TOYOTA AVENSIS 2005 Service Repair Manual

A56699
A56700
SST
B07987
New Gasket
Seal
Packing Seal Width
2to4mm
(0.08 to 0.16 in.)
B08024
17−14
− LUBRICATIONOIL PUMP ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
38. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying between the oil pump and
main bearing cap using a screwdriver.
(c) Remove the gasket.
39. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316−60011 (09316−00011, 09316−00021)
40. INSTALL OIL PUMP ASSY
(a) Remove any old packing (FIPG). Be careful not to drop
any oil on the contact surfaces of the oil pump and cylin-
der block.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces and seal-
ing groove.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non−residue solvent, clean both the sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
(1) Install a nozzle of which opening is cut to 2 to 4 mm
(0.08 to 0.16 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install a new gasket to the oil pump.
(d) Pour 0.5 cm
3(0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Apply engine oil to the cylinder block side which contacts
the oil pump driven rotor.

A57099
A56702
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −15
AVENSIS Supplement (RM1045E)
(f) Install the oil pump with the 9 bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
(g) Measure the oil pump rotating torque. (1) Check that the pump rotates smoothly without mak- ing a noise.
(2) Using a torque wrench, check the pump rotating torque.
Rotating torque: 3.0 N
m (31 kgf
cm, 27 in.
lbf) or less
41. INSTALL CRANKSHAFT POSITION SENSOR (See page 14 −138)
42. INSTALL OIL PAN SUB −ASSY
(a) Remove any old packing (FIPG). Be careful not to drop any oil on the contact surfaces of the No. 1 oil pan, cylin-
der block, oil pump and rear oil seal retainer.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non −residue solvent, clean both the sealing
surfaces.

A56703
Seal Width
4to7mm
(0.16 to 0.28 in.)
AB
A
B
A56697
AAA
A
AA B B DBBB
BC C
C CC
CCDD
A56696
17−16
− LUBRICATIONOIL PUMP ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Apply seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826−00080 or equivalent
(1) Install a nozzle of which opening is cut to 4 to 7 mm
(0.16 to 0.28 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install the oil pan with the 19 bolts and 3 nuts.
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for bolt A
21 N
m (209 kgf
cm, 15 ft
lbf) for bolt B
11 N
m (112 kgf
cm, 8 ft
lbf) for bolt C
11 N
m (112 kgf
cm, 8 ft
lbf) for nut D
43. INSTALL OIL PAN INSULATOR
(a) Install the oil pan insulator with the bolt.
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
44. INSTALL OIL STRAINER SUB−ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (209 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
45. INSTALL OIL PAN SUB−ASSY NO.2
(a) Remove any old packing (FIPG). Be careful not to drop
any oil on the contact surfaces of the No. 1 and No. 2 oil
pans.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.

A56704
Seal Width
4to7mm
(0.16 to 0.28 in.)
A
A
B
B
B08016
New O −ring
SST
A09583
Inward
Angle Sensor
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −17
AVENSIS Supplement (RM1045E)
(3) Using a non −residue solvent, clean both the sealing
surfaces.
NOTICE:
Do not use a solvent. It will affect the painted surfaces.
(b) Apply seal packing to the oil pan as shown in the illustra- tion.
Seal packing: Part No. 08826 −00080 or equivalent
(1) Install a nozzle of which opening is cut to 4 to 7 mm (0.16 to 0.28 in.).
(2) The parts must be set within 3 minutes and must be assembled within 15 minutes after applying seal
packing. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
Torque: 12 N
m (119 kgf
cm, 9 ft
lbf)
46. INSTALL ENGINE OIL LEVEL SENSOR Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
47. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O −ring to the oil level gage guide.
(b) Apply engine oil to the O −ring.
(c) Push the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d) Install the oil level gage guide with the bolt. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
(e) Apply engine oil to the O −ring on the oil level gage.
(f) Install the oil level gage.
48. INSTALL V −RIBBED BELT TENSIONER ASSY (See page 14 −138)
49. INSTALL TIMING BELT IDLER SUB −ASSY NO.1 (See page 16 −21)
50. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
51. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
52. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
53. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located on the camshaft, then slide the pulley into place.
(b) Using SST and a hammer, tap in the timing pulley with the
angle sensor facing inward.
SST 09223 −46011

A57102
Turn
17
−18
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
54. INSTALL TIMING BELT IDLER SUB −ASSY NO.2
(a) Install the idler pulley with bolt. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
(b) Check that the idler pulley moves smoothly.
55. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
56. INSTALL TIMING BELT (See page 14 −138)
57. CHECK VALVE TIMING (See page 14 −138)
58. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
59. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
60. INSTALL TIMING BELT GUIDE (See page 14 −138)
61. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
62. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
63. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
64. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
65. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
66. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
67. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
68. INSTALL INJECTOR DRIVER (See page 14 −108)
69. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
70. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
71. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
72. CHECK FOR ENGINE OIL LEAKS

170IY−01
A56466
20 W−50
15 W−40
10 W−30
5W−30 PREFERRED
Before Next Oil Change Temperatuer Range Anticipated416 2738
0 20 40 60 80 100 −29
−20−18−7 _C
_F
Recommended Viscosity (SAE)
B14332
Oil Pressure Switch
B14333
Oil Pressure Gauge
− LUBRICATIONLUBRICATION SYSTEM (1CD−FTV)(From September,
2003)17−9
AVENSIS Supplement (RM1045E)
LUBRICATION SYSTEM (1CD−FTV)(From September, 2003)
ON−VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) Warm up the engine. Stop the engine, then wait for 5 minutes.
(b) Check that the engine oil level is between the 2 marks on the oil level gage.
If low, check for leakage and add oil up to the upper mark.
NOTICE:
Do not fill with engine oil above the upper mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, water intrusion, discoloring
or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
Use ACEA B1, API grade CF−4, CF or G−DLD−1.
(You may also use API CE or CD.)
SAE 5W−30 is the best choice for your vehicle in
terms of good fuel economy and good starting in cold
weather.
3. REMOVE OIL PRESSURE SWITCH ASSY
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24mm, remove the oil pres-
sure switch.
4. INSTALL OIL PRESSURE GAUGE
(a) Install the oil pressure gauge.
5. WARM UP ENGINE
6. CHECK OIL PRESSURE
Oil pressure:
At idle29 kPa (0.3 kgf/cm2, 4.3 psi) or more
At 4,500 rpm245 to 588 kPa (2.5 to 6.0 kgf/cm2, 36 to 85 psi) or more
7. REMOVE OIL PRESSURE GAUGE

P13638
Adhesive 17−10
− LUBRICATIONLUBRICATION SYSTEM (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
8. INSTALL OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to the 2 or 3 threads of the oil pressure
switch.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a deep socket wrench 24mm, 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 after the installation.
(c) Connect the oil pressure switch connector.
9. START ENGINE AND CHECK FOR LEAKS

160MQ−02
A56451
A77424
10 _10_
Jiggle Valve
16 −14
−
COOLING THERMOSTAT (2AZ −FSE)
AVENSIS Supplement (RM1045E)
THERMOSTAT (2AZ −FSE)
REPLACEMENT
1. DRAIN COOLANT (See page 16 −7)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
8. REMOVE GENERATOR ASSY (See page 19 −8)
9. REMOVE WATER INLET
(a) Remove the 2 nuts and water inlet.
10. REMOVE THERMOSTAT 11. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat while aligning the jiggle valve withits right position described in the illustration.
HINT:
The jiggle valve may be set within 10 _ of either side of the pre-
scribed position.
12. INSTALL WATER INLET Torque: 9.0 N
m (92 kgf
cm, 7 in.
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

160MR−02
B12054
SST
B12052
B12053
Pry
PryPry
16
−12
−
COOLING WATER PUMP ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
WATER PUMP ASSY (2AZ −FSE)
REPLACEMENT
1. DRAIN COOLANT (See page 16 −7)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
8. REMOVE GENERATOR ASSY (See page 19 −8)
9. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and pump pulley. SST 09960 −10010 (09962 −01000, 09963 −00700)
(b) Disconnect the crankshaft position sensor wire clamp
from the water pump.
(c) Disconnect the crankshaft position sensor wire from the clamp on the water pump.
10. REMOVE WATER PUMP ASSY
(a) Remove the 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry out between the water pump and cylinder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
−
COOLING WATER PUMP ASSY (2AZ −FSE)
16 −13
AVENSIS Supplement (RM1045E)
11. INSTALL WATER PUMP ASSY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump assy.
(b) Apply a continuous bead of the seal packing (diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)) as shown in the illustra-
tion.
Seal packing: Part No. 08826 − 00100 or equivalent
NOTICE:
Install the water pump assy within 5 minutes after applying
seal packing. Otherwise the material must be removed and
reapplied.
(c) Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d) Install the crankshaft position sensor wire harness clamp
to the water pump.
(e) I nst all t he cr ankshaf t posit ion s ensor wir e t o t he wir e clamp on the water pump.
12. INSTALL WATER PUMP PULLEY
(a) Using SST, install the pump pulley with 4 bolts. SST 09960 −10010 (09962 −01000, 09963 −00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)