2005 TOYOTA AVENSIS gas type

A77319
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Cooler Bracket
(LHD (w/ Air Conditioner)
Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant
Suction Hose No. 1
(LHD (w/ Air Conditioner)
Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator ASSY
Exhaust Pipe Assy Front
43 (440, 32)

Gasket
43 (440, 32)
7.0 (71, 62 in.
lbf)
52 (530, 38)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
Vane Pump Assy
37 (377, 27)
14±136
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A79802
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Bearing Cap No. 3
Bearing Cap No. 2
Camshaft
No. 2 Camshaft
Camshaft Timing Gear
Unleaded Gasoline type:
Camshaft Timing Gear Assy
54 (551, 40)
Chain Tensioner Assy No. 1
30 (301, 22)
Bearing Cap No. 1
30 (301, 22)
9.0 (92, 80 in.
lbf)
54 (551, 40)
9.0 (92, 80 in.
lbf)
Chain Sub±assy
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
14±239
AVENSIS REPAIR MANUAL (RM1018E)

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.

A77319
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
GasketCooler Bracket
(LHD Steering Position Type)
113 (1,152, 83)
Cooler Refrigerant Suction Hose No. 1
(LHD Steering Position Type)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
52 (530, 38)
Transverse Engine Engine
Mounting Insulator
Vane Pump Oil Reservoir Assy
Return Tube Sub±assy
52 (530, 38)
21 (214, 16)
9.8 (100, 7.2)
Generator Assy
Exhaust Pipe Assy Front
43 (440, 32)

Gasket
43 (440, 32)
7.0 (71, 62 in.
lbf)
52 (530, 38)
7.0 (71, 62 in.
lbf)
Oil Reservoir Bracket No. 1
52 (530, 38)
52 (530, 38)
Engine Mounting Bracket No. 2 RH
7.0 (71, 62 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
52 (530, 38)
Exhaust Pipe Assy Center
52 (530, 38)
Vane Pump Assy
37 (377, 27)
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
14±219
AVENSIS REPAIR MANUAL (RM1018E)

141BM±01
A77339
A77301
14±204
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±33)
2.REMOVE FRONT WHEELS
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 COOLANT (See page 16±31)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove the 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD STEERING POSITION TYPE)
(a)Remove the bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±36)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±185)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(a) Remove the 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
20. REMOVE BATTERY

A77299
A77303
A77308
A77306
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FSE)
14±255
AVENSIS REPAIR MANUAL (RM1018E)
19. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts and separate the return tube shown
in the illustration.
20. SEPARATE COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD STEERING POSITION TYPE)
(a) Remove the 2 nuts and separate the suction hose.
21. SEPARATE VANE PUMP OIL RESERVOIR ASSY
22. REMOVE OIL RESERVOIR BRACKET NO.1
(a) Remove the 2 bolts and the oil reservoir bracket No. 1.
23. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate a clamp and the engine
wire.

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)