2005 TOYOTA AVENSIS fuel pressure

A77331
SST
A77353
14±210
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
61.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.
62.REMOVE STARTER ASSY (See page 19±12)
63. 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.
64.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
65.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
66.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
67.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
68.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
69.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42±26) 70. 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
71. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Remove the bolt, O±ring and the camshaft timing oil control valve.
72. REMOVE THROTTLE BODY BRACKET
(a) Separate the engine wire.
(b) Remove the 4 bolts and the throttle body bracket.
73.REMOVE THROTTLE BODY ASSY (See page 10±44)
74. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
75. DISCONNECT FUEL TUBE SUB±ASSY
76.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52)
77.REMOVE FUEL PUMP ASSY (See page 11±52)
78. REMOVE WATER BY±PASS HOSE 79. REMOVE INTAKE MANIFOLD
(a) Remove the 5 bolts and 2 nuts.
(b) Remove the intake manifold and the insulator.

A77332
23
145
A77350
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±213
AVENSIS REPAIR MANUAL (RM1018E)
106.INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a)Install a new gasket and the exhaust manifold converter
with the 5 nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(b)Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
107.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
108.INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 60 N
m (607 kgf
cm,44 ft
lbf)
109.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
110.INSTALL FUEL INJECTOR ASSY (See page 11±42)
111.INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±42)
112.INSTALL NOZZLE HOLDER CLAMP (See page 11±42)
113. INSTALL SURGE TANK STAY NO.1
(a) Install the surge tank stay with insulator No. 2. Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
114. INSTALL INTAKE MANIFOLD
(a) Install a new gasket on the cylinder head.
(b) Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
115.INSTALL FUEL PUMP ASSY (See page 11±52)
116.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
117.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±49)
118.INSTALL THROTTLE BODY ASSY (See page 10±44)
119. INSTALL THROTTLE BODY BRACKET Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
120. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Apply a light coat of engine oil to the new O±ring and install it to the c\
amshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)

A77498
Engine Wire
Engine Wire
Ignition Coil
Ventilation Hose No. 2
V±ribbed Belt Tensioner
ASSYFuel Pipe Sub±assy No. 1

Gasket

Gasket

Gasket Fuel Pump AssyFuel Pressure
Pulsation Damper
ASSY
9.0 (90, 80 in.
lbf)
60 (607, 44)
25 (255, 18)
33 (331, 24)
9.0 (90, 80 in.
lbf)
Fuel Pipe No. 1

Fuel Injector
Back±up Ring No. 1

O±ring

Fuel Injector
Back±up Ring No. 3
Fuel Injector
Back±up Ring No. 2
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
30 (306, 22)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±201
AVENSIS REPAIR MANUAL (RM1018E)

A77370
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
O±ring
13 (127, 9.0)

E±ring

O±ring
Nozzle Holder Clamp
Fuel Injector

Gasket

Fuel Injector Seal
Fuel Delivery Pipe Sub±assy
19 (194, 14)
Camshaft Timing
Oil Control Valve

O±ring
20 (208, 15)
Knock Sensor
Insulator No. 2
15 (153, 11)
Engine Oil Pressure
Switch Assy
20 (208, 15)
E. F. I. Engine Coolant
Temperature Sensor
Surge Tank Stay No. 1
9.0 (92, 79 in.
lbf)
21 (210, 15)

Back Up Ring No. 3

Back Up Ring No. 2

Back Up Ring No. 1
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±203
AVENSIS REPAIR MANUAL (RM1018E)

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.

±
ENGINE MECHANICAL VALVE CLEARANCE(1AZ±FSE)
14±191
AVENSIS REPAIR MANUAL (RM1018E)
(h)Install the camshafts. (See page 14±240)
(i)Install the chain tensioner. (See page 14±240)
14.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±240)
15.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
16.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST09023±12900
17.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
18.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
19.CHECK FOR ENGINE OIL LEAKS
20.CHECK FOR FUEL LEAKS (
See page 11±33)

21. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

141BO±01
A77339
A77292
14±254
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
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.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
10.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
11.SEPARATE FUEL TUBE SUB±ASSY (See page 11±33)
12.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
13.REMOVE FUEL PUMP ASSY (See page 11±52)
14.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
15.REMOVE GENERATOR ASSY (See page 19±20)
16.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
17. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
18. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.

14±262
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)