TOYOTA AVENSIS 2005 Service Repair Manual

140KL±01
A62179
A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Groove
14±4
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE OIL FILLER CAP SUB±ASSY
(a) Remove the oil filler cap from the cylinder head cover.
2. REMOVE OIL FILLER CAP GASKET
(a) Remove the gasket from the oil filler cap.
3. REMOVE VENTILATION VALVE SUB±ASSY
(a) Remove the ventilation valve from the cylinder head cover.
4. REMOVE SPARK PLUG
(a) Using a spark plug wrench, remove the 4 spark plugs.
5. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 9 bolts, 2 seal washer, 2 nuts and cylinder head cover.
6. REMOVE CYLINDER HEAD COVER GASKET
(a) Remove the gasket from the cylinder head cover.
7. REMOVE WATER PUMP ASSY
(a) Remove the 6 bolts, water pump and O±ring.
8. REMOVE CRANKSHAFT PULLEY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley, and align its groove with
timing mark º0º of the timing chain cover.
(2) Check that the point marks of the camshaft timing
sprocket and VVT timing sprocket are in straight line
on the timing chain cover surface as shown in the
illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.

A62837SST
A10076
A30848
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Using SST, remove the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
(c) Remove the crankshaft pulley from the crankshaft.
9. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and chain tensioner.
NOTICE:
Be sure not to revolve the crank shaft without the chain tensioner.
10. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 11 bolts and nuts.
(b) Remove the timing chain cover by prying the portions be-
tween the cylinder head and cylinder block with a screw±
driver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
11. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a screwdriver remove the oil seal.
12. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Remove the crankshaft position sensor plate from the crankshaft.
13. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.
14. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolts and chain vibration damper.

A30857
A62814
4 2531
A32167
A62190
Advance
Side Path Retard Side
Path
Open
Close
Rubber Vinyl Tape Open Close
14±6
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. REMOVE CHAIN SUB±ASSY
(a) Using screwdrivers, ply out the timing chain with the
crankshaft timing gear as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution for
valves not to touch the pistons.
16. REMOVE CAMSHAFT
(a) Uniformly loosen and remove the 19 bearing cap bolts, in
several passes, in the sequence shown, and remove the
9 bearing caps, intake and exhaust camshafts.
17. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and remove the bolt and
camshaft timing gear.
NOTICE:
Be careful not to damage the camshaft.
18. INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Check the lock of camshaft timing gear.
(1) Grip the camshaft with a vice, and confirm the cam-
shaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
(b) Release lock pin.
(1) Cover 4 oil paths of cam journal with vinyl tape as
shown in the illustration.
HINT:
Two advance side paths are provided in the groove of the cam-
shaft. Plug one of the path with a rubber piece.
(2) Break through the tapes of the advance side path
and the retard side path on the opposite side of the
groove.

A62191
Advanced
Side Path Retard
Side Path
A62192
Hold Pressure
DecompressAdvanced
Side Path Retard
Side Path
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(3) Put air pressure into two broken paths (the advance
side path and the retard side path) with about 150
kPa {1.5 kgf
cm}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.
(4) Confirm if the camshaft timing gear assembly re-
volves in the timing advance direction when weak-
ening the air pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear, revolves in
the advance direction.
(5) When the camshaft timing gear comes to the most
advanced position, take out the air pressure of the
timing retard side path, and then, take out that of
timing advance side path.
CAUTION:
Camshaft timing assembly gear occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before retard side path. It often
causes the breakage of the lock pin.
(c) Check smooth revolution
(1) Revolve the camshaft timing gear assembly within
the movable range except for the most retarded
position several times, and check the smooth revo-
lution.
CAUTION:
Be sure to perform this check by hand, instead of air pres-
sure.
(d) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear assembly is
locked at the most retarded position.

A62190
Advance
Side Path Retard Side
Path
Open
Close
Rubber Vinyl Tape Open Close
A62191
Advanced
Side Path Retard
Side Path
A62192
Hold Pressure
DecompressAdvanced
Side Path Retard
Side Path
14±8
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
19. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Grip the camshaft with a vice, and confirm that the gear
is locked.
CAUTION:
Be careful not to damage the camshaft.
(b) Cover 4 oil paths of cam journal with vinyl tape as shown
in the illustration.
HINT:
Two advance side paths are provided in the groove of the cam-
shaft. Plug one of the path with a rubber piece.
(c) Break through the tapes of the advance side path and the
retard side path on the opposite side of the groove.
(d) Put air pressure into two broken paths (the advance side
path and the retard side path) with about 150 kPa {1.5 kgf/
cm
2}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.
(e) Confirm if the camshaft timing gear assembly revolves in
the timing advance direction when weakening the air
pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear revolves in
the advance direction.
(f) When the camshaft timing gear comes to the most ad-
vanced position, take out the air pressure of the timing re-
tard side path, and then, takeout that of timing advance
side path.
CAUTION:
Camshaft timing gear assembly occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before retard side paths. It often
causes the breakage of the lock pin.

A62193
Straight Pin Fringe Bolt
A62815
Mesh
A62816
37 9 62
4 8 10 5 1
B08737
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±9
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(g) Remove the fringe bolt of camshaft timing gear assembly.
NOTICE:

Be sure not to remove the other 4 bolts.

In case of reusing the camshaft timing gear, release
the strait pin locking first, and then install the gear.
20. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt and camshaft timing oil control valve.
21. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the bolt, gasket and oil control valve filter.
22. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using a bi±hexagon wrench 10, uniformly loosen and re-
move the 10 cylinder head bolts, in several passes, in the
sequence shown. Remove the 10 cylinder head bolts and
plate washers.
NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cracking could result from remov-
ing bolts in an incorrect order.
23. REMOVE CYLINDER HEAD GASKET
(a) Remove the gasket from the cylinder block.
24. REMOVE OIL PUMP ASSY
(a) Remove the 5 bolts, oil pump and gasket.

A62817SST
A62202
Cut Position
A01153
A01456
14±10
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
25. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter.
SST 09228±06501
26. REMOVE OIL FILTER UNION
(a) Using a socket hexagon wrench 12, remove the oil filter union.
27. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If there is, mend it with a sandpaper (# 400).
28. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket from the oil pan.
29. REMOVE OIL PAN SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Insert the blade of SST between the bearing cap sub±as-
sembly and oil pan, and cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the oil pan contact surface of the
bearing cap sub±assembly and the oil pan flange.

A62818
Raise
Move
Lock
A62819
Measuring Area
012345 16
A30206
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±11
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
30. REMOVE OIL STRAINER SUB±ASSY
(a) Remove the bolt, 2 nuts, oil strainer and gasket.
31. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Remove the cylinder block water drain cock from the cylinder block.
32. INSPECT CHAIN TENSIONER ASSY NO.1
(a) Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) Release the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.
33. INSPECT CHAIN SUB±ASSY
(a) Using a spring tension gauge and vernier calipers, pull
the timing chain with 140 N (4.3 kgf, 315 lb) and measure
the length of it.
Maximum chain elongation : 112.6 mm (4.433 in.)
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
34. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di-
ameter with the chain.
Minimum sprocket diameter (w / chain):
97.3mm (3.831 in.)
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.

EM2378
A32118
A32119
A62820
Overall Length 14±12
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
35. INSPECT CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di-
ameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for the mea-
suring.
Minimum sprocket diameter (w / chain):
51.6mm (2.032 in.)
36. INSPECT CHAIN TENSIONER SLIPPER
(a) Using a vernier calipers, measure the chain tensioner
slipper wears.
Maximum wear: 1.0 mm (0.039 in.)
37. INSPECT CHAIN VIBRATION DAMPER NO.1
(a) Using a vernier calipers, measure the vibration damper
wears.
Maximum wear: 1.0 mm (0.039 in.)
38. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of head bolts
from the seat to the end.
Standard bolt length:
156.0 ± 159.0 mm (6.142±6.260 in.)
Maximum bolt length: 159.5 mm (6.280 in.)

EM1628
EM2011
EM2538
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±13
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
39. INSPECT CAMSHAFT
(a) Inspect camshaft for runout.
(1) Place the camshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
(b) Inspect cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.333 ± 44.433 mm (1.7454 ± 1.7493 in.)
Exhaust 43.761 ± 43.861 mm (1.7229 ± 1.7268 in.)
Minimum cam lobe height:
Intake 44.18 mm (1.7394 in.)
Exhaust 43.61 mm (1.7169 in.)
(c) Inspect camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
34.449 ± 34.465 mm (1.3563 ± 1.3569 in.)
Others journal diameter:
22.949 ± 22.965 mm (0.9035 ± 0.9041 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
40. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Apply two or three threads of adhesive to the drain union, and install it within 3 minutes.
Torque: 20 N
m (204 kgf
cm15 ft
lbf)
(b) After applying the specified torque, rotate the drain union clockwise until its drain port faces downward.
NOTICE:

Do not put into coolant in an hour after the installation.

Do not rotate the drain union more than 360 in (b), and never loosen it after setting the union
correctly.
41. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 nuts and a bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)