engine installation TOYOTA AVENSIS 2005 Service Repair Manual

010LF±01



 

D25016
± INTRODUCTIONREPAIR INSTRUCTION
01±5
AVENSIS REPAIR MANUAL (RM1018E)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1Looks
Always wear a clean uniform.

Hat and safety shoes must be worn.
2Vehicle protection
Set a grill cover, fender cover, seat cover and floor mat before starting operation.
3Safe operation

When working with 2 or more persons, be sure to check the safety of one another.

When working with the engine running, pay attention to providing ventilation for exhaust fumes in the work-
shop.

When working with high±temperatures, rotating, moving or vibrating parts, be careful not to burn or injure
yourself.

When jacking up the vehicle, be sure to support the specified location with a safety stand.

When lifting up the vehicle, use safety equipment.
4Preparation of tools and
measuring gauge
Before starting repairs, prepare the tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations

Diagnose with a thorough understanding of the trouble condition and perform effective operation.

Before removing the parts, check the general condition of the assembly, and for deformation and damage.

When the structure is complicated, take a notes or make matchmarks as not to make mistakes that affect the
function of the parts.

Clean and wash the removed parts if necessary and assemble them after a thorough check.
6Removed parts

Place the removed parts in the correct order to avoid mixing them up or making them dirty.

As for non±reusable parts such as gaskets, O±rings, and self±locking nuts, replace them with new ones
following the instructions in this manual.

Organize the parts that were replaced in a box and show them to the customer.

D01556
WRONG
D01563
01±16
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(±) terminal cable is disconnected. If necessary, be
sure to initialize the system.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless
absolutely necessary (If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity).
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not be reused.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission±re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a place with good air ventilation and without anything that could cause combustion
around you such as a welder, grinder, drill, electric motor or stove.
(2) Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel
will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operations.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do
not spray much water so as to prevent slipping.
(3) Never use any electric equipment like an electric motor or a working light, as they may create
sparks or a high temperature.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of shop rags containing fuel deposits separately.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal tip is mixed in the inlet pass, this may give a
bad effect to the engine and turbocharger.
(b) When removing and installing the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean waste cloth or gum tape.
(c) When installing the inlet system parts, check that there is
no mixing of a metal tip.

01±18
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

Confirm that the VSC warning light blinks.

VSC system will be reset when the engine is re-
started.

Fasten the vehicle with lock chains.
(b) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and re-
moval as it might disorder the adjustment of related
parts to VSC.
(2) Be sure to carry out the preparation for operation
and the confirmation of operation completion in ac-
cordance with the instruction of the text and when
the related operations to VSC are performed.
10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline flows into the converter, it may cause overheating and is a
fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
create an extra load on the converter.

± DIAGNOSTICSAUDIO SYSTEM
05±1419
AVENSIS REPAIR MANUAL (RM1018E)
NOISE OCCURS
INSPECTION PROCEDURE
1 CHECK OF SPEAKER INSTALLATION
(a) Check the speaker installation condition.
(1) Check that each speaker is securely installed.
Standard: Malfunction disappears.
HINT:
The radio is equipped with the noise prevention system that works against only the excessively large noise,
thereby excessively large noise do not occur in the radio. If large noise occurs, check whether or not the earth
on the antenna installation part and the proper noise±prevention equipment are all installed, and whether
or not the improper wiring is held.
Condition in which noise occursNoise type
Depressing the acceleration pedal increases noise, and stopping the engine
erases the noise immediately.Alternator noise
Noise occurs during the A/C or the heater operation.Blower motor noise
Rapid acceleration during the drive on the unpaved road or after the IG
switch is turned ON makes noise.Fuel pump noise
Pressing and then releasing the horn switch, and keeping pressing the horn
switch makes noise.Horn noise
Stopping the engine erases the small noise that has been heard.Ignition noise
Noise occurs in turn with the blink of the turn signal flash.Flasher noise
Noise occurs during the window washer operation.Washer noise
Noise occurs during the engine running, and it continues to occur after the
engine is stopped.Water temperature sensor noise
Noise occurs during the wiper operation.Wiper noise
Noise occurs when the brake pedal is depressed.Stop light switch noise
Others.Static electricity on the vehicle
HINT:

Identify the condition under which the noise occurs, and check the noise filter on the related part.

Make sure first that there is no noise from outside. Failing to do so makes the noise occurrence source
detection impossible and leads to misunderstanding.

The noise should be removed in descending order of loudness.
NG INSTALL IT PROPERLY
OK
IDENTIFICATION OF NOISE SOURCE
054A1±09

100FH±01
A778975 Claws
A77902
A77872
10±26
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE ENGINE ROOM COVER SIDE
(a)Remove the retainer and 4 clips.
(b)Unfasten the 5 claws and remove the radiator support opening cover.
2.REMOVE RADIATOR SUPPORT OPENING COVER
(a)Remove the 2 clips, and then remove the engine room cover side.
3.DRAIN ENGINE COOLANT (See page 16±19)
4. REMOVE ENGINE COVER SUB±ASSY NO.1
(a) Remove the 2 nuts, and then remove the engine cover No. 1.

100FE±01
A78497
A78498
(a)
(b)
(c)
A78499
(d)
(e)
A78500
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(3ZZ±FE)
10±15
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
3.DRAIN ENGINE COOLANT (See page 16±7)
4.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
5.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±9)
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator controlcable.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the ventilation hose.
(b) Disconnect the water by±pass hose.
(c) Disconnect the water by±pass hose No. 2.
(d) Disconnect the throttle position sensor.
(e) Disconnect the ISC valve connector.
(f) Remove the bolt and 2 nuts, and then remove the acceler- ator control bracket and the throttle body.
(g) Remove the gasket from the intake manifold.
8. REMOVE ISC VALVE
(a) Remove the 4 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.

100FC±01
A784575 Claws
A78458
A78459
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1ZZ±FE)
10±9
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER
(a)Remove the retainer and 4 clips.
(b)Unfasten the 5 claws and remove the radiator support
opening cover.
2.REMOVE ENGINE ROOM COVER SIDE
(a)Remove the 2 clips, and then remove the engine room cover side.
3.DRAIN ENGINE COOLANT (See page 16±7)
4. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, and then remove the cylin- der head cover No. 2.

100FO±01
A80092
B08171
A64328
2 to 7 mm0 to 4 mm
± ENGINE CONTROL SYSTEMINTAKE SHUTTER ASSY (1CD±FTV)
10±61
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
3. REMOVE BATTERY
4. REMOVE AIR HOSE NO.4
(a) Loosen the 2 hose clamps.
(b) Remove the 2 bolts and separate the air tube No. 2.
(c) Remove the air hose No. 4.
5. REMOVE INTAKE SHUTTER ASSY
(a) Disconnect the 2 connectors.
(b) Remove the 3 nuts, then remove the intake shutter and
the gasket.
6. INSTALL INTAKE SHUTTER ASSY
(a) Install a new gasket and the intake shutter with the 3 nuts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
7. INSTALL AIR HOSE NO.4
(a) Install the air hose No. 4 to the air tube No. 2.
(b) Install the air tube No. 2 with the 2 bolts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(c) Install the air hose and hose clamp as shown in the il-
lustration.

A77913
Turn
Push
A77914
Turn
A81621
Fuel Pipe
Clamp
Push
11±28
±
FUEL FUEL INJECTOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply a light coat of spindle oil or gasoline on the place where a fuel delivery pipe contacts the O±ring.
(c)Push the fuel injector while twisting it back and forth to
install it to the fuel delivery pipe.
NOTICE:

Be careful not to twist the O±ring.

After installing the fuel injectors, check that they turn
smoothly. If not, reinstall it with a new O±ring.
8.INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a)Install 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head.
(b)Place the fuel delivery pipe and the 4 fuel injectors togeth- er to the cylinder head.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(c)Temporarily install 2 bolts which are used to secure the fuel delivery pipe to the cylinder head.
(d)Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause
is incorrect installation of O±ring. Replace with the O±ring.
(e)Tighten the 2 bolts. Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(f)Connect the 4 fuel injector connectors.
(g)Install the 2 wire harness clamps.
(h)Connect the ventilation hose.
9.CONNECT FUEL TUBE SUB±ASSY
(a)Push in the connector to the pipe until it makes ºclickº sound.
NOTICE:

Check if there is any damage or foreign objects on the
connected part.

After connecting, check if the connector and the pipe
are securely connected by pulling on them.
(b)Install the fuel pipe clamp.
10.INSTALL AIR CLEANER CAP SUB±ASSY
11.CHECK FOR FUEL LEAKS (See page 11±19)
12.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)

110U5±01
A78493
A80060
w/o HID Sensor:
w/ HID Sensor:
(c)
(d)
(c)
±
FUEL FUEL TANK ASSY(GASOLINE)
11±93
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.DISCHARGE FUEL SYSTEM PRESSURE
HINT:

1ZZ±FE/3ZZ±FE: 11±1

1AZ±FE: 11±15

1AZ±FSE: 11±30
2.REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
3.REMOVE COVER, RR FLOOR SERVICE HOLE (See page 11±85)
4.DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(See page 11±85)
5.DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
6.DISCONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
7.REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85)
SST 09808±14010
8. DRAIN FUEL
9. REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR)
10.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
11. REMOVE EXHAUST PIPE ASSY CENTER(1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Using a clip remover, remove the 2 clips. (w/o HID Sensor)
(b) Open the floor carpet. (w/o HID Sensor)
(c) Disconnect the heated oxygen sensor connector.
(d) Remove the grommet. (w/o HID Sensor)