2005 TOYOTA AVENSIS drive shaft assy

C67413F45461
Matchmarks
C86269
SST
Hold
Turn
C86270SST
C91598
30−14
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
AVENSIS Supplement (RM1045E)
(h) Aligning the matchmarks, install the inboard joint assy LH
to the outboard joint shaft assy LH.
38. INSTALL FR AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assy LH and outboard joint shaft assy LH.
39. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) Install the inboard joint boot clamp.
(1) Hold the drive shaft in a soft vise.
(2) Secure the 2 inboard joint boot clamps onto the
boot.
(3) Place SST onto the inboard joint large boot clamp.
SST 09521−24010
(4) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(5) Using SST, adjust the clearance of the large clamp.
SST 09240−00020
Clearance: 0.8 mm (0.031in.) or less
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.
(b) Install the inboard joint boot LH clamp following the same
procedure as for the inboard joint boot LH No.2 clamp.
40. INSPECT FRONT DRIVE SHAFT
(a) Check that there is no excessive play in the radial direc-
tion of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust
direction.
(c) Check that there is no excessive play in the radial direc-
tion of the inboard joint.
(d) Check the boots for damage.
NOTICE:
Keep the drive shaft assy level during inspection.

C81796F45254
(A)
C83851
C83155
C80293
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
30−15
AVENSIS Supplement (RM1045E)
HINT:
For dimension (A), refer to the following table.
Drive shaft typeDimension (A) mm (in.)
LH546.1(21.50)á5.0 (0.20)
RH884.0 (34.80)á5.0 (0.20)
41. INSTALL FRONT DRIVE SHAFT ASSY LH
(a) Coat the inboard joint shaft assy LH spline with gear oil.
(b) Align the shaft splines and install the drive shaft assy LH
with a brass bar and hammer.
NOTICE:
SSet the snap ring with the opening side facing down-
wards.
SBe careful not to damage the oil seal, boot and dust
cover.
42. INSTALL FRONT DRIVE SHAFT ASSY RH (RH DRIVE
SHAFT)
(a) Coat the inboard joint shaft assy RH spline with gear oil.
(b) Align the shaft splines and install the drive shaft assy RH
with the 2 bolts.
Torque: 64 N
m (650 kgf
cm, 47 ft
lbf)
NOTICE:
Do not damage the oil seal, boot and dust cover.
43. INSTALL FRONT AXLE ASSY LH
(a) Install the drive shaft assy LH to the front axle assy LH.
NOTICE:
SBe careful not to damage the outboard joint boot.
SBe careful not to damage the speed sensor rotor.
44. INSTALL FRONT SUSPENSION ARM SUB−ASSY
LOWER NO.1LH
(a) Install the lower ball joint to the front suspension arm sub−
assy lower No.1LH with the bolt and 2 nuts.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)

F44775
C80291
F13686
Hold
Turn
C68609
30−16
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
AVENSIS Supplement (RM1045E)
45. INSTALL TIE ROD END SUB−ASSY LH
(a) Install the tie rod end sub−assy LH to the steering knuckle with the nut.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 60_further.
46. CONNECT SPEED SENSOR FRONT LH
(a) Install the speed sensor front LH to the steering knuckle
with the bolt.
Torque: 8.0 N
m (82 kgf
cm, 71in.
lbf)
(b) Connect the speed sensor wire and flexible hose to the
shock absorber with the bolt.
Torque:19N
m(194 kgf
cm,14ft
lbf)
NOTICE:
SBe careful not to damage the speed sensor.
SKeep the speed sensor clean.
SDo not twist the sensor wire when installing the sen-
sor.
47. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the nut.
Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
48. INSTALL FRONT AXLE HUB LH NUT
(a) Install a new axle hub LH nut.
Torque: 216N
m (2,200 kgf
cm,159 ft
lbf)
(b) Using a chisel and hammer, stake the axle hub LH nut.

170IZ−01
A57104
SST
A09582
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −11
AVENSIS Supplement (RM1045E)
OIL PUMP ASSY (1CD −FTV)(From September, 2003)
REPLACEMENT
1. DRAIN ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE ROOM COVER SIDE
4. REMOVE FRONT WHEEL RH
5. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
8. REMOVE INJECTOR DRIVER (See page 14 −108)
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
10. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
11. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
12. DISCONNECT ENGINE WIRE (See page 14 −138)
13. DISCONNECT VACUUM HOSE (See page 14 −108)
14. REMOVE ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
15. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
16. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
17. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
18. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
19. REMOVE TIMING BELT GUIDE
20. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
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 TIMING BELT IDLER SUB −ASSY NO.2
25. 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)

A56696
B08009
A56697
A56698
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −13
AVENSIS Supplement (RM1045E)
34. REMOVE OIL STRAINER SUB −ASSY
(a) Remove the 2 bolts and 2 nuts, then remove the oil strain- er and gasket.
35. REMOVE OIL PAN INSULATOR
(a) Remove the bolt and oil pan insulator.
36. REMOVE OIL PAN SUB −ASSY
(a) Remove the 19 bolts and 3 nuts.
(b) Using a screwdriver, remove the oil pan by prying be-
tween the cylinder block and No. 1 oil pan.
NOTICE:
Be careful not to damage the cylinder block and No. 1 oil
pan.
37. REMOVE CRANKSHAFT POSITION SENSOR (See page 14 −138)

A56699
A56700
SST
B07987
New Gasket
Seal
Packing Seal Width
2to4mm
(0.08 to 0.16 in.)
B08024
17−14
− LUBRICATIONOIL PUMP ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
38. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying between the oil pump and
main bearing cap using a screwdriver.
(c) Remove the gasket.
39. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316−60011 (09316−00011, 09316−00021)
40. INSTALL OIL PUMP ASSY
(a) Remove any old packing (FIPG). Be careful not to drop
any oil on the contact surfaces of the oil pump and cylin-
der block.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces and seal-
ing groove.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non−residue solvent, clean both the sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
(1) Install a nozzle of which opening is cut to 2 to 4 mm
(0.08 to 0.16 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install a new gasket to the oil pump.
(d) Pour 0.5 cm
3(0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Apply engine oil to the cylinder block side which contacts
the oil pump driven rotor.

A57102
Turn
17
−18
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
54. INSTALL TIMING BELT IDLER SUB −ASSY NO.2
(a) Install the idler pulley with bolt. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
(b) Check that the idler pulley moves smoothly.
55. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
56. INSTALL TIMING BELT (See page 14 −138)
57. CHECK VALVE TIMING (See page 14 −138)
58. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
59. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
60. INSTALL TIMING BELT GUIDE (See page 14 −138)
61. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
62. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
63. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
64. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
65. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
66. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
67. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
68. INSTALL INJECTOR DRIVER (See page 14 −108)
69. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
70. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
71. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
72. CHECK FOR ENGINE OIL LEAKS

160MR−02
B12054
SST
B12052
B12053
Pry
PryPry
16
−12
−
COOLING WATER PUMP ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
WATER PUMP ASSY (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 PUMP PULLEY
(a) Using SST, remove the 4 bolts and pump pulley. SST 09960 −10010 (09962 −01000, 09963 −00700)
(b) Disconnect the crankshaft position sensor wire clamp
from the water pump.
(c) Disconnect the crankshaft position sensor wire from the clamp on the water pump.
10. REMOVE WATER PUMP ASSY
(a) Remove the 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry out between the water pump and cylinder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.