2005 TOYOTA AVENSIS water pump

A62174
SST
A62175
Seal Width
4 to 5 mm
Seal Packing
A65676
Timing Chain Cover side:
3 (0.118)3 (0.118)
A
ABB
C
C
7 (0.276)
4.5 (0.177)
12 (0.472)6 (0.236)
3 (0.118)
Width 4 (0.157)
A ± AB ± B
C ± C
08826±00100 or equivalent
08826±00080 or equivalent
(mm (in.)) 14±90
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
58. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to a new oil seal lip.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip free of foreign objects.
59. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material (FIPG) from the contact
surface.
(b) Apply a continuous bead of seal packing (Diameter 3.5
mm to 4.5 mm (0.1379 to 0.177 in.)) as shown in the il-
lustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent.
NOTICE:

Remove any oil from the contact surface.

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

Do not expose the seal to engine oil within 2 hours af-
ter installing.

A12816
A11858
A62837SST
A62180
DisconnectHook
PinTurn
A62181
Plunger
Turn
Push
14±92
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
62.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a)Install the transverse engine engine mounting bracket
with the 3 bolts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
63.INSTALL WATER PUMP ASSY (See page 16±9)
64. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt. Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
65. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
(b) Using SST, install the crankshaft pulley bolt. SST 09960±10010 (09962±01000, 09963±01000)
Torque: 138 N
m (1,407 kgf
cm, 102 ft
lbf)
(c) Turn the crankshaft counterclockwise and take the hook off the knock pin to release the plunger.
(d) Turn the crankshaft clockwise, and check that the plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.

A60625
Crankshaft Pulley V±ribbed Belt
Tensioner Assy
Water Pump AssyTransverse Engine
Engine Mounting Bracket
Crankshaft Position Sensor Chain Tensioner Assy No. 1
Timing Chain or
Belt Cover Sub±assy

Oil Seal
Crankshaft Position Sensor
Plate No. 1Chain Sub±assy
Chain Tensioner Slipper
Crankshaft timing Sprocket
O±ring

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
47 (479, 35)
29 (296, 21)
69 (704, 51)
138 (1,047, 102)
13 (133, 10)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
19 (194, 14)
9.0 (92, 80 in.
lbf) (L=20)
11 (112, 8) (L=35)
9.5 (97, 84 in.
lbf)
13 (133, 10) (M6)
19 (194, 14) (M8)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±79
AVENSIS REPAIR MANUAL (RM1018E)

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

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.

A79423
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket

O±ring
* Use SST
Gasket
Gasket

Gasket

Gasket

Gasket3.6 to 6.9 (40 to 70, 35 to 61 in.
lbf)
5.0 (51, 44 in.
lbf)
7.4 (76, 66 in.
lbf)
* 31 (316, 23)
34 (347, 25)
43 (438, 32)
21 (214, 15)
18 (184, 13)
21 (214, 15)
21 (214, 15)
21 (214, 15)
64 (650, 47)
21 (214, 15)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
Common Rail Assy
Fuel Hose No. 4
Vacuum Pump Assy
Nozzle Leakage Pipe No. 2Fuel Inlet Pipe Sub±assy
EGR Valve Assy
Water Outlet Sub±assy
Engine Coolant
Temperature Sensor
Intake Air Connector Sub±assy
Intake Manifold
Wiring Harness Clamp Bracket Injection Pump
Drive Pulley Timing Belt
No. 3 CoverSeal Washer Camshaft Position Sensor
Check Valve
8.8 (90, 78 in.
lbf)
8.8 (90, 78 in.
lbf)
21 (214, 15)
21 (214, 15)
14±284
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

A79424
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
8.8 (90, 65 in.
lbf)
8.8 (90, 6.5 in.
lbf)
8.4 (86, 74 in.
lbf)
21 (209, 15)
8.8 (90, 78 in.
lbf)
34 (347, 25)
18 (184, 13)21 (210, 15)
21 (210, 15)
42 (428, 31)
37 (377, 27)
59 (600, 43)
21 (214, 15)
45 (454, 33)

O±ring

O±ring

Gasket

O±ring

O±ring
Vacuum Pump Oil Pipe
Union Bolt
Oil Cooler AssyFuel Filter To Injection Pump
Fuel Pipe
Rear End Plate
Crankshaft Position
Sensor
Thermostat
Water Inlet
Oil Level Gage Guide Oil Filter Bracket Sub±assy
Injection or Supply Pump Assy Compressor Mounting
Bracket No. 1Generator Bracket No. 1 V±ribbed Belt
Tensioner
AssyGenerator Assy
Oil Cooler Pipe

Gasket
Turbo Oil Outlet Pipe No. 2
31 (320, 23)

Gasket
33 (331, 24)
8.8 (90, 78 in.
lbf)
47 (475, 34)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±285
AVENSIS REPAIR MANUAL (RM1018E)

141CA±01
14±332
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.DRAIN ENGINE COOLANT (See page 16±44)
6.DRAIN ENGINE OIL (See page 14±342)
7. REMOVE RADIATOR SUPPORT OPENING COVER
8. REMOVE ENGINE ROOM COVER SIDE
9. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
10.REMOVE VACUUM RESERVOIR SUB±ASSY (See page 13±11)
11.REMOVE AIR CLEANER ASSY (See page 14±286)
12. REMOVE BATTERY
13.REMOVE AIR TUBE NO.2 (See page 14±286)
14.REMOVE AIR TUBE NO.1(See page 14±270)
15.REMOVE INJECTOR DRIVER (See page 14±286)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
17.REMOVE GENERATOR V BELT (See page 14±269)
18.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
19.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
20.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
21.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
22.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
23.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
24. REMOVE TIMING BELT GUIDE
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
27.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
28.REMOVE TIMING BELT(See page 14±307)
HINT:
If re±using the timing belt, draw a direction arrow on the timing belt (\
in direction of engine revolution), and
place matchmarks on the pulleys and the timing belt.
29.REMOVE FUEL FILTER ASSY (See page 11±82)
30.REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13±11)
31.REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13±11)
32.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
34.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
35. DISCONNECT RADIATOR HOSE INLET
36. DISCONNECT HEATER INLET WATER HOSE
37. DISCONNECT HEATER OUTLET WATER HOSE
38. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
39. DISCONNECT OIL COOLER HOSE
40.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
41.REMOVE TURBO INSULATOR NO.1 (See page 13±11)