TOYOTA AVENSIS 2005 Service Repair Manual

A77391
Seal Packing
4mm
2.5 mm
A
A
AA

3 to 4 mm
A77251
Nut
Nut
C
CC
C
B
B
B
BB
B
B
B
AC
A13759
14±232
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Apply a continuous bead (Diameter 3 to 4 mm (0.118 to
0.157 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826 ± 00080 or equivalent
(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 N
m (92 kgf
cm, 80 in.
lbf)
Bolt B 21 N
m (214 kgf
cm, 15 ft
lbf)
Bolt C 43 N
m (438 kgf
cm, 32 ft
lbf)
Nut 9.0 N
m (92 kgf
cm, 80 in.
lbf)
51. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the bolt and nut.
Torque: 60 N
m (610 kgf
cm, 44 ft
lbf)
NOTICE:
As the drive tensioner should be fastened together with the
timing chain cover, so be sure install it within 15 minutes
after the timing chain cover is installed.

A77392
Seal Packing6mm
A64641
A77393
SST
A77394
Raise
Pin Hook
Push
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FSE)
14±233
AVENSIS REPAIR MANUAL (RM1018E)
52.INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a)Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b)Apply a continuous bead (Diameter 3 mm to 4 mm (0.157 in.)) of seal packing as shown in the illustration, and install
the oil pan.
Seal packing: part No. 08826 ± 00080 or equivalent
(c)Install the oil pan with the 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
53.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17) 54. INSTALL CRANKSHAFT PULLEY
(a) Using SST, tighten the set bolt.SST 09213±54015 (91651±60855), 09330±00021
Torque: 170 N
m (1,733 kgf
cm, 125 ft
lbf)
55. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap- ply the hook to the pin so that the plunger is located in
position.

A77395
Engine
Front
A77396
Hook
Pin
Turn
Disconnect
A77397
Push
Turn
Plunger
A77398
A
B
A
A 14±234
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install a new gasket chain tensioner with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is released wile inserting, apply the hook again,
and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise, and check that the
hook is disengaged from the plunger knock pin.
(d) Turn the crankshaft clockwise, and check that the plunger
is extended.
56. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
57. 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)
58. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.

A77399
Seal Packing
A77346
AA
A AA
BB
C
C
Nut Nut
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FSE)
14±235
AVENSIS REPAIR MANUAL (RM1018E)
(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 5 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c)install the cylinder head cover with the 9 bolts and 2 nuts. Torque:
Nut 11 N
m (112 kgf
cm, 8 ft
lbf)
Bolt A 11 N
m (112 kgf
cm, 8 ft
lbf)
Bolt B 14 N
m (143 kgf
cm, 10 ft
lbf)
Bolt C 21 N
m (214 kgf
cm, 16 ft
lbf)
59.INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
60.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
61.INSTALL ENGINE WIRE
Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
62.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
63.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
64.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
65.INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
66.INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
67.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
68.INSTALL GENERATOR ASSY (See page 19±20)
69.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
70.INSTALL FUEL PUMP ASSY (See page 11±52)
71.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
72.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
73.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
74. ADD ENGINE OIL
75. CHECK FOR ENGINE OIL LEAKS
76. CHECK FOR FUEL LEAKS

14±236
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
77. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
78. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

141BC±01
A77310
Engine Cover Sub±assy No. 1
Radiator Support
Opening Cover
Engine Room
Cover Side
Fan and Generator V Belt
Engine Under Cover RH
Engine Under Cover LH
N´m (kgf´cm, ft´lbf)
: Specified torque
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
14±218
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1AZ±FSE)
COMPONENTS

A77319
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
GasketCooler Bracket
(LHD Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant Suction Hose No. 1
(LHD Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator Assy
Exhaust Pipe Assy Front
43 (440, 32)

Gasket
43 (440, 32)
7.0 (71, 62 in.
lbf)
52 (530, 38)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
Vane Pump Assy
37 (377, 27)
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
14±219
AVENSIS REPAIR MANUAL (RM1018E)

A77374
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Cylinder Head Cover Sub±assy
11 (115, 8.0)
Ventilation Hose No. 1
Gasket
Fuel Tube Sub±assy
Gasket Fuel Pipe
Sub±assy No. 1
Fuel Pressure
Pulsation Damper
Assy
Fuel Pump Assy

Gasket14 (143, 10)
Ignition Control
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)

O±ring
Ventilation Hose No. 2
33 (331, 24)
25 (255, 18)
Fuel Pipe No. 1

Fuel Injector
Back±up Ring No. 1

Fuel Injector Back±up
Ring No. 3
Fuel Injector
Back±up Ring No. 2
30 (306, 22)
14±220
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A77321
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
43 (440, 32)

Gasket
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover
Sub±assy
Crankshaft Position
Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt
Tensioner Assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
43 (440, 32)
170 (1,735, 125)
Crank Shaft Pulley

Oil Seal
43 (440, 32)
Chain Sub±assy
Chain Tensioner
Slipper
Chain Vibration
Damber No. 1
Crankshaft
Timing Gear
or Sprocket
19 (195, 14)
Crankshaft Position
Sensor Plate No. 1
Timing Chain Guide
Oil Pump
Drive Gear
12 (122, 9.0)
Spring
Chain Tensioner
Oil Pump Drive Shaft Gear
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
30 (301, 22)
No. 2 Chain Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
14±221
AVENSIS REPAIR MANUAL (RM1018E)

141BM±01
A77339
A77301
14±204
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±33)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±31)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove the 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD STEERING POSITION TYPE)
(a)Remove the bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±36)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±185)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(a) Remove the 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
20. REMOVE BATTERY