TOYOTA AVENSIS 2005 Service Repair Manual

±
ENGINE MECHANICAL ENGINE(1AZ±FE)
14±103
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:
1000 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 is low, pour a small amount of engine oil into the cylinder through the
spark plug hole and inspect again.
HINT:

If adding oil increases 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 tail\
pipe during idling.
(d)Check CO/HC concentration at idle. Idle CO concentration: 0 to 0.5 %
Idle HC concentration: Applicable local regulation
(e)If the CO/HC concentration does not conform to specifications, perform troubleshooting in the order given below.
(1)Check heated oxygen sensor operation. (See page 12±6)
(2) See the table below for possible causes, and then inspect and repair the applicable causes ifnecessary.

14±104
± ENGINE MECHANICALENGINE (1AZ±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 from 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

141CO±01
A62838SST
A62838SST
A62202
Cut Position
A62203
SST
14±98
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 5. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
6. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
7. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grid sandpa-
per.
8. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223±15020, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.

A62838SST
A62205
1
5
3
82
6
4
7
A62206
90

A62838SST
A62204
1
5
3
82
6
4
7
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
14±99
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a)Fix the crankshaft with SST.
SST09960±10010 (09962±01000, 09963±01000)
(b)Clean the bolt and bolt hole.
(c)Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d)Using several steps, Install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(e)Mark the bolts with paint as shown in the illustration.
(f)Retighten the bolts by an additional 90
in the same se-
quence as step (d).
(g)Check that the paint marks of each bolt are at 90
angle
from the original position.
10.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
11. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
12. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Fix the crankshaft with SST. SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
(e) Fix the crankshaft with SST.
Torque: 88 N
m (897 kgf
cm, 65 ft
lbf)

14±100
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
13.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
14.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)

141CN±01
A60622
A01045
A64005
A62837SST
14±96±
ENGINE MECHANICAL TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
TIMING GEAR COVER OIL SEAL(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE FRONT WHEEL RH (See page 14±27)
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
3.REMOVE ENGINE UNDER COVER RH (See page 14±27)
4.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±27) 6. 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.
7. 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.
8. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the crankshaft pulley bolt. SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the crankshaft pulley from the crankshaft.

A62183
Cut Position
Pry
A62184
SST
A62837SST
A64005
± ENGINE MECHANICALTIMING CHAIN OR BELT COVER OIL
SEAL (1ZZ±FE/3ZZ±FE)14±97
AVENSIS REPAIR MANUAL (RM1018E)
9. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpa-
per.
10. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223±22010
NOTICE:
Wipe off extra grease on the crankshaft.
11. 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)
12. 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)
13. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. CHECK FOR ENGINE OIL LEAKS

141CM±01
A78459
A78461
1ZZ±FE
A78497
3ZZ±FE
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
14±81
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE(See page 11±1)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
3.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
6.REMOVE ENGINE UNDER COVER RH (See page 14±27)
7.DRAIN ENGINE COOLANT(See page 16±7)
8.REMOVE CYLINDER HEAD COVER NO.2
(a)Remove the 2 nuts and 2 clips and detach the cylinderhead cover No.2.
9.SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a)Loosen the nut and separate the accelerator control cable.
10.REMOVE AIR CLEANER HOSE NO.1
(a)Disconnect the VSV connector.
(b)Disconnect the fuel vapor feed No. 1 hose from the VSV.
(c)Disconnect the fuel vapor feed hose from the VSV.
(d)Loosen the 2 air cleaner hose clamp bolts and remove the air cleaner hos\
e.
11.DISCONNECT WATER BY±PASS HOSE
(a)Disconnect the water by±pass hose from the throttle body.
12.DISCONNECT WATER BY±PASS HOSE NO.2
(a)Disconnect the water by±pass hose from the throttle body.
13.REMOVE EFI FUEL PIPE CLAMP (See page 11±11)

A60622
A79324
A76713
A64023
14±82
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±11) SST09268±21010
15.DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a)Disconnect the union to connector tube hose from the hose to hose tube.
16.DISCONNECT RADIATOR HOSE INLET
(a)Disconnect radiator hose inlet from the cylinder head.
17.DISCONNECT HEATER INLET WATER HOSE
(a)Disconnect the heater inlet water hose from the cylinder head.
18.REMOVE FAN AND GENERATOR V BELT
(a)Turn the V±ribbed belt tensioner clockwise slowly andloosen it. Remove the fan and generator V belt and put
back the V±ribbed belt tensioner carefully.
19.REMOVE V±RIBBED IDLER ASSY NO.1
(a)Remove the nut, bolt, tube and idler.
20.REMOVE GENERATOR ASSY (See page 19±7)
21. DISCONNECT 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.
(d) Remove the 4 bolts and the 4 ignition coils.

A65078
A64058
A79363
A64026
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±83
AVENSIS REPAIR MANUAL (RM1018E)
22. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head
cover.
23. DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head
cover.
24. REMOVE INTAKE MANIFOLD
(a) Disconnect the 2 water hoses from the throttle body.
(b) Disconnect the ventilation hose and ventilation hose No.
2 from the cylinder head cover.
(c) Disconnect the vacuum hose from the water by±pass
pipe No. 1.
(d) Remove the 4 bolts, 2 nuts and 2 wire brackets.
(e) Remove the intake manifold and the throttle body assem-
bly.
(f) Remove the gasket from the intake manifold and the
throttle body assembly.
25. REMOVE OIL LEVEL GAGE SUB±ASSY
(a) Remove the oil level gage from the oil level gage guide.
26. REMOVE OIL LEVEL GAGE GUIDE
(a) Disconnect the crankshaft position sensor cramp.
(b) Remove the bolt and the oil level gage guide.
27. SEPARATE WATER BY±PASS PIPE NO.1
(a) Remove the 2 bolts which are used to secure the water
by±pass pipe.