TOYOTA AVENSIS 2005 Service Repair Manual

A7740612 3
4 109
8 56 7
A77407
Overall Length
A77408
Lot No.
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±259
AVENSIS REPAIR MANUAL (RM1018E)
59. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 10 cylinder head bolts,
with 10 mm bi±hexagon wrench uniformly in the se-
quence shown in the illustration.
(b) Remove 10 cylinder head bolts and plate washers.
NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cranking could result from remov-
ing bolts and installing incorrect order.
60. REMOVE CYLINDER HEAD GASKET
61. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of the cylin-
der head set bolts from the seat to the end.
Standard bolt length:
161.3 to 162.3 mm (6.350 to 6.390 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the cylinder head
set bolts.
62. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
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.
63. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head set bolts are tightened in 2 successive steps.

A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
12.5 to 1.5 mm
A7741012
3
4
10 9
85
67
A00976A77411
90
Engine
Front Paint Mark
14±260
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(a)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:

Remove any oil from contact surface.

Install the cylinder head within 3 minutes after apply-
ing seal packing.

After installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.

Do not start the engine within 2 hours after installing.
(b)Apply a light coat of engine oil on the threads of the cylin- der head bolts.
(c)Install bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d)Using several steps, install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi±hexagon
wrench uniformly, in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e)Mark the front side of the cylinder head set bolts with paint.
(f)Retighten the cylinder head set bolts by 90  in the same
sequence as a step (d).
(g)Check that each paint mark is now at a 90  angle to the
front.
64.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a)Install a light coat of the engine oil to the new O±ring and install \
it to the oil control valve.
(b)Install the oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm,79 in.
lbf)
65.INSTALL CAMSHAFT (See page 14±240)
66.INSTALL NO.2 CAMSHAFT (See page 14±240)

A77332
23
145
A77350
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
14±261
AVENSIS REPAIR MANUAL (RM1018E)
67.INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a)Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(b)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)
68.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
69.INSTALL INTAKE AIR CONTROL VALVE ASSY
(a)Install a new gasket and the intake air control valve.
70.INSTALL INTAKE MANIFOLD
(a)Install the 2 stud bolts. Torque: 10 N
m (97 kgf
cm,84 in.
lbf)
(b)Install the intake manifold and insulator with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
71.INSTALL THROTTLE BODY ASSY (See page 10±44)
72. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
73. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
74.INSTALL CHAIN SUB±ASSY (See page 14±222)
75. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
76. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 N
m (195 kgf
cm, 15 ft
lbf)
77.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±240)
78.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±222)
79.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±222)
80.INSTALL OIL PAN SUB±ASSY (See page 14±222)
81.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
82.INSTALL CRANKSHAFT PULLEY (See page 14±222) SST 09213±54015 (91651±60855), 09330±00021
83.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±222)
84. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
85.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)

14±262
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

141BN±01
A77310
Engine Room
Cover Side
Radiator Support
Opening CoverEngine Cover Sub±assy No. 1
Fan and Generator V Belt
Engine Under Cover RH
Engine Under Cover LH
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
N´m (kgf´cm, ft´lbf)
: Specified torque 14±246
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
CYLINDER HEAD GASKET (1AZ±FSE)
COMPONENTS

A77319
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
GasketCooler Bracket
(LHD Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant Suction Hose No. 1
(LHD Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator Assy
Exhaust Pipe Assy Front
43 (440, 32)
43 (440, 32)
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
52 (530, 38)
Vane Pump Assy

Gasket
8.0 (82, 44 in.
lbf)
37 (377, 38)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±247
AVENSIS REPAIR MANUAL (RM1018E)

A77373
Throttle Body Assy
Water By±pass Hose No. 2
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Water By±pass
Hose No. 1
Throttle Body Bracket
8.0 (82, 71 in.
lbf)
8.4 (86, 74 in.
lbf)
Heater Inlet Water Hose
Union to Connector Tube Hose
Radiator Hose Inlet
Fuel Tube Sub±assy
Fuel Pipe Clamp
5.0 (51, 44 in.
lbf)
Air Cleaner Assembly
with Hose
5.0 (51, 44 in.
lbf)
Battery Clamp
Battery
Battery Tray 14±248
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A77374
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Cylinder Head Cover Sub±assy
11 (115, 8.0)
Ventilation Hose No. 1
Gasket
Fuel Tube Sub±assy
Gasket Fuel Pipe
Sub±assy No. 1
Fuel Pressure
Pulsation Damper
Assy
Fuel Pump Assy

Gasket14 (143, 10)
Ignition Control
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)

O±ring
Ventilation Hose No. 2
33 (331, 24)
25 (255, 18)
Fuel Pipe No. 1

Fuel Injector
Back±up Ring No. 1

Fuel Injector Back±up
Ring No. 3
Fuel Injector
Back±up Ring No. 2
30 (306, 22)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±249
AVENSIS REPAIR MANUAL (RM1018E)

A77327
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
9.0 (90, 80 in.
lbf)
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover Sub±assy
Crank Position Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt Tensioner
Sub±assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
170 (1,735, 125)
Crankshaft Pulley
Chain Sub±assy
43 (440, 32)
Chain Tensioner
Slipper
19 (195, 14)
Camshaft Position
Sensor Plate No. 1
Oil Pump
Drive Gear
Chain Vibration
Damper No. 1

Oil Seal
Timing Chain Guide
9.0 (90, 80 in.
lbf)
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
43 (440, 32)
43 (440, 32)
9.0 (90, 80 in.
lbf)
14±250
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A79801
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
10 (97, 84 in.
lbf)
10 (97, 84 in.
lbf)
Intake Manifold
10 (97, 84 in.
lbf)
Insulator
Intake Air Control Valve
Assy

Gasket
Water By±pass Hose No. 1
Heater Water Inlet Hose
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±251
AVENSIS REPAIR MANUAL (RM1018E)