2005 TOYOTA AVENSIS km count

A77382
Groove90

A77383
Groove
A66833
B11424
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±145
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90
, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil
pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner
and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
38. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Orient the flat portion of the drive shaft upward.

A77395
Engine
Front
A77396
Hook
Pin
Turn
Disconnect
A77397
Push
Turn
Plunger
A77398
A
B
A
A
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
14±151
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install a new gasket chain tensioner with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is released wile inserting, apply the hook again,
and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise, and check that the
hook is disengaged from the plunger knock pin.
(d) Turn the crankshaft clockwise, and check that the plunger
is extended.
52. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
53. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
54. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.

A77382
Groove90

A77383
Groove
A66833
B11424
14±228
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
41. REMOVE NO.2 CHAIN SUB±ASSY
(a) Turn the crankshaft counterclockwise 90
, and align an
adjusting hole of the oil pump drive shaft gear with the
groove of the oil pump.
(b) Put a 4 mm diameter bar in the adjusting hole of the oil
pump drive shaft gear to lock in position, and remove the
nut.
(c) Remove the bolt, and then remove the chain tensioner
and spring.
(d) Remove the oil pump drive shaft gear and chain No. 2.
42. INSTALL NO.2 CHAIN SUB±ASSY
(a) Set the crankshaft key to the left side position.
(b) Position the flat portion of the drive shaft upward.

A77395
Engine
Front
A77396
Hook
Pin
Turn
Disconnect
A77397
Push
Turn
Plunger
A77398
A
B
A
A 14±234
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install a new gasket chain tensioner with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook is released wile inserting, apply the hook again,
and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise, and check that the
hook is disengaged from the plunger knock pin.
(d) Turn the crankshaft clockwise, and check that the plunger
is extended.
56. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
57. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
58. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old seal packing (FIPG) material.

A77309
15973
481062
A56228
A77413
Advance
Side Port
A31032
14±242
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 10 camshaft
bearing cap bolts uniformly in the sequence shown in the
illustration.
(b) Remove 5 camshaft bearings.
(c) Remove the camshaft.
(d) Tie the timing chain as shown in the illustration.
NOTICE:

Be careful not to drop anything inside the timing
chain cover.

Do not expose the chain to water, and prevents dust.
16. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Clamp the camshaft in a vise, and make sure the cam-
shaft timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except an advance
side port shown in the illustration.
(c) Put air pressure into the oil port with 150 kpa (1.5 kgf/cm
2
21 psi), and turn the camshaft timing gear to the advance
direction (counterclockwise) by hand.
CAUTION:
Cover the ports with shop rag to avoid oil splashing.
HINT:
Depending on the air pressure, the camshaft timing gear will
turn to the advance angle side without applying force by hand.
Also, under the condition that the pressure can be hardly ap-
plied because of the air leakage from the port, there may be the
case that the lock pin could be hardly released.

A77395
Engine
Front
A77396
HookPinTurn
Disconnect
A77397
Push Turn
Plunger
±
ENGINE MECHANICAL CAMSHAFT(1AZ±FSE)
14±245
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket chain tensioner No. 1 with 2 nuts.
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
NOTICE:
If the hook is disengaged while installing, apply the hook
again, and then resume the installation.
(c)Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d)Turn the crankshaft clockwise, and check the plunger is extended.
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
22.INSTALL FUEL PUMP ASSY (See page 11±52)
23.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
24.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
25.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
26. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
27. CHECK FOR ENGINE OIL LEAKS
28. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)

A61194
Pry
A09555
Measuring Point
16 mm (0.63 in.)
A09569
Measuring Tip
Protrusion Hight
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±335
AVENSIS REPAIR MANUAL (RM1018E)
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
67. REMOVE CYLINDER HEAD GASKET
68. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolts.
Standard outside diameter:
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
69. INSTALL CYLINDER HEAD GASKET
(a) Measure protrusion height of the piston heads.
(1) Clean the cylinder block with solvent.
(2) Set the piston to be measured to slightly before
TDC.
(3) Place a dial indicator on the cylinder block, and cali-
brate the dial indicator at 0 mm (0 in.).
HINT:

Place measuring tip of the dial indicator as shown in the
illustration.

Make sure that the measuring tip is square to the cylinder
block gasket and the piston head when measuring.
(4) Find the most overhung position of the piston head
by slowly turning the crankshaft clockwise and
counterclockwise.

320VT±01
G23220
G23175
F43108
Stop Lamp Switch Assy
Cushion
1.5 ± 2.5 mm (0.059 ± 0.098 in.)
±
BRAKE BRAKE PEDAL SUB±ASSY
32±9
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE COMBINATION METER ASSEMBLY (See page 71±21)
2. REMOVE BRAKE PEDAL SUPPORT SUB±ASSY
(a) Remove the bolt from the brake pedal support sub±assy.
(b) Disconnect the stop lamp switch connector.
(c) Remove the clip and clevis pin, and disconnect the brakemaster cylinder push rod clevis from the brake pedal sub±
assy.
(d) Remove the 4 nuts and brake pedal support sub±assy.
3. REMOVE BRAKE PEDAL SUB±ASSY
(a) Remove the brake pedal shaft and nut from the brake pedal support sub±\
assy.
(b) Remove the brake pedal sub±assy and 2 bushes.
4. REMOVE STOP LAMP SWITCH ASSY
(a) Turn the stop lamp switch assy counterclockwise and remove the stop lamp \
switch assy.
(b) Remove the stop lamp switch mounting adjuster from the brake pedal suppo\
rt sub±assy.
5. REMOVE BRAKE PEDAL PAD
(a) Remove the brake pedal pad from the brake pedal sub±assy.
6. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal sub±assy. 7. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch mounting adjuster to thebrake pedal support sub±assy.
(b) Install the stop lamp switch assy until the body hits the cushion.
NOTICE:
When inserting the stop lamp switch assy, support the ped-
al from behind so that the pedal is not pushed in.
(c) Make a quarter turn clockwise to install the stop lamp switch assy.
NOTICE:
The turning torque for installing the stop lamp switch assy. Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf) or less