width TOYOTA AVENSIS 2005 Service Service Manual

A56699
A56700
SST
B07987
New Gasket
Seal
Packing Seal Width
2to4mm
(0.08 to 0.16 in.)
B08024
17−14
− LUBRICATIONOIL PUMP ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
38. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying between the oil pump and
main bearing cap using a screwdriver.
(c) Remove the gasket.
39. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316−60011 (09316−00011, 09316−00021)
40. INSTALL OIL PUMP ASSY
(a) Remove any old packing (FIPG). Be careful not to drop
any oil on the contact surfaces of the oil pump and cylin-
der block.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces and seal-
ing groove.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non−residue solvent, clean both the sealing
surfaces.
(b) 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.
(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. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install a new gasket to the oil pump.
(d) Pour 0.5 cm
3(0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Apply engine oil to the cylinder block side which contacts
the oil pump driven rotor.

A56703
Seal Width
4to7mm
(0.16 to 0.28 in.)
AB
A
B
A56697
AAA
A
AA B B DBBB
BC C
C CC
CCDD
A56696
17−16
− LUBRICATIONOIL PUMP ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Apply seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826−00080 or equivalent
(1) Install a nozzle of which opening is cut to 4 to 7 mm
(0.16 to 0.28 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install the oil pan with the 19 bolts and 3 nuts.
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for bolt A
21 N
m (209 kgf
cm, 15 ft
lbf) for bolt B
11 N
m (112 kgf
cm, 8 ft
lbf) for bolt C
11 N
m (112 kgf
cm, 8 ft
lbf) for nut D
43. INSTALL OIL PAN INSULATOR
(a) Install the oil pan insulator with the bolt.
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
44. 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 (209 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
45. INSTALL OIL PAN SUB−ASSY NO.2
(a) Remove any old packing (FIPG). Be careful not to drop
any oil on the contact surfaces of the No. 1 and No. 2 oil
pans.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.

A56704
Seal Width
4to7mm
(0.16 to 0.28 in.)
A
A
B
B
B08016
New O −ring
SST
A09583
Inward
Angle Sensor
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −17
AVENSIS Supplement (RM1045E)
(3) Using a non −residue solvent, clean both the sealing
surfaces.
NOTICE:
Do not use a solvent. It will affect the painted surfaces.
(b) Apply seal packing to the oil pan as shown in the illustra- tion.
Seal packing: Part No. 08826 −00080 or equivalent
(1) Install a nozzle of which opening is cut to 4 to 7 mm (0.16 to 0.28 in.).
(2) The parts must be set within 3 minutes and must be assembled within 15 minutes after applying seal
packing. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install the oil pan with the 17 bolts and 2 nuts. Tighten the
bolts and nuts uniformly in several steps.
Torque: 12 N
m (119 kgf
cm, 9 ft
lbf)
46. INSTALL ENGINE OIL LEVEL SENSOR Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
47. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O −ring to the oil level gage guide.
(b) Apply engine oil to the O −ring.
(c) Push the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d) Install the oil level gage guide with the bolt. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
(e) Apply engine oil to the O −ring on the oil level gage.
(f) Install the oil level gage.
48. INSTALL V −RIBBED BELT TENSIONER ASSY (See page 14 −138)
49. INSTALL TIMING BELT IDLER SUB −ASSY NO.1 (See page 16 −21)
50. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
51. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
52. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
53. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located on the camshaft, then slide the pulley into place.
(b) Using SST and a hammer, tap in the timing pulley with the
angle sensor facing inward.
SST 09223 −46011

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
−
COOLING WATER PUMP ASSY (2AZ −FSE)
16 −13
AVENSIS Supplement (RM1045E)
11. INSTALL WATER PUMP ASSY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump assy.
(b) Apply a continuous bead of the seal packing (diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)) as shown in the illustra-
tion.
Seal packing: Part No. 08826 − 00100 or equivalent
NOTICE:
Install the water pump assy within 5 minutes after applying
seal packing. Otherwise the material must be removed and
reapplied.
(c) Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d) Install the crankshaft position sensor wire harness clamp
to the water pump.
(e) I nst all t he cr ankshaf t posit ion s ensor wir e t o t he wir e clamp on the water pump.
12. INSTALL WATER PUMP PULLEY
(a) Using SST, install the pump pulley with 4 bolts. SST 09960 −10010 (09962 −01000, 09963 −00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

D03569
D03629
O−ring
D03630Seal Bend Width 1.2 mm (0.047 in.) FIPG
40−64
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Bearing and bearing race diameter: mm (in.)
InsideOutside
Bearing57.2 (2.252)84.96 (3.345)
Bearing race56.4 (2.22)83 (3.268)
130. INSTALL OIL PUMP ASSY
(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.0 Nm (226 kgfcm,16ftlbf)
(b) Coat the O−ring of oil pump with ATF.
NOTICE:
Confirm the input shaft rotates smoothly with the manual
operation after assembling the oil pump.
131. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil
on the contacting surface of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826−00090, THREE BOND1281or equiva-
lent

A78602
Reference (Sensor 2 System Diagram):Heated Oxygen Sensor
EFI Relay
Heater
Sensor OX1B
HT1BECM
From
Battery EFI Fuse
E2MREL
OX
HT
E1
+B
05–46
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0037 OXYGEN SENSOR HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
DTC P0038 OXYGEN SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
CIRCUIT DESCRIPTION
Refer to DTC P0130 on page 05–74.
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
P0037Heated current is 0.25 A or less when heater operates
(1 trip detection logic)
 Open in heater circuit of heated oxygen sensor
 Heated oxygen sensor heater (sensor 2)
 EFI relay
 ECM
P0038Heater current exceeds 2 A when heater operates
(1 trip detection logic)
Short in heater circuit of heated oxygen sensor
 Heated oxygen sensor heater (sensor 2)
 EFI relay
 ECM
HINT:
Sensor 1 refers to the sensor mounted in front of the Three–Way Catalytic Converter (TWC) and lo-
cated near the engine assembly.
Sensor 2 refers to the sensor mounted behind the TWC and located far fro\
m the engine assembly.
WIRING DIAGRAM
Refer to DTC P0130 on page 05–74.
05KNW–02

A78602
EFI RelayHeater
Sensor OX1A
HT1AECM
From
Battery EFI Fuse
E2
MREL
Reference (Sensor 1 System Diagram):
Heated Oxygen Sensor
OX
HT
E1
+B
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–43
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0031 OXYGEN SENSOR HEATER CONTROL
CIRCUIT LOW (BANK 1 SENSOR 1)
DTC P0032 OXYGEN SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
CIRCUIT DESCRIPTION
Refer to DTC P0130 on page 05–74.
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
P0031Heated current is 0.8 A or less when heater operates
(1 trip detection logic)
 Open or short in heater circuit of heated oxygen sensor
 Heated oxygen sensor heater (sensor 1)
 EFI relay
 ECM
P0032Heated current exceeds 10 A when the heater operates
(1 trip detection logic)
Open or short in heater circuit of heated oxygen sensor
 Heated oxygen sensor heater (sensor 1)
 EFI relay
 ECM
HINT:
Sensor 1 refers to the sensor mounted in front of the Three–Way Catalytic Converter (TWC) and lo-
cated near the engine assembly.
Sensor 2 refers to the sensor mounted behind the TWC and located far fro\
m the engine assembly.
WIRING DIAGRAM
Refer to DTC P0130 on page 05–74.
05KNV–02

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.

A65676
Timing Chain Cover Side:
3 (0.118)3 (0.118)
A
A’BB’
C
C’
7 (0.276)
4.5 (0.177)
12 (0.472)6 (0.236)
3 (0.118)
Width 4 (0.157)
A – A’B – B’
C – C’
08826–00100 or equivalent
08826–00080 or equivalent
(mm (in.))
A65677
A
A
AA
A
A
AAA B
B
B
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–41
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Apply a continuous bead of seal packing (Diameter 3.5
mm to 4.5 mm (0.1379 to 0.177 in.)) as shown in the il-
lustration.
Seal packing:
Water pump part: part No. 08826–00100 or equivalent
Other part: part No. 08826–00080 or equivalent.
NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal
packing.
Do not expose the seal to engine oil for at least 2
hours after installation.
Do not apply seal packing too much more than the
specified amount.
(c) Install the timing chain cover with the 10 bolts and 2 nuts.
Torque:
13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) for A
19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) for B
(d) Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.5 N⋅m (97 kgf⋅cm, 84 in.⋅lbf)