wheel bolts TOYOTA AVENSIS 2005 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2005, Model line: AVENSIS, Model: TOYOTA AVENSIS 2005Pages: 5135, PDF Size: 95.28 MB
Page 170 of 5135
030G7±04
03±60
± SERVICE SPECIFICATIONSPOWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedNmkgfcmftlbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in.lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356
81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in.lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)
Page 1910 of 5135
110UA±01
A15950
±
FUEL INJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
11±69
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.DRAIN ENGINE COOLANT(See page 16±44)
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
9.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
10.DISCONNECT RADIATOR HOSE OUTLET
(a)Disconnect the radiator hose outlet from the water inlet.
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.REMOVE INJECTOR DRIVER
(a)Remove the 2 nuts which are used to secure the injector driver.
(b)Disconnect the injector driver connector and the harness clamp.
(c)Remove the injector driver.
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
15.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
16.REMOVE IDLER PULLEY SUB±ASSY
(a)Remove the bolt and washer, then remove the idler pulley.
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
(a) Remove the 6 bolts and the engine mounting bracket.
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)
Page 2049 of 5135
A76718
A76719
A62838SST
A62838SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±33
AVENSIS REPAIR MANUAL (RM1018E)
60. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Remove the through bolt and nut, detach the engine
mounting insulator FR from the engine mounting bracket.
(b) Remove the through bolt, detach the engine mounting in- sulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the suspension crossmember and the engine mounting
member.
61.REMOVE STARTER ASSY(See page 19±3)
62.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
63.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
64.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
65.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) 66. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
67. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the
drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
68. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
Page 2057 of 5135
A76713
A62838SST
A62205
1
5
3
82
6
4
7
A62206
90
A62838SST
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±41
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
113. INSTALL FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts.
Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni-
formly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgfcm, 36 ftlbf)
(e) Mark each bolt head with paint.
(f) Retighten the bolts by an additional 90 in the same se-
quence as step (d).
(g) Check that the paint marks are at 90 angle about the
original position.
114. INSTALL DRIVE PLATE & RING GEAR SUB±ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST.
SST 09960±10010 (09962±01000, 09963±01000)
Page 2060 of 5135
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
Page 2069 of 5135
141BF±01
A77281
A77301
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
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 COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil.
Torque: 25 N m (255 kgf cm,18 ft lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N m (500 kgf cm,36 ft lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
Page 2075 of 5135
A77402SST
A56446
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±127
AVENSIS REPAIR MANUAL (RM1018E)
63.SEPARATE VANE PUMP ASSY
(a)Disconnect the PS oil pressure switch connector.
(b)Remove the 2 bolts and separate the vane pump from the engine.
64.REMOVE STARTER ASSY (See page 19±12)
65.REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Remove the through bolt and nut from the engine mounting insulator FR.
(b)Remove the through bolt and nut from the engine mounting insulator RR.
66.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
67.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
68.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
69.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
70.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
71.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
72. REMOVE DRIVE PLATE AND RING GEAR ORFLYWHEEL
(a) Using SST, fix the crankshaft pulley and remove the drive plate and ring gear or flywheel.
SST 09213±54015 (91651±60855), 09330±00021
73. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Remove a bolt, O±ring and the camshaft timing oil control valve. 74. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts, and then remove the in-take manifold.
75. REMOVE VENTILATION HOSE
76. REMOVE VENTILATION HOSE NO.2
77. REMOVE ENGINE WIRE
78. REMOVE INTAKE MANIFOLD INSULATOR NO.1
79. REMOVE OIL LEVEL GAGE SUB±ASSY
80. REMOVE OIL LEVEL GAGE GUIDE
81. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
(a) Remove the 4 bolts and the manifold converter insulator No. 1.
Page 2078 of 5135
A52499
A56446
A77333SST 14±130
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the No. 1 and No. 2 exhaust manifold stays with the
2 bolts and 2 nuts.
Torque: 44 Nm (449 kgfcm, 32 ftlbf)
105. INSTALL MANIFOLD CONVERTER INSULATOR NO.1
Torque: 12 Nm (122 kgfcm, 9.0 ftlbf)
106. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O±ring, install it to the oil level gauge guide.
(b) Install the oil level gauge and guide with the bolt.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
107. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 5
bolts and 2 nuts.
Torque: 30 Nm (306 kgfcm, 22 ftlbf)
108. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (W/ VVT±i)
(a) Apply light coat of engine oil to the new O±ring and install it to the camshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt.
Torque: 9.0 Nm (92 kgfcm, 79 in.lbf)
109. I N S TA L L D R I V E P L AT E A N D R I N G G E A R O R
FLYWHEEL
(a) Hold the crankshaft with SST.
SST 09213±54015 (91651±60855), 09330±00021
Adhesive:
Part No. 08833±00070, THREE BOND or equivalent
Page 2079 of 5135
A77403
15
3
7
2
6
4 8
A63273
A77404
B
A
BBBB
A
B
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±131
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the drive plate. (A/T)
(1)Clean the bolt and bolt hole.
(2)Apply adhesive to the bolts.
(3)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 98 N m (1,000 kgf cm, 72 ft lbf)
(c)Install the flywheel. (M/T)
(1)Clean the bolt hole.
(2)Using several steps, install and tighten the 8 boltsuniformly in the sequence shown in the illustration.
Torque: 130 N m (1,327 kgf cm, 96 ft lbf)
NOTICE:
Do not reuse the flywheel bolt.
110.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26)
111.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
112.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
113.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
114.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
115.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
116.INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
(a)Install the engine mounting insulator FR with the through bolt and nut. Torque: 87 N m (887 kgf cm,64 ft lbf)
(b)Install the engine mounting insulator RR with the through bolt and nut. Torque: 87 N m (887 kgf cm,64 ft lbf)
117.INSTALL STARTER ASSY (See page 19±12)
118. INSTALL VANE PUMP ASSY
Torque: 37 N m (370 kgf cm, 27 ft lbf)
119. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the 2 bolts and 2 nuts as shown in the illustration. Torque:
Bolt 45 N m (459 kgf cm, 33 ft lbf)
Nut 133 N m (1,356 kgf cm, 98 ft lbf)
(b) Install the front suspension member braces with the 8 bolts.
Torque:
Bolt A 133 N m (1,356 kgf cm, 98 ft lbf)
Bolt B 80 N m (816 kgf cm, 59 ft lbf)
Page 2103 of 5135
141CO±01
A62838SST
A62838SST
A62202
Cut Position
A62203
SST
14±98
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 5. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
6. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
7. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grid sandpa-
per.
8. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223±15020, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.