TOYOTA AVENSIS 2005 Service Repair Manual

141UL–01
A93669
A60622
14–32–
ENGINE MECHANICAL CYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See Pub. No. RM1018E on page 11–1)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14–9)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14–9)
4. REMOVE FRONT WHEEL RH
5. REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 (See page 14–9)
6. REMOVE ENGINE UNDER COVER RH (See page 14–9)
7. DRAIN ENGINE COOLANT (See page 16–5)
8. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, then detach cylinder headcover No.2.
9. REMOVE AIR CLEANER HOSE NO.1
(a) Disconnect the VSV connector.
(b) Disconnect fuel vapor feed No. 1 hose from the VSV.
(c) Disconnect the fuel vapor feed hose from the VSV.
(d) Disconnect the ventilation hose from air cleaner hose No. 1.
(e) Loosen the 2 air cleaner hose clamp bolts, then remove the air cleaner h\
ose.
10. DISCONNECT WATER BY–PASS HOSE
(a) Disconnect the water by–pass hose from the throttle body.
11. DISCONNECT WATER BY–PASS HOSE NO.2
(a) Disconnect water by–pass hose No. 2 from the throttle body.
12. REMOVE EFI FUEL PIPE CLAMP (See Pub. No. RM1018E on page 11–11)
13. DISCONNECT FUEL TUBE SUB–ASSY (See Pub. No. RM1018E on page 11–11)
14. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose from the hose to hose tube.
15. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the cylinder head.
16. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose from the cylinder head. 17. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V–ribbed belt tensioner clockwise slowly andloosen it. Remove the fan and generator V belt, then put
back the V–ribbed belt tensioner carefully.

A96566
A76713
(c)(c)
A64023
A65078
A64058
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–33
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
18. REMOVE V–RIBBED IDLER ASSY NO.1
(a) Remove the nut, bolt, tube and idler.
19. REMOVE GENERATOR ASSY
(See Pub. No. RM1018E on page 19–7)
20. DISCONNECT IGNITION COIL ASSY
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine
wire.
(d) Remove the 4 bolts and 4 ignition coils.
21. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head
cover.
22. DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head
cover.

A93668
A64026
B06777
A76720
A76721
14–34– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
23. REMOVE INTAKE MANIFOLD
(a) Disconnect the throttle motor connector.
(b) Disconnect the vacuum hose from water by–pass pipe
No. 1.
(c) Remove the 4 bolts, 2 nuts and 2 wire brackets.
(d) Remove the intake manifold and throttle body assembly.
(e) Remove the gasket from the intake manifold and the
throttle body assembly.
24. REMOVE OIL LEVEL GAGE SUB–ASSY
(a) Remove the oil level gage from the oil level gage guide.
25. REMOVE OIL LEVEL GAGE GUIDE
(a) Disconnect the crankshaft position sensor clamp.
(b) Remove the bolt and oil level gage guide.
26. SEPARATE WATER BY–PASS PIPE NO.1
(a) Remove the 2 bolts which are used to secure the water
by–pass pipe.
27. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Remove the bolt and camshaft timing oil control valve.
28. SEPARATE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs which are
used to secure the front side of exhaust pipe.
(b) Remove the gasket.
29. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and manifold stay.
30. REMOVE MANIFOLD STAY NO.2
(a) Remove the 3 bolts and manifold stay No. 2.

A01045
A64005
A64856
A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Timing
Notch
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–35
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
31. REMOVE ENGINE MOUNTING INSULATOR
SUB–ASSY RH
(a) Place a wooden block on a jack underneath the engine.
Remove the 4 bolts and 2 nuts, then detach the engine
mounting insulator RH.
32. REMOVE CYLINDER HEAD COVER SUB–ASSY
(a) Remove the 9 bolts, 2 seal washers, 2 nuts and 3 clamp
brackets.
(b) Remove the cylinder head cover.
33. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until the timing notch is aligned
with the timing mark ”0” of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock-
et and VVT timing sprocket are in a straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360) to align the marks
as above.

A62837SST
A77551
A11858
A12816
A76692
14–36– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
34. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09960–10010 (09962–01000, 09963–01000)
(b) Remove the crankshaft pulley from the crankshaft.
HINT:
If the crankshaft pulley key is stuck, tap it with a plastic–sur-
faced hammer so that it can be removed.
35. REMOVE V–RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, then detach the V–ribbed belt
tensioner.
HINT:
Jack up and down to remove the bolt.
36. REMOVE WATER PUMP ASSY
(See Pub. No. RM1018E on page 16–9)
37. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and transverse engine engine mount-
ing bracket.
38. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts which are used to secure the crank-
shaft position sensor.

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.

A62816
2
5 3
110 8 4 796
A96569
Lot No.
A62820
Under head Length
A62816
84 2 59
7 3 1 6 10
A62823
Paint Mark
90
Front
14–38– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
47. REMOVE CYLINDER HEAD SUB–ASSY
(a) Using several steps, loosen and remove the 10 cylinder
head bolts with a 10 mm hexagon wrench uniformly in the
sequence shown in the illustration. Remove the 10 cylin-
der head bolts and 10 plate washers.
(b) Remove the cylinder head.
48. REMOVE CYLINDER HEAD GASKET
49. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the Lot No. stamp facing upward.
NOTICE:
Pay attention to the mounting orientation.
Place the cylinder head on the gasket gently in order
not to damage the gasket.
50. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of cylinder
head bolt from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum length: 148.5 mm (5.846 in.)
If the length exceeds the maximum, replace the bolt.
51. INSTALL CYLINDER HEAD SUB–ASSY
HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil to the threads of the cylin-
der head bolts.
(b) Using several steps, install and tighten the 10 cylinder
head bolts and plate washers with a 10 mm hexagon
wrench uniformly in the sequence shown in the illustra-
tion.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts by an additional 90 in
the same sequence as step (b).
(e) Check that the paint mark of each bolt is at a 90 angle
to the front.

A62150
Camshaft No. 2
Camshaft
A62825
62 4 8
51 3 7 11
10
9
A10079
A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–39
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
52. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the camshaft journals.
(b) Place the 2 camshafts on the cylinder head as shown in
the illustration.
(c) Examine the front marks and numbers, then tighten the
bolts in the sequence shown in the illustration.
Torque:
23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bearing cap No. 1
13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) for bearing cap No. 3
53. INSTALL CHAIN SUB–ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Using a wrench, turn the camshafts until the timing
marks of the 2 camshaft timing sprockets are
aligned.
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain onto the crankshaft timing sprock-
et with the yellow color link and the timing mark on the
crankshaft timing sprocket aligned.
HINT:
Three yellow color links are on the chain.

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)