clock TOYOTA AVENSIS 2005 Service User Guide

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.

A64058
A64856
A60622
A01045
A64005
±
ENGINE MECHANICAL CAMSHAFT(1ZZ±FE/3ZZ±FE)
14±65
AVENSIS REPAIR MANUAL (RM1018E)
6.DISCONNECT VENTILATION HOSE NO.2
(a)Disconnect the ventilation hose from the cylinder head
cover.
7.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts, and 3 clamp brackets.
(b)Remove the cylinder head cover.
8.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
9. REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
10. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly and loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
11. REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine. Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.

A62191
Advanced
Side Path Retard
Side Path
A62192
Hold Pressure
DecompressAdvanced
Side Path Retard
Side Path
A62193
Straight Pin Fringe Bolt
A62194
Straight Pin
Key Groove
14±70
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Put air pressure into two broken paths (the advance side
path and the retard side path) with about 150 kPa {1.5
kgf
cm}.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
(d) Confirm if the camshaft timing gear assembly revolves in
the timing advance direction when weakening the air
pressure of the timing retard path.
HINT:
When the lock pin is released, the camshaft timing gear re-
volves in the advance direction.
(e) When the camshaft timing gear comes to the most ad-
vanced position, take out the air pressure of the timing re-
tard side path, next, take out that of timing advance side
path.
CAUTION:
Camshaft timing gear assembly occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released first. It often causes the breakage of
the lock pin.
(f) Remove the fringe bolt of camshaft timing gear assembly.
NOTICE:

Be sure not to remove the other 4 bolts.

In case of reusing the camshaft timing gear, release
the straight pin lock first, and then install the gear.
17. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft
together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly clockwise (as
shown in the illustration) while pushing it lightly against
the camshaft. Push further at the position where the pin
gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).

A62178
Push
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
A11858
A64005
±
ENGINE MECHANICAL CAMSHAFT(1ZZ±FE/3ZZ±FE)
14±73
AVENSIS REPAIR MANUAL (RM1018E)
(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 fix it.
(3)Turn the crankshaft counter clockwise, and take thehook 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.
19.ADJUST VALVE CLEARANCE(See page 14±6)
20. 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
21. 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)

141CI±01
A78459
A60622
A79324
A76713
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1ZZ±FE/3ZZ±FE)
14±49
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
3.REMOVE FRONT WHEEL RH
4.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
5.REMOVE ENGINE UNDER COVER RH (See page 14±27)
6.DRAIN ENGINE COOLANT (See page 16±7)
7.REMOVE CYLINDER HEAD COVER NO.2
(a)Remove the 2 nuts and 2 clips and detach the cylinderhead cover No.2.
8.REMOVE FAN AND GENERATOR V BELT
(a)Turn the V±ribbed belt tensioner clockwise slowly and loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
9.REMOVE V±RIBBED IDLER ASSY NO.1
(a)Remove the nut, bolt, tube and idler.
10.REMOVE GENERATOR ASSY (See page 19±7)
11. REMOVE IGNITION COIL ASSY
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.

A30857
A10079
A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
A62172
SST
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±53
AVENSIS REPAIR MANUAL (RM1018E)
27. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain with the crankshaft timing gear
by plying it using screwdrivers as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise for valves not to touch the pistons.
28. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the camshafts with a wrench and align the
point marks of the camshaft timing sprockets.
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain to the crankshaft timing sprocket
with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
HINT:
Three yellow color links are on the chain.
(c) Using SST, install the crankshaft timing sprocket.
SST 09223±22010

A62837SST
A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A62182
Seal Packing
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±57
AVENSIS REPAIR MANUAL (RM1018E)
38. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, and 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, and take the hook
off the knock pin to release the plunger.
(d) 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.
39. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old pacing (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.

A77338
A79320
A79296
A60622
14±30
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
32. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE) (See page 41±15)
33. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
(See page 41±15)
34. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)
35.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
36.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
37. REMOVE INSTRUMENT PANEL UNDER COVER SUB±ASSY NO.2
38. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junctionblock.
(b) Pull out the engine wire.
(c) Remove the engine room relay block No.2 cover.
(d) Remove a nut and disconnect a connector as shown in the illustration.
(e) Remove the bolt and disconnect the ground terminal.
(f) Disconnect the ground terminal connector.
(g) Remove the nut and disconnect the battery terminal B.
39. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly and loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.

141B6±01
A77281
A77378
No. 1 Cylinder TDC/Compression
IN
EX
A77379
No. 4 Cylinder TDC/Compression
IN
EX
14±106
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1AZ±FE)
ADJUSTMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.REMOVE ENGINE UNDER COVER RH 4.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
5.REMOVE IGNITION COIL ASSY
(a)Remove 4 bolts and the ignition coils.
6.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±171)
7.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±171) 8. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
(b) Turn the crankshaft clockwise 1 revolution (360
) and set
No. 4 cylinder to TDC/compression.
(c) Check only the valve indicated in the illustration. (1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)

141B5±01
A77293
SST
± ENGINE MECHANICALFAN AND GENERATOR V BELT (1AZ±FE)
14±105
AVENSIS REPAIR MANUAL (RM1018E)
FAN AND GENERATOR V BELT (1AZ±FE)
REPLACEMENT
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE ROOM COVER SIDE
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FAN AND GENERATOR V BELT
(a) Using SST, loosen the V±ribbed belt tensioner arm clock-
wise, and remove the fan and generator V belt.
SST 09249±63010
5. INSTALL FAN AND GENERATOR V BELT
(a) Using SST, loosen the V±ribbed belt tensioner arm clockwise, and install the fan and generator V belt.
SST 09249±63010