width TOYOTA AVENSIS 2005 Service Owner's Guide

A62173
Yellow Color Mark
Timing Mark
A30867
A62174
SST
A62175
Seal Width
4 ± 5 mm
Seal Packing
14±18
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Install the timing chain on the camshaft timing sprockets
with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
56. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
57. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
58. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing forward.
59. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to the oil seal lip.
(b) Using SST, tap in a new oil seal until its surface is flush
with the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip off foreign materials.
60. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material from the contact sur-
face.

A62176
Chain Cover
Groove
Cylinder Head
GrooveSeal Width
4 ± 5 mm
AB
7 mm
4.5 mm
3 mm 6 mm 12 mm
B
A
A ± A B ± BA
A
A62177
Raise
Push
Hook
Pin
A62178
Push
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Apply seal packing in the shape of bead (Diameter 3.5
mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent
(c) Install the timing chain cover, with the 12 bolts and nut.
Torque:
M6 13 N
m (133 kgf
cm, 10 ft
lbf)
M8 19 N
m (194 kgf
cm, 14 ft
lbf)
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not put into engine oil within 2 hours after instal-
ling.
61. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check the O±ring is clean, and set the hook as shown in
the illustration.
(b) Apply engine oil to the chain tensioner and install it with
the 2 nuts..
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
When installing the tensioner, set the hook again if the
hook releases the plunger.

A56053
Width
45
25

Z03988
45

70

A57105Contacting Width
A09537
14±30
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360
around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the following width.
Intake1.2 ± 1.6 mm (0.047 ± 0.063 in.)
Exhaust1.6 ± 2.0 mm (0.063 ± 0.079 in.)
19. REPAIR INTAKE VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 25
and
45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 70
and
45
cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
SST 99999±60014

A09519
Hexagon
Wrench
(8mm)
A09476
Seal Width
2 ± 3 mm
A56701
Seal Width
2 ± 4 mm
Seal
PackingNew Gasket
14±10
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
31. INSTALL OIL CHECK VALVE SUB±ASSY
(a) Using hexagon wrench (8mm), install a new gasket and
the pressure valve.
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)
32. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 6 bolts. Uniformly tighten
the bolt in several passes.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
33. INSTALL OIL PUMP ASSY
(a) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Avoid applying an excessive amount to the surface.

Install a nozzle that has been cut to a 2 ± 4 mm (0.08
± 0.16 in.) opening

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install a new gasket to the oil pump.

B08024
A57099
A56702
A56703
Seal Width
4 ± 7 mm AB
B A
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±11
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Pour in 0.5 cm3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(d) Apply engine oil to the cylinder block side where it con-
tacts with the oil pump driven rotor.
(e) Install the oil pump with the 9 bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
(f) Measure the oil pump rotating torque
(1) Check that the pump rotates smoothly without ab-
normal noise.
(2) Using a torque wrench, check the pump rotating
torque.
Rotating torque: 3.0 N
m (30 kgf
cm, 26 in.
lbf) or less
34. INSTALL OIL PAN SUB±ASSY
(a) Apply seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 4 ± 7 mm (0.16
± 0.28 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 19 bolts and 3 nuts.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for 10 mm head bolt and
nut
21 N
m (210 kgf
cm, 15 ft
lbf) for 12 mm head bolt
42 N
m (429 kgf
cm, 31 ft
lbf) for 14 mm head bolt

A56696
A56704
Seal Width
4 ± 7 mmBA
A
B
A56706
Front
Measuring Point
A57100
Measuring Tip
Protrusion 14±12
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
35. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (210 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
36. INSTALL OIL PAN SUB±ASSY NO.2
(a) Apply a seal packing to the oil pan as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 4 ± 7 mm (0.16
± 0.28 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 16 bolts and 3 nuts. Uniformly tight-
en the bolts and nuts in several passes.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
37. INSTALL CYLINDER HEAD SUB±ASSY
(a) Check piston protrusions for each cylinder.
(1) Find where the piston head protrudes most by slow-
ly turning the crankshaft clockwise and counter-
clockwise.
(2) Measure each cylinder at 2 places as shown in the
illustration, marking a total of 8 measurements.
(3) For the piston protrusion valve of each cylinder, use
the average of the 2 measurements of each cylin-
der.
Protrusion: 0.165 ± 0.425 mm (0.0065 ± 0.0168 in.)

A57098
A09600
Seal Width
2 ± 4 mm
Seal Packing
SST
A57101
Inward
Angle Sensor
A57102
Turn
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±17
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
42. INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 7bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
43. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 2 ± 4 mm (0.08
± 0.16 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 4 bolts. Uniformly tighten
the 4 bolts in several passes.
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
44. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the timing
pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the angle sensor inward.
SST 09223±46011
45. INSTALL TIMING BELT IDLER SUB±ASSY NO.2
(a) Install the idler pulley with the bolt.
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
(b) Check that the idler pulley moves smoothly.

A72920
Reference (Bank1 Sensor 1 System Drawing)
Heated Oxygen Sensor
EFI Relay
Heater
SensorOX1A
HT
1A
Duty
Control
ECM
From
Battery EFI Fuse
E2
EFI No. 2
Fuse
MREL
OX HT
E 1
+B
05
−50
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
CIRCUIT DESCRIPTION
Refer to DTC P0 130 on page 05 −82.
HINT:
The ECM provides a pulse width modulated control circuit to adjust current through the heater. The heated
oxygen sensor heater circuit uses a relay on the B+ side of the circuit.
DTC No.DTC Detection ConditionTrouble Area
P003 1
P0037
P005 1
P0057( 1 ) Heated current is 0.2 A or less when heater operates with
+B voltage between 10.5 V and 11 .5 V ( 1 trip detection logic)
(2) Heated current is 0.25 A or less when heater operates with
+B greater than 11 .5 V ( 1 trip detection logic)S Open in heater circuit of heated oxygen sensor
S Heated oxygen sensor heater
S EFI relay
S EFI No. 2 fuse
S ECM
P0032
P0038
P0052
P0058
When heater operates, heater current exceeds 2 A
(1 trip detection logic)
S Short in heater circuit of heated oxygen sensor
S Heated oxygen sensor heater
S EFI relay
S ECM
WIRING DIAGRAM
Refer to DTC P0 130 on page 05 −82.
INSPECTION PROCEDURE
HINT:
SIf different DTCs related to different systems that have terminal E2 as the ground terminal are output
simultaneously, terminal E2 may have an open circuit.
SRead freeze frame data using the hand−held tester . Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the
vehicle was running or stopped, if the engine was warmed up or not, if the air −fuel ratio was lean or
rich, and other data from the time the malfunction occurred.

B62793
Reference:
A/F Sensor A/F Sensor
Heater Relay
Heater
Sensor
AF2+ HAF2
Duty
Control ECM
From
Battery
A/F Fuse
AF2−
MREL 05−306
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
HINT:
The ECM provides a pulse width modulated control circuit to adjust current through the heater. The A/F sen-
sor heater circuit uses a relay on the B+ side of the circuit.
DTC No.DTC Detection ConditionTrouble Area
P0031Heated current is 1.5 A or less when the heater operates
(1 trip detection logic)
SOpen in A/F sensor heater circuit
SA/F sensor heater
SA/F sensor heater relay
SECM
MONITOR DESCRIPTION
The inner surface of the A/F sensor element is exposed to outside air. The outer surface of the sensor ele-
ment is exposed to exhaust gases. The sensor element is made of platinum coated zirconia and includes
an integrated heating element. The zirconia element generates small voltage when there is a large differ-
ence in the oxygen concentrations of the exhaust and the outside air. The platinum coating amplifies the
voltage generation. When heated, the sensor becomes very efficient. If the temperature of the exhaust is
low, the sensor will not generate useful voltage signals without supplemental heating. The ECM regulates
the supplemental heating using a duty−cycle approach to regulate the average current in the heater ele-
ment. If the heater current is out of the normal range, the sensor’s output signals will be inaccurate and the
ECM can not regulate the air−fuel ratio properly. When the heater current is out of the normal operating
range, the ECM interprets this as a malfunction and sets a DTC.

A85428
Seal Width
2to4mm
(0.08 to 0.16 in.)Seal Packing
A62592
SST
A85760
90_
14
−156
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826 −00080 or equivalent
(1) Install a nozzle of which opening is cut to 2 to 4 mm
(0.08 to 0.16 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing.
(3) Immediately remove the nozzle from the tube, then reinstall the cap.
(c) Install the oil seal retainer with the 4 bolts. Tighten the 4 bolts uniformly in several steps.
Torque: 9.8 N
m (100 kgf
cm, 7.2 ft
lbf)
52. INSTALL CAMSHAFT TIMING PULLEY
(a) Install the pulley set key to the groove of the camshaft.
(b) Align the keyway of the timing pulley with the key located on the camshaft, then slide the pulley into place.
(c) Using SST, install the pulley bolt. SST 09960 −10010 (09962 −01000, 09963 −01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
53. INSTALL CAMSHAFT POSITION SENSOR (See page 14 −108)
54. INSTALL INJECTOR ASSY 55. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Remove the bolt which is tightened at the center of thecamshaft bearing cap No. 4.
(b) Install the nozzle leakage pipe and 4 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint of the gasket
comes within the ranges shown in the illustration.
(c) Apply a light coat of engine oil to the 4 hollow screws and bolt.
(d) Tighten the 4 hollow screws and bolt by hand.
(e) Tighten the 4 hollow screws and bolt. Torque:
16 N
m (163 kgf
cm, 12 ft
lbf) for hollow screw
20 N
m (204 kgf
cm, 15 ft
lbf) for flange bolt
NOTICE:
In any case, when the torque exceeds the upper limit, re-
place the leakage pipe hollow screw and gaskets with new
ones.
(f) Check that there are no leaks from the nozzle leakage pipe connection.