steering wheel TOYOTA AVENSIS 2005 Service Workshop Manual

±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±217
AVENSIS REPAIR MANUAL (RM1018E)
158.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
159.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
160.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
161.INSTALL BATTERY CARRIER
162.INSTALL AIR CLEANER ASSEMBLY WITH HOSE
Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
163.INSTALL COMPRESSOR AND MAGNETIC CLUTCH Torque: 25 N
m (255 kgf
cm,18 in.
lbf)
164.INSTALL GENERATOR ASSY (See page 19±20)
165.INSTALL FAN AND GENERATOR V BELT (See page 14±185)
166.INSTALL RADIATOR ASSY (See page 16±36)
167. INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
168. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
169. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
170. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
171. ADD ENGINE OIL
172.ADD COOLANT (See page 16±31)
173.ADD POWER STEERING FLUID (See page 51±4)
174. BLEED POWER STEERING FLUID
175. CHECK FOR ENGINE OIL LEAKS
176.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
177.CHECK FOR FUEL LEAKS (See page 11±30)
178. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
179.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
180.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±204)
181. INSPECT CO/HC
182. CHECK ABS SPEED SENSOR SIGNAL

14±262
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

141CB±01
A61184
A79179
14±342
±
ENGINE MECHANICAL CRANKSHAFT SEAL(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT SEAL(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 34 N
m (350 kgf
cm,25 ft
lbf)
2.REMOVE FRONT WHEEL RH
3.REMOVE ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE INJECTOR DRIVER (See page 14±286)
8.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
9.REMOVE GENERATOR V BELT (See page 14±269)
10.REMOVE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11.REMOVE ENGINE MOUNTIN G INSULATOR
SUB±ASSY RH
(a)Place a wooden block on a jack underneath the engine.
(b)Remove the 3 bolts and 3 nuts, and then detach the en- gine mounting insulator sub assy.
12.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
13.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
14.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
15.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
16. REMOVE TIMING BELT GUIDE
17.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
18.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
19.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)

14±344
±
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
29.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
30.INSTALL TIMING BELT GUIDE(See page 14±307)
31.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
32.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
33.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
34.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
35.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
36.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
37. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
38.INSTALL INJECTOR DRIVER (See page 14±286)
39. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
40. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
41. ADD ENGINE OIL
42. CHECK FOR ENGINE OIL LEAKS

141CA±01
14±332
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.DRAIN ENGINE COOLANT (See page 16±44)
6.DRAIN ENGINE OIL (See page 14±342)
7. REMOVE RADIATOR SUPPORT OPENING COVER
8. REMOVE ENGINE ROOM COVER SIDE
9. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
10.REMOVE VACUUM RESERVOIR SUB±ASSY (See page 13±11)
11.REMOVE AIR CLEANER ASSY (See page 14±286)
12. REMOVE BATTERY
13.REMOVE AIR TUBE NO.2 (See page 14±286)
14.REMOVE AIR TUBE NO.1(See page 14±270)
15.REMOVE INJECTOR DRIVER (See page 14±286)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
17.REMOVE GENERATOR V BELT (See page 14±269)
18.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
19.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
20.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
21.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
22.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
23.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
24. REMOVE TIMING BELT GUIDE
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
27.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
28.REMOVE TIMING BELT(See page 14±307)
HINT:
If re±using the timing belt, draw a direction arrow on the timing belt (\
in direction of engine revolution), and
place matchmarks on the pulleys and the timing belt.
29.REMOVE FUEL FILTER ASSY (See page 11±82)
30.REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13±11)
31.REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13±11)
32.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
34.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
35. DISCONNECT RADIATOR HOSE INLET
36. DISCONNECT HEATER INLET WATER HOSE
37. DISCONNECT HEATER OUTLET WATER HOSE
38. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
39. DISCONNECT OIL COOLER HOSE
40.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
41.REMOVE TURBO INSULATOR NO.1 (See page 13±11)

±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±341
AVENSIS REPAIR MANUAL (RM1018E)
95.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
96.INSTALL TURBO INSULATOR NO.2 (See page 13±11)
97.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
98.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
99.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
100.INSTALL HEATER BRACKET (W/ COLD AREA)(See page 13±11)
101.INSTALL HEATER PUMP ASSY (W/ COLD AREA)(See page 13±11)
102.INSTALL FUEL FILTER ASSY(See page 11±82)
103.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
SST 09960±10010 (09962±01000, 09963±01000)
104.INSTALL TIMING BELT(See page 14±307)
105.CHECK VALVE TIMING(See page 14±307)
106.TIMING CHAIN COVER PLATE(See page 14±307)
107.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
108.INSTALL TIMING BELT GUIDE(See page 14±307)
109.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
110.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
111.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
112.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
113.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
114.INSTALL POWER STEERING IDLE PULLEY BRACKET(See page 14±307)
115. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
116.INSTALL INJECTOR DRIVER (See page 14±286)
117.INSTALL AIR TUBE NO.1(See page 14±270)
118.INSTALL AIR TUBE NO.2 (See page 14±286)
119.INSTALL AIR CLEANER ASSY (See page 14±286)
120.INSTALL VACUUM RESERVOIR SUB±ASSY (See page 13±11)
121. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
122. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
123. ADD ENGINE OIL
124.ADD ENGINE COOLANT(See page 16±44)
125.CHECK FOR FUEL LEAKS(See page 11±60)
126. CHECK FOR ENGINE OIL LEAKS
127.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
128. CHECK FOR EXHAUST GAS LEAKS

141C8±01
SSTA61187
14±318
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
9.REMOVE AIR TUBE NO.1 (See page 14±270)
10.REMOVE INJECTOR DRIVER (See page 14±286)
11. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH (See page 14±307)
15.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
16.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
17.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
19. REMOVE TIMING BELT GUIDE
20.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
23.REMOVE TIMING BELT (See page 14±307)
24.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
25. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the timing pulley.
HINT:
Using a plastic±faced hammer, tap out the pulley.
(c) Remove the set key.

±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±325
AVENSIS REPAIR MANUAL (RM1018E)
59.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
60.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
61.INSTALL TIMING BELT GUIDE(See page 14±307)
62.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
63.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
64.INSTALL IDLER PULLEY SUB±ASSY(See page 14±307)
65.INSTALL CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021
66.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
67.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
68. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
69.INSTALL INJECTOR DRIVER (See page 14±286)
70.INSTALL AIR TUBE NO.1 (See page 14±270)
71. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
72.INSTALL AIR CLEANER ASSY (See page 14±286)
73. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
74. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
75.CHECK FOR FUEL LEAKS(See page 11±60)

141C6±01
A61184
A79179
A61182
SST (B)
SSTSST (A)
±
ENGINE MECHANICAL TIMING BELT(1CD±FTV)
14±307
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.REMOVE ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE INJECTOR DRIVER (See page 14±286)
8.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
9.REMOVE GENERATOR V BELT (See page 14±269)
10.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
11. REMOVE ENGINE MOUNTING INSULATORSUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine.
(b) Remove the 3 bolts and 3 nuts, and then detach the en- gine mounting insulator sub assy RH.
12. REMOVE CRANKSHAFT PULLEY
(a) Using SSTs, remove the pulley bolt. SST 09213±54015 (90105±08076), 09330±00021
HINT:
When using SST (A) (90105±08076), a plate washer (5 mm or
0.20 in.) must be inserted between SST (A) and SST (B).

170FP±01
SST
A09582
17±22
±
LUBRICATION OIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL(See page 17±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER(See page 14±307)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17.REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22.REMOVE TIMING BELT IDLER SUB±ASSY NO.2(See page 14±307)
23.REMOVE CRANKSHAFT TIMING PULLEY
(a)If the timing pulley can not be removed by hand, use SSTto remove the pulley.
SST09950±50013 (09951±05010, 09952±05010, 09953±05010, 09953±05020, 09954±05021)
24.REMOVE GENERATOR ASSY(See page 19±29)
25. REMOVE TIMING BELT IDLER SUB±ASSY NO.1
26. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the 2 bolts and the V±ribbed belt tensioner.