TOYOTA AVENSIS 2005 Service Repair Manual

A62821
Seal Width 4 ± 5 mm
6 mmSeal Packing
A62822
SST
A62817SST
14±14
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
42. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing material from the contact sur-
face.
(b) 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.
Seal packing: 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 put into engine oil within 2 hours after instal-
ling.
(c) Install the oil pan with the 14 bolts and 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
43. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install it.
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
44. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with
the oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crank shaft.
45. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter union.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
46. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation 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.
SST 09228±06501

A30890
A62826
Lot No.
A62816
84 2 59
7 3 1 6 10
A62823
Paint Mark
90
Front
A62815
Mesh
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±15
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
47. INSTALL OIL PUMP ASSY
(a) Engage the spline teeth of the oil pump drive rotor with the
large teeth of the crankshaft, and side the oil pump.
(b) Install the oil pump with the 5 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
48. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:

Pay attention to the installation direction.

Place the cylinder head quietly in order not to damage
the gasket with the bottom part of the head.
49. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using a bi±hexagon wrench 10, install and uniformly tight-
en the 10 cylinder head bolts with plate washers, in sever-
al passes, in the sequence shown.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90 in the numerical or-
der shown.
(e) Check that the point marked bolts are moved at 90 
angle.
50. INSTALL OIL CONTROL VALVE FILTER
(a) Confirm that the filter is clear.
(b) Install the oil control valve filter to the cylinder head.
(c) Place a new gasket on the bolt, and install it.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)

A62824
Straight Pin
Key Groove
A32167
A62150
14±16
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Install a new O±ring to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
52. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft
together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
(e) 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.
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and install the camshaft tim-
ing gear.
Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
NOTICE:
Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT
(a) Apply light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head with the No.
1 cam lobes facing as shown the illustration.

A62825
62 4 8
51 3 7 11
10
9
A10079
Mark
A62170
Set KeyUpward
A62171
Yellow
Color Line
Timing Mark
A62172
SST
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±17
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(c) 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)
55. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the hexagonal wrench head portion of the
camshafts, and align the point marks of the cam-
shaft timing gears.
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain on the crankshaft timing sprocket
with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
(c) Using a SST, install the sprocket.
SST 09223±22010

A62173
Yellow Color Mark
Timing Mark
A30867
A62174
SST
A62175
Seal Width
4 ± 5 mm
Seal Packing
14±18
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Install the timing chain on the camshaft timing sprockets
with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
56. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
57. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
58. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing forward.
59. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to the oil seal lip.
(b) Using SST, tap in a new oil seal until its surface is flush
with the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip off foreign materials.
60. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material from the contact sur-
face.

A62176
Chain Cover
Groove
Cylinder Head
GrooveSeal Width
4 ± 5 mm
AB
7 mm
4.5 mm
3 mm 6 mm 12 mm
B
A
A ± A B ± BA
A
A62177
Raise
Push
Hook
Pin
A62178
Push
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) 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.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent
(c) Install the timing chain cover, with the 12 bolts and nut.
Torque:
M6 13 N
m (133 kgf
cm, 10 ft
lbf)
M8 19 N
m (194 kgf
cm, 14 ft
lbf)
NOTICE:

Remove any oil from the contact surface.

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

Do not put into engine oil within 2 hours after instal-
ling.
61. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check 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:
When installing the tensioner, set the hook again if the
hook releases the plunger.

A62837SST
A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A10085
A62179
A
ABB B
B 14±20
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
62. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install the 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 disconnect
the plunger knock pin from the hook.
(d) Turn the crankshaft clockwise, and check that the slipper
is pushed by the plunger.
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.
63. INSTALL WATER PUMP ASSY
(a) Place a new O±ring on the timing chain cover.
(b) Install the water pump with the 6 bolts.
Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in
lbf)
Bolt B 11 N
m (112 kgf
cm, 8 ft
lbf)
HINT:
Each bolt length is indicated in the illustration.

A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Groove
A01131
A01132
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±21
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
64. INSPECT VALVE CLEARANCE
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley, and align its groove with
timing mark º0º of the timing chain cover.
(2) 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.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
(b) Check only the valves indicated.
(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 0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust 0.25 ± 0.35 mm (0.010 ± 0.014 in.)
(c) Turn the crankshaft 1 revolution (360
) and set No. 4 cyl-
inder to TDC/compression.
(d) Check only the valves indicated.
(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 0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust 0.25 ± 0.35 mm (0.010 ± 0.014 in.)

A62186
Paint Mark
A62187
Fix
Tighten
A62188
24 5 3 1
A32124
A6218924 31 14±22
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
65. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the timing chain and camshaft tim-
ing sprockets.
(c) Remove the 2 bolts and chain tensioner.
(d) Fix the camshaft with a spanner and so on, then loosen
the camshaft timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.
(e) Loosen the camshaft bearing cap bolts on No. 2 camshaft
in the order as shown in the illustration in several passes,
and remove the caps.
(f) Remove the camshaft timing gear as shown in the illustra-
tion.
(g) Loosen the camshaft bearing cap bolts on camshaft in the
order as shown in the illustration in several passes, and
remove the caps.

A32125
A32556
A01082
A62195
Painted Link
Timing Mark
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±23
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(h) Remove the camshaft with holding the timing chain.
(i) 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-
er.
(j) Remove the valve lifters.
(k) Using a micrometer, measure the thickness of the re-
moved lifters.
(l) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified value.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Intake: A = B + (C ± 0.20 mm (0.008 in.))
Exhaust: A = B + (C ± 0.30 mm (0.012 in.))
HINT:

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

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.).
(m) As shown in the illustration, install the timing chain on the
camshaft timing gear, with the painted links aligned with
the timing marks on the camshaft timing sprockets.