wheel torque TOYOTA AVENSIS 2005 Service Owner's Guide
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2005, Model line: AVENSIS, Model: TOYOTA AVENSIS 2005Pages: 5135, PDF Size: 95.28 MB
Page 2038 of 5135
A79324
A78459
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1ZZ±FE/3ZZ±FE)
14±59
AVENSIS REPAIR MANUAL (RM1018E)
43.INSTALL V±RIBBED IDLER ASSY NO.1
(a)Install the tube and idler with the nut and bolt.
Torque: 39.2 N m (400 kgf cm, 29 ft lbf)
44.INSTALL CYLINDER HEAD COVER NO.2
(a)Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
45.INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
46.ADD ENGINE COOLANT(See page 16±7)
47.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
48. CHECK FOR ENGINE OIL LEAKS
Page 2057 of 5135
A76713
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90
A62838SST
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±41
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
113. INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts.
Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni-
formly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgfcm, 36 ftlbf)
(e) Mark each bolt head with paint.
(f) Retighten the bolts by an additional 90 in the same se-
quence as step (d).
(g) Check that the paint marks are at 90 angle about the
original position.
114. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
Page 2060 of 5135
A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N m (131 kgf cm, 9 ft lbf)
138. INSTALL BATTERY Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N m (194 kgf cm, 14 ft lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
145. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL
Page 2066 of 5135
A79349N´m (kgf´cm, ft´lbf): Specified torqueAutomatic Transaxle Assy
Drive Plate Spacer
RR
Drive Plate & Ring Gear Sub±assy
Drive Plate Spacer
FR
A/T:
28 (286, 21)
88 (897, 65)
Clutch Disk Assy
Clutch Cover Assy
Manual Transaxle Assy
Starter Assy
Flywheel Sub±assy
See page 14±27
1st 49 (500, 36)
2nd Turn 90
37 (377, 27)
37 (377, 27)
64 (653, 47)
19 (194, 14)
64 (653, 47)
9.8 (100, 7)
47 (479, 35)
47 (479, 35)
14±24
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2069 of 5135
141BF±01
A77281
A77301
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil.
Torque: 25 N m (255 kgf cm,18 ft lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N m (500 kgf cm,36 ft lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
Page 2078 of 5135
A52499
A56446
A77333SST 14±130
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the No. 1 and No. 2 exhaust manifold stays with the
2 bolts and 2 nuts.
Torque: 44 Nm (449 kgfcm, 32 ftlbf)
105. INSTALL MANIFOLD CONVERTER INSULATOR NO.1
Torque: 12 Nm (122 kgfcm, 9.0 ftlbf)
106. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil level gauge guide.
(b) Install the oil level gauge and guide with the bolt.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
107. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 5
bolts and 2 nuts.
Torque: 30 Nm (306 kgfcm, 22 ftlbf)
108. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Apply light coat of engine oil to the new O±ring and install it to the camshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt.
Torque: 9.0 Nm (92 kgfcm, 79 in.lbf)
109. I N S TA L L D R I V E P L AT E A N D R I N G G E A R O R
FLYWHEEL
(a) Hold the crankshaft with SST.
SST 09213±54015 (91651±60855), 09330±00021
Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
Page 2079 of 5135
A77403
15
3
7
2
6
4 8
A63273
A77404
B
A
BBBB
A
B
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±131
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the drive plate. (A/T)
(1)Clean the bolt and bolt hole.
(2)Apply adhesive to the bolts.
(3)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 98 N m (1,000 kgf cm, 72 ft lbf)
(c)Install the flywheel. (M/T)
(1)Clean the bolt hole.
(2)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 130 N m (1,327 kgf cm, 96 ft lbf)
NOTICE:
Do not reuse the flywheel bolt.
110.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
111.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
112.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
113.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
114.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
115.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
116.INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Install the engine mounting insulator FR with the through bolt and nut. Torque: 87 N m (887 kgf cm,64 ft lbf)
(b)Install the engine mounting insulator RR with the through bolt and nut. Torque: 87 N m (887 kgf cm,64 ft lbf)
117.INSTALL STARTER ASSY (See page 19±12)
118. INSTALL VANE PUMP ASSY
Torque: 37 N m (370 kgf cm, 27 ft lbf)
119. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the 2 bolts and 2 nuts as shown in the illustration. Torque:
Bolt 45 N m (459 kgf cm, 33 ft lbf)
Nut 133 N m (1,356 kgf cm, 98 ft lbf)
(b) Install the front suspension member braces with the 8 bolts.
Torque:
Bolt A 133 N m (1,356 kgf cm, 98 ft lbf)
Bolt B 80 N m (816 kgf cm, 59 ft lbf)
Page 2082 of 5135
14±134
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
155.INSTALL RADIATOR ASSY (See page 16±24)
156.INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N m (51 kgf cm,44 in. lbf)
157.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm,62 in. lbf)
158.ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
159.ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
160.ADD ENGINE OIL
161.ADD COOLANT (See page 16±19)
162. ADD POWER STEERING FLUID
163. BLEED POWER STEERING FLUID
164. CHECK FOR ENGINE OIL LEAKS
165.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
166.CHECK FOR FUEL LEAKS (See page 11±15)
167. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
168.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
169.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±101)
170.INSPECT CO/HC (See page 14±101)
171. CHECK ABS SPEED SENSOR SIGNAL
Page 2089 of 5135
A77497
Engine Assy
Drive Shaft Bearing Bracket
Wire Clamp Bracket
Manual Transaxle Assy
Starter AssyClutch Disc Assy Flywheel Sub±Assy8
7
Clutch Cover Assy
N´m (kgf´cm, ft´lbf)
: Specified torque M/T:
34 (347, 25)
46 (470, 34)
13 (130, 9)
39 (398, 29)
64 (650, 47)
19 (194, 14)
44 (440, 32)
46 (470, 34)
130 (1327, 96)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
14±117
AVENSIS REPAIR MANUAL (RM1018E)
Page 2104 of 5135
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90
A62838SST
A62204
1
5
3
82
6
4
7
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
14±99
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a)Fix the crankshaft with SST.
SST09960±10010 (09962±01000, 09963±01000)
(b)Clean the bolt and bolt hole.
(c)Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d)Using several steps, Install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 49 N m (500 kgf cm, 36 ft lbf)
(e)Mark the bolts with paint as shown in the illustration.
(f)Retighten the bolts by an additional 90 in the same se-
quence as step (d).
(g)Check that the paint marks of each bolt are at 90 angle
from the original position.
10.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
11. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
12. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Fix the crankshaft with SST. SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
(e) Fix the crankshaft with SST.
Torque: 88 N m (897 kgf cm, 65 ft lbf)