2005 TOYOTA AVENSIS drive shaft assy

±
DIAGNOSTICS SFI SYSTEM(1AZ±FE)
05±177
AVENSIS REPAIR MANUAL (RM1018E)
9REPLACE CAMSHAFT TIMING GEAR ASSY
GO
10CHECK FOR BLOCKAGE(OCV, OIL CHECK VALVE AND OIL HOLE)
NGREPAIR OR REPLACE
OK
11READ OUTPUT DTC(CHECK IF DTC OUTPUT RECURS)
(a)Clear the DTC. (1)Operating the hand±held tester to erase the codes, or disconnecting the batter\
y terminal or the
EFI and ECTS fuses for more than 60 sec.
(b)Start and warm up the engine.
(c)Drive the vehicle around for 10 minutes or more.
(d)Read output DTC using the hand±held tester.
Standard: No DTC output.
HINT:
*: DTCs P0011/59 or P0012/59 is output when a foreign object in engine oil is caught\
in some part of the
system. These codes will stay registered even if the system returns to normal a\
fter a short time. These for-
eign objects are then captured by the oil filter, thus eliminating the source of the problem.
OKVVT SYSTEM OK*
NG
CHECK AND REPLACE ECM (See page 01±32)
When not using hand±held tester:
1CHECK VALVE TIMING (See page 14±139)
NGADJUST VALVE TIMING (See page 14±139)
OK

05±180
±
DIAGNOSTICS SFI SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9REPLACE CAMSHAFT TIMING GEAR ASSY
GO
10CHECK FOR BLOCKAGE(OCV, OIL CHECK VALVE AND OIL HOLE)
NGREPAIR OR REPLACE
OK
11READ OUTPUT DTC(CHECK IF DTC OUTPUT RECURS)
(a)Clear the DTC. (1)Disconnecting the battery terminal or removing the EFI and ECTS fuses for more than 6\
0 sec.
(b)Start and warm up the engine.
(c)Drive the vehicle around for 10 minutes or more.
(d)Read output DTC.
Standard: No DTC output.
HINT:
*: DTCs P0011/59 or P0012/59 is output when a foreign object in engine oil is caught in some part of \
the
system. These codes will stay registered even if the system returns to normal a\
fter a short time. These for-
eign objects are then captured by the oil filter, thus eliminating the source of the problem.
OKVVT SYSTEM OK*
NG
CHECK AND REPLACE ECM (See page 01±32)

A09496
A09497
A08026
A85943
14−46− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
5. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.040 to 0.300 mm (0.0016 to 0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washer as a set.
Thrust washer thickness:
Standard2.680 to 2.730 mm (0.1055 to 0.1075 in.)
Oversize 0.1252.743 to 2.793 mm (0.1080 to 0.1100 in.)
Oversize 0.2502.805 to 2.855 mm (0.1104 to 0.1124 in.)
6. REMOVE CRANKSHAFT
(a) Uniformly loosen and remove the 10 main bearing cap
bolts.
(b) Using the removed main bearing cap bolts, wiggle the cap
back and forth, then remove the 5 main bearing caps, 5
lower bearings and 2 lower thrust washers (the No. 3 main
bearing cap only).
HINT:
SKeep the lower bearing and main bearing cap together.
SArrange the main bearing caps and lower thrust washers
in the correct order.
(c) Lift the crankshaft out.
HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.
7. REMOVE SUB−ASSY OIL NOZZLE NO.1
(a) Remove the 4 bolts and 4 oil nozzles.

031H2−02
03−14
− SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by−pass pipe No.1 x Cylinder block9.09280 in.
lbf
Water by−pass pipe No. 3 x Cylinder block9.09280 in.
lbf
Oil cooler pipe x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
V−ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Exhaust manifold heat insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Drive plate & ring gear x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub−assy front x Body Bolt
Nut45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133
801,356
81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356
81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No. 2 RH x Transverse engine
engine mounting insulator A
B
52
11 3530
1,15238
83
Vane pump assy x Timing chain cover3737027
Front suspension arm sub−assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub−assy x Frame8.08271 in.
lbf
Radiator reserve tank Sub−assy x Body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 5
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Engine cover No. 1 x Cylinder head cover9.09280 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90 _806
Turn 90 _58
Turn 90 _
Camshaft timing oil control valve assy x Cylinder head9.09279 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Battery carrier x Frame131319.5
Battery clamp x Body Bolt
Nut5.0
3.551
3644 in. lbf
31 in. lbf
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14 −45) Bolt A
Bolt B
Bolt C
Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1 CD −FTV:
Part TightenedN
mkgf
cmft
lbf
Air tube No. 1 hose clamp bolt6.06153 in.
lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover sub −assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub −assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020014
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5657542
Compressor mounting bracket x Cylinder block4242831
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf

03−1 6
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Intake manifold x Cylinder head2120915
Power steering idle pulley bracket x Cylinder head
(See page 14 −108) Bolt A
Bolt B
72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Injection pipe x Common rail
With SST
Without SST
31
34316
34723
25
Injection pipe x Injector
For used pipe With SST Without SST
For new pipe With SST
Without SST
36
40
31
34372
408
316
34727
30
23
25
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe x injection pump With SST
Without SST
31
34316
34723
25
Nozzle leakage pipe No.2 x Cylinder head cover sub −assy8.89078 in.
lbf
Nozzle leakage pipe No.2 x Cylinder head8.89078 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2120915
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub −assy x Cylinder head2120915
Exhaust manifold x Cylinder head4747434
EGR pipe sub −assy x Cylinder head Bolt
Nut37
25375
25027
18
Vacuum pump oil pipe x Cylinder block Bolt Nut21
8.8214 9015
78 in.
lbf
Vacuum transmitting pipe No. 2 x Manifold converter
For nut With SST
Without SST
For bolt
27
30
25275
306
25520
22
18
Vacuum transmitting pipe No. 1 x Manifold converter
For nut With SST Without SST
For bolt
27
30
25275
306
25520
22
18
Exhaust gas temperature sensor x Manifold converter With SST
Without SST27
30275
30620
22
Exhaust gas temperature sensor x Vacuum transmitting pipe No. 26.46557 in.
lbf
Oil filter bracket x Oil pan sub −assy3434725
V −ribbed belt tensioner bracket x Cylinder block2020415
V −ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub −assy x V −ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub −assy center x Body4545933

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 7
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Front suspension crossmember sub −assy x Rear engine mounting bracket8788764
Front suspension crossmember sub −assy x Front engine mounting bracket5253038
Front suspension crossmember sub −assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub −assy1331,35698
Front suspension member brace x Body8081659
Return tube sub −assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting blacket5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Air tube No. 2 hose clamp bolt Intake shutter side
Air hose No. 3 side6.0
5.361
5453 in.
lbf
47 in.
lbf
Injector driver x Engine mounting insulator RH5.55649 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay block x Radiator assy5.35447 in.
lbf
Differential pressure sensor x Body5.55649 in.
lbf
Air cleaner assy x Body x Engine mounting bracket LH7.07162 in.
lbf
Battery clamp x Body Body
Nut5.0
3.0 to 4.051
31 to 4144 in.
lbf
27 to 35 in.
lbf
Battery terminal5.45548 in.
lbf
Timing belt tensioner x Cylinder block2121415
Timing chain cover plate x Camshaft oil seal retainer9.09280 in.
lbf
Transverse engine engine mounting bracket x
Cylinder block (See page 14 −138) Bolt A
Bolt B
37
64375
65027
47
Timing belt No. 1 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 1 cover x Oil pump assy7.47565 in.
lbf
Timing belt No. 2 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 2 cover x Cylinder head cover sub −assy7.47565 in.
lbf
Timing belt No. 2 cover x Camshaft oil seal retainer7.47565 in.
lbf
Timing belt No. 2 cover x Timing belt cover No. 37.47565 in.
lbf
Crankshaft pulley x Crankshaft1801,835133
Camshaft bearing cap x Cylinder head2020415
Camshaft oil seal retainer x Cylinder head9.81007.2
Camshaft timing pulley x Camshaft8889965
Nozzle leakage pipe x Injector1616312
Nozzle leakage pipe x Camshaft bearing cap No. 42020415
Cylinder head cover x Cylinder head131359.7
Vacuum reservoir sub −assy x Cowl top panel outer8.38573 in.
lbf
Cylinder head x Cylinder block 1st
2nd3rd4th45
Turn 90 _
Turn 90 _
Turn 90 _459
Turn 90 _
Turn 90 _
Turn 90 _33
Turn 90 _
Turn 90 _
Turn 90 _
Exhaust fuel addition injector x Cylinder head1211 78.5
Drain plug (oil pan)3435025

023N8−01
− PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02−31
AVENSIS Supplement (RM1045E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
09308−00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U151E)
09316−60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U151E)
(09316−00011)Replacer PipeFRONT DIFFERENTIAL OIL
SEAL(U151E)
09350−32014TOYOTA Automatic Transmission
Tool SetAUTOMATIC TRANSAXLE
ASSY(U151E)
(09351−32010)One−way Clutch Test ToolAUTOMATIC TRANSAXLE
ASSY(U151E)
(09351−32020)Stator StopperAUTOMATIC TRANSAXLE
ASSY(U151E)
09520−01010Drive Shaft Remover AttachmentAUTOMATIC TRANSAXLE
ASSY(U151E)
09520−24010Differential Side Gear Shaft
PullerAUTOMATIC TRANSAXLE
ASSY(U151E)
(09520−32040)Shocker SetAUTOMATIC TRANSAXLE
ASSY(U151E)
09628−62011Boll Joint PullerAUTOMATIC TRANSAXLE
ASSY(U151E)
09649−17010Steering Knuckle ToolFRONT DIFFERENTIAL OIL
SEAL(U151E)
09930−00010Drive Shaft Nut ChiselAUTOMATIC TRANSAXLE
ASSY(U151E)