engine TOYOTA AVENSIS 2005 Service Repair Manual

A62239
Standard depth:
Engine front
1.7 to 2.7 mm (0.067 to 0.106 in.)
Engine rear
2.2 to 3.2 mm (0.087 to 0.126 in.)
A92499
18 mm
(0.71 in.)
9mm
(0.35 in.) 31.5 mm
(1.24 in.)
84 mm
(3.31 in.)
20 mm
(0.79 in.)16 mm
(0.63 in.)14 mm
(0.55 in.)
9mm
(0.35 in.) 27.5 mm
(1.08 in.)
A (M16)B (M10)C (M6) A
BAC
Front SideExhaust Side
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−67
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
28. INSTALL TIGHT PLUG
(a) Apply adhesive around the tight plugs.
Adhesive: Part No. 08833−00070, THREE BOND 1324
or equivalent
(b) Using SST, install new tight plugs as shown in the illustra-
tion.
SST 09950−60010 (09951−00200), 09950−70010
(09951−07100)
29. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for stud bolt A
10 N
m (102 kgf
cm, 7 ft
lbf) for stud bolt B
5.0 N
m (51 kgf
cm, 44 in.
lbf) for stud bolt C

A92500
8mm
(0.31 in.)
15 mm
(0.59 in.)10 mm
(0.39 in.)
22 mm
(0.87 in.)7.5 mm (0.30 in.)
for Pin A
12 mm (0.47 in.)
for Pin B
Back SideBottom SideFront Side
ABAA
A
A B
B
P12418A32958
Front Mark
Front Mark
A13497
14−68
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
30. INSTALL STRAIGHT PIN
(a) Using a plastic−faced hammer, tap into the straight pin.
31. INSTALL PISTON
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
(b) Gradually heat the piston to approximately 80 to 90_C
(176 to 194_F).
(c) Align the front marks of the piston and connecting rod,
and push in the piston with your thumb.
(d) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.

A94209
A94210
Coil Joint Oil Ring Ends
A94208
Upward
No. 1
No. 2
Code Mark (T2)Painted Mark
A94211
Front30_
No. 1 Compression
and Oil Ring
No. 2 Compression
30_
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−69
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
32. INSTALL PISTON RING SET
(a) Install the coil by hand.
(b) Using a piston ring expander, install the oil ring.
HINT:
Face the end gap of the oil ring in the opposite direction of coil
joint.
(c) Using a piston ring expander, install the 2 compression
rings with the painted mark as shown in the illustration.
NOTICE:
Install the compression ring No. 2 with the code mark (T2)
facing upward.
(d) Position the piston rings so that the ring ends are as
shown in the illustration.

A53029
A33379
A13501
A13502
73159
10 6 2 4 8
A36657
14−70
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
33. INSTALL CRANKSHAFT BEARING
(a) Install the upper bearing with an oil groove on the cylinder
block.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oil.
34. INSTALL CRANKSHAFT BEARING NO.2
(a) Install the lower bearing on bearing cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oil.
35. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
36. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crank-
shaft on the cylinder block.
(b) Apply engine oil to the lower bearing.
(c) Examine the front marks and install the bearing caps on
the cylinder block.
(d) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.
(e) Uniformly install and tighten the 16 main bearing cap bolts
in the sequence shown in the illustration.
Torque:
20 N
m (204 kgf
cm, 15 ft
lbf) for 1st
40 N
m (408 kgf
cm, 30 ft
lbf) for 2nd

90_
Engine FrontPaint
Mark
A50671
Claw
A50672
Front Mark
Front
A52528
Front Mark
A52515
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−71
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
(f) Mark the front of the bearing cap bolts with paint.
(g) Retighten the bearing cap bolts by 90_same sequence
as step (e).
(h) Check that the painted mark is now at a 90_angle to the
front.
(i) Check that the crankshaft turns smoothly.
37. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oil.
38. INSTALL PISTON
NOTICE:
The connecting rod cap bolts are tightened in 2 progres-
sive steps.
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(e) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(f) Using a 12 mm socket wrench, uniformly tighten the 2
bolts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(g) Mark the front of the connecting cap bolts with paint.

90_
Engine FrontPaint
Mark
A50671
14−72
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
(h) Retighten the cap bolts by 90_as shown in the illustration.
(i) Check that the crankshaft turns smoothly.

141Q8−01
A88217
Piston Ring Set
zSnap Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Bearing
Cylinder Block Assy
Crankshaft Thrust Washer
Crankshaft Bearing
Crankshaft
Crankshaft Bearing
Crankshaft Bearing Cap BoltConnecting Rod Bearing
Connecting Rod Cap
Crankshaft Bearing Cap
: Specified torqueN
m (kgf
cm, ft
lbf)
zNon−reusable part
1st: 20 (204, 15)
2nd: 40 (410, 30)
3rd: Turn 90_
Connecting Rod Cap Bolt
1st: 25 (250, 18)
2nd: Turn 90_
See page 14−56
zSnap Ring
See page 14−56
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−55
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
CYLINDER BLOCK ASSY (2AZ−FSE)
COMPONENTS

141Q6−01
A77366
Intake Valve Guide Bush
zNon−reusable partzValve Stem Oil SealValve Lifter
Valve Retainer Lock
Retainer
Inner Compression Spring
Valve Spring Seat
Exhaust Valve Guide Bush
Stud Bolt
Cylinder Head Assy
Intake Valve Exhaust Valve Ring w/ Head Pin
− ENGINE MECHANICALCYLINDER HEAD ASSY (2AZ−FSE)
14−41
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
CYLINDER HEAD ASSY (2AZ−FSE)
COMPONENTS

05JOB–03
– DIAGNOSTICSSFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–21
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
FAIL–SAFE CHART
If any of the following DTCs are recorded, the ECM enters fail–safe mode.
DTC No.Fail–Safe OperationFail–Safe Deactivation Condition
P0031
P0032Heated oxygen sensor (Sensor 1) heater is turned offIgnition switch turned to OFF
P0037
P0038Heated oxygen sensor (Sensor 2) heater is turned offIgnition switch turned to OFF
P0100
P0102
P0103Ignition timing is calculated from engine RPM and Throttle
Position (TP)”Pass” condition detected
P0110
P0112
P0113
Intake Air Temperature (IAT) is fixed at 20
C (68
F)”Pass” condition detected
P0115
P0117
P0118
Engine Coolant Temperature (ECT) is fixed at 80
 
”Pass” condition detected
P0120
P0122
P0123
P0220
P0222
P0223
P2102
P2103
P2111
P2112
P2118
P2119
P2135
When Electronic Throttle Control System (ETCS) is mal-
functioning, electric current to throttle actuator is cut off and
throttle valve returns to throttle position (TP) 16 by its
spring.
Then, required engine power is calculated using ignition
timing and Accelerator Pedal Position (APP). Engine is
controlled by intermittent fuel–cut.
As a result, fully slowly depressing accelerator pedal en-
ables driving at minimum speed. However, quickly depress-
ing pedal would vary vehicle speed remarkably.
”Pass” condition detected followed by the ignition switch
turned to OFF
P0121Fuel is cut intermittently”Pass” condition detected followed by the ignition switch
turned to OFF
P0325
P0327
P0328
Maximum ignition timing retardationIgnition switch turned to OFF
P0351
P0352
P0353
P0354
Fuel is cut”Pass” condition detected
P2120
P2121
P2122
P2123
P2125
P2127
P2128
P2138
Accelerator Pedal Position (APP) sensor has main circuit
and associate circuit. When one of circuits is malfunction-
ing, APP is calculated by output of other circuit. When both
of circuits are malfunctioning, it is interpreted that accelera-
tor pedal is releasing. As a result, throttle valve is closed
and engine idles.
”Pass” condition detected followed by the ignition switch
turned to OFF

05KNS–02
A93652
DLC3
Intelligent Tester ll
A90409
Powertrain
Engine and ECT DTC
Example:
A90410
Clear
Example:
05–18
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC CHECK/CLEAR
NOTICE:
Intelligent tester II only:
When the diagnosis system is changed from normal mode
to check mode or vice–versa, all DTCs and freeze frame
data recorded in normal mode will be er ased. Before
changing modes, always check and make a note of DTCs
and freeze frame data.
1. CHECK DTC (using the intelligent tester II)
(a) Connect the intelligent tester II to the DLC3.
(b) Turn the ignition switch to ON and turn the intelligent tes-
ter ll ON.
(c) Select the following menu items: Powertrain / Engine and ECT / DTC.
(d) Check DTCs and freeze frame data, and then write them down.
HINT:
If you need help using the intelligent tester II, refer to the instruc-
tion manual.
(e) See page 05–27 to confirm the details of the DTCs.
2. FREEZE FRAME DATA
(a) Connect the intelligent tester II to the DLC3.
(b) Turn the ignition switch to ON and turn the intelligent tes- ter II ON.
(c) Read DTCs by selecting the following menu items: Pow- ertrain / Engine and ECT / DTC.
(d) Select a parameter(s) to check the freeze frame data.
(e) Note down the DTC(s) and freeze frame data.
HINT:
If you need help using the intelligent tester II, refer to the instruc-
tion manual.
3. CLEAR DTCs AND FREEZE FRAME DATA
(using the intelligent tester II)
(a) Connect the intelligent tester II to the DLC3.
(b) Turn the ignition switch to ON (do not start the engine) and
turn the intelligent tester II ON.
(c) Select the following menu items: Powertrain / Engine and ECT / DTC / Clear.
(d) Erase DTCs and freeze frame data by pressing the YES
button on the tester.
HINT:
If you need help using the intelligent tester II, refer to the instruc-
tion manual.