ECU TOYOTA AVENSIS 2005 Service Repair Manual

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.

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.

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

A76717
A76716
A62830Front SideRear Side
A76718
14–14– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(d) Remove the 2 bolts and 2 nuts as shown in the illustration.
(e) Remove the 8 bolts and front suspension member brace
rear RH and LH.
(f) Carefully remove the engine with transaxle from the en-
gine compartment.
(g) Install the engine hanger No. 1 (12281–15040) and bolt
(91512–B1016).
Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf)
(h) Install the engine hanger (12281–22021) and bolt
(91512–B1016).
Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf)
HINT:
Securely install the front engine hanger (12281–22021) and
rear engine hanger No. 1 (12281–15040) onto the engine as-
sembly.
(i) Attach the engine sling, then hang the engine with the
chain block.
59. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Remove the through bolt and nut, then detach the engine
mounting insulator FR from the engine mounting bracket.

A76719
A62838SST
A62838SST
A76713
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–15
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Remove the through bolt, then detach the engine mount-
ing insulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the
suspension crossmember and engine mounting member.
60. REMOVE STARTER ASSY (See Pub. No. RM1018E on page 19–3)
61. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
62. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
63. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
64. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
65. REMOVE FLYWHEEL SUB–ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
flywheel.
SST 09960–10010 (09962–01000, 09963–01000)
66. REMOVE DRIVE PLATE & RING GEAR SUB–ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
drive plate & ring gear.
SST 09960–10010 (09962–01000, 09963–01000)
67. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
(b) Remove the 2 nuts which are used to secure the engine
wire.

A76719
A76718
A76717
A76717
A
B
A
B 14–24
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
114. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
SST 09301–00210
115. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
SST 09301–00210
116. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)

(See Pub. No. RM1018E on page 41–15)
117. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
118. INSTALL STARTER ASSY (See Pub. No. RM1018E on page 19–3)
119. INSTALL FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen-
sion crossmember and engine mounting member.
(b) Install the bolt which is used to secure the rear engine
mounting bracket onto the mounting insulator.
Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf)
(c) Install the bolt which is used to secure the front engine
mounting bracket onto the mounting insulator.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
120. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670–00010
(a) Set the engine assembly with transaxle on the engine lift-
er.
(b) Temporarily install the suspension crossmember with the
2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf)
(d) Install the engine mounting insulator RH.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) for bolt A
133 N⋅m (1,356 kgf⋅cm, 98 ft⋅lbf) for nut B