2005 TOYOTA AVENSIS oil

A87967
Upward90_
Clamp
Bolt
Turbocharger Side:
Air Hose No. 2 Side:
Front 90
_ Clamp Bolt
20.4_
14
−134
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(b) Tighten the 2 hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
208. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
209. INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See Pub. No. RM1018E on page 16 −51)
210. INSTALL ENGINE ROOM RELAY BLOCK NO.3
Torque: 5.3 N
m (54 kgf
cm, 47 in.
lbf)
211. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
212. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
213. INSTALL BATTERY Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt
3.0 to 4.0 N
m (31 to 41 kgf
cm, 27 to 35 in.
lbf) for nut
5.4 N
m (55 kgf
cm, 48 in.
lbf) for terminal
214. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
215. BLEED CLUTCH PIPE LINE (See Pub. No. RM1018E on page 42 −12)
216. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
217. ADD MANUAL TRANSAXLE OIL (See Pub. No. RM1018E on page 41 −5)
218. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
219. ADD ENGINE COOLANT (See page 16 −19)
220. CHECK CLUTCH FLUID LEAKAGE
221. CHECK FLUID LEVEL IN RESERVOIR
222. CHECK BRAKE FLUID LEAKAGE
223. CHECK FOR ENGINE OIL LEAKS
224. CHECK FOR FUEL LEAKS (See page 11 −46)
225. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
226. CHECK FOR EXHAUST GAS LEAKS
227. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See Pub. No. RM1018E on page 26 −6)

141ND−01
A57063
Measure Point for Belt
Deflection and Tension
Alternator
Crankshaft Compressor
P/SP/S
Alternator Crankshaft
A/C Equipped
A/C Not Equipped
−
ENGINE MECHANICAL ENGINE (1CD−FTV)(From September, 2003)
14 −87
AVENSIS Supplement (RM1045E)
ENGINE (1CD −FTV)(From September, 2003)
INSPECTION
1. INSPECT ENGINE COOLANT (See page 16 −15)
2. INSPECT ENGINE OIL (See page 17 −9)
3. INSPECT BATTERY (See Pub. No. RM1018E on page 19 −26)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB −ASSY
5. INSPECT DRIVE BELT
(a) Inspect the vane pump V −ribbed belt.
(1) Measure the belt deflection.
Pressing force: 98 N (10 kgf, 22 lbf)
New Belt
mm (in.)Used Belt mm (in.)
A/C Equipped8.0 to 10.5
(0.31 to 0.41)10.5 to 12.5
(0.41 to 0.49)
A/C Not Equipped10 to 12
(0.39 to 0.47)14 to 17
(0.55 to 0.67)
(2) Measure the belt tension.
New Belt
N (kgf, lbf)Used Belt
N (kgf, lbf)
A/C Equipped647 to 843
(66 to 86, 145 to 189)441 to 637
(45 to 65, 99 to 143)
A/C Not Equipped686 to 784
(70 to 80, 154 to 176)294 to 441
(30 to 45, 66 to 99)
NOTICE:
SCheck the drive belt deflection at the specified point.
SWhen installing a new belt, set its tension value as
specified.
SWhen inspecting the belt which has been used for
over 5 minutes, apply the specifications of ”Used
Belt.”
SWhen reinstalling the belt which has been used for
over 5 minutes, adjust its deflection and tension to
the intermediate value of each specification of ”Used
Belt.”
SThe V −ribbed belt tension and deflection should be
checked after 2 revolutions of engine cranking.
SWhen using a belt tension gauge, confirm the accura-
cy by using a master gauge first.

A61174
SST
Compression Gauge
− ENGINE MECHANICALENGINE (1CD−FTV)(From September, 2003)
14−89
AVENSIS Supplement (RM1045E)
(2) Connect SST (a compression gauge) to SST (the
attachment).
SST 09992−00025 (09992−00121, 09992−00211)
(3) Fully open the throttle valve, then start the engine.
(4) While cranking the engine, measure the compres-
sion pressure.
NOTICE:
SAlways use a fully−charged battery to obtain engine
speed of 250 rpm or more.
SCheck the other cylinder compression pressure in
the same way.
SThis measurement must be done as quickly as pos-
sible.
Compression pressure:
2,628 kPa (26.8 kgf/cm
2, 381 psi) or more
Minimum pressure:
2,157 kPa (22.0 kgf/cm
2, 312 psi) or more
Difference between each cylinder:
490 kPa (5.0 kgf/cm
2, 71 psi) or less
(5) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
glow plug hole, then measure the compression
pressure again.
HINT:
SIf adding oil raises the compression pressure, the piston
rings and/or cylinder bore may be worn or damaged.
SIf the compression pressure stays low, the valve may be
sticking or seating improperly, or there may be leakage
past the gasket.

141BS−02
A77421
Cut Position
A77422SST
14
−86
−
ENGINE MECHANICAL ENGINE REAR OIL SEAL (2AZ −FSE)
AVENSIS Supplement (RM1045E)
ENGINE REAR OIL SEAL (2AZ −FSE)
REPLACEMENT
1. REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40 −3)
2. REMOVE DRIVE PLATE & RING GEAR SUB −ASSY (See page 14 −23)
SST 09213 −54015 (91651 −60855), 09330 −00021
3. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the engine rear oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the engine rear oil seal.
HINT:
After the removal, check that the crankshaft is not damaged.
If damaged, smooth the surface with 400 −grit sandpaper.
4. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST 09223 −15030, 09950 −70010 (09951 −07100)
NOTICE:
Wipe off extra grease on the crankshaft.
5. INSTALL DRIVE PLATE & RING GEAR SUB −ASSY (See page 14 −23)
SST 09213 −54015 (91651 −60855), 09330 −00021
6. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40 −3)

141NC−01
Cut Position
A13332
A77419
SST
−
ENGINE MECHANICAL TIMING GEAR CASE OR TIMING CHAIN CASE OIL
SEAL (2AZ−FSE)14 −85
AVENSIS Supplement (RM1045E)
TIMING GEAR CASE OR TIMING CHAIN CASE OIL
SEAL (2AZ −FSE)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −45)
8. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
9. REMOVE CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05021)
10. REM O VE TI M I NG G EAR CASE O R T I M I NG CHAI NCASE OIL SEAL
(a) Using a screwdriver with tip wrapped in the tape, pry out the oil seal.
HINT:
After removal, check that the crankshaft is not damaged.
If damaged, smooth the surface with 400 −grit sandpaper.
11. I NSTALL TI M I NG G EAR CASE O R T I M I NG CHAI N 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.
SST 09223 −22010
NOTICE:
Wipe off extra grease on the crankshaft.
12. INSTALL CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021
13. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
14. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
15. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
16. CHECK FOR ENGINE OIL LEAKS

141NB−01
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
14 −79
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11 −4)
2. REMOVE FRONT WHEEL RH
3. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
4. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
5. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
7. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
8. DRAIN COOLANT (See page 16 −7)
9. DRAIN ENGINE OIL (See page 17 −6)
10. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −45)
11. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
12. SEPARATE FUEL TUBE SUB −ASSY (See page 11 −4)
13. REMOVE FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
14. REMOVE FUEL PUMP ASSY (See page 11 −24)
15. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
16. REMOVE GENERATOR ASSY (See page 19 −8)
17. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −2)
18. SEPARATE VANE PUMP ASSY (See page 14 −45)
19. REMOVE IGNITION COIL ASSY (See page 14 −45)
20. SEPARATE RETURN TUBE SUB −ASSY (See page 14 −45)
21. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14 −45)
22. REMOVE VANE PUMP OIL RESERVOIR ASSY (See page 14 −45)
23. REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14 −45)
24. SEPARATE ENGINE WIRE (See page 14 −23)
25. REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14 −45)
26. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(See page 14 −45)
27. REMOVE CYLINDER HEAD COVER SUB −ASSY (See page 14 −45)
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −45)
29. REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14 −45)
30. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14 −45)
31. REMOVE CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05021)
32. REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14 −45)
33. REMOVE CRANKSHAFT POSITION SENSOR (See page 14 −45)
34. REMOVE OIL PAN SUB −ASSY (See page 14 −45)
SST 09032 −00100
35. REMOVE V −RIBBED BELT TENSIONER ASSY (See page 14 −45)
36. REMOVE TIMING CHAIN OR BELT COVER SUB −ASSY (See page 14 −45)
37. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14 −45)
38. REMOVE CHAIN TENSIONER SLIPPER (See page 14 −45)
39. REMOVE CHAIN VIBRATION DAMPER NO.1 (See page 14 −45)
40. REMOVE TIMING CHAIN GUIDE (See page 14 −45)
41. REMOVE CHAIN SUB −ASSY (See page 14 −45)

A32664
A56213
Wooden Block
A83481
14−80
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
AVENSIS Supplement (RM1045E)
42. REMOVE BATTERY (See page 14 −45)
43. REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 14 −23)
44. DISCONNECT RADIATOR HOSE INLET (See page 14 −23)
45. DISCONNECT UNION TO CONNECTOR TUBE HOSE (See page 14 −23)
46. DISCONNECT HEATER INLET WATER HOSE (See page 14 −23)
47. SEPARATE FUEL TUBE SUB −ASSY (See page 11 −1)
48. SEPARATE ENGINE WIRE
49. REMOVE THROTTLE BODY ASSY (See page 10 −8)
50. REMOVE CHARCOAL CANISTER ASSY
51. REMOVE INTAKE MANIFOLD (See page 11 −13)
52. REMOVE MANIFOLD CONVERTER INSULATOR NO.1 (See page 14 −23)
53. REMOVE EXHAUST MANIFOLD CONVERTER SUB −ASSY (See page 14 −23)
54. REMOVE NO.2 CAMSHAFT (See page 14 −64)
55. REMOVE CAMSHAFT (See page 14 −64)
56. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See page 14 −23)
57. REMOVE CAMSHAFT BEARING NO.2
58. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub −assy.
(b) Set the jack under the engine assembly with transaxle,
then place a wooden block on the jack.
(c) Remove the chain block and sling devise.
59. REMOVE CYLINDER HEAD SUB −ASSY
(a) Remove the bolt, then separate the water by −pass pipe.
(b) Remove the camshaft housing plug.

A7740612 3
4 109
8 56 7
A77407
Overall Length
A77408
Lot No.
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
14−81
AVENSIS Supplement (RM1045E)
(c) Using several steps, loosen the 10 cylinder head bolts
with10mmbi−hexagon wrench uniformly in the se-
quence shown in the illustration.
(d) Remove the 10 cylinder head bolts and plate washers.
NOTICE:
SBe careful not to drop washers into the cylinder head.
SHead warpage or cranking could result from remov-
ing bolts and installing incorrect order.
60. REMOVE CYLINDER HEAD GASKET
61. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of the cylin-
der head set bolts from the seat to the end.
Standard bolt length:
161.3 to 162.3 mm (6.350 to 6.390 in.)
Maximum bolt length: 164.2 mm (6.465 in.)
If the length is greater than maximum, replace the cylinder head
set bolts.
62. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
SRemove any oil from contact surface.
SBe careful of the installation direction.
SPlace the cylinder head gently in order not to damage
the gasket with the bottom part of the head.