TOYOTA AVENSIS 2005 Service Repair Manual

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

A62837SST
A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A62182
Seal Packing
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–43
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
64. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the
crankshaft, then slide the pulley into place.
(b) Using SST, install the crankshaft pulley bolt.
SST 09960–10010 (09962–01000, 09963–01000)
Torque: 138 N⋅m (1,407 kgf⋅cm, 102 ft⋅lbf)
(c) Turn the crankshaft counterclockwise, then take the hook
off the knock pin to release the plunger.
(d) Turn the crankshaft clockwise, then check that the plung-
er is extended.
HINT:
If the plunger is not extended, press the slipper into the chain
tensioner using a screwdriver so that the hook is taken off from
the knock pin and the plunger can be extended.
65. INSTALL CYLINDER HEAD COVER SUB–ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes of ap-
plying seal packing.
Do not expose the seal to engine oil for at least 2
hours after installation.

A65687
A
A
A
A A A
A A
B
B A
A64005
A76720
AAB
A76721
14–44– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(c) Install the cylinder head cover and 3 cable brackets with
the 9 bolts, 2 seal washers and 2 nuts. Tighten the bolts
and nuts uniformly in several steps.
Torque:
11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) for A
9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for B
66. INSTALL ENGINE MOUNTING INSULATOR
SUB–ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
67. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque:
37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) for bolt A
49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) for bolt B
68. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay with the 3 bolts.
Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf)
69. INSTALL EXHAUST PIPE ASSY FRONT
(See Pub. No. RM1018E on page 15–2)

B06777
A64026
A93668
A64023
A76713
– ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–45
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
70. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Apply a light coat of engine oil on a new O–ring, then
install it onto the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
71. INSTALL WATER BY–PASS PIPE NO.1
(a) Install a new gasket and water by–pass pipe with the 2
nuts and 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
72. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil on a new O–ring, then
install it onto the oil level gage guide.
(b) Install the oil level gage guide with the bolt.
Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)
73. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.
(b) Install the intake manifold and the throttle body assembly
with the 2 brackets, 4 bolts and 2 nuts.
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
(c) Connect the vacuum hose to water by–pass pipe No. 1.
(d) Connect the throttle motor connector.
74. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
75. INSTALL GENERATOR ASSY
(See Pub. No. RM1018E on page 19–7)

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

141UK–01
A784575 Claws
A78458
A78505
A78515
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–9
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
(a) Remove the retainer and 4 clips.
(b) Unfasten the 5 claws, then remove the radiator support
opening cover.
3. REMOVE ENGINE ROOM COVER SIDE
(a) Remove the 2 clips and engine room cover side.
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER SUB–ASSY NO.1
(a) Remove the 5 clips, 2 screws and bolt, then detach the
engine under cover.
6. REMOVE ENGINE UNDER COVER LH
(a) Remove the 6 screws and 5 clips, then detach the engine
under cover.

A78516
A93669
14–10–
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
7. REMOVE ENGINE UNDER COVER RH
(a) Remove the 6 screws and 3 clips, then detach the engine under cover.
8. DRAIN ENGINE COOLANT (See page 16–5)
9. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil.
Torque: 37 N ⋅m (377 kgf ⋅cm, 27 ft ⋅lbf)
10. DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (See Pub. No. RM1018E on p\
age 41–15)
11. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–42)
12. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, then detach cylinder head
cover No.2.
13. REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 10–6)
14. REMOVE AIR CLEANER FILTER ELEMENT SUB–ASSY
15. REMOVE AIR CLEANER CASE SUB–ASSY
(a) Remove the 3 bolts and air cleaner case.
16. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the radiator.
17. DISCONNECT RADIATOR HOSE OUTLET
(a) Disconnect the radiator hose outlet from the radiator.
18. DISCONNECT OIL COOLER INLET HOSE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet hose from the radiator.
19. DISCONNECT OIL COOLER OUTLET HOSE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet hose from the radiator.
20. DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
21. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.

A76724
A76714
A77338
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–11
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
22. REMOVE RADIATOR ASSY
(a) Remove the 2 bolts and relay block.
(b) Disconnect the connector and 2 harness clamps.
(c) Remove the 2 bolts, 2 radiator support uppers and radia-
tor.
23. REMOVE BATTERY
24. REMOVE BATTERY TRAY
25. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts, battery carrier and bracket.
26. REMOVE EFI FUEL PIPE CLAMP

(See Pub. No. RM1018E on page 11–11)
27. DISCONNECT FUEL TUBE SUB–ASSY

(See Pub. No. RM1018E on page 11–11)
28. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose.
29. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose from the heater core inlet tube.
30. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose from the heater core outlet tube.
31. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)

(See Pub. No. RM1018E on page 41–15)
32. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
33. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
34. SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
35. REMOVE GLOVE COMPARTMENT DOOR ASSY (See Pub. No. RM1018E on page 71–11)
36. REMOVE INSTRUMENT PANEL UNDER COVER SUB–ASSY NO.2
37. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junction
block.
(b) Pull out the engine wire.
(c) Remove the engine room relay block No.2 cover.
(d) Remove a nut, then disconnect a connector as shown in
the illustration.

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

A64005
A76715
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–13
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
49. REMOVE FRONT AXLE HUB RH NUT
SST 09930–00010
HINT:
Perform the same procedure as above on the opposite side.
50. SEPARATE TIE ROD END SUB–ASSY LH (See Pub. No. RM1018E on page 30–6)
SST 09628–62011
51. SEPARATE TIE ROD END SUB–ASSY RH
SST 09628–62011
HINT:
Perform the same procedure as above on the opposite side.
52. SEPARATE FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30–6)
53. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
54. SEPARATE FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30–6)
55. SEPARATE FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
56. SEPARATE FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30–6)
57. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts and 2 nuts, then detach the engine
mounting insulator.
(c) Remove the through bolt and nut, then detach the engine
mounting insulator from the vehicle.