2005 TOYOTA AVENSIS drive shaft assy

Cut Position
A13332
A77419
SST
A13697
SST
SST
14±264
±
ENGINE MECHANICAL TIMING GEAR CASE OR TIMING CHAIN CASE OIL
SEAL(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
(a)Using a screwdriver with tip wrapped in the tape, pry out
the oil seal.
HINT:
After removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpaper.
9.INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
(a)Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the oil seal until its sur- face is flush with the rear oil seal retainer edge.
SST09223±22010
NOTICE:
Wipe off extra grease on the crankshaft.
10.INSTALL CRANKSHAFT PULLEY
(a)Align the pulley set key with the key groove of the pulley.
(b)Using SST, install the pulley bolt. SST09213±54015 (91651±60855), 09330±00021
Torque: 170 N
m (1,733 kgf
cm, 125 ft
lbf)
11.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
12. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
13. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. CHECK FOR ENGINE OIL LEAKS

A77327
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
9.0 (90, 80 in.
lbf)
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover Sub±assy
Crank Position Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt Tensioner
Sub±assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
170 (1,735, 125)
Crankshaft Pulley
Chain Sub±assy
43 (440, 32)
Chain Tensioner
Slipper
19 (195, 14)
Camshaft Position
Sensor Plate No. 1
Oil Pump
Drive Gear
Chain Vibration
Damper No. 1

Oil Seal
Timing Chain Guide
9.0 (90, 80 in.
lbf)
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
43 (440, 32)
43 (440, 32)
9.0 (90, 80 in.
lbf)
14±250
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

141CC±01
A61182
SST
A09447
SST
A09448
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1CD±FTV)
14±345
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1CD±FTV)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (See page 41±33)
SST 09930±00010, 09628±62011, 09520±01010, 09520±24010 (09520±32040)
2.REMOVE CLUTCH COVER ASSY (See page 42±26)
3.REMOVE CLUTCH DISC ASSY (See page 42±26)
4. REMOVE FLYWHEEL SUB±ASSY
(a) Hold the crankshaft with SST.SST 09213±54015 (90105±08076), 09330±00021
(b) Using a torx socket wrench (T55), remove the 8 torx screws and the flywheel.
5. REMOVE REAR END PLATE
(a) Remove the 2 bolts and the rear end plate. 6. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, 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±grit sandpa-
per.
7. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign objects.
(b) Using SST and a hammer, tap in the oil seal until its sur-face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
8. INSTALL REAR END PLATE Torque: 8.4 N
m (86 kgf
cm, 74 in.
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)

A09656
A79144
A09566
1
234 5
67 89
1011
12 13
1415
16
1718
14±334
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
57.REMOVE INJECTION PIPE SUB±ASSY NO.4 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
58.REMOVE VACUUM PUMP ASSY (See page 14±318)
59. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
60. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, the cylinder head cover and thegasket.
61.REMOVE NOZZLE LEAKAGE PIPE ASSY(See page 11±60)
62.REMOVE INJECTOR ASSY(See page 11±60)
HINT:
Since each injector assembly has a characteristic fuel injecting behavior, store them in correct order so that
they can be returned to the original locations when re±assembling.
63.REMOVE CAMSHAFT OIL SEAL RETAINER (See page 14±318)
64.REMOVE NO.2 CAMSHAFT (See page 14±318)
65.REMOVE CAMSHAFT (See page 14±318) 66. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen the 18 cylinder head boltsuniformly in the sequence shown in the illustration. Re-
move the 18 cylinder head bolts and the plate washers.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.

±
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