engine TOYOTA AVENSIS 2005 Service Repair Manual

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
−
COOLING WATER PUMP ASSY (2AZ −FSE)
16 −13
AVENSIS Supplement (RM1045E)
11. INSTALL WATER PUMP ASSY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump assy.
(b) Apply a continuous bead of the seal packing (diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)) as shown in the illustra-
tion.
Seal packing: Part No. 08826 − 00100 or equivalent
NOTICE:
Install the water pump assy within 5 minutes after applying
seal packing. Otherwise the material must be removed and
reapplied.
(c) Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d) Install the crankshaft position sensor wire harness clamp
to the water pump.
(e) I nst all t he cr ankshaf t posit ion s ensor wir e t o t he wir e clamp on the water pump.
12. INSTALL WATER PUMP PULLEY
(a) Using SST, install the pump pulley with 4 bolts. SST 09960 −10010 (09962 −01000, 09963 −00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

141NN−01
A61184
A85928
−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)14 −177
AVENSIS Supplement (RM1045E)
CRANKSHAFT SEAL (1CD −FTV)(From September, 2003)
REPLACEMENT
1. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil.
Torque: 34 N
m (350 kgf
cm, 25 ft
lbf)
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE RADIATOR SUPPORT OPENING COVER
6. REMOVE ENGINE ROOM COVER SIDE
7. REMOVE ENGINE COVER NO.1 (See page 14 −90)
8. REMOVE INJECTOR DRIVER (See page 14 −108)
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
10. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
11. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
12. DISCONNECT ENGINE WIRE (See page 14 −138)
13. DISCONNECT VACUUM HOSE (See page 14 −108)
14. REM O VE ENG I NE M O UNTI NG I NSULATO R SUB−ASSY RH
(a) Place a wooden block on a jack underneath the engine.
(b) Remove the 3 bolts and 3 nuts, then detach the engine mounting insulator sub −assembly.
15. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
16. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
17. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
18. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
19. REMOVE TIMING BELT GUIDE
20. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)

SST
A09582
B07973
Cut PositionPry
SST
A08528
SST
A09583
Angle
SensorInward
14
−178−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
22. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
23. REMOVE TIMING BELT (See page 14 −138)
24. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the timing pulley cannot be removed by hand, use SST to remove the pulley.
SST 09950 − 50013 ( 09951 − 05010, 09952 − 05010,
09953 −05010, 09953 −05020, 09954 −05021)
25. REMOVE CRANKSHAFT SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Wrap the tip of the
screwdriver with tape.
26. INSTALL CRANKSHAFT SEAL
(a) Apply multipurpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the oil seal until its sur- face is flush with the oil pump edge.
SST 09316 −60011 (09316 −00011)
27. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located on the crankshaft, then slide the pulley into place.
(b) Using SST and a hammer, tap in the timing pulley with the
angle sensor facing inward.
SST 09223 −46011
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
29. INSTALL TIMING BELT (See page 14 −138)
30. CHECK VALVE TIMING (See page 14 −138)

−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)14 −179
AVENSIS Supplement (RM1045E)
31. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
32. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
33. INSTALL TIMING BELT GUIDE (See page 14 −138)
34. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
35. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
36. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
37. INSTALL CRANKSHAFT PULLEY (See page 14 −138 )
SST 09213 −54015 (09213 −70020), 09330 −00021
38. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
39. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
40. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
41. INSTALL INJECTOR DRIVER (See page 14 −108)
42. INSTALL ENGINE COVER NO.1 (See page 14 −90)
43. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
44. ADD ENGINE OIL
45. CHECK FOR ENGINE OIL LEAKS

551AN−01
I35326
I35327
I35328
55 −4
−
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1 . DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(See Pub. No. RM 1018E, page 55 −38)
SST 07110 −58060 ( 07117 −58080, 07117 −58090, 07117 −78050, 07117 −88060, 07117 −88070,
07117 −88080)
2. DI SCO NNECT CO O L ER REFRI G ERANT SUCTI O NHOSE NO. 1
(a) Remove the bolt and disconnect the cooler refrigerant
suction hose No.1 from the w/pulley compressor assy.
(b) Remove the O −ring from the cooler refrigerant suction
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
3. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO. 1
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the w/pulley compressor assy.
(b) Remove the O −ring from the cooler refrigerant discharge
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
4. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14− 5)
5. REMOVE ENGINE ROOM COVER SIDE (See page 14− 5)
6. REMOVE ENGINE UNDER COVER RH (See page 14− 5)
7. REMOVE FAN AND GENERATOR V BELT (See page 14− 5)
SST 09249 −63010
8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.

I35327
I35326
55−6
− HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
(d) Install the cooler refrigerant discharge hose No.1 on the
w/pulley compressor assy with the bolt.
Torque: 9.8 N
m(100 kgf
cm, 87 in.
lbf)
13. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O−ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND−OIL 8 or equivalent
(c) Install the O−ring on the cooler refrigerant suction hose
No.1.
(d) Install the cooler refrigerant suction hose No.1 on the w/
pulley compressor assy with the bolt.
Torque: 9.8 N
m(100 kgf
cm, 87 in.
lbf)
14. CHARGE REFRIGERANT (See Pub. No. RM1018E, page 55−38)
SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050,
07117−88060, 07117−88070, 07117−88080)
Specified amount: 440á30 g (15.51á1.06 oz.)
15. WARM UP ENGINE (See Pub. No. RM1018E, page 55−38)
16. INSPECT LEAKAGE OF REFRIGERANT (See Pub. No. RM1018E, page 55−38)

40189−01
D25831
SST
D25832
SST
D25833
SST
40 −24
−
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U151E)
AVENSIS Supplement (RM1045E)
FRONT DIFFERENTIAL OIL SEAL (U 151E)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE ENGINE UNDER COVER LH
4. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and the drain plug. Torque: 47 N
m (480 kgf
cm, 35 ft
lbf)
5. REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30 −4)
6. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30 −4)
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, pull out the oil seal. SST 09308 −00010
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308 −00010
9. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal. SST 09316 −60011 (09316 −00011)
Oil seal drive in depth:
0 á 0.5 mm (0 á0.020 in.)
(b) Coat the lip of the oil seal with MP grease.

40188−01
C91925
D30865
AT0103
C91927
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
40−19
AVENSIS Supplement (RM1045E)
TRANSMISSION VALVE BODY ASSY (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all of the oil
pan bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Collect any steel chips with the removed magnets.
Look at the chips and particles in the pan and on the
magnets carefully to see the type of wear which
might be found in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.

40187−01
C91925
D30865
AT0103
C91927
40−16
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
AVENSIS Supplement (RM1045E)
TRANSMISSION WIRE (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all of the oil
pan bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Collect any steel chips with the removed magnets.
Look at the chips and particles in the pan and on the
magnets carefully to see the type of wear which
might be found in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.

141Q9−01
A36642
A13397
A13400
14−56
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
HINT:
The connecting rod cap bolts are tightened in 2 progressive
steps.
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure the correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring the correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 connecting
rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and the lower bearing by wiggling
the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
(f) Lay a strip of Plastigage on the crank pin.