TOYOTA AVENSIS 2005 Service Repair Manual

170FS±01
A79297
A79298
SST
A79299
3/4 turn
SST 17±4
± LUBRICATIONOIL FILTER SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1ZZ±FE/3ZZ±FE)
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.

Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Wear protective clothes and gloves. Wash your skin thoroughly
with soap and water, or use water±less hand cleaner to remove any used engine oil. Do not use
gasoline, thinners, or solvents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil pan drain plug and drain engine oil.
2. REMOVE OIL FILTER SUB±ASSY
(a) Remove the screw and open the under cover.
(b) Using SST, remove the oil filter
SST 09228±06501
3. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter mounting surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn as shown in the
illustration.
SST 09228±06501

± LUBRICATIONOIL FILTER SUB±ASSY (1ZZ±FE/3ZZ±FE)
17±5
AVENSIS REPAIR MANUAL (RM1018E)
4. INSTALL OIL PAN DRAIN PLUG
(a) Clean and install the oil pan drain plug with a new gasket.
Torque: 37 N
m (377 kgf
cm, 27 in.
lbf)
5. 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. qts)
Dry fill: 4.2 liters (4.4 US qts, 3.7 lmp. qts)
6. CHECK FOR ENGINE OIL LEAKS

170FR±01
B08737
A30890
±
LUBRICATION OIL PUMP ASSY(1ZZ±FE/3ZZ±FE)
17±3
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Remove the oil pan drain plug and drain engine oil.
2.REMOVAL & INSTALLATION CHAIN SUB±ASSY (See page 14±49)
3.REMOVE CHAIN VIBRATION DAMPER NO.1
(a)Remove the 2 bolts and the chain vibration damper No. 1.
4.REMOVE OIL PUMP ASSY
(a)Remove the 5 bolts.
(b)Remove the oil pump assy and the gasket.
5.INSTALL OIL PUMP ASSY
(a)Place a new gasket on the cylinder block.
(b)Align the keyway of the oil pump drive rotor with the rect-angular portion of the crankshaft and slide the oil pump
into place.
(c)Install the oil pump with the 5 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
6.INSTALL CHAIN VIBRATION DAMPER NO.1
(a)Install the chain vibration damper No. 1 with 2 bolts. Torque: 9.0 N
m (92 kgf
cm,8.0 in.
lbf)
7.INSTALL OIL PAN DRAIN PLUG
(a)Clean and install the oil pan drain plug with a new gasket.
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
8.ADD ENGINE OIL (See page 17±4)
9.ADD ENGINE COOLANT (See page 16±7)
10. CHECK FOR ENGINE OIL LEAKS
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)

1700F±10
A56466
Recommended Viscosity (SAE)
BEFORE NEXT OIL CHANGE TEMPERATURE RANGE ANTICiPATED416 2738
0 20 40 60 80 100 ±29
±20±18 ±7
C

F20 W ± 50
15 W ± 40
10 W ± 30
5 W ± 30 PREFERRED
Oil Pressure
Switch
A80004
Oil Pressure GaugeOil Pressure Gauge
A50711
± LUBRICATIONLUBRICATION SYSTEM (1ZZ±FE/3ZZ±FE)
17±1
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION SYSTEM (1ZZ±FE/3ZZ±FE)
ON±VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) 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.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, entry of water, discoloring
or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
API grade ºSJº Energy±Conserving, ºSLº Energy±
Conserving or ILSAC multi grade engine oil. Recom-
mended viscosity is as shown in the illustration.
3. REMOVE OIL PRESSURE SWITCH ASSY
(a) Disconnect the oil pressure switch connector.
(b) Using a 24mm deep socket wrench, remove the oil pres-
sure switch.
4. INSTALL OIL PRESSURE GAUGE
(a) Install the oil pressure gauge.
5. WARM UP ENGINE

Adhesive
A50082
17±2
± LUBRICATIONLUBRICATION SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
6. CHECK OIL PRESSURE
Oil pressure:
At idle29 kPa (0.3 kgf/cm2, 4.3 psi) or more
At 3,000 rpm294 to 539 kPa (3.0 to 5.5 kgf/cm2, 43 to 78 psi) or more
7. REMOVE OIL PRESSURE GAUGE
8. INSTALL OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a 24mm deep socket wrench, install the oil pres-
sure switch.
Torque: 15 N
m (153 kgf
cm, 11 ft
lbf)
NOTICE:
Do not start the engine within 1 hour of installation.
(c) Connect the oil pressure switch connector.
9. START ENGINE AND CHECK FOR LEAKS

160MG±01
±
COOLING RADIATOR ASSY(1CD±FTV)
16±51
AVENSIS REPAIR MANUAL (RM1018E)
RADIATOR ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
5.DISCONNECT RADIATOR HOSE INLET
6.DISCONNECT RADIATOR HOSE OUTLET
7.REMOVE RADIATOR ASSY
(a)Remove the 2 bolts and separate the relay box.
(b)Remove the 2 upper support and radiator assy.
8.REMOVE RADIATOR SUPPORT LOWER
9.REMOVE FAN ASSY W/MOTOR
(a)Remove the 2 bolts and the fan w/motor.
10.INSTALL FAN ASSY W/MOTOR
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
11.INSTALL RADIATOR ASSY
(a)Install the 2 upper support and the radiator assembly to the vehicle. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b)Install the 2 bolts and the relay box.
Torque: 5.3 N
m (54 kgf
cm, 47 in.
lbf)
12.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
13.ADD ENGINE COOLANT(See page 16±44)
14.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)

160MF±01
A79171
A79172
10
10

16±50
±
COOLING THERMOSTAT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
THERMOSTAT(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE RADIATOR RESERVE TANK ASSY
(a)Disconnect the water by±pass hose No. 1 and water by±pass hose No.\
2.
(b)Remove the 2 bolts and the reserve tank assembly.
5.REMOVE RADIATOR HOSE OUTLET 6.REMOVE WATER INLET
(a)Remove the 2 bolts and the water inlet.
7.REMOVE THERMOSTAT 8.INSTALL THERMOSTAT
(a)Install a new gasket to the thermostat.
(b)Install the thermostat with the jiggle valve facing upward.
HINT:
The jiggle valve may be set within 10
on either side as shown
in the illustration.
9.INSTALL WATER INLET Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
10.INSTALL RADIATOR RESERVE TANK ASSY
Torque: 6.0 N
m (61 kgf
cm,53 in.
lbf)
11.ADD ENGINE COOLANT(See page 16±44)
12.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)

160ME±01
A79148
SST
16±46
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)

A09580
8 mm
Hexagon
Wrench
A79170
A79170
A09581
8 mm
Hexagon
Wrench
Plate Washer
±
COOLING WATER PUMP ASSY(1CD±FTV)
16±47
AVENSIS REPAIR MANUAL (RM1018E)
29.REMOVE INJECTION PUMP DRIVE PULLEY(See page 11±69)
SST09960±10010 (09962±01000, 09963±01000), 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
30.REMOVE INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
31.REMOVE TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, remove the idler pulleyshaft, the idler pulley and the plate washer.
32.REMOVE WATER PUMP ASSY
(a)Remove the 7 bolts, then remove the water pump and the gasket.
33.INSTALL WATER PUMP ASSY
(a)Install a new gasket and the water pump with the 7 bolts. Torque: 31 N
m (320 kgf
cm, 23 ft.
lbf)
34.INSTALL TIMING BELT IDLER SUB±ASSY NO.1
(a)Using an 8 mm hexagon wrench, install the plate washer and the idler pulley with the idler pulley shaft.
Torque: 35 N
m (357 kgf
cm, 26 ft
lbf)
(b)Check that the pulley bracket moves smoothly.
35.INSTALL INJECTION OR SUPPLY PUMP ASSY(See page 11±69)
36.INSTALL INJECTION PUMP DRIVE PULLEY(See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
37.INSTALL WATER INLET(See page 16±50)
38.INSTALL OIL LEVEL GAGE GUIDE(See page 17±22)

A79148
SST
A79149
SST
16±48
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
39.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69) 40. 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.
(a) Temporarily install the new fuel inlet pipe.
(b) Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST 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
SST
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
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe to the injec- tion pump side.
SST 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
SST
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
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.