2005 TOYOTA AVENSIS service

A77308
A77303
A77307
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±123
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITION ER) STEER ING
POSITION TYPE)
(a)Remove 2 nuts and separate the suction hose.
28.REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a)Remove a bolt and the service cover bracket RH. 29.REMOVE COOLER BRACKET (LHD(W/ AIRCONDITIONER) STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the cooler bracket.
30.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
31.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
32.DISCONNECT HEATER OUTLET WATER HOSE (W/ AIR CONDITIONING)
33.REMOVE CHARCOAL CANISTER ASSY
34.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±15)
35. DISCONNECT UNION TO CONNECTOR TUBE HOSE
36.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
38.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
39.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09330±00030

±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±133
AVENSIS REPAIR MANUAL (RM1018E)
128.INSTALL FRONT AXLE ASSY LH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
129.INSTALL FRONT AXLE ASSY RH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
130.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
131.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE)
Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
132.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
133.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
134.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
135.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
136.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
137.INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
138.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
139.INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
140.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
141.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
142.INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
143.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
144.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
145.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
146.INSTALL COOLER REFRIGE RANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
147.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
148.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
149.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
150.INSTALL BATTERY CARRIER
151.INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
152.INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
Torque: 25 N
m (255 kgf
cm,18 in.
lbf)
153.INSTALL GENERATOR ASSY (See page 19±20)
154.INSTALL FAN AND GENERATOR V BELT (See page 14±105)

A77303
A77308
A77306
A77307
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FE)
14±161
AVENSIS REPAIR MANUAL (RM1018E)
16. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
17. SEPARATE VANE PUMP OIL RESERVOIR ASSY
NOTICE:
Do not disconnect the 2 hoses.
18. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil reservoir bracket No. 1.
19. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the clamp and the engine
wire.
20. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove the bolt and the engine service cover bracket RH.
21. REMOVE COOLER BRACKET (LHD(W/ AIR
CONDITIONER) STEERING POSITION TYPE)
(a) Remove the bolt and the cooler hose bracket.

A77302
14±162
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
22.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove the bolt and the engine service cover bracket RH.
23.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
24.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
25.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
26.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)
27.REMOVE CRANKSHAFT PULLEY (See page 14±139)
SST09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
28.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±139)
29.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17)
30.REMOVE OIL PAN SUB±ASSY (See page 14±139) SST09032±00100
31.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±139)
32.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
33.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
34.REMOVE CHAIN TENSIONER SLIPPER
35.REMOVE CHAIN VIBRATION DAMPER NO.1
36.REMOVE TIMING CHAIN GUIDE (See page 14±139)
37.REMOVE CHAIN SUB±ASSY
38.REMOVE BATTERY 39.REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a)Disconnect the 2 connectors.
(b)Disconnect the air cleaner hose from the throttle body.
(c)Raise a clamp up, and slide it toward the air cleaner cap,then remove the air cleaner cap from its case.
(d)Remove the air cleaner element.
(e)Remove the 4 bolts and the air cleaner case.
40.DISCONNECT RADIATOR HOSE INLET
41.DISCONNECT UNION TO CONNECTOR TUBE HOSE
42.DISCONNECT HEATER INLET WATER HOSE (W/ AIR CONDITIONING)
43.SEPARATE FUEL TUBE SUB±ASSY (See page 11±26)
44. SEPARATE ENGINE WIRE

±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FE)
14±167
AVENSIS REPAIR MANUAL (RM1018E)
69.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
70.INSTALL CHAIN SUB±ASSY (See page 14±139)
71.INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
72.INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N
m (195 kgf
cm,15 ft
lbf)
73.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±171)
74.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
75.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
76.INSTALL OIL PAN SUB±ASSY (See page 14±139)
77.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
78.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST09213±54015 (91651±60855), 09330±00021
79.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
80.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm,38 ft
lbf)
81.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
82.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
83.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
84.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
85.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
86.INSTALL ENGINE WIRE
87.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
88.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
89.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
90.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
91.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
92.INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
93.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
94.INSTALL GENERATOR ASSY (See page 19±20)
95.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
96.ADD COOLANT (See page 16±19)
97. ADD ENGINE OIL
98.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
99. CHECK FOR ENGINE OIL LEAKS
100. CHECK FOR FUEL LEAKS
101. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

A77303
A77308
A77306
A77307
14±140
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
13. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
14. SEPARATE VANE PUMP OIL RESERVOIR ASSY
NOTICE:
Do not disconnect the 2 hoses.
15. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil pump reservoir bracket No.
1.
16. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the clamp and engine wire.
17. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove the bolt and the engine service cover bracket RH.
18. REMOVE COOLER BRACKET (LHD(W/ AIR
CONDITIONER) STEERING POSITION TYPE)
(a) Remove the bolt and cooler bracket.

A77283
A77284
A77285
Unleaded Gasoline
Timing
Marks

eaded Gasoline
Timing
Marks
Timing
Marks
Timing
Marks
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±141
AVENSIS REPAIR MANUAL (RM1018E)
19. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
(a) Remove the bolt and the engine service cover bracket RH.
20. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
21. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Disconnect the 2 PCV hoses from the cylinder head cov-
er.
(b) Remove the 8 bolts and 2 nuts, and then remove the cylin-
der head cover and gasket.
22. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its timing notch with
timing mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing gear
are aligned with the timing marks located on the No. 1 and
No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.

A77399
Seal Packing
A77400NutNut
A
BC
A A
AAB
14±152
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply seal packing to the 2 locations as shown in the il- lustration.
Seal Packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 5 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c)install the cylinder head cover with the 8 bolts and 2 nuts. Torque:
Bolt A 11 N
m (112 kgf
cm, 8 ft
lbf)
Bolt B 14 N
m (143 kgf
cm, 10 ft
lbf)
Bolt C 21 N
m (214 kgf
cm, 15 ft
lbf)
Nut 11 N
m (112 kgf
cm, 8 ft
lbf)
55.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
56.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
57.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING
POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
58.INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
59.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
60.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
61.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
62.INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
63.INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
64.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
65.INSTALL GENERATOR ASSY (See page 19±20)
66.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
67. ADD ENGINE OIL
68. CHECK FOR ENGINE OIL LEAKS
69. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
70. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)