TOYOTA AVENSIS 2005 Service Repair Manual

A62187
Hold
Tighten
A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Timing
Notch
A62177
Raise
Push
Hook
Pin
A62178
Push
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±15
AVENSIS REPAIR MANUAL (RM1018E)
(s) Hold the camshaft with a wrench, tighten the camshaft
timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not damage the valve lifter.
(t) Check the match marks on the 2 camshaft sprockets are
aligned with each other and aligned with the painted links
of the timing chain as shown in the illustration. Also, check
the timing notch is aligned with the timing mark º0º of the
chain cover.
(u) Install chain tensioner.
(1) Check that the O±ring is clean, and set the hook as
shown in the illustration.
(2) Apply engine oil to the chain tensioner and install it
with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fixit.

A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A11858
A64005
14±16
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(3) Turn the crankshaft counterclockwise, and take the
hook off the knock pin to release the plunger.
(4) Turn the crankshaft clockwise, and check that the
plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
16. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt.
Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
17. INSTALL ENGINE MOUNTING INSULATOR
SUB±ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)

A62182
Seal Packing
A65687
A
AAA
A
A A A
ABB
A64023
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±17
AVENSIS REPAIR MANUAL (RM1018E)
18. 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 after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover and cable bracket with the
9 bolts, 2 seal washers and 2 nuts. Tighten the bolts and
nuts uniformly in the several steps.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for A
9.0 N
m (92 kgf
cm, 80 in
lbf) for B
19. 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)

A76713
A78459
14±18
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
20. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
21. CHECK FOR ENGINE OIL LEAKS

141CD±01
A60622
±
ENGINE MECHANICAL FAN AND GENERATOR V BELT(1ZZ±FE/3ZZ±FE)
14±5
AVENSIS REPAIR MANUAL (RM1018E)
FAN AND GENERATOR V BELT(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
4. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly andloosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.

140KR±02
A62199
TCCG
A62200
±
ENGINE MECHANICAL ENGINE(1ZZ±FE/3ZZ±FE)
14±1
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1ZZ±FE/3ZZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±1)
2.INSPECT ENGINE OIL (See page 17±1)
3.INSPECT BATTERY (See page 19±5)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±3)
6.INSPECT FAN AND GENERATOR V BELT
HINT:
You don't need to check the belt deflection because auto tensioner is ado\
pted.
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:
(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12 BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester: (1) Using SST, connect terminal 13 (TC) and 4 (CG) ofthe DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the 2 nuts, and 2 clips, and then remove the cylinder head cover.
(3) Pull out the wire harness as shown in the illustration.
(4) Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.

TA C
A52006
A01037
14±2
± ENGINE MECHANICALENGINE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Inspect ignition timing at idle.
Ignition timing: 8 to 12BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.
(6) Disconnect the terminal 13 (TC) and 4 (CG) of the
DLC3.
(7) Inspect ignition timing at idle.
Ignition timing:
10 to 18 BTDC (1ZZ±FE)
3.5 to 11.5 BTDC (3ZZ±FE)
(8) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(9) Remove the timing light.
(10) Install the cylinder head cover with the 2 nuts and
2 clips.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect the tachometer test prove to
terminal 9 (TAC) of DLC3.
SST 09843±18040
(d) Check the idle speed.
Idle speed: 600 to 700 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the ignition coil.
(c) Remove the spark plugs.
(d) Inspect cylinder compression pressure.
SST 09992±00500
(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.

± ENGINE MECHANICALENGINE (1ZZ±FE/3ZZ±FE)
14±3
AVENSIS REPAIR MANUAL (RM1018E)
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure


1,300 kPa (13.3 kgf
cm
2, 189 psi)
Minimum pressure: 1,000 kPa (10.2 kgf
cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf
cm
2, 14 psi)
NOTICE:

Always use a fully charged battery to obtain engine
speed of 250 rpm or more.

Check other cylinder's compression pressure in the
same way.

This measurement must be done in as short a time as
possible.
(4) If the cylinder compression in one or more cylinders
is low, pour a small amount of engine oil into the cyl-
inder through the spark plug hole and repeat steps
(1) through (3) for the cylinders that have low com-
pression.
HINT:

If adding oil helps increase the compression, the piston
rings and/or cylinder bore may be worn or damaged.

If pressure stays low, a valve may be sticking or seating
improperly, or there may be leakage past the gasket.
10. INSPECT CO/HC
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Check CO/HC concentration at idle.
Idle CO concentration: 0 to 0.5 %
Idle HC concentration: Applicable local regulation
If the CO/HC concentration does not conform to specifications, perform troubleshooting in the order given
below.

Check heated oxygen sensor operation.

See the table below for possible causes, and then inspect and repair the applicable causes if
necessary.

14±4
± ENGINE MECHANICALENGINE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:

Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

ISC valve

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke form exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:

Faulty pressure regulator

Defective water temperature sensor

Defective mass air flow meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor

13070±01
A79168
A80112
A80113
A64328
2 to 7 mm0 to 5 mm
13±18
±
INTAKE INTERCOOLER ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INTERCOOLER ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE FRONT BUMPER COVER (See page 76±3) 2. REMOVE INTERCOOLER COOLING AIR DUCTSUB±ASSY
(a) Remove the 2 bolts and the cooling air duct.
3. REMOVE INTERCOOLER ASSY
(a) Disconnect the vacuum hose, the air hose No. 2 and No. 3 from the intercooler.
(b) Remove the 3 bolts and nut, and then detach the inter- cooler assy.
4. INSTALL INTERCOOLER ASSY
(a) Install the intercooler assembly with the 3 bolts and a new nut.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
(b) Install the air hose and hose clamps as shown in the il- lustration.