gas type TOYOTA AVENSIS 2005 Service Workshop Manual

170FX±01
A77339
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±15
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16.SEPARATE VANE PUMP ASSY (See page 14±222)
17.SEPARATE RETURN TUBE SUB±ASSY (See page 14±222)
18. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14±222)
19. SEPARATE VANE PUMP OIL RESERVOIR ASSY
20.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±222)
21. SEPARATE ENGINE WIRE
22.REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14±222)
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
25.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
27.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
28.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±222)

170FU±01
A77281
17±8
±
LUBRICATION OIL PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil. Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
10.REMOVE GENERATOR ASSY (See page 19±20)
11.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
12.SEPARATE VANE PUMP ASSY (See page 14±139)
13.SEPARATE RETURN TUBE SUB±ASSY (See page 14±139)
14. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) (See page 14±139)
15. SEPARATE VANE PUMP OIL RESERVOIR ASSY
16.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±139)
17. SEPARATE ENGINE WIRE
18. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove a bolt and the engine service cover bracket RH.
19.REMOVE COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE\
) (See
page 14±139)
20. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
21. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
22.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
23.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
24.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)

F45161
Brake Master
Cylinder Sub±assy
Clutch Master Cylinder AssyM/T Transaxle: Vacuum Tank Diesel Engine Type:
Brake Fulid Level
Switch Connector Accelerator Control
Cable Support
20 (204, 15)
19 (194, 14)
Clutch Reservoir
Hose M/T Transaxle: Brake Booster Assy
Brake Booster Gasket
Brake Master Cylinder
ClevisClip Clevis Pin
13 (130, 9)
15 (155, 11) *1
29 (296, 21) *2
15 (155, 11)
N
m (kgf
cm, ft
lbf)
: Specified torque
5.4 (55, 48 in.
lbf)
8.3 (85, 73 in.
lbf)
Wave Washer
Check Valve Grommet
15 (155, 11)
5.4 (55, 48 in.
lbf)
*1 w/ ABS:
*2 w/ VSC:
32±24
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)

320W7±01
F40019
F42620
±
BRAKE BRAKE BOOSTER ASSY (LHD)
32±19
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
3. SEPARATE ENGINE ROOM RELAY BLOCK
4. REMOVE CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
5.REMOVE FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
6.REMOVE BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
7.REMOVE HEATER ASSY (W/ COLD AREA) (See page 55±100)
8. REMOVE FRONT WHEEL LH
9. DISCONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, disconnect the brake line fromthe flexible hose of the front brake LH.
SST 09023±00100
10. REMOVE BRAKE BOOSTER ASSY
(a) Disconnect the vacuum hose from the brake booster assy.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts.
(d) Pull out the brake booster assy.
11. REMOVE BRAKE BOOSTER GASKET
(a) Pull out the brake booster gasket from the brake booster assy.
12. REMOVE CHECK VALVE
(a) Remove the check valve and grommet from the brake booster assy.
13. INSTALL CHECK VALVE
(a) Install the check valve and grommet to the brake booster assy.
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assy.

F42620
F40019
32±20
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Install the clevis pin and clip to the brake master cylinder clevis.
(c) Connect the vacuum hose to the brake booster assy.
16. CONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, connect the brake tube to the flexible hose.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
17. INSTALL FRONT WHEEL LH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18.INSTALL HEATER ASSY (W/ COLD AREA) (See page 55±100)
19.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
20. INSTALL CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
21.INSTALL FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
22. CONNECT ENGINE ROOM RELAY BLOCK
23. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
24.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
25.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
26.BLEED BRAKE LINE (See page 32±4)
27.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
28.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
29.CHECK PEDAL FREE PLAY (See page 32±6)
30.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
31. CHECK FUEL LEAK
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
33. CHECK BRAKE FLUID LEAKAGE

320VU±01
F45162
Vacuum Hose
ClipBrake Vacuum
Check Valve
Check Valve
Grommet
Clevis Pin
Clip Wave Washer
13 (130, 9)
Engine Room Relay Block Way
Clutch Reservoir Tube M/T Transaxle:
Front Brake
Tube No.5
15 (155, 11) *1
29 (296, 21) *2
Brake Fluid Level
Switch Connector

Brake Booster Gasket
20 (204, 15)
20 (204, 15)
Brake Master
Cylinder Sub±assy

Brake Booster Assy
Brake Master
Cylinder clevis
15 (155, 11)
Fuel Filter Assy Diesel Engine Type: Heater Assy w/ Cold Area:
Air Cleaner Assembly
With Hose
Clutch Tube M/T Transaxle:Gasoline Engine Type:
15 (155, 11)
*1
w/ ABS:
*2
w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
5.4 (55, 48 in.
lbf)
Charcoal Canister
Assy
32±18
± BRAKEBRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

320W4±01
G24211
F42291
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±25
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2.REMOVE BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
3.REMOVE CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
4. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
5. REMOVE ENGINE COVER NO.1
6.REMOVE IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
7.REMOVE CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
8.REMOVE TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)
9.REMOVE CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
10.REMOVE INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
11. REMOVE FRONT WHEEL RH
12. REMOVE BRAKE TUBE
(a) w/o VSC:Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100
(b) w/ VSC: Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100, 09023±38400

F45361
F45362
F45367
F45363Vacuum tank
C81275
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±27
AVENSIS REPAIR MANUAL (RM1018E)
(f) Using SST, disconnect the 3 brake tubes from the ways.
SST 09023±00100
(g) Disconnect the brake tube from the clamp and remove
the brake tubes.
(h) Disconnect the 3 brake tubes from the clamp and remove
the brake tubes.
13. REMOVE BRAKE BOOSTER ASSY
(a) Gasoline engine type:
Remove the 2 bolts and separate the vacuum pipe from
the body.
(b) Diesel engine type:
Remove the 2 bolts and remove the vacuum tank from the
body.
(c) Disconnect the vacuum hose from the brake booster
assy.
(d) Remove the engine under cover.
(e) Remove the 2 nuts from the engine mounting bracket RH.
(f) Remove the bolt from the rear engine mounting bracket.
(g) Remove the bolt and nut from the front engine mounting
bracket.

C80805
C82119
C81275
C81274
F45367
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±29
AVENSIS REPAIR MANUAL (RM1018E)
18. INSTALL BRAKE BOOSTER ASSY
(a) Install the clevis to the booster push rod.
(b) Install the brake booster assy with the 4 nuts.
Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(c) Connect the vacuum hose to the check valve.
(d) Install the engine mounting bracket RH to the body with
the 3 bolts.
Torque: 52 N
m (530 kgf
cm, 39 ft
lbf)
(e) Install the bolt to the rear engine mounting bracket.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(f) Install the bolt and nut to the front engine mounting brack-
et.
Torque: 52 N
m (530 kgf
cm, 39 ft
lbf)
(g) Install the 2 nuts to the engine mounting bracket RH.
Torque: 52 N
m (530 kgf
cm, 39 ft
lbf)
(h) Install the engine under cover.
(i) Connect the vacuum hose to the brake booster assy.
(j) Gasoline engine type:
Install the vacuum pipe with 2 bolts to the body.
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)

F45057
w/o VSC:
w/ VSC:
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
A
To
Master
Cylinder
FrontTo Master
Cylinder
Rear
To Rear
Wheel RH
To Front Wheel LHTo Front Wheel RH
To Rear
Wheel LH
AA
AA
BB
C80806
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±31
AVENSIS REPAIR MANUAL (RM1018E)
(e) w/o VSC:
Using SST, connect the 6 brake tubes to the brake actua-
tor, as shown in the illustration.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(f) w/ VSC: Using SST, connect the 6 brake tubes to the brake actua-
tor as shown in the illustration.
SST 09023±00100, 09023±38400
Torque:
A: 15 N
m (155 kgf
cm, 11 ft
lbf)
B: 29 N
m (296 kgf
cm, 21 ft
lbf)
(g) Install the brake tube clamps with the 2 bolts. Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
20. INSTALL FRONT WHEEL RH
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
22.INSTALL IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
23.INSTALL INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
24.INSTALL CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
25.INSTALL TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)