TOYOTA AVENSIS 2005 Service Repair Manual

A62239
Standard depth:
Engine front
1.7 to 2.7 mm (0.067 to 0.106 in.)
Engine rear
2.2 to 3.2 mm (0.087 to 0.126 in.)
A92499
18 mm
(0.71 in.)
9mm
(0.35 in.) 31.5 mm
(1.24 in.)
84 mm
(3.31 in.)
20 mm
(0.79 in.)16 mm
(0.63 in.)14 mm
(0.55 in.)
9mm
(0.35 in.) 27.5 mm
(1.08 in.)
A (M16)B (M10)C (M6) A
BAC
Front SideExhaust Side
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−67
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
28. INSTALL TIGHT PLUG
(a) Apply adhesive around the tight plugs.
Adhesive: Part No. 08833−00070, THREE BOND 1324
or equivalent
(b) Using SST, install new tight plugs as shown in the illustra-
tion.
SST 09950−60010 (09951−00200), 09950−70010
(09951−07100)
29. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for stud bolt A
10 N
m (102 kgf
cm, 7 ft
lbf) for stud bolt B
5.0 N
m (51 kgf
cm, 44 in.
lbf) for stud bolt C

A92500
8mm
(0.31 in.)
15 mm
(0.59 in.)10 mm
(0.39 in.)
22 mm
(0.87 in.)7.5 mm (0.30 in.)
for Pin A
12 mm (0.47 in.)
for Pin B
Back SideBottom SideFront Side
ABAA
A
A B
B
P12418A32958
Front Mark
Front Mark
A13497
14−68
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
30. INSTALL STRAIGHT PIN
(a) Using a plastic−faced hammer, tap into the straight pin.
31. INSTALL PISTON
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
(b) Gradually heat the piston to approximately 80 to 90_C
(176 to 194_F).
(c) Align the front marks of the piston and connecting rod,
and push in the piston with your thumb.
(d) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.

A94209
A94210
Coil Joint Oil Ring Ends
A94208
Upward
No. 1
No. 2
Code Mark (T2)Painted Mark
A94211
Front30_
No. 1 Compression
and Oil Ring
No. 2 Compression
30_
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−69
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
32. INSTALL PISTON RING SET
(a) Install the coil by hand.
(b) Using a piston ring expander, install the oil ring.
HINT:
Face the end gap of the oil ring in the opposite direction of coil
joint.
(c) Using a piston ring expander, install the 2 compression
rings with the painted mark as shown in the illustration.
NOTICE:
Install the compression ring No. 2 with the code mark (T2)
facing upward.
(d) Position the piston rings so that the ring ends are as
shown in the illustration.

A53029
A33379
A13501
A13502
73159
10 6 2 4 8
A36657
14−70
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
33. INSTALL CRANKSHAFT BEARING
(a) Install the upper bearing with an oil groove on the cylinder
block.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oil.
34. INSTALL CRANKSHAFT BEARING NO.2
(a) Install the lower bearing on bearing cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oil.
35. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
36. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crank-
shaft on the cylinder block.
(b) Apply engine oil to the lower bearing.
(c) Examine the front marks and install the bearing caps on
the cylinder block.
(d) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.
(e) Uniformly install and tighten the 16 main bearing cap bolts
in the sequence shown in the illustration.
Torque:
20 N
m (204 kgf
cm, 15 ft
lbf) for 1st
40 N
m (408 kgf
cm, 30 ft
lbf) for 2nd

90_
Engine FrontPaint
Mark
A50671
Claw
A50672
Front Mark
Front
A52528
Front Mark
A52515
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−71
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
(f) Mark the front of the bearing cap bolts with paint.
(g) Retighten the bearing cap bolts by 90_same sequence
as step (e).
(h) Check that the painted mark is now at a 90_angle to the
front.
(i) Check that the crankshaft turns smoothly.
37. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod. The surface should be free of dust
and oil.
38. INSTALL PISTON
NOTICE:
The connecting rod cap bolts are tightened in 2 progres-
sive steps.
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(e) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(f) Using a 12 mm socket wrench, uniformly tighten the 2
bolts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(g) Mark the front of the connecting cap bolts with paint.

90_
Engine FrontPaint
Mark
A50671
14−72
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
(h) Retighten the cap bolts by 90_as shown in the illustration.
(i) Check that the crankshaft turns smoothly.

141Q8−01
A88217
Piston Ring Set
zSnap Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Bearing
Cylinder Block Assy
Crankshaft Thrust Washer
Crankshaft Bearing
Crankshaft
Crankshaft Bearing
Crankshaft Bearing Cap BoltConnecting Rod Bearing
Connecting Rod Cap
Crankshaft Bearing Cap
: Specified torqueN
m (kgf
cm, ft
lbf)
zNon−reusable part
1st: 20 (204, 15)
2nd: 40 (410, 30)
3rd: Turn 90_
Connecting Rod Cap Bolt
1st: 25 (250, 18)
2nd: Turn 90_
See page 14−56
zSnap Ring
See page 14−56
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−55
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
CYLINDER BLOCK ASSY (2AZ−FSE)
COMPONENTS

141Q6−01
A77366
Intake Valve Guide Bush
zNon−reusable partzValve Stem Oil SealValve Lifter
Valve Retainer Lock
Retainer
Inner Compression Spring
Valve Spring Seat
Exhaust Valve Guide Bush
Stud Bolt
Cylinder Head Assy
Intake Valve Exhaust Valve Ring w/ Head Pin
− ENGINE MECHANICALCYLINDER HEAD ASSY (2AZ−FSE)
14−41
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
CYLINDER HEAD ASSY (2AZ−FSE)
COMPONENTS

4006N−02
C50182
Match−marks
Front Differential Ring Gear
C50183
Front Differential
Ring Gear
C50184Front Differential Ring Gear
C50187
Differential
Case Assy
Differential
LH Case
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−115
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FRONT DIFFERENTIAL ASSY (U151F)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match−marks on the ring gear and differential
case.
(b) Remove the16 bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the case.
2. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the differential LH case from the differential case
assy.

C50188
Differential
Case No.2
Differential
Case LH
C50189
Differential
Case LH
Center
Differential
Side Gear
Thrust Washer
No.2Conical Spring
Front
Differential
Side Gear
Thrust WasherFront
Differential
Side Gear
D25610
C50190
C50191
40−116
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Remove the differential case No.2 from the differential
case LH.
(c) Remove the front differential side gear, front differential
side gear thrust washer, conical spring and center differ-
ential side gear thrust washer No.2 from the differential
case LH.
(d) Using a snap ring expander, remove the pinion shaft
spacer snap ring.
(e) Using a pin punch and a hammer, remove 3 straight pins.
(f) Remove the center differential pinion shaft and 2 differen-
tial pinion shafts.