Radiator TOYOTA AVENSIS 2005 Service Manual PDF

141CK±01
A78459
A76713
A64023
A65078
14±64
±
ENGINE MECHANICAL CAMSHAFT(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE UNDER COVER RH (See page 14±27) 3. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove and the 2 screw and 2 clips and detach the en-gine under cover No.2.
4. DISCONNECT COIL, IGNITION
(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 the 4 ignition coils.
5. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head cover.

141CJ±01
A79321
Clip
Engine Room Side Cover RH
Retainer Clip
Radiator Cover Assy
Clip
Engine Under Cover RH
Engine Under Cover No. 1
Clip
14±60
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT (1ZZ±FE/3ZZ±FE)
COMPONENTS

141CI±01
A78459
A60622
A79324
A76713
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1ZZ±FE/3ZZ±FE)
14±49
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
3.REMOVE FRONT WHEEL RH
4.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
5.REMOVE ENGINE UNDER COVER RH (See page 14±27)
6.DRAIN ENGINE COOLANT (See page 16±7)
7.REMOVE CYLINDER HEAD COVER NO.2
(a)Remove the 2 nuts and 2 clips and detach the cylinderhead cover No.2.
8.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.
9.REMOVE V±RIBBED IDLER ASSY NO.1
(a)Remove the nut, bolt, tube and idler.
10.REMOVE GENERATOR ASSY (See page 19±7)
11. REMOVE 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.

141CH±01
A79321
Clip
Engine Room Side Cover RH
Retainer Clip
Radiator Cover Assy
Clip
Engine Under Cover RH
Engine Under Cover No. 1
Clip
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±45
AVENSIS REPAIR MANUAL (RM1018E)
CHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS

141CG±01
A784575 Claws
A78458
A78505
A78515
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±27
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±1)
2. REMOVE RADIATOR SUPPORT OPENING COVER
(a) Remove the retainer and the 4 clips.
(b) Unfasten the 5 claws, and remove the radiator supportopening cover.
3. REMOVE ENGINE ROOM COVER SIDE
(a) Remove the 2 clips and the engine room cover side.
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
(a) Remove the 5 clips, 2 screws, bolt and 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
A78459
14±28
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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±7)
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 page 41±15)
11.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±42)
12. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, then detach cylinder headcover No.2.
13.REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
14. REMOVE AIR CLEANER FILTER ELEMENT SUB±ASSY
15. REMOVE AIR CLEANER CASE SUB±ASSY
(a) Remove the 3 bolts and the 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 TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
19. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.

A76724
A76714
A78461
1ZZ±FE
A78497
3ZZ±FE
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±29
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE RADIATOR ASSY
(a) Remove the 2 bolts and the relay block.
(b) Disconnect the connector and the 2 harness clamps.
(c) Remove the 2 bolts, the 2 radiator support upper and the
radiator.
21. REMOVE BATTERY
22. REMOVE BATTERY TRAY
23. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts, the battery carrier and the bracket.
24.REMOVE EFI FUEL PIPE CLAMP(See page 11±11)
25. DISCONNECT FUEL TUBE SUB±ASSY (See page 11±11)
26. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator control cable.
27. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose.
28. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose from the heater core inlet tube.
29. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose from the heater core outlet tube\
.
30. DISCONNECT OIL COOLER INLET HOSE (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet hose from the automatic transaxle.
31. DISCONNECT OIL COOLER OUTLET HOSE (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet hose from the automatic transaxle.

A76722
A76723
A64033
A64034
A64034
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±37
AVENSIS REPAIR MANUAL (RM1018E)
85. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 3 bolts and the nut, and then remove the ex-
haust manifold heat insulator.
86. REMOVE EXHAUST MANIFOLD
(a) Remove the 5 nuts, then remove the exhaust manifold
and the gasket.
87. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the engine coolant temperature sen-
sor.
SST 09817±33190
88. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and the condenser.
89. REMOVE WATER BY±PASS HOSE NO.2
90. REMOVE RADIATOR HOSE INLET
91. REMOVE HEATER INLET WATER HOSE
92. REPLACE PARTIAL ENGINE ASSY
93. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)

A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N
m (131 kgf
cm, 9 ft
lbf)
138. INSTALL BATTERY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. 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)
145. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL

141CF±01
A76700
Cylinder Head
Cover No. 2 Radiator Support
Upper
Radiator Support Upper
Radiator
Hose Inlet
Radiator Hose Outlet
Radiator AssyClip
7.0 (71, 62 in.
lbf)
19 (194, 14)
Engine Under Cover LH Engine Under Cover RH
Clip
Clip
N´m (kgf´cm, ft´lbf)
: Specified torque
Clip
Engine Under Cover No.1
19 (194, 14)
Retainer
Clip
Clip
Engine Room Cover Side
Radiator Suport Opening Cover
5.0 (51, 44)
Relay Block
Oil Cooler Inlet Tube No.1 Oil Cooler
Outlet Tube No.1
x2
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS