belt TOYOTA AVENSIS 2005 Service Repair Manual

A62178
Push
A93670
A30848
A30857
A62814
4 2531
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–37
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
39. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and chain tensioner.
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
40. REMOVE TIMING CHAIN OR BELT COVER
SUB–ASSY
(a) Remove the 10 bolts and 2 nuts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by using a screwdriver to
pry between the cylinder block and cylinder head.
NOTICE:
Be careful not to damage the timing chain cover, the cylin-
der head and the cylinder block.
41. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.
42. REMOVE CRANKSHAFT POSITION SENSOR PLATE
NO.1
43. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.
44. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolts and chain vibration damper.
45. REMOVE CHAIN SUB–ASSY
(a) Remove the timing chain by prying the crankshaft timing
gear using screwdrivers as shown in the illustration.
NOTICE:
Put a shop rag to protect the engine.
In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise to prevent the valves from touch-
ing the pistons.
46. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 19 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 9 bearing caps and both intake and ex-
haust camshafts.

A62172
SST
A62173
Yellow Color Mark
Timing Mark
A30867
A62174
SST
A62175
Seal Width
4 to 5 mm
Seal Packing
14–40– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(c) Using SST, install the crankshaft timing sprocket.
SST 09223–22010
(d) Install the timing chain onto the camshaft timing sprockets
with the yellow color links and timing marks on the cam-
shaft timing sprockets aligned.
54. 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)
55. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)
56. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ”F” mark facing forward.
57. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
(a) Apply multi–purpose grease to a new oil seal lip.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223–22010
NOTICE:
Keep the lip free of foreign objects.
58. INSTALL TIMING CHAIN OR BELT COVER SUB–ASSY
(a) Remove any old packing material (FIPG) from the contact
surface.

A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
A12816
A11858
14–42– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
59. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check that the O–ring is clean, then 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:
If the hook released the plunger during installation, re–
hook the plunger.
60. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of the engine oil to the O–ring on the
crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
61. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the transverse engine engine mounting bracket
with the 3 bolts.
Torque: 47 N⋅m (479 kgf⋅cm, 35 ft⋅lbf)
62. INSTALL WATER PUMP ASSY
(See Pub. No. RM1018E on page 16–9)
63. INSTALL V–RIBBED BELT TENSIONER ASSY
(a) Install the V–ribbed belt tensioner with the nut and bolt.
Torque:
29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf) for nut
69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf) for bolt

A96566
A93669
14–46–
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
76. INSTALL V–RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt.
Torque: 39 N ⋅m (400 kgf ⋅cm, 29 ft ⋅lbf)
77. INSTALL FAN AND GENERATOR V BELT
(See Pub. No. RM1018E on page 14–5)
78. INSTALL AIR CLEANER HOSE NO.1
Torque: 1.5 N ⋅m (15 kgf ⋅cm, 13 in. ⋅lbf)
79. 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)
80. INSTALL FRONT WHEEL RH
Torque: 103 N ⋅m (1,050 kgf ⋅cm, 76 ft ⋅lbf)
81. ADD ENGINE COOLANT (See page 16–5)
82. INSPECT COMPRESSION (See Pub. No. RM1018E on page 14–1)
SST 09992–00500
83. INSPECT CO/HC (See Pub. No. RM1018E on page 14–1)
84. INSPECT IGNITION TIMING (See Pub. No. RM1018E on page 14–1)
SST 09843–18040
85. CHECK FOR ENGINE COOLANT LEAKS (See page 16–1)
86. CHECK FOR ENGINE OIL LEAKS
87. CHECK FOR EXHAUST GAS LEAKS

A79320
(f)
(e)
A79296
A60622
14–12– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(e) Remove the bolt, then disconnect the ground terminal.
(f) Disconnect the ground terminal connector.
(g) Remove the nut and disconnect battery terminal B.
38. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V–ribbed belt tensioner clockwise slowly and
loosen it. Then, remove the fan and generator V belt and
put back the V–ribbed belt tensioner carefully.
39. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19–7)
40. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:
Secure the compressor and hoses off to the side instead of discharging the A/C system.
1ZZ–FE (See Pub. No. RM1018E on page 55–74)
3ZZ–FE (See Pub. No. RM1018E on page 55–70)
41. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and column hole cover silencer sheet.
42. SEPARATE STEERING INTERMEDIATE SHAFT (See Pub. No. RM1018E on page 50–9)
43. REMOVE FRONT DOOR SCUFF PLATE RH (See Pub. No. RM1018E on page 71–11)
44. REMOVE COWL SIDE TRIM BOARD RH (See Pub. No. RM1018E on page 71–11)
45. REMOVE FRONT FLOOR FOOTREST (RHD STEERING POSITION TYPE)
46. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and floor panel brace front.
47. REMOVE EXHAUST PIPE ASSY FRONT (See Pub. No. RM1018E on page 15–2)
48. REMOVE FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30–6)
SST 09930–00010

A64059
A64060
A76720
A76721
A76722
(a)
(b)
(b)
(b)(b) 14–18
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
80. REMOVE V–RIBBED BELT TENSIONER ASSY
(a) Remove the bolt, nut and V–ribbed belt tensioner.
81. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and transverse engine mounting
bracket.
82. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and manifold stay.
83. REMOVE MANIFOLD STAY NO.2
(a) Remove the 3 bolts and manifold stay.
84. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 3 bolts and nut, then remove the exhaust
manifold heat insulator.

A64059
A96566
A76692
B00084
A64028
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–21
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
99. INSTALL V–RIBBED BELT TENSIONER ASSY
(a) Install the V–ribbed belt tensioner with the bolt and nut.
Torque:
29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf) for nut
69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf) for bolt
100. INSTALL V–RIBBED IDLER ASSY NO.1
(a) Install the tube and idler with the nut and bolt.
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
101. INSTALL KNOCK SENSOR
(See Pub. No. RM1018E on page 10–17)
102. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O–ring on the crank-
shaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
103. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O–ring on the cam-
shaft position sensor.
(b) Install the camshaft position sensor with the bolt.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
104. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
(See Pub. No. RM1018E on page 17–1)
Adhesive: Part No.08833 – 00080, THREE BOND 1344.
105. INSTALL THERMOSTAT

(See Pub. No. RM1018E on page 16–9)
106. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf)

710FY–02
71–4– INSTRUMENT PANEL/METERINSTRUMENT PANEL SUB–ASSY LOWER (From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
INSTRUMENT PANEL SUB–ASSY LOWER (From February,
2004)
PRECAUTION
1. PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
(a) Some operations in this section may affect the SRS airbags. Prior to performing the corresponding
operations, read the SRS airbag NOTICE.

600A7–04
H42767
60–4– SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIR BAG SENSOR ASSY LH (From February,
2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
REPLACEMENT
HINT:
Use the same procedures for the RH side and LH side.
1. PRECAUTION (SEE PUB. NO. RM1018E, PAGE 60–1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
3. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PUB. NO. RM1018E, PAGE 76–36)
4. REMOVE REAR DOOR SCUFF PLATE LH (SEE PUB. NO. RM1018E, PAGE 76–36)
5. REMOVE FRONT DOOR WEATHERSTRIP LH (SEE PUB. NO. RM1018E, PAGE 76–36)
6. REMOVE REAR DOOR WEATHERSTRIP LH (SEE PUB. NO. RM1018E, PAGE 76–36)
7. REMOVE CENTER PILLAR GARNISH LOWER LH (SEE PUB. NO. RM1018E, PAGE 76–36)
8. REMOVE FRONT SEAT OUTER BELT ASSY LH (SEE PUB. NO. RM1018E, PAGE 61–7)
9. REMOVE SIDE AIR BAG SENSOR ASSY LH
(a) Disconnect the connector from the side airbag sensor
assy LH.
(b) Remove the nut and the side airbag sensor assy LH.
10. INSTALL SIDE AIR BAG SENSOR ASSY LH
(a) Check that the ignition switch is off.
(b) Check that the battery negative (–) terminal is disconnected.
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
(c) Install the side airbag sensor assy LH with the nut.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
NOTICE:

If the side airbag sensor assy LH has been dropped, or there are any cracks, dents or other de-
fects in the case, bracket or connector, replace it with a new one.

When installing the side airbag sensor assy LH, be careful that the SRS wiring does not interfere
with other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor assy LH.
(e) Connect the connector to the side airbag sensor assy LH.
11. INSTALL FRONT SEAT OUTER BELT ASSY LH (SEE PUB. NO. RM1018E, PAGE 61–7)
12. CONNECT BATTERY NEGATIVE TERMINAL
13. INSPECT SRS WARNING LIGHT (SEE PUB. NO. RM1018E, PAGE 05–1184)

600UO–01
H44212N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Rear Door Opening
Trim Weatherstrip LH
Rear Door Scuff
Plate LH
Center Pillar
Garnish Lower LH
Front Door Scuff
Plate LHFront Door Opening Trim
Weatherstrip LHFront Seat
Outer Belt Assy LH
9.0 (92, 80 in.⋅lbf)
Side Airbag Sensor Assy LH
42 (428, 31)
7.5 (77, 66 in.⋅lbf)
– SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIR BAG SENSOR ASSY LH (From February,
2004)60–3
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
SIDE AIR BAG SENSOR ASSY LH (From February, 2004)
COMPONENTS