2005 TOYOTA AVENSIS drive shaft assy

A30857
A62814
4 2531
A62816
2
5 3
110 8 4 796
A62827
Lot No.
A62820
Overall Length
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±87
AVENSIS REPAIR MANUAL (RM1018E)
46. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain by prying the crankshaft timing
gear using screwdrivers as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise to prevent the valves from touch-
ing the pistons.
47. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 19 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 9 bearing caps, and both the intake and
exhaust camshafts.
48. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen and remove the 10 cylinder
head bolts with a 10 mm hexagon wrench uniformly in the
sequence shown in the illustration. Remove the 10 cylin-
der head bolts and 10 plate washers.
(b) Remove the cylinder head.
49. REMOVE CYLINDER HEAD GASKET
50. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the Lot No. stamp facing upward.
NOTICE:

Pay attention to the mounting orientation.

Place the cylinder head on the gasket gently in order
not to damage the gasket with the bottom part of the
head.
51. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of cylinder
head bolt from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum length: 148.5 mm (5.846 in.)
If the length exceeds the maximum, replace the bolt.

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.

141BI±01
A77421
Cut Position
A77422SST
14±180
±
ENGINE MECHANICAL ENGINE REAR OIL SEAL(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE REAR OIL SEAL(1AZ±FE)
REPLACEMENT
1.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
2.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)
3.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
4.REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
5.REMOVE ENGINE REAR OIL SEAL
(a)Using a knife, cut off the engine rear oil seal lip.
(b)Using a screwdriver with the tip wrapped in tape, pry outthe engine rear oil seal.
HINT:
After the removal, check if the crankshaft is not damaged.
If is damaged, smooth the surface with 400±grit sandpaper.
6.INSTALL ENGINE REAR OIL SEAL
(a)Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crankshaft.
7.INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See page 14±121) SST09213±54015 (91651±60855), 09330±00021
8.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
9.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±24)
10.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±25)

A77418
Cut Position
A77419
SST
A77420
SST
SST
±
ENGINE MECHANICAL TIMING GEAR CASE OR TIMING CHAIN CASE OIL
SEAL(1AZ±FE)14±179
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE TIMING GEAR CASE OR TIMING CHAIN
CASE OIL SEAL
(a)Using a screwdriver with tip wrapped in the tape, pry out
the oil seal.
HINT:
After removal, check if the crankshaft is not damaged.
If it is damaged, smooth the surface with 400±grit sandpaper.
9.INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
(a)Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b)Using SST and a hammer, tap in the oil seal until its sur- face is flush with the rear oil seal retainer edge.
SST09223±22010
NOTICE:
Wipe off extra grease on the crankshaft.
10.INSTALL CRANKSHAFT PULLEY
(a)Align the pulley set key with the key groove of the pulley.
(b)Using SST, install the pulley bolt. SST09213±54015 (91651±60855), 09330±00021
Torque: 170 N
m (1,733 kgf
cm, 125 ft
lbf)
11.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
12. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
13. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. CHECK FOR ENGINE OIL LEAKS

A77327
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
9.0 (90, 80 in.
lbf)
Chain Tensioner Assy No. 1
Timing Chain or Belt Cover Sub±assy
Crank Position Sensor
9.0 (90, 80 in.
lbf)
V±ribbed Belt Tensioner
Sub±assy
60 (610, 44)
60 (610, 44)
43 (440, 32)
170 (1,735, 125)
Crankshaft Pulley
Chain Sub±assy
43 (440, 32)
Chain Tensioner
Slipper
19 (195, 14)
Camshaft Position
Sensor Plate No. 1
Oil Pump
Drive Gear
Chain Vibration
Damper No. 1

Oil Seal
Timing Chain Guide
9.0 (90, 80 in.
lbf)
Oil Pan Sub±assy
9.0 (90, 80 in.
lbf)
9.0 (90, 80 in.
lbf)
43 (440, 32)
43 (440, 32)
9.0 (90, 80 in.
lbf)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1AZ±FE)
14±157
AVENSIS REPAIR MANUAL (RM1018E)

A77289
Pry
A77243
14±144
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
30. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Using a screwdriver, pry between the timing chain cover
and cylinder head or cylinder block.
(c) Remove the timing chain cover.
NOTICE:
Be careful not to damage the contact surface of the timing
chain cover, cylinder head and cylinder block.
31. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
32. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the 2 bolts and the chain tensioner slipper.
33. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the bolt and the chain vibration damper No. 1
34. REMOVE TIMING CHAIN GUIDE
(a) Remove the bolt and the timing chain guide.
35. REMOVE CHAIN SUB±ASSY
36. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

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.

A77384
Mark Link
Timing Mark
Timing Mark
Mark Link
A77385
Groove
A77386
Groove
A77387
90
14±146
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Align the mark links (yellow colored links) with the timing
marks of each gear as shown in the illustration.
(d) Install the gears to the crankshaft and oil pump shaft with
the chain wrapped.
(e) Temporarily tighten the oil pump drive shaft gear with the
nut.
(f) Insert the damper spring into the adjusting hole, and
install the chain tensioner plate with the bolt.
Torque: 12 N
m (122 kgf
cm, 9.0 ft
lbf)
(g) Align an adjusting hole of the sprocket with the groove of
the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole of the
sprocket to lock in position, and tighten the nut.
Torque: 30 N
m (301 kgf
cm, 22 ft
lbf)
(i) Rotate the crankshaft clockwise 90
, and position the
crankshaft key upward.