2005 TOYOTA AVENSIS check engine

P13638
Adhesive 17−10
− LUBRICATIONLUBRICATION SYSTEM (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
8. INSTALL OIL PRESSURE SWITCH ASSY
(a) Apply adhesive to the 2 or 3 threads of the oil pressure
switch.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a deep socket wrench 24mm, install the oil pres-
sure switch.
Torque: 15 N
m (153 kgf
cm, 11 ft
lbf)
NOTICE:
Do not start the engine within 1 hour after the installation.
(c) Connect the oil pressure switch connector.
9. START ENGINE AND CHECK FOR LEAKS

160MQ−02
A56451
A77424
10 _10_
Jiggle Valve
16 −14
−
COOLING THERMOSTAT (2AZ −FSE)
AVENSIS Supplement (RM1045E)
THERMOSTAT (2AZ −FSE)
REPLACEMENT
1. DRAIN COOLANT (See page 16 −7)
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 FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
8. REMOVE GENERATOR ASSY (See page 19 −8)
9. REMOVE WATER INLET
(a) Remove the 2 nuts and water inlet.
10. REMOVE THERMOSTAT 11. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat while aligning the jiggle valve withits right position described in the illustration.
HINT:
The jiggle valve may be set within 10 _ of either side of the pre-
scribed position.
12. INSTALL WATER INLET Torque: 9.0 N
m (92 kgf
cm, 7 in.
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
−
COOLING WATER PUMP ASSY (2AZ −FSE)
16 −13
AVENSIS Supplement (RM1045E)
11. INSTALL WATER PUMP ASSY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump assy.
(b) Apply a continuous bead of the seal packing (diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)) as shown in the illustra-
tion.
Seal packing: Part No. 08826 − 00100 or equivalent
NOTICE:
Install the water pump assy within 5 minutes after applying
seal packing. Otherwise the material must be removed and
reapplied.
(c) Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d) Install the crankshaft position sensor wire harness clamp
to the water pump.
(e) I nst all t he cr ankshaf t posit ion s ensor wir e t o t he wir e clamp on the water pump.
12. INSTALL WATER PUMP PULLEY
(a) Using SST, install the pump pulley with 4 bolts. SST 09960 −10010 (09962 −01000, 09963 −00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

SST
A09582
B07973
Cut PositionPry
SST
A08528
SST
A09583
Angle
SensorInward
14
−178−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
22. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
23. REMOVE TIMING BELT (See page 14 −138)
24. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the timing pulley cannot be removed by hand, use SST to remove the pulley.
SST 09950 − 50013 ( 09951 − 05010, 09952 − 05010,
09953 −05010, 09953 −05020, 09954 −05021)
25. REMOVE CRANKSHAFT SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Wrap the tip of the
screwdriver with tape.
26. INSTALL CRANKSHAFT SEAL
(a) Apply multipurpose 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 oil pump edge.
SST 09316 −60011 (09316 −00011)
27. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the keyway of the timing pulley with the key located on the crankshaft, then slide the pulley into place.
(b) Using SST and a hammer, tap in the timing pulley with the
angle sensor facing inward.
SST 09223 −46011
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
29. INSTALL TIMING BELT (See page 14 −138)
30. CHECK VALVE TIMING (See page 14 −138)

−
ENGINE MECHANICAL CRANKSHAFT SEAL (1CD−FTV)(From September,
2003)14 −179
AVENSIS Supplement (RM1045E)
31. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
32. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
33. INSTALL TIMING BELT GUIDE (See page 14 −138)
34. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
35. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
36. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
37. INSTALL CRANKSHAFT PULLEY (See page 14 −138 )
SST 09213 −54015 (09213 −70020), 09330 −00021
38. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
39. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
40. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
41. INSTALL INJECTOR DRIVER (See page 14 −108)
42. INSTALL ENGINE COVER NO.1 (See page 14 −90)
43. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
44. ADD ENGINE OIL
45. CHECK FOR ENGINE OIL LEAKS

141Q9−01
A36642
A13397
A13400
14−56
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
HINT:
The connecting rod cap bolts are tightened in 2 progressive
steps.
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure the correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring the correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 connecting
rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and the lower bearing by wiggling
the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
(f) Lay a strip of Plastigage on the crank pin.

Front Mark
A52515
A36644
Mark
1, 2 or 3Mark
1, 2 or 3
A13840
A13469
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−57
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
(g) Check that the front mark of the connecting rod cap is fac-
ing in the correct direction.
(h) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(i) Install the connecting cap (see step 37).
NOTICE:
Do not turn the crankshaft.
(j) Remove the 2 bolts and connecting rod cap.
(k) Measure the Plastigage at its widest point.
Standard oil clearance:
0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
HINT:
If replacing a bearing, replace it with one that has the same
number as the connecting rod. There are 3 sizes of standard
bearings: 1, 2 and 3.
Standard bearing center wall thickness:
Mark 11.485 to 1.488 mm (0.0585 to 0.0586 in.)
Mark 21.489 to 1.491 mm (0.0586 to 0.0587 in.)
Mark 31.492 to 1.494 mm (0.0587 to 0.0588 in.)
(l) Completely remove the Plastigage.
3. REMOVE PISTON SUB−ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
SKeep the bearing, connecting rod and cap together.
SArrange the piston and connecting rod assemblies in the
correct order.
4. REMOVE CONNECTING ROD BEARING

A87780
1
2
3
4
5
68
79
10
A87781
A87782
Plastigage
A87783
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−59
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
9. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts in the sequence shown in the illustration.
(b) Use 2 removed main bearing cap bolts to remove the 5
main bearing caps and 5 lower bearings.
NOTICE:
Insert the bolts into one of the caps. Ease the cap out by
gently pulling up and applying force toward the front and
back side of the cylinder block, as shown in the illustration.
Take care not to damage the contact surfaces of the cap
and cylinder block.
HINT:
SKeep the lower bearing and main bearing cap together.
SArrange the main bearing caps in the correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (see step 36).
HINT:
Do not turn the crankshaft.
(i) Remove the main bearing cap (see steps (a) to (b)
above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
0.017 to 0.040 mm (0.00067 to 0.00157 in.)
Maximum oil clearance: 0.050 mm (0.002 in.)
If the oil clearance is greater than the maximum, replace the
bearings. If necessary, replace the crankshaft.