TOYOTA AVENSIS 2005 Service Repair Manual

A32664
A56213
Wooden Block
A83481
14−80
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
AVENSIS Supplement (RM1045E)
42. REMOVE BATTERY (See page 14 −45)
43. REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 14 −23)
44. DISCONNECT RADIATOR HOSE INLET (See page 14 −23)
45. DISCONNECT UNION TO CONNECTOR TUBE HOSE (See page 14 −23)
46. DISCONNECT HEATER INLET WATER HOSE (See page 14 −23)
47. SEPARATE FUEL TUBE SUB −ASSY (See page 11 −1)
48. SEPARATE ENGINE WIRE
49. REMOVE THROTTLE BODY ASSY (See page 10 −8)
50. REMOVE CHARCOAL CANISTER ASSY
51. REMOVE INTAKE MANIFOLD (See page 11 −13)
52. REMOVE MANIFOLD CONVERTER INSULATOR NO.1 (See page 14 −23)
53. REMOVE EXHAUST MANIFOLD CONVERTER SUB −ASSY (See page 14 −23)
54. REMOVE NO.2 CAMSHAFT (See page 14 −64)
55. REMOVE CAMSHAFT (See page 14 −64)
56. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See page 14 −23)
57. REMOVE CAMSHAFT BEARING NO.2
58. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub −assy.
(b) Set the jack under the engine assembly with transaxle,
then place a wooden block on the jack.
(c) Remove the chain block and sling devise.
59. REMOVE CYLINDER HEAD SUB −ASSY
(a) Remove the bolt, then separate the water by −pass pipe.
(b) Remove the camshaft housing plug.

A7740612 3
4 109
8 56 7
A77407
Overall Length
A77408
Lot No.
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
14−81
AVENSIS Supplement (RM1045E)
(c) Using several steps, loosen the 10 cylinder head bolts
with10mmbi−hexagon wrench uniformly in the se-
quence shown in the illustration.
(d) Remove the 10 cylinder head bolts and plate washers.
NOTICE:
SBe careful not to drop washers into the cylinder head.
SHead 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:
SRemove any oil from contact surface.
SBe careful of the installation direction.
SPlace the cylinder head gently in order not to damage
the gasket with the bottom part of the head.

A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
1.25 to 1.5 mm
A7741012
3 4
109 85
67
A00976A77411
90_
Engine
Front
Paint Mark
A83497
14−82
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
AVENSIS Supplement (RM1045E)
63. INSTALL CYLINDER HEAD SUB−ASSY
HINT:
The cylinder head set bolts are tightened in the 2 successive
steps.
(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:
SRemove any oil from contact surface.
SInstall the cylinder head within 3 minutes after apply-
ing seal packing.
SAfter installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.
SDo not start the engine within 2 hours of installation.
(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.
(h) Install the camshaft housing plug as shown in the illustra-
tion.

A83481
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
14 −83
AVENSIS Supplement (RM1045E)
(i) Install the water by −pass pipe with a bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
65. INSTALL CAMSHAFT (See page 14 −64)
66. INSTALL NO.2 CAMSHAFT (See page 14 −64)
67. INSTALL EXHAUST MANIFOLD CONVERTER SUB −ASSY (See page 14 −23)
68. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14 −23)
69. INSTALL INTAKE MANIFOLD (See page 11 −13)
70. INSTALL THROTTLE BODY ASSY (See page 10 −8)
71. INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 14 −23)
72. INSTALL BATTERY
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for Bolt
3.5 N
m (36 kgf
cm, 31 in.
lbf) for Nut
73. INSTALL CHAIN VIBRATION DAMPER NO.1 (See page 14 −45)
74. INSTALL CHAIN SUB −ASSY (See page 14 −45)
75. INSTALL TIMING CHAIN GUIDE (See page 14 −45)
76. INSTALL CHAIN TENSIONER SLIPPER (See page 14 −45)
77. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14 −45)
78. INSTALL TIMING CHAIN OR BELT COVER SUB −ASSY (See page 14 −45)
79. INSTALL V −RIBBED BELT TENSIONER ASSY (See page 14 −45)
80. INSTALL OIL PAN SUB −ASSY (See page 14 −45)
81. INSTALL CRANKSHAFT POSITION SENSOR (See page 14 −45)
82. INSTALL CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021
83. INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14 −45)
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 −45)
86. INSTALL CYLINDER HEAD COVER SUB −ASSY (See page 14 −45)
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 −24)

14−84
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
AVENSIS Supplement (RM1045E)
94. INSTALL FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
95. INSTALL FUEL TUBE SUB −ASSY (See page 11 −24)
96. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11 −24)
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 −2)
100. INSTALL GENERATOR ASSY (See page 19 −8)
101. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
102. ADD COOLANT (See page 16 −7)
103. ADD ENGINE OIL (See page 17 −6)
104. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS (See page 11 −4)
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
108. ADD POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
109. BLEED POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
110. CHECK POWER STEERING FULUID LEVEL IN RESERVOIR
(See Pub. No. RM1018E on page 51 −4)
111. CHECK FUNCTION OF THROTTLE BODY

141NA−01
A89203N·m (kgf·cm, ft·lbf)
: Specified torque
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
Engine Under Cover LHEngine Under
Cover No. 4 RH
Engine Under
Cover RH
Fan and Generator V Belt
Radiator Support Opening Cover
Clip Engine Room Cover Side
RetainerClipEngine Cover Sub−assy No. 1x4 x2
x4x4x2
x3 x2
x5
x6
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
14−69
AVENSIS Supplement (RM1045E)
CYLINDER HEAD GASKET (2AZ−FSE)
COMPONENTS

A89212
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketCooler 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)
8.0 (82, 71 in.
lbf)
8.0 (82, 71 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
52 (530, 38)
Vane Pump Assy
zGasket
8.0 (82, 44 in.
lbf)
37 (377, 27)
14−70
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
AVENSIS Supplement (RM1045E)

A84696zNon−reusable part
N·m (kgf·cm, ft·lbf) : Specified torqueThrottle Body AssyThrottle Control Motor
Connector
zThrottle Body Gasket
Water By−pass Hose
No. 2
Water By−pass Hose
No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground TerminalWiring Harness
Protector
8.4 (86, 74 in.
lbf)
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
14−71
AVENSIS Supplement (RM1045E)

A93079
Air Cleaner Cap
w/ Hose
Air Cleaner Element
5.0 (51, 44 in.
lbf)
Battery Tray
Battery
Battery Clamp
Heater Inlet Water Hose
Union to Connector Tube Hose
N·m (kgf·cm, ft·lbf)
: Specified torque
5.0 (51, 44 in.
lbf)
Air Cleaner Case
Radiator Hose Inlet
x3
3.5 (36, 31 in.
lbf)
14−72
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
AVENSIS Supplement (RM1045E)

A89214
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketzGasketFuel Tube Sub−assy
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy
zFuel Pump
Insulator
Fuel HoseFuel Pipe Sub−assy No. 1
zFuel Injector Back−up Ring No. 1
zFuel Injector Back−up Ring No. 2
zFuel Injector Back−up Ring No. 3
25 (255, 18)x2
zO−ring
9.0 (92, 80 in.
lbf)
30 (306, 22)
x2
33 (331, 24)
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
14−73
AVENSIS Supplement (RM1045E)