TOYOTA AVENSIS 2005 Service Repair Manual

A77308
A77303
A77307
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±123
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITION ER) STEER ING
POSITION TYPE)
(a)Remove 2 nuts and separate the suction hose.
28.REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a)Remove a bolt and the service cover bracket RH. 29.REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the cooler bracket.
30.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
31.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
32.DISCONNECT HEATER OUTLET WATER HOSE (W/ AIR CONDITIONING)
33.REMOVE CHARCOAL CANISTER ASSY
34.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±15)
35. DISCONNECT UNION TO CONNECTOR TUBE HOSE
36.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
38.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
39.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09330±00030

A77298
LHD Steering Position typeRHD Steering Position type
14±124
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE FRONT AXLE HUB RH NUT SST09330±00030
HINT:
Perform the same procedure as above on the opposite side.
41.SEPARATE TIE ROD END SUB±ASSY LH (See page 51±36)
42.SEPARATE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
43.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
44.SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
(See page 26±21)
46.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) (See page 26±16)
47.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
48.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
49.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
50.SEPARATE FRONT AXLE ASSY RH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side. 51.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
(a)Remove 7 bolts as shown in the illustration.
52.SEPARATE TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
53.SEPARATE TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
54. SEPARATE ACCELERATOR CONTROL CABLE ASSY

A77338
A77337
A77336
A57550
Engine Hanger No. 1 Engine Hanger No. 2
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
14±125
AVENSIS REPAIR MANUAL (RM1018E)
55. SEPARATE ENGINE ROOM RELAY BLOCK NO.2
(a) Remove the nut and disconnect the connector as shown
in the illustration.
56. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the grand terminal.
(b) Separate the grand terminal connector.
(c) Remove the glove compartment door panel.
(d) Separate the engine wire.
57.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9) 58. INSTALL ENGINE HANGERS
(a) Install the engine hanger No. 1 (12281±28010, 28020,28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Install the engine hanger No. 2 (12282±28010, 28020, 28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)

A77401
A77305
A77304
A59793
A63273
14±126
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
59. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
(a) Set the engine lifter.
(b) Remove 2 bolts and 2 nuts, and then remove the mount-
ing bracket No. 2.
60. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove 3 bolts and the engine mounting insulator.
61. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the through bolt and nut, and then detach the en-
gine mounting insulator.
62. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Remove the8 bolts and the front suspension member
braces.
(b) Remove the 2 bolts and 2 nuts shown in the illustration.
(c) Carefully remove the engine assembly with transaxle
from the vehicle.

A77402SST
A56446
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±127
AVENSIS REPAIR MANUAL (RM1018E)
63.SEPARATE VANE PUMP ASSY
(a)Disconnect the PS oil pressure switch connector.
(b)Remove the 2 bolts and separate the vane pump from the engine.
64.REMOVE STARTER ASSY (See page 19±12)
65.REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Remove the through bolt and nut from the engine mounting insulator FR.
(b)Remove the through bolt and nut from the engine mounting insulator RR.
66.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
67.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
68.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
69.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
70.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
71.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
72. REMOVE DRIVE PLATE AND RING GEAR ORFLYWHEEL
(a) Using SST, fix the crankshaft pulley and remove the drive plate and ring gear or flywheel.
SST 09213±54015 (91651±60855), 09330±00021
73. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Remove a bolt, O±ring and the camshaft timing oil control valve. 74. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts, and then remove the in-take manifold.
75. REMOVE VENTILATION HOSE
76. REMOVE VENTILATION HOSE NO.2
77. REMOVE ENGINE WIRE
78. REMOVE INTAKE MANIFOLD INSULATOR NO.1
79. REMOVE OIL LEVEL GAGE SUB±ASSY
80. REMOVE OIL LEVEL GAGE GUIDE
81. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a) Remove the 4 bolts and the manifold converter insulator No. 1.

A60067
A52497
A32676
A78645
Oil Pressure Switch
14±128
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
82.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY
(a)Remove the 3 bolts and 2 nuts, and then detach the No.
1 and No. 2 exhaust manifold stays.
(b)Remove the 5 nuts, and then remove the exhaust man- ifold converter and gasket.
83.REMOVE WATER INLET
(a)Remove the 2 nuts and the water inlet.
84.REMOVE THERMOSTAT
85.REMOVE IGNITION COIL ASSY
(a)Remove the 4 bolts and the 4 ignition coils. 86.REMOVE V±RIBBED BELT TENSIONER ASSY
(a)Remove the bolt and nut, and then remove the V±ribbedbelt tensioner.
87.REMOVE DRIVE SHAFT BEARING BRACKET
(a)Remove the 3 bolts and the drive shaft bearing bracket.
88.REMOVE FUEL DELIVERY PIPE W/INJECTOR (See page 11±26)
89. REMOVE WATER BY±PASS PIPE NO.1
(a) Remove the bolt and 2 nuts, and then detach the water by±pass pipe No\
. 1. 90. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
(a) Using SST, remove the engine oil pressure switch.SST 09268±46021

A77332
23
145
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±129
AVENSIS REPAIR MANUAL (RM1018E)
91.REMOVE KNOCK SENSOR
(a)Remove the nut and the knock sensor.
92.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a)Using SST, remove the engine coolant temperature sensor.
SST09817±33190
93.REPLACE PARTIAL ENGINE ASSY
94.INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a)Install a new gasket to the engine coolant temperature sensor.
(b)Install the engine coolant temperature sensor. Torque: 20 N
m (208 kgf
cm,15 ft
lbf)
SST09817±33190
95.INSTALL KNOCK SENSOR
Torque: 20 N
m (208 kgf
cm,15 ft
lbf)
96.INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(a)Clean the threads of the oil pressure switch, apply adhesive there. Adhesive: Part No. 08833±00080 THREE BOND 1344 or equivalent
(b)Install the oil pressure switch. Torque: 15 N
m (153 kgf
cm,11 ft
lbf)
97.INSTALL WATER BY±PASS PIPE NO.1
(a)Install a new gasket and the water by±pass pipe No. 1 with the bolt a\
nd 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
98.INSTALL FUEL DELIVERY PIPE W/INJECTOR (See page 11±26)
99.INSTALL DRIVE SHAFT BEARING BRACKET Torque: 54 N
m (551 kgf
cm,40 ft
lbf)
100.INSTALL V±RIBBED BELT TENSIONER ASSY
Torque: 60 N
m (607 kgf
cm,44 ft
lbf)
101.INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
102.INSTALL THERMOSTAT (See page 16±23)
103. INSTALL WATER INLET
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
104. I N S TA L L E X HAUST MANIFOLD CONVERTER
SUB±ASSY
(a) Install a new gasket and the exhaust manifold converter
with the 5 nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)

A52499
A56446
A77333SST 14±130
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the No. 1 and No. 2 exhaust manifold stays with the
2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
105. INSTALL MANIFOLD CONVERTER INSULATOR NO.1
Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
106. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil level gauge guide.
(b) Install the oil level gauge and guide with the bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
107. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 5
bolts and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
108. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Apply light coat of engine oil to the new O±ring and install it to the camshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt.
Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)
109. I N S TA L L D R I V E P L AT E A N D R I N G G E A R O R
FLYWHEEL
(a) Hold the crankshaft with SST.
SST 09213±54015 (91651±60855), 09330±00021
Adhesive:
Part No. 08833±00070, THREE BOND or equivalent

A77403
15
3
7
2
6
4 8
A63273
A77404
B
A
BBBB
A
B
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±131
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the drive plate. (A/T)
(1)Clean the bolt and bolt hole.
(2)Apply adhesive to the bolts.
(3)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 98 N
m (1,000 kgf
cm, 72 ft
lbf)
(c)Install the flywheel. (M/T)
(1)Clean the bolt hole.
(2)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 130 N
m (1,327 kgf
cm, 96 ft
lbf)
NOTICE:
Do not reuse the flywheel bolt.
110.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
111.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
112.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
113.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
114.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
115.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
116.INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Install the engine mounting insulator FR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
(b)Install the engine mounting insulator RR with the through bolt and nut. Torque: 87 N
m (887 kgf
cm,64 ft
lbf)
117.INSTALL STARTER ASSY (See page 19±12)
118. INSTALL VANE PUMP ASSY
Torque: 37 N
m (370 kgf
cm, 27 ft
lbf)
119. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the 2 bolts and 2 nuts as shown in the illustration. Torque:
Bolt 45 N
m (459 kgf
cm, 33 ft
lbf)
Nut 133 N
m (1,356 kgf
cm, 98 ft
lbf)
(b) Install the front suspension member braces with the 8 bolts.
Torque:
Bolt A 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B 80 N
m (816 kgf
cm, 59 ft
lbf)

A77304
A77305
A77405
A
B
A
A
A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±132
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
120.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
121.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
122.INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
123.REMOVE ENGINE HANGERS
124.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
125.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (
See page 41±24)

126.INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25) 127. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
Torque:
Bolt A 12 N
m (122 kgf
cm, 89 ft
lbf)
Bolt B 9.0 N
m (92 kgf
cm, 79 in.
lbf)
Bolt C 5.0 N
m (51 kgf
cm, 44 in.
lbf)