O±ring is clean, and set the hook as shown in the illustration.
(b)Apply engine oil to the chain tensioner and install it with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
34.INSTALL CRANKSHAFT POSITION SENSOR
(a)Apply a coat of the engine oil to the O±ring of the crank- shaft position sensor.
(b)Install the crankshaft position sensor with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
35.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a)Install the transverse engine engine mounting bracket with the 3 bolts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
36.INSTALL WATER PUMP ASSY(See page 16±9)
37. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt

A62837SST
A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A62182
Seal Packing
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±57
AVENSIS REPAIR MANUAL (RM1018E)
38. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, and slide the pulley into place.
(b) Using SST, install the crankshaft pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
Torque: 138 N
m (1,407 kgf
cm, 102 ft
lbf)
(c) Turn the crankshaft counterclockwise, and take the hook
off the knock pin to release the plunger.
(d) Turn the crankshaft clockwise, and check that the plunger
is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
39. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old pacing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.

A65687
AAA
A
A
A
A
A
A
BB
A64005
A64023
A76713
14±58
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c)Install the cylinder head cover and 3 cable brackets with the 9 bolts, 2 seal washers and 2 nuts. Tighten the bolts
and nuts uniformly in the several steps.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for A
9.0 N
m (92 kgf
cm, 80 in.
lbf) for B
40.INSTALL ENGINE MOUNTIN G INSULATOR
SUB±ASSY RH
(a)Install the engine mounting insulator with the 4 bolts and 2 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
41.INSTALL IGNITION COIL ASSY
(a)Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(b)Install the engine wire with the 2 nuts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
42.INSTALL GENERATOR ASSY (See page 19±7)

A79324
A78459
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1ZZ±FE/3ZZ±FE)
14±59
AVENSIS REPAIR MANUAL (RM1018E)
43.INSTALL V±RIBBED IDLER ASSY NO.1
(a)Install the tube and idler with the nut and bolt.
Torque: 39.2 N
m (400 kgf
cm, 29 ft
lbf)
44.INSTALL CYLINDER HEAD COVER NO.2
(a)Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
45.INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
46.ADD ENGINE COOLANT(See page 16±7)
47.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
48. CHECK FOR ENGINE OIL LEAKS

141CH±01
A79321
Clip
Engine Room Side Cover RH
Retainer Clip
Radiator Cover Assy
Clip
Engine Under Cover RH
Engine Under Cover No. 1
Clip
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±45
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS

A76708
Fan and Generator V Belt
V±Ribbed Idler Assy No. 1
Generator Assy Terminal Cap
No. 1
Cylinder Head Cover No. 2 Clip
Engine Mounting
Insulator RH
N´m (kgf´cm, ft´lbf) : Specified torque
54 (551, 40)
25 (255, 18)
39.2 (400, 29)
7.0 (71, 62 in.
lbf)52 (530, 38)
52 (530, 38)
9.8 (100, 7)
Tube 14±46
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)