tow TOYOTA AVENSIS 2005 Service User Guide

A09687
UpwardCam Lobe
Clearance
A80107
A81553
Upward
Notch
Cam Lobe
Intake
Manifold
Side
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
14±271
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10.REMOVE INJECTION PIPE SUB±ASSY NO.3
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
11.REMOVE INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
12.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 11±60)
13.REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11±60)
14.REMOVE INJECTOR ASSY (See page 11±60)
HINT:
Since each injector assembly has characteristic fuel injecting behavior, store them in correct order so that
they can be returned to the original locations when re±assembling.
15. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe located over theinspecting valve faces upward.
(b) Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
(c) Measure the clearance at 16 places.
(d) Record the out±of specification valve clearance mea- surements. They will be used later to determine the re-
quired replacement adjusting shim.
Valve clearance (Cold):
Intake0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust0.35 to 0.45 mm (0.014 to 0.018 in.)
16. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.(1) Turn the crankshaft so that the cam lobe located
over the adjusting valve faces upward.
(2) Position the notch of the valve lifter toward the in- take manifold side.

A77302
A77353
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
14±257
AVENSIS REPAIR MANUAL (RM1018E)
(e)Raise a clamp up, and slide it toward the air cleaner cap,
then remove the air cleaner cap from its case.
(f)Remove the air cleaner element.
(g)Remove the 4 bolts and the air cleaner case.
43.DISCONNECT RADIATOR HOSE INLET
44.DISCONNECT UNION TO CONNECTOR TUBE HOSE
45.DISCONNECT HEATER INLET WATER HOSE
46.SEPARATE FUEL TUBE SUB±ASSY
47.SEPARATE ENGINE WIRE
48.REMOVE THROTTLE BODY ASSY (See page 10±44)
49. REMOVE CHARCOAL CANISTER ASSY 50. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts.
(b) Disconnect the 2 vacuum hoses.
(c) Remove the 2 stud bolts.
(d) Remove the intake manifold and insulator.
51. REMOVE INTAKE AIR CONTROL VALVE ASSY
(a) Remove the intake air control valve and gasket.
52. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts and nut, and then remove the manifold insulator.

C83023
C80293
30±26
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
19.INSTALL LOWER BALL JOINT ASSY FRONT LH
(a)Install the lower ball joint and torque the nut. Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b)Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 6\
0  further.
20.INSTALL FRONT AXLE ASSY LH
(a)Install the 2 bolts, nuts and steering knuckle with 2 bolts and nuts to the shock absorber.
Torque: 220 N
m (2,243 kgf
cm, 162 ft
lbf)
NOTICE:
Only when reusing the bolts and nuts, apply engine oil to
the screw part of the nuts.
(b)Push the front axle assy toward the outside of the vehicle, fit the splined part of the drive shaft assy to that of the front
axle assy and insert the drive shaft assy into the front axle
assy.
NOTICE:

Do not push out the front axle assy excessively.

Be careful not to damage the drive shaft outboard
joint boot.

Be careful not to damage the speed sensor rotor.
21.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a)Install the front suspension arm sub±assy lower No.1 LH and lower ball joint with the 2 nuts and bolt.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)
22.INSTALL TIE ROD END SUB±ASSY LH
(a)Install the tie rod end sub±assy LH to the steering knuckle.
(b)Install the nut and a new cotter pin. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 6\
0  further.
23.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
24. INSTALL FRONT DISC

C86268
SST
C67417
Matchmarks
30±16
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
(5) Using SST, adjust the clearance of the damper
clamp.
SST 09240±00020
Clearance: 0.8 mm (0.031 in.) or less
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.
HINT:

Install the damper clamp to inboard joint side.

Except 1AZ±FSE, FE (MT)/ 1CD±FTV

Perform the above procedure only when reassembling
the RH side
38. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
(a) Wrap the spline of the outboard joint shaft assy LH with
vinyl tape to prevent them from being damaged.
(b) Install new parts to the outboard joint shaft assy LH in the
following order.
(1) Inboard joint boot LH clamp
(2) Inboard joint boot
(3) Inboard joint boot LH No.2 clamp
(c) Place the beveled side of the tripod axial spline toward the
outboard joint.
(d) Align the matchmarks placed before removal.
(e) Using a brass bar and hammer, tap in the tripod joint assy
to the drive shaft assy LH.
NOTICE:

Do not tap the roller.

Be sure to install the tripod joint assy in the correct
direction.
(f) Pack the inboard joint shaft and boot with grease in the
boot kit.
Engine typeGrease capacity g (oz.)
1AZ±FSE, 1AZ±FE, 1CD±FTV170 ± 190 g
(6.0 ± 6.7 oz.)
3ZZ±FE, 1ZZ±FE125.5 ± 135.5 g
(4.4 ± 4.8 oz.)

400DI±02
D25118
D25119
± AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT ASSY
40±69
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When the shift lever from P to R position with the ignition switch is ON and the brake pedal is de-
pressed, make sure that the shifting lever moves smoothly and can be moderately operated.
(b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position
and moves rearward when shifting to R position.
2. ADJUST SHIFT LEVER POSITION
(a) Loosen the nut on the control shaft lever.
(b) Push the control shaft fully downward.
(c) Return the control shaft lever 2 notches to N position.
(d) Set the shift lever to N position.
(e) While holding the shift lever lightly toward the R position
side, tighten the shift lever nut.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
(f) Start the engine and make sure that the vehicle moves
forward when shifting the lever from N to D position and
moves rearward when shifting it to R position.

F44793Matchmarks
F44794
Screw
Extractor
F44795
SST
F44796
F44797
50±14
±
STEERING COLUMN STEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
33. REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (LHD STEERING POSITION TYPE)
(a) Place matchmarks on the steering intermediate shaft
assy No. 2 and steering main shaft.
(b) Remove the bolt and steering intermediate shaft assy No. 2.
(c) W/VSC:
Remove the steering sensor (See page 32±65).
34. REMOVE STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
(a) Using a centering punch, mark the center of the 2 ta- pered±head bolts.
(b) Using a 3 ± 4 mm (0.12 ± 0.16 in.)drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts and steering column upper with switch bracket assy.
NOTICE:
Do not give the strong force to the motor part.
35. INSPECT STEERING COLUMN ASSY (ELECTRIC POWER STEERING)
(a) Using SST and a torque wrench, check the rotating torque.
SST 09616±00011
Rotating torque (1 turn for 2 sec.):
0.4 ± 1.1 N
m (4 ± 11 kgf
cm, 3.5 ± 9.5 in.
lbf)
36. REMOVE TRANSPONDER KEY AMPLIFIER
(a) Widen the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver.
(b) Pull the transponder key amplifier toward the rear of the
vehicle with the claw open.
NOTICE:
Take care not to use excessive force to prevent the case
from being damaged.
37. REMOVE IGNITION SWITCH LOCK CYLINDER ASSY
(a) Place the ignition switch lock cylinder assy at the ACC position.
(b) Push down the stop pin with a screwdriver, and pull out the cylinder assy.

H42762
Tires
(5 or more)
SST(s)
H42763
SST(s)
H42764
Battery SST(s)
10 m (33 ft) or more
± SUPPLEMENTAL RESTRAINT SYSTEMCURTAIN SHIELD AIR BAG ASSY LH
60±45
AVENSIS REPAIR MANUAL (RM1018E)
(f) Place the tires.
CAUTION:
Do not place the deployment direction of the curtain shield
airbag assy LH facing toward the ground.
(1) Place at least 2 tires under the tire to which the cur-
tain shield airbag assy LH is tied.
(2) Place at least 2 tires over the tire to which the curtain
shield airbag assy is tied. The top tire should have
the wheel installed.
NOTICE:
Do not place the SST(s) connector under the tire because
the SST connector could be damaged.
(3) Tie the tires together with 2 wire harnesses.
CAUTION:
Make sure that the wire harness is tight. It is highly danger-
ous when looseness in the wire harness results in the tires
coming free due to the shock from the airbag deployment.
HINT:
Place the SST(s) connector and the wire harness inside tires.
Secure at least 1 m (3 ft) of slack for the wire harness.
(g) Install the SST(s).
Connect one SST(s) connector to the SST(s) connector
connected to the curtain shield airbag.
SST 09082±00700
NOTICE:
To avoid damaging the SST(s) connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST(s) wire harness inside the tire.
(h) Deploy the airbag.
(1) Connect the red clip of the SST(s) to the battery
positive (+) terminal and the black clip of the SST(s)
to the battery negative (±) terminal.
(2) Check that no one is within a 10 m (33 ft) radius of
the tire to which the curtain shield airbag assy LH is
tied.
(3) Press the activation switch of the SST(s) and
deploy the airbag.
HINT:
The airbag deploys as the LED of the SST(s) activation switch
comes on.

C81320
C81321
C81322
40±74
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL FRONT DIFFERENTIAL SIDE GEAR
[ 41331F / 4301 ]
(a) After applying ATF to the 2 front differential side gears, 2
side gear thrust washers No. 1, 2 front differential pinions
and 2 pinion thrust washers, install them to the front differ-
ential case.
HINT:
At the time of installation, set the alignment of the front differen-
tial pinions perpendicular to that of the side gear and rotate
them so that their holes will be aligned with the holes in the dif-
ferential case.
11. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
[ 41342F / 4301 ]
(a) Install the pinion shaft so as to align the lock pin holes on
the pinion shaft and differential case.
12. INSPECT BACKLASH
(a) Measure the side gear backlash while holding 1 pinion
gear toward the case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
If the backlash is out of specification, install the correct thrust
washer to the side gear.
(b) Referring to the table below, select thrust washers which
will ensure that the backlash is within for both sides.
Thrust washer thickness: mm (in.)
ThicknessThickness
0.95 (0.0374)1.10 (0.0433)
1.00 (0.0394)1.15 (0.0453)
1.05 (0.0413)1.20 (0.0472)
If the backlash is not within the specification, install a thrust
washer of a different thickness.

A09687
UpwardCam Lobe
Clearance
A87966
A81553
Upward
Notch
Cam Lobe
Intake
Manifold
Side
−
ENGINE MECHANICAL VALVE CLEARANCE (1CD−FTV)(From September,
2003)14 −91
AVENSIS Supplement (RM1045E)
12. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
13. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
14. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
15. REMOVE NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
16. REMOVE CYLINDER HEAD COVER SUB −ASSY (See page 14 −151)
17. REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11 −46)
18. REMOVE INJECTOR ASSY (See page 11 −46)
HINT:
Since each injector assembly has characteristic fuel injecting behavior, keep them in the correct order so
that they can be returned to the original locations when reassembling.
19. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe located over theinspecting valve faces upward.
(b) Using a feeler gauge, measure the clearance between
the valve lifter and camshaft.
(c) Measure the clearance at 16 places.
(d) Record the out −of −specification valve clearance mea-
surements. They will be used later to select an adjusting
shim to replace.
Valve clearance (Cold):
Intake0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust0.35 to 0.45 mm (0.014 to 0.018 in.)
20. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft so that the cam lobe located over the adjusting valve faces upward.
(2) Position the notch of the valve lifter toward the in- take manifold side.

A92433
B
B
AA
A79444A79164A80106
A
A
B
B
− INTAKETURBOCHARGER SUB−ASSY (1CD−FTV)(From
September, 2003)13−17
AVENSIS Supplement (RM1045E)
33. INSTALL TURBO WATER PIPE SUB−ASSY NO.1
(a) Install a new gasket and the turbo water pipe with the 2 nuts.
Torque: 13 N
m (135 kgf
cm, 9.8 ft
lbf)
34. INSTALL TURBOCHARGER SUB−ASSY
(a) Install a new gasket and the turbocharger with the 3 nuts.
Torque: 60 N
m (612 kgf
cm, 44 ft
lbf)
35. INSTALL TURBO OIL INLET PIPE SUB−ASSY
(a) Install a new gasket and the oil pipe with the 2 nuts.
Torque: 13 N
m (135 kgf
cm, 9.8 ft
lbf)
36. INSTALL TURBOCHARGER STAY
(a) Install the turbocharger stay, then temporarily tighten
bolts A.
(b) Temporarily tighten nuts B while pushing the cylinder
head toward the turbocharger stay.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c) Tighten bolts A.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d) Tighten nuts B.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
37. INSTALL EXHAUST MANIFOLD CONVERTER
SUB−ASSY
(a) Install the manifold stay, then temporarily tighten the cyl-
inder block side of the manifold stay.
(b) Install a new gasket and the manifold converter, then tem-
porarily tighten bolts A and bolts B while pushing the up-
per portion of the converter toward the turbocharger.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c) Tighten the 3 nuts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(d) Tighten bolts A.
Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
(e) Tighten bolts B.
Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)