TOYOTA AVENSIS 2005 Service Repair Manual

A77317
Intake ManifoldIgnition Coil
Ventilation Hose No. 2
Ventilation Hose
Unleaded type:
Manifold Converter
Insulator No. 1 Intake Manifold Insulator
No. 1
V±ribbed Belt
Tensioner ASSY
Unleaded type:
Exhaust Manifold
Converter Sub±assy
Exhaust Manifold Stay
Exhaust Manifold
Stay No. 2 Manifold Converter
Insulator No. 1
Exhaust Manifold
Converter Sub±assy
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
9.0 (92, 80 in.
lbf)

Gasket
Gasket
12 (122, 9.0)
12 (122, 9.0)
37 (378, 27)
44 (449, 32)
44 (449, 32)
44 (449, 32)

Gasket
Leaded type:
30 (306, 22)
30 (306, 22)
30 (306, 22)
12 (122, 9.0)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
14±119
AVENSIS REPAIR MANUAL (RM1018E)

A79295
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
5.0 (50, 43 in.
lbf)

O±ring

Gasket
Gasket
Gasket
Gasket

O±ring
15 (153, 11)
20 (204, 15)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
Fuel Delivery Pipe
w/ Injector
Oil Control Valve
Knock Control SensorSpacer
Water By±pass Pipe No. 1
Oil Level Gauge
Sub±assy
Oil Level Gauge Guide
Water Inlet
9.0 (92, 79 in.
lbf)Engine Oil Pressure Switch Assy
Water Temperature Sensor
Thermostat
9.0 (92, 80 in.
lbf)
19 (194, 14)
19 (194, 14)
20 (204, 15)
14±120
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

141B6±01
A77281
A77378
No. 1 Cylinder TDC/Compression
IN
EX
A77379
No. 4 Cylinder TDC/Compression
IN
EX
14±106
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1AZ±FE)
ADJUSTMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.REMOVE ENGINE UNDER COVER RH 4.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
5.REMOVE IGNITION COIL ASSY
(a)Remove 4 bolts and the ignition coils.
6.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±171)
7.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±171) 8. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
(b) Turn the crankshaft clockwise 1 revolution (360
) and set
No. 4 cylinder to TDC/compression.
(c) Check only the valve indicated in the illustration. (1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)

A01082
EXAMPLE: (Intake)
Measure valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) ± 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in\
.)
(Measured ± Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)\

(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. º50º
A77295
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FE)
14±107
AVENSIS REPAIR MANUAL (RM1018E)
9.ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to turn the crankshaft without the chain ten-
sioner.
(a)Set the No. 1 cylinder to TDC/compression.
(See page 14±171)
(b)Remove the chain tensioner. (See page 14±171)
(c)Remove the camshafts. (See page 14±171)
(d) Tie the timing chain with a string.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(e) Remove the valve lifters.
(f) Using a micrometer, measure the thickness of the re-
moved lifter.
(g) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified valve.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Valve clearance:
Intake: A = B + (C ± 0.24 mm (0.0094 in.))
Exhaust: A = B + (C ± 0.35 mm (0.0138 in.))
HINT:

Select a new lifter with a thickness as close as possible
to the calculated valves.

Lifter are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).

Identification number inside the valve lifter shows the val-
ue of the 2 decimal places. (The illustration shows 5.380
mm (0.2118 in.))

Refer to the New Lifter Thickness table on the next 2
pages.

A77296
mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Intake)
Intake valve clearance (Cold):
0.19 to 0.29 mm (0.008 to 0.011 in.)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter is installed, and
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter.
New Lifter Thickness
14±108
± ENGINE MECHANICALVALVE CLEARANCE (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A77297
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.30 to 0.40 mm (0.0118 to 0.0157 in.)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter is installed, and
the measured clearance is 0.440 mm (0.0173 in.).
Replace the 5.340 mm (0.2102 in.) lifter with a new No. 44 lifter.
± ENGINE MECHANICALVALVE CLEARANCE (1AZ±FE)
14±109
AVENSIS REPAIR MANUAL (RM1018E)

14±110
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(h)Install the camshafts. (See page 14±171)
(i)Install the chain tensioner. (See page 14±171)
10.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±171)
11. INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
12. CHECK FOR ENGINE OIL LEAKS
13. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

141B5±01
A77293
SST
± ENGINE MECHANICALFAN AND GENERATOR V BELT (1AZ±FE)
14±105
AVENSIS REPAIR MANUAL (RM1018E)
FAN AND GENERATOR V BELT (1AZ±FE)
REPLACEMENT
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE ROOM COVER SIDE
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FAN AND GENERATOR V BELT
(a) Using SST, loosen the V±ribbed belt tensioner arm clock-
wise, and remove the fan and generator V belt.
SST 09249±63010
5. INSTALL FAN AND GENERATOR V BELT
(a) Using SST, loosen the V±ribbed belt tensioner arm clockwise, and install the fan and generator V belt.
SST 09249±63010

140D1±02
CG
TCA51075
A52004
±
ENGINE MECHANICAL ENGINE(1AZ±FE)
14±101
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±13)
2.INSPECT ENGINE OIL (See page 17±6)
3. INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±9)
6. INSPECT V±RIBBED BELT
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using hand±held tester:(1) Connect the hand±held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF.
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) 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.

TA C
A52006
A13304
14±102
± ENGINE MECHANICALENGINE (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 15 BTDC
(7) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
Idle speed: 650 to 750 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester.
(1) Using SST, connect the tachometer test prove to
terminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 650 to 750 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.
(e) Inspect cylinder compression pressure.
SST 09992±00500
(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.