TOYOTA AVENSIS 2005 Service Repair Manual

A76717
A76716
A62830Front SideRear Side
A76718
14–14– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(d) Remove the 2 bolts and 2 nuts as shown in the illustration.
(e) Remove the 8 bolts and front suspension member brace
rear RH and LH.
(f) Carefully remove the engine with transaxle from the en-
gine compartment.
(g) Install the engine hanger No. 1 (12281–15040) and bolt
(91512–B1016).
Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf)
(h) Install the engine hanger (12281–22021) and bolt
(91512–B1016).
Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf)
HINT:
Securely install the front engine hanger (12281–22021) and
rear engine hanger No. 1 (12281–15040) onto the engine as-
sembly.
(i) Attach the engine sling, then hang the engine with the
chain block.
59. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Remove the through bolt and nut, then detach the engine
mounting insulator FR from the engine mounting bracket.

A76719
A62838SST
A62838SST
A76713
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–15
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Remove the through bolt, then detach the engine mount-
ing insulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the
suspension crossmember and engine mounting member.
60. REMOVE STARTER ASSY (See Pub. No. RM1018E on page 19–3)
61. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
62. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
63. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
64. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
65. REMOVE FLYWHEEL SUB–ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
flywheel.
SST 09960–10010 (09962–01000, 09963–01000)
66. REMOVE DRIVE PLATE & RING GEAR SUB–ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
drive plate & ring gear.
SST 09960–10010 (09962–01000, 09963–01000)
67. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
(b) Remove the 2 nuts which are used to secure the engine
wire.

A64023
A93668
A64026
A96570
14–16– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(c) Remove the 4 bolts and 4 ignition coils.
68. REMOVE FUEL DELIVERY PIPE SUB–ASSY
(See Pub. No. RM1018E on page 11–11)
69. REMOVE INTAKE MANIFOLD
(a) Disconnect the throttle motor connector.
(b) Disconnect the 2 water hoses from the throttle body.
(c) Disconnect the ventilation hose and ventilation hose No.
2 from the cylinder head cover.
(d) Disconnect the vacuum hose from water by–pass pipe
No. 1.
(e) Remove the 4 bolts, 2 nuts and 2 wire brackets,then re-
move the intake manifold and throttle body assembly.
(f) Remove the gasket from the intake manifold and the
throttle body assembly.
70. REMOVE OIL LEVEL GAGE SUB–ASSY
(a) Remove the oil level gage from the oil level gage guide.
71. REMOVE OIL LEVEL GAGE GUIDE
(a) Disconnect the crankshaft position sensor clamp.
(b) Remove the bolt and oil level gage guide.
72. REMOVE WATER BY–PASS PIPE NO.1
(a) Disconnect the knock sensor clamp.
(b) Remove the 2 bolts and 2 nuts, then detach the water by–
pass pipe and gasket.

A64028
B00084
A76692
A64029
A96566
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–17
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
73. REMOVE WATER INLET
(a) Remove the 2 nuts and water inlet.
74. REMOVE THERMOSTAT
75. REMOVE ENGINE OIL PRESSURE SWITCH ASSY

(See Pub. No. RM1018E on page 17–1)
76. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor.
77. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and crankshaft position sensor.
78. REMOVE KNOCK SENSOR
(a) Remove the nut and knock sensor.
79. REMOVE V–RIBBED IDLER ASSY NO.1
(a) Remove the nut, bolt, tube and idler.

A64059
A64060
A76720
A76721
A76722
(a)
(b)
(b)
(b)(b) 14–18
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
80. REMOVE V–RIBBED BELT TENSIONER ASSY
(a) Remove the bolt, nut and V–ribbed belt tensioner.
81. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and transverse engine mounting
bracket.
82. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and manifold stay.
83. REMOVE MANIFOLD STAY NO.2
(a) Remove the 3 bolts and manifold stay.
84. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 3 bolts and nut, then remove the exhaust
manifold heat insulator.

A76723
A64033
A64034
A64034
A64033
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–19
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
85. REMOVE EXHAUST MANIFOLD
(a) Remove the 5 nuts, then remove the exhaust manifold
and gasket.
86. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the engine coolant temperature sen-
sor.
SST 09817–33190
87. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and condenser.
88. REMOVE WATER BY–PASS HOSE NO.2
89. REMOVE RADIATOR HOSE INLET
90. REMOVE HEATER INLET WATER HOSE
91. REPLACE PARTIAL ENGINE ASSY
92. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)
93. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Install a new gasket onto the engine coolant temperature
sensor.
(b) Using SST, install the engine coolant temperature sensor.
SST 09817–33190
Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf)

A76723
A76722
(a)
(b)
(a)(a)
(a)
A76721
A76720
ABB
A64060
14–20– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
94. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf)
95. INSTALL EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Install the exhaust manifold heat insulator, then install the
3 bolts and nut.
Torque:
18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt
12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) for nut
(b) Connect the heated oxygen sensor connector.
96. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay with the 3 bolts.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
97. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque:
49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) for A
37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) for B
98. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the transverse engine mounting bracket with the 3
bolts.
Torque: 47 N⋅m (479 kgf⋅cm, 35 ft⋅lbf)

A64059
A96566
A76692
B00084
A64028
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–21
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
99. INSTALL V–RIBBED BELT TENSIONER ASSY
(a) Install the V–ribbed belt tensioner with the bolt and nut.
Torque:
29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf) for nut
69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf) for bolt
100. INSTALL V–RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt.
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
101. INSTALL KNOCK SENSOR
(See Pub. No. RM1018E on page 10–17)
102. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O–ring on the crank-
shaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
103. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O–ring on the cam-
shaft position sensor.
(b) Install the camshaft position sensor with the bolt.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
104. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(See Pub. No. RM1018E on page 17–1)
Adhesive: Part No.08833 – 00080, THREE BOND 1344.
105. INSTALL THERMOSTAT

(See Pub. No. RM1018E on page 16–9)
106. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf)

A96570
A64026
A93668
A64023
A76713
14–22– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
107. INSTALL WATER BY–PASS PIPE NO.1
(a) Install a new gasket and water by–pass pipe with the 2
nuts and 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
108. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to a new O–ring and install
it onto the oil level gage guide.
(b) Install the oil level gage guide with the bolt.
Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)
109. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.
(b) Install the intake manifold and 2 clamp brackets with the
2 nuts and 4 bolts.
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
110. INSTALL FUEL DELIVERY PIPE SUB–ASSY

(See Pub. No. RM1018E on page 11–11)
111. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)

A62838SST
A62205
1
5
3
82
6
4
7
A62206
90
A62838SST
A62204
1
5
3
82
6
4
7
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–23
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
112. INSTALL FLYWHEEL SUB–ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960–10010 (09962–01000, 09963–01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts.
Adhesive:
Part No. 09330–00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni-
formly in the sequence shown in the illustration.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(e) Mark each bolt head with paint.
(f) Retighten the bolts by an additional 90 in the same se-
quence as step (d).
(g) Check that the paint marks are at a 90 angle to the origi-
nal position.
113. INSTALL DRIVE PLATE & RING GEAR SUB–ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960–10010 (09962–01000, 09963–01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts.
Adhesive:
Part No. 09330–00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni-
formly in the sequence shown in the illustration.
Torque: 88 N⋅m (897 kgf⋅cm, 65 ft⋅lbf)