key TOYOTA AVENSIS 2005 Service Repair Manual

A79196
New O−ring
New O−ring
A79182
Collar
Groove
14−126− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(c) Using SST, tighten the nut of the fuel inlet pipe on the
pump side.
SST 09023−12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
143. INSTALL NOZZLE LEAKAGE PIPE NO.2
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
144. INSTALL VACUUM PUMP ASSY
(a) Install 2 new O−rings to the vacuum pump.
(b) Align the key of the vacuum pump with the keyway of the
exhaust camshaft, then insert the vacuum pump into
place. Secure the pump with the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
145. INSTALL WATER OUTLET SUB−ASSY
(a) Install a new gasket and the water outlet with the 2 bolts.
Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
146. INSTALL EGR VALVE ASSY
(a) Install a new gasket and the EGR valve with the bolt and 2 nuts.
Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
147. INSTALL INTAKE AIR CONNECTOR
(a) Install a new gasket and the intake air connector together with the diesel throttle body with the 3 bolts.
Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
148. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket, the exhaust manifold and 8 collars
with new 8 nuts.
Torque: 47 N
m (474 kgf
cm, 34 ft
lbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. The ring groove of the collar should be outward. Re-
fer to the illustration on the left.

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

SST
A09582
B07973
Cut PositionPry
SST
A08528
SST
A09583
Angle
SensorInward
14
−178−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
22. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
23. REMOVE TIMING BELT (See page 14 −138)
24. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the timing pulley cannot be removed by hand, use SST to remove the pulley.
SST 09950 − 50013 ( 09951 − 05010, 09952 − 05010,
09953 −05010, 09953 −05020, 09954 −05021)
25. REMOVE CRANKSHAFT SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Wrap the tip of the
screwdriver with tape.
26. INSTALL CRANKSHAFT SEAL
(a) Apply multipurpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the oil seal until its sur- face is flush with the oil pump edge.
SST 09316 −60011 (09316 −00011)
27. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located on the crankshaft, 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
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
29. INSTALL TIMING BELT (See page 14 −138)
30. CHECK VALVE TIMING (See page 14 −138)

A62837SST
A77551
A11858
A12816
A76692
14–36– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
34. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09960–10010 (09962–01000, 09963–01000)
(b) Remove the crankshaft pulley from the crankshaft.
HINT:
If the crankshaft pulley key is stuck, tap it with a plastic–sur-
faced hammer so that it can be removed.
35. REMOVE V–RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, then detach the V–ribbed belt
tensioner.
HINT:
Jack up and down to remove the bolt.
36. REMOVE WATER PUMP ASSY
(See Pub. No. RM1018E on page 16–9)
37. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and transverse engine engine mount-
ing bracket.
38. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts which are used to secure the crank-
shaft position sensor.

A62150
Camshaft No. 2
Camshaft
A62825
62 4 8
51 3 7 11
10
9
A10079
A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–39
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
52. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the camshaft journals.
(b) Place the 2 camshafts on the cylinder head as shown in
the illustration.
(c) Examine the front marks and numbers, then tighten the
bolts in the sequence shown in the illustration.
Torque:
23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bearing cap No. 1
13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) for bearing cap No. 3
53. INSTALL CHAIN SUB–ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Using a wrench, turn the camshafts until the timing
marks of the 2 camshaft timing sprockets are
aligned.
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain onto the crankshaft timing sprock-
et with the yellow color link and the timing mark on the
crankshaft timing sprocket aligned.
HINT:
Three yellow color links are on the chain.

A62837SST
A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A62182
Seal Packing
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–43
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
64. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
(b) Using SST, install the crankshaft 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, then take the hook
off the knock pin to release the plunger.
(d) Turn the crankshaft clockwise, then check that the plung-
er is extended.
HINT:
If the plunger is not extended, press the slipper into the chain
tensioner using a screwdriver so that the hook is taken off from
the knock pin and the plunger can be extended.
65. INSTALL CYLINDER HEAD COVER SUB–ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes of ap-
plying seal packing.
Do not expose the seal to engine oil for at least 2
hours after installation.

141TJ–01
A84914
Compression Ring No. 1Compression Ring No. 2 Oil Ring (Side Rail)

Snap Ring Piston
Piston Pin

Snap Ring
Connecting Rod Bearing
Cylinder Block Sub–assy
Crankshaft BearingCrankshaft Bearing Cap Sub–assy
Crankshaft Bearing
Crankshaft Thrust Washer Upper
Key
Crankshaft
Connecting Rod Bearing
Connecting Rod Bearing Cap
Oil Ring (Expander)
See page 14–51
1st 44 (449, 33)
2nd Turn 90 
1st 20 (204, 15)
2nd Turn 90
19 (194, 14)

Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torque Crankshaft
Thrust Washer Upper
Connecting Rod25 (255, 18)
Cylinder Block Water Drain Cock Sub–assy
See
page 14–51
14–50
–
ENGINE MECHANICAL CYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
CYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
COMPONENTS