set clock TOYOTA AVENSIS 2005 Service Repair Manual

L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
±
INTRODUCTION REPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench is combined with SST oran extension tool to extend the length, and you
tighten until the torque wrench reads the specified
torque value, the actual torque becomes excessive.
(2)In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.
(3)Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
lbf 
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)
2.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS is equipped with an SRS (Supplemental Restraint System), which \
includes the driver airbag,
front passenger airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause\
the supplemental restraint
system to unexpectedly deploy while servicing. This could cause a seriou\
s accident.
Furthermore, if a mistake is made when servicing the supplemental restra\
int system, it is possible that the
SRS will fail to operate when required. Before servicing (including remova\
l or installation of parts, inspection
or replacement), be sure to read the following items carefully. Then follow the correct procedures described
in this manual.
(a)GENERAL NOTICE
(1)Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag-nostic trouble codes become the most important source of information when trou\
bleshooting.
When troubleshooting the supplemental restraint system, always check the dia\
gnostic trouble
codes before disconnecting the battery (See page 05±1184).
(2) Work must be started after 90 seconds from the time that the ignition switch\
is turned to the LOCK position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The supplemental restraint system is equipped with a back±up power sourc\
e. So, if work is
started within 90 seconds after disconnecting the negative (±) terminal ca\
ble from the battery,
the SRS may deploy).
When the negative (±) terminal cable is disconnected from the battery, memory of the clock and
audio systems is cancelled. So, before starting work, make a record of the contents recorded
in each memory system. Then, when work is finished, reset the clock and audio systems as be-
fore.

D26613
Example:
D25080
Negative (±)
Terminal
± INTRODUCTIONREPAIR INSTRUCTION
01±15
AVENSIS REPAIR MANUAL (RM1018E)
(8) Oil or water should not be put on the front seat outer belt and the front seat outer belt should be
cleaned with the appropriate detergents.
(i) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved in a collision where the SRS has deployed.
(2) The connectors to the airbag sensor assembly should be connected or disconnected with the
sensor mounted on the floor. If the connectors are connected or disconnected while the airbag
sensor assembly is not mounted to the floor, it could cause an undesired ignition of the supple-
mental restraint system.
(3) Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº
position and the negative (±) terminal cable is disconnected from the battery, even if only loosen-
ing the set bolts of the airbag sensor assembly.
(j) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All connec-
tors in the system are a standard yellow color. If the SRS wire harness becomes disconnected
or the connector becomes broken due to an accident, etc., repair or replace it.
3. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
NAL
(1) Before performing electronic work, disconnect the
battery negative (±) terminal cable beforehand in
order to prevent it from shorting and burning out.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF, and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal.
(3) When the battery terminal cable is removed, the
memories of the clock, radio, DTCs, etc. are erased.
So before removing it, check them and make a note
of their settings.
(4) When the battery negative (±) terminal cable is dis-
connected, memories of various systems are
erased. Therefore, refer to the PRE±CHECK for
each system to make sure whether or not the sys-
tem needs to be initialized after the battery negative

A01132
A60622
A01045
A64005
14±8
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Turn the crankshaft 1 revolution (360
) and set No. 4 cyl-
inder to TDC/compression.
(c) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifter.
Valve clearance (Cold):
Intake 0.15 to 0.25 mm (0.0059 to 0.0098 in.)
Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 in.)
12. 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.
13. REMOVE ENGINE MOUNTING INSULATOR
SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine.
Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.

A30857
A10079
A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
A62172
SST
± ENGINE MECHANICALCHAIN SUB±ASSY (1ZZ±FE/3ZZ±FE)
14±53
AVENSIS REPAIR MANUAL (RM1018E)
27. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain with the crankshaft timing gear
by plying it using screwdrivers as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise for valves not to touch the pistons.
28. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the camshafts with a wrench and align the
point marks of the camshaft timing sprockets.
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain to the crankshaft timing sprocket
with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
HINT:
Three yellow color links are on the chain.
(c) Using SST, install the crankshaft timing sprocket.
SST 09223±22010

141B6±01
A77281
A77378
No. 1 Cylinder TDC/Compression
IN
EX
A77379
No. 4 Cylinder TDC/Compression
IN
EX
14±106
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1AZ±FE)
ADJUSTMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.REMOVE ENGINE UNDER COVER RH 4.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
5.REMOVE IGNITION COIL ASSY
(a)Remove 4 bolts and the ignition coils.
6.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±171)
7.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±171) 8. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
(b) Turn the crankshaft clockwise 1 revolution (360
) and set
No. 4 cylinder to TDC/compression.
(c) Check only the valve indicated in the illustration. (1) Using a feeler gauge, measure the clearance be-tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)

A30857
A62814
4 2531
A62816
2
5 3
110 8 4 796
A62827
Lot No.
A62820
Overall Length
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±87
AVENSIS REPAIR MANUAL (RM1018E)
46. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain by prying the crankshaft timing
gear using screwdrivers as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise to prevent the valves from touch-
ing the pistons.
47. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 19 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 9 bearing caps, and both the intake and
exhaust camshafts.
48. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen and remove the 10 cylinder
head bolts with a 10 mm hexagon wrench uniformly in the
sequence shown in the illustration. Remove the 10 cylin-
der head bolts and 10 plate washers.
(b) Remove the cylinder head.
49. REMOVE CYLINDER HEAD GASKET
50. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the Lot No. stamp facing upward.
NOTICE:

Pay attention to the mounting orientation.

Place the cylinder head on the gasket gently in order
not to damage the gasket with the bottom part of the
head.
51. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of cylinder
head bolt from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum length: 148.5 mm (5.846 in.)
If the length exceeds the maximum, replace the bolt.

A77382
Groove90

A77383
Groove
A66833
B11424
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±145
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90
, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil
pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner
and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
38. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Orient the flat portion of the drive shaft upward.

A77382
Groove90

A77383
Groove
A66833
B11424
14±228
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
41. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90
, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil
pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner
and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
42. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Position the flat portion of the drive shaft upward.

141BL±01
A77339
A77343
No. 1 Cylinder TDC / CompressionIN
EX
14±186
±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1AZ±FSE)
ADJUSTMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±33)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH 5.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
6.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
7.REMOVE FUEL TUBE SUB±ASSY (See page 11±33)
8.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
9. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and the ignition coils.
10.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±240)
11.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±240)
12. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated in the illustration.(1) Using a feeler gauge, measure the clearance be-tween the valve lifter and the camshaft.
(2) Record the out±of specification valve clearance measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.)
Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
(b) Turn the crankshaft clockwise 1 revolution (360
) and set
No. 4 cylinder to TDC/compression.

A61194
Pry
A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring Tip
Protrusion Hight
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±335
AVENSIS REPAIR MANUAL (RM1018E)
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
67. REMOVE CYLINDER HEAD GASKET
68. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolts.
Standard outside diameter:
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
69. INSTALL CYLINDER HEAD GASKET
(a) Measure protrusion height of the piston heads.
(1) Clean the cylinder block with solvent.
(2) Set the piston to be measured to slightly before
TDC.
(3) Place a dial indicator on the cylinder block, and cali-
brate the dial indicator at 0 mm (0 in.).
HINT:

Place measuring tip of the dial indicator as shown in the
illustration.

Make sure that the measuring tip is square to the cylinder
block gasket and the piston head when measuring.
(4) Find the most overhung position of the piston head
by slowly turning the crankshaft clockwise and
counterclockwise.