TOYOTA AVENSIS 2005 Service Repair Manual

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)

A62182
Seal Packing
A65687
A
A
A
A A A
A A
BB A
A64023
14±74
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
22. 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 3 cable brackets 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
23. 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
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
14±75
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
24. 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)
25. CHECK FOR ENGINE OIL LEAKS

141CJ±01
A79321
Clip
Engine Room Side Cover RH
Retainer Clip
Radiator Cover Assy
Clip
Engine Under Cover RH
Engine Under Cover No. 1
Clip
14±60
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1ZZ±FE/3ZZ±FE)
COMPONENTS

A76710
Fan and Generator V Belt
Cylinder Head Cover No. 2 Clip
Engine Mounting
Insulator RH
N´m (kgf´cm, ft´lbf) : Specified torque
7.0 (71, 62 in.
lbf)
52 (530, 38)
52 (530, 38)
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
14±61
AVENSIS REPAIR MANUAL (RM1018E)

A76709
Ventilation Hose No. 2
Clamp Bracket
Ventilation Hose Ignition Coil AssyEngine Wire
Clamp Bracket
Clamp Bracket
Gasket
Cylinder Head Cover
Sub±assy
Seal Washer
N´m (kgf´cm, ft´lbf) : Specified torque
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
11 (112, 8)
11 (112, 8)11 (112, 8)
11 (112, 8)
14±62
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A64006
V±ribbed Belt
Tensioner Assy
Camshaft Bearing Cap No. 1
Camshaft Timing Gear
or Sprocket
Camshaft Timing Gear Assy
Chain Tensioner
Assy No. 1Camshaft Camshaft No. 2 Camshaft Bearing Cap No. 3
69 (704, 51)
29 (296, 21)
9.0 (92, 80 in.
lbf)
23 (235, 17)
54 (551, 40)
54 (551, 40)
13 (133, 10)
N´m (kgf´cm, ft´lbf) : Specified torque
Timing Chain Sub±assy
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
14±63
AVENSIS REPAIR MANUAL (RM1018E)

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.

A64023
A65078
A64058
A01045
A64005
14±50
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove the 4 bolts and the 4 ignition coils.
12. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head
cover.
13. DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head
cover.
14. 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.

A64856
A62185
MarkMark
Mark Timing Chain
Cover Surface
Timing
Notch
A62837SST
A11858
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1ZZ±FE/3ZZ±FE)
14±51
AVENSIS REPAIR MANUAL (RM1018E)
15.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts and 3 clamp
brackets and detach the cylinder head cover.
16.SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a)Turn the crankshaft pulley to align the timing notch with timing mark º0º of the timing chain cover.
(b)Check that the point marks of the camshaft timing sprock- et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
17.REMOVE CRANKSHAFT PULLEY
(a)Using SST, remove the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
(b)Remove the crankshaft pulley from the crankshaft.
18.REMOVE V±RIBBED BELT TENSIONER ASSY
(a)Remove the bolt and nut and detach V±ribbed belt ten- sioner.
HINT:
Jack up and down to remove the bolt.
19.REMOVE WATER PUMP ASSY(See page 16±9)