TOYOTA AVENSIS 2005 Service Repair Manual

A77372
Engine Assy
Drive Shaft Bearing Bracket
Hole Plug
Drive Plate & Ring Gear
Sub±Assyx6
Wire Clamp Bracket
Starter Wire Starter Assy
34 (347, 25)
41 (420, 32)
98 (1,000, 72)
46 (469, 34)
13 (132, 10)
x8
N´m (kgf´cm, ft´lbf)
: Specified torque A/T:
Automatic Transaxle
46 (469, 34)
46 (469, 34)
37 (378, 27)
37 (378, 27)
64 (653, 47)
41 (418, 30)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±199
AVENSIS REPAIR MANUAL (RM1018E)

A77369
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
10 (97, 84 in.
lbf)
10 (97, 84 in.
lbf)

Gasket
Intake Air Control Valve

GasketInsulator
10 (97, 84 in.
lbf)
Intake Manifold

Gasket
Water By±pass
Hose No. 1
Throttle Body Assy
Water By±pass
Hose No. 2
21 (210, 15)
Throttle Body
Bracket
8.4 (86, 74 in.
lbf)
8.0 (82, 71 in.
lbf)
Water By±pass Hose No. 1
Heater Water Inlet Hose 14±200
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A77498
Engine Wire
Engine Wire
Ignition Coil
Ventilation Hose No. 2
V±ribbed Belt Tensioner
ASSYFuel Pipe Sub±assy No. 1

Gasket

Gasket

Gasket Fuel Pump AssyFuel Pressure
Pulsation Damper
ASSY
9.0 (90, 80 in.
lbf)
60 (607, 44)
25 (255, 18)
33 (331, 24)
9.0 (90, 80 in.
lbf)
Fuel Pipe No. 1

Fuel Injector
Back±up Ring No. 1

O±ring

Fuel Injector
Back±up Ring No. 3
Fuel Injector
Back±up Ring No. 2
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
30 (306, 22)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±201
AVENSIS REPAIR MANUAL (RM1018E)

A77499
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
GasketWater By±pass
Pipe No. 1
Gasket
Thermostat
9.0 (90, 80 in.
lbf)
Water Inlet
37 (378, 27)Oil Level Gauge
Guide

O±ring
Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy Manifold Stay No. 1
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)

Gasket
9.0 (90, 80 in.
lbf)
12 (122, 9.0)12 (122, 9.0)
12 (122, 9.0)
44 (449, 32)
44 (449, 32)
Oil Level Gauge Sub±assy
14±202
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A77370
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
O±ring
13 (127, 9.0)

E±ring

O±ring
Nozzle Holder Clamp
Fuel Injector

Gasket

Fuel Injector Seal
Fuel Delivery Pipe Sub±assy
19 (194, 14)
Camshaft Timing
Oil Control Valve

O±ring
20 (208, 15)
Knock Sensor
Insulator No. 2
15 (153, 11)
Engine Oil Pressure
Switch Assy
20 (208, 15)
E. F. I. Engine Coolant
Temperature Sensor
Surge Tank Stay No. 1
9.0 (92, 79 in.
lbf)
21 (210, 15)

Back Up Ring No. 3

Back Up Ring No. 2

Back Up Ring No. 1
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±203
AVENSIS REPAIR MANUAL (RM1018E)

141BL±01
A77339
A77343
No. 1 Cylinder TDC / CompressionIN
EX
14±186
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1AZ±FSE)
ADJUSTMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±33)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH 5.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
6.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
7.REMOVE FUEL TUBE SUB±ASSY (See page 11±33)
8.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
9. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and the ignition coils.
10.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±240)
11.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±240)
12. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and the camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
(b) Turn the crankshaft clockwise 1 revolution (360
) and set
No. 4 cylinder to TDC/compression.

A77344
IN
EX
No. 4 Cylinder TDC / Compression
A01082
EXAMPLE: (Intake)
Measure valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) ± 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in\
.)
(Measured ± Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)\

(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. º50º
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FSE)
14±187
AVENSIS REPAIR MANUAL (RM1018E)
(c)Check only the valve indicated in the illustration.
(1)Using a feeler gauge, measure the clearance be-tween the valve lifter and the camshaft.
(2)Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
13.ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to turn the crankshaft without the chain ten-
sioner.
(a)Set the No. 1 cylinder to TDC/compression. (See page 14±240)
(b)Remove the chain tensioner. (See page 14±240)
(c)Remove the camshafts. (See page 14±240)
(d) Tie the timing chain with a string.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(e) Remove the valve lifters.
(f) Using a micrometer, measure the thickness of the re-
moved lifter.
(g) Calculate the thickness of a new lifter so that the valve clearance comes within the specified valve.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Valve clearance:
Intake: A = B + (C ± 0.24 mm (0.0094 in.))
Exhaust: A = B + (C ± 0.35 mm (0.0138 in.))

A77295
14±188
± ENGINE MECHANICALVALVE CLEARANCE (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
HINT:

Select a new lifter with a thickness as close as possible
to the calculated valves.

Lifter are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).

Identification number inside the valve lifter shows the val-
ue of the 2 decimal places. (The illustration shows 5.380
mm (0.2118 in.))

Refer to the New Lifter Thickness table on the next 2
pages.

A77296
mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Intake)
Intake valve clearance (Cold):
0.19 to 0.29 mm (0.008 to 0.011 in.)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter is installed, and
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 5.250 mm (0.2067 in.) lifter with a new No. 44 lifter.
New Lifter Thickness
± ENGINE MECHANICALVALVE CLEARANCE (1AZ±FSE)
14±189
AVENSIS REPAIR MANUAL (RM1018E)

A77297
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.30 to 0.40 mm (0.0118 to 0.0157 in.)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter is installed, and
the measured clearance is 0.440 mm (0.0173 in.).
Replace the 5.340 mm (0.2102 in.) lifter with a new No. 44 lifter.
14±190
± ENGINE MECHANICALVALVE CLEARANCE (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)