TOYOTA AVENSIS 2005 Service Repair Manual

A82647
Length
A82648
No Continuity
A82649
Free Lock
A82650
Apply Grease
A82651
± STARTING & CHARGINGSTARTER ASSY
19±5
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
9. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the starter brush
holder assy.
(b) Check the brush holder.
(1) Using an ohmmeter, check that there is no continu-
ity between the positive (+) and negative (±) brush
holders.
If there is continuity, repair or replace the starter commutator
end frame assy.
10. INSPECT REPAIR SERVICE STARTER KIT
(a) Check the starter clutch.
(1) Rotate the clutch pinion gear counterclockwise and
check that it turns freely. Try to rotate the clutch pin-
ion gear clockwise and check that it locks.
If necessary, replace the repair service starter kit.
11. INSTALL PLANET GEAR
(a) Apply grease to the planet gears and pin parts of the plan-
etary shaft.
(b) Install the 3 planet gears.
12. INSTALL STARTER BRUSH HOLDER ASSY
(a) Install the brush holder to the starter armature assy.

A82652
A82653
A82654
KeywayKey
A81586
Keyway Key
A82636
19±6
± STARTING & CHARGINGSTARTER ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
13. INSTALL STARTER COMMUTATOR END FRAME
ASSY
(a) Install the commutator end frame with the 2 screws.
14. INSTALL STARTER ARMATURE ASSY
(a) Align the rubber with the convex cutout of starter yoke.
(b) Install starter armature with the brush holder to the starter
yoke.
15. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter yoke.
(b) Align the keyway of the starter plate with the key inside the
starter yoke, and install the starter plate.
16. INSTALL STARTER YOKE ASSY
(a) Align the key of the starter yoke with the keyway located
on the starter drive housing.
(b) Using a torx driver T25, install the starter yoke with the 2
through bolts.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
17. INSTALL REPAIR SERVICE STARTER KIT
(a) Apply grease to the plunger and hook.
(b) Set the plunger and hook of the repair service starter kit
to the drive lever.
(c) Install the plunger and return spring.

A82635
A81555
± STARTING & CHARGINGSTARTER ASSY
19±7
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(d) Install the repair service starter kit with the 3 nuts.
Torque: 2.3 N
m (24 kgf
cm, 21 in.
lbf)
(e) Connect the lead wire to the repair service starter kit and
then fasten it with the nut.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)

170FM±01
A77229
A77233
A77230
Mark
A77231
17±2
± LUBRICATIONOIL PUMP ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
OVERHAUL
1. REMOVE OIL PUMP RELIEF VALVE PLUG
(a) Using a 27 mm socket wrench, remove the oil pump relief plug.
SST 09011±12271
2. REMOVE OIL PUMP RELIEF VALVE SPRING
3. REMOVE OIL PUMP RELIEF VALVE
4. INSPECT OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil.
(b) Check that it falls smoothly into the oil pump relief valve
hole by its own weight.
If it does not, replace the oil pump relief valve.
If necessary, replace the oil pump assembly.
5. REMOVE OIL PUMP COVER
(a) Remove 7 bolts and the oil pump cover.
6. INSPECT OIL PUMP ROTOR SET
(a) Place the drive and driven rotors into the oil pump body
with the marks facing the oil pump cover.
7. INSPECT ROTOR TIP CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the drive and driven rotor tip.
Standard tip clearance:
0.080 to 0.160 mm (0.0031 to 0.0063 in.)
Maximum tip clearance: 0.35 mm (0.0138 in.)
If the tip clearance is greater than maximum, replace the rotors
as a set.

A77232
A38022
A77234
Marks
± LUBRICATIONOIL PUMP ASSY
17±3
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
8. INSPECT ROTOR BODY CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the driven rotor and body.
Standard body clearance:
0.100 to 0.170 mm (0.0039 to 0.067 in.)
Maximum body clearance: 0.325 mm (0.0128 in.)
If the body clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
9. INSPECT ROTOR SIDE CLEARANCE
(a) Using a feeler gauge and precision straight edge, mea-
sure the clearance between the rotors and precision
straight edge.
Standard side clearance:
0.030 to 0.085 mm (0.0012 to 0.0033 in.)
Maximum side clearance: 0.16 mm (0.0063 in.)
If the side clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
10. REMOVE OIL PUMP ROTOR SET
11. INSTALL OIL PUMP ROTOR SET
(a) Coat the drive rotor and driven rotor with engine oil.
(b) Place the drive rotor and driven rotor into the pump body
with marks facing the pump body cover.
12. INSTALL OIL PUMP COVER
Torque: 8.8 N
m (90 kgf
cm, 80 in.
lbf)
13. INSTALL OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil, and insert the oil pump relief valve into oil pump body
hole.

17±4
± LUBRICATIONOIL PUMP ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
14. INSTALL OIL PUMP RELIEF VALVE SPRING
15. INSTALL OIL PUMP RELIEF VALVE PLUG
(a) Using a 27 mm socket wrench, install the oil pump relief valve plug.
Torque: 49 N
m (500 kgf
cm, 35 ft
lbf)
SST 09011±12271

141BU±01
A13845
A77271
Plastigage
A77272
Front Mark
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±53
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
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.)
(b) If the thrust clearance is greater than maximum, replace
the connecting rod assembly(s). If necessary, replace the
crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
HINT:
The connecting rod cap bolts are tightened in 2 successive
steps.
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 connecting
rod cap bolts.
SST 09011±38121
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of Plastigage on the crank pin.
(f) Check that the front mark of the connecting rod cap is fac-
ing the correct direction.
(g) Apply a light coat of engine oil on the threads of the con-
necting rod cap bolts.
(h) Using a 12 mm socket wrench, tighten the bolts in several
steps with the specified torque.
SST 09011±38121
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)

A77470
90
Engine FrontPaint
Mark
A38162
A77471
Mark
1, 2 or 3
Mark
1, 2 or 3
A13469
14±54
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(i) Place the front mark on each connecting rod cap bolt
head with paint.
(j) Retighten the cap bolts by 90 as shown in the illustration.
NOTICE:
Do not turn the crankshaft.
(k) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
(l) Measure the Plastigage at its widest point.
Standard oil clearance:
0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the Plastigage.
(m) If replacing the bearing, replace it with one having the
same number as marked on the connecting rod. There
are 3 sizes of standard bearings, marked º1º, º2º and º3º
accordingly.
HINT:
Standard bearing center wall thickness.
Mark 11.485 to 1.488 mm (0.0585 to 0.0586 in.)
Mark 21.488 to 1.491 mm (0.0586 to 0.0587 in.)
Mark 31.491 to 1.494 mm (0.0587 to 0.0588 in.)
3. REMOVE PISTON SUB±ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearing, connecting rod and cap together.

Store the piston and connecting rod assemblies in correct
order so they can be returned to the original locations
when re±installing.
4. REMOVE CONNECTING ROD BEARING

A14289
A13861
A01178
A01179
A13851
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±55
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
5. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
6. REMOVE PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 to 90 C (176 to 194 F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Store the pistons, pins, rings, connecting rods and bear-
ings in correct order so that they can be returned to the
original locations when re±assembling.
7. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.040 to 0.240 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
(b) If the thrust clearance is greater than maximum, replace
the thrust washers as a set.
Thrust washer thickness:
1.930 to 1.980 mm (0.0760 to 0.0780 in.)

A77475
1
2 3
45
6 7
89
10
A38165
14±56
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
8. REMOVE CRANKSHAFT
(a) Using several steps, loosen and remove the 10 bearing
cap sub±assembly bolts uniformly in the sequence
shown.
(b) Remove the bearing cap and the crankshaft.
9. REMOVE CRANKSHAFT THRUST WASHER UPPER
10. REMOVE CRANKSHAFT BEARING
NOTICE:
Store the bearings in correct order so they can be returned to the original locations when re±assem-
bling.
11. REMOVE CRANKSHAFT BEARING NO.2
NOTICE:
Store the bearings in correct order so they can be returned to the original locations when re±assem-
bling.
12. REMOVE STUD BOLT
13. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)