2005 TOYOTA AVENSIS service

A77307
A77346
A77284
A77345
Timing
Marks
Timing
Marks 14±224
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
22. REMOVE COOLER BRACKET (LHD STEERING
POSITION TYPE)
(a) Remove the bolt and cooler bracket.
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove the bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
25. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Disconnect the 2 PCV hoses from the cylinder head cov-
er.
(b) Remove the 9 bolts and 2 nuts, then remove the cylinder
head cover and gasket.
26. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
(b) Check that each timing mark of the camshaft timing gears
is aligned with the timing marks of 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
A77346
AA
A AA
BB
C
C
Nut Nut
±
ENGINE MECHANICAL CHAIN SUB±ASSY(1AZ±FSE)
14±235
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 9 bolts and 2 nuts. Torque:
Nut 11 N
m (112 kgf
cm, 8 ft
lbf)
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, 16 ft
lbf)
59.INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
60.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
61.INSTALL ENGINE WIRE
Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
62.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
63.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
64.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
65.INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
66.INSTALL VANE PUMP ASSY
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
67.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
68.INSTALL GENERATOR ASSY (See page 19±20)
69.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
70.INSTALL FUEL PUMP ASSY (See page 11±52)
71.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
72.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
73.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
74. ADD ENGINE OIL
75. CHECK FOR ENGINE OIL LEAKS
76. CHECK FOR FUEL LEAKS

A77308
A77303
A77340
14±206
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
25.SEPARATE VANE PUMP OIL RESERVOIR ASSY 26.REMOVE OIL RESERVOIR BRACKET NO.1
(a)Remove the 2 bolts and the oil reservoir bracket No. 1.
27.SEPARATE COOLER REFRIGERANT SUCTION HOSENO.1 (LHD STEERING POSITION TYPE)
(a)Remove the 2 nuts and separate the suction hose.
28.REMOVE COOL ER BRACKET (LHD STEER ING
POSITION TYPE)
(a)Remove the nut and separate the cooler bracket.
29.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a)Remove the bolt and the service cover bracket RH.
30.DISCONNECT HEATER INLET WATER HOSE
31.DISCONNECT HEATER OUTLET WATER HOSE
32.REMOVE CHARCOAL CANISTER ASSY
33.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±30)
34. DISCONNECT UNION TO CONNECTOR TUBE HOSE
35.REMOVE FLOOR PANEL BRACE FRONT (See page 15±7)
36.REMOVE EXHAUST PIPE ASSY CENTER (See page 15±7)
37.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
38.REMOVE FRONT AXLE HUB LH NUT (See page 30±6) SST 09330±00030

A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±216
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
139.INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
Torque:
Bolt A 12 N
m (122 kgf
cm, 89 ft
lbf)
Bolt B 9.0 N
m (92 kgf
cm,79 in.
lbf)
Bolt C 5.0 N
m (51 kgf
cm,44 in.
lbf)
140.INSTALL FRONT AXLE ASSY LH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
141.INSTALL FRONT AXLE ASSY RH Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
142.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
143.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
144.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
145.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
146.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
147.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
148.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
149. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
150.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
151. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
152.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
153.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
154. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
155. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
156. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
157. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

A77340
A77335
14±256
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
24.REMOVE COOL ER BRACKET (LHD STEER ING
POSITION TYPE)
(a)Remove the bolt and the cooler bracket.
25.REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a)Remove the bolt and the engine service cover bracket RH.
26.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
27.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
28.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (
See page 14±222)
29.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (
See page 14±222 )

30.REMOVE CRANKSHAFT PULLEY (See page 14±222) SST 09213±54015 (91651±60855), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05021)
31.REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14±222)
32.REMOVE CRANKSHAFT POSITION SENSOR (See page 18±17)
33.REMOVE OIL PAN SUB±ASSY (See page 14±222)
SST 09032±00100
34.REMOVE V±RIBBED BELT TENSIONER ASSY (See page 14±222)
35.REMOVE TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±222)
36.REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±222)
37. REMOVE CHAIN TENSIONER SLIPPER
38. REMOVE CHAIN VIBRATION DAMPER NO.1
39.REMOVE TIMING CHAIN GUIDE (See page 14±222)
40. REMOVE CHAIN SUB±ASSY
41. REMOVE BATTERY
42. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a) Disconnect the 2 connectors.
(b) Disconnect the 2 vacuum hoses.
(c) Disconnect the ventilation hose.
(d) Disconnect the air cleaner hose from the throttle body.

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)

170FX±01
A77339
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±15
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
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 ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16.SEPARATE VANE PUMP ASSY (See page 14±222)
17.SEPARATE RETURN TUBE SUB±ASSY (See page 14±222)
18. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14±222)
19. SEPARATE VANE PUMP OIL RESERVOIR ASSY
20.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±222)
21. SEPARATE ENGINE WIRE
22.REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14±222)
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
25.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
27.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
28.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±222)

A77392Seal Packing6mm
A64641
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±17
AVENSIS REPAIR MANUAL (RM1018E)
46.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
47.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
48.INSTALL CHAIN SUB±ASSY (See page 14±139)
49.INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
50.INSTALL CHAIN TENSIONER SLIPPER (See page 14±139)
51.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±139)
52.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
53.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
54.INSTALL OIL PAN SUB±ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine within 2 hours after installing.
(a)Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder
block and oil pan.
(b)Apply seal packing in the shape of bead (Diameter 3 to 4
mm (0.157 in.)) as shown in the illustration, and install the
oil pan.
Seal Packing: Part No. 08826 ± 00080 or equivalent
(c)Insert the oil pan with 12 bolts and 2 nuts. Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
55.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
56.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST 09213±54015 (91651±60855), 09330±00021
57. INSTALL CHAIN TENSIONER ASSY NO.1
58. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
60.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
61. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
62. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
63. INSTALL ENGINE WIRE Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)