2005 TOYOTA AVENSIS oil

A62817SST
A62202
Cut Position
A01153
A01456
14±10
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
25. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter.
SST 09228±06501
26. REMOVE OIL FILTER UNION
(a) Using a socket hexagon wrench 12, remove the oil filter union.
27. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If there is, mend it with a sandpaper (# 400).
28. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket from the oil pan.
29. REMOVE OIL PAN SUB±ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Insert the blade of SST between the bearing cap sub±as-
sembly and oil pan, and cut off applied sealer and remove
the oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the oil pan contact surface of the
bearing cap sub±assembly and the oil pan flange.

A62818
Raise
Move
Lock
A62819
Measuring Area
012345 16
A30206
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±11
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
30. REMOVE OIL STRAINER SUB±ASSY
(a) Remove the bolt, 2 nuts, oil strainer and gasket.
31. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Remove the cylinder block water drain cock from the cylinder block.
32. INSPECT CHAIN TENSIONER ASSY NO.1
(a) Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) Release the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.
33. INSPECT CHAIN SUB±ASSY
(a) Using a spring tension gauge and vernier calipers, pull
the timing chain with 140 N (4.3 kgf, 315 lb) and measure
the length of it.
Maximum chain elongation : 112.6 mm (4.433 in.)
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
34. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier calipers, measure the timing sprocket di-
ameter with the chain.
Minimum sprocket diameter (w / chain):
97.3mm (3.831 in.)
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.

EM1628
EM2011
EM2538
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±13
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
39. INSPECT CAMSHAFT
(a) Inspect camshaft for runout.
(1) Place the camshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
(b) Inspect cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.333 ± 44.433 mm (1.7454 ± 1.7493 in.)
Exhaust 43.761 ± 43.861 mm (1.7229 ± 1.7268 in.)
Minimum cam lobe height:
Intake 44.18 mm (1.7394 in.)
Exhaust 43.61 mm (1.7169 in.)
(c) Inspect camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
34.449 ± 34.465 mm (1.3563 ± 1.3569 in.)
Others journal diameter:
22.949 ± 22.965 mm (0.9035 ± 0.9041 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
40. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
(a) Apply two or three threads of adhesive to the drain union, and install it within 3 minutes.
Torque: 20 N
m (204 kgf
cm15 ft
lbf)
(b) After applying the specified torque, rotate the drain union clockwise until its drain port faces downward.
NOTICE:

Do not put into coolant in an hour after the installation.

Do not rotate the drain union more than 360 in (b), and never loosen it after setting the union
correctly.
41. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 nuts and a bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

A62821
Seal Width 4 ± 5 mm
6 mmSeal Packing
A62822
SST
A62817SST
14±14
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
42. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing material from the contact sur-
face.
(b) Apply seal packing in the shape of bead (Diameter 3.5
mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing: 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 put into engine oil within 2 hours after instal-
ling.
(c) Install the oil pan with the 14 bolts and 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
43. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install it.
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
44. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with
the oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crank shaft.
45. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter union.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
46. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501

A30890
A62826
Lot No.
A62816
84 2 59
7 3 1 6 10
A62823
Paint Mark
90
Front
A62815
Mesh
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±15
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
47. INSTALL OIL PUMP ASSY
(a) Engage the spline teeth of the oil pump drive rotor with the
large teeth of the crankshaft, and side the oil pump.
(b) Install the oil pump with the 5 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
48. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:

Pay attention to the installation direction.

Place the cylinder head quietly in order not to damage
the gasket with the bottom part of the head.
49. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using a bi±hexagon wrench 10, install and uniformly tight-
en the 10 cylinder head bolts with plate washers, in sever-
al passes, in the sequence shown.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90 in the numerical or-
der shown.
(e) Check that the point marked bolts are moved at 90 
angle.
50. INSTALL OIL CONTROL VALVE FILTER
(a) Confirm that the filter is clear.
(b) Install the oil control valve filter to the cylinder head.
(c) Place a new gasket on the bolt, and install it.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)

A62824
Straight Pin
Key Groove
A32167
A62150
14±16
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Install a new O±ring to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
52. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft
together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
(e) Check that the camshaft timing gear assembly can move
to the retard angle side (the right angle), and is locked at
the most retarded position.
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and install the camshaft tim-
ing gear.
Torque: 54 N
m (551 kgf
cm 40 ft
lbf)
NOTICE:
Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT
(a) Apply light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head with the No.
1 cam lobes facing as shown the illustration.

A62173
Yellow Color Mark
Timing Mark
A30867
A62174
SST
A62175
Seal Width
4 ± 5 mm
Seal Packing
14±18
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Install the timing chain on the camshaft timing sprockets
with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.
56. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
57. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
58. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing forward.
59. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to the oil seal lip.
(b) Using SST, tap in a new oil seal until its surface is flush
with the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip off foreign materials.
60. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material from the contact sur-
face.

A62176
Chain Cover
Groove
Cylinder Head
GrooveSeal Width
4 ± 5 mm
AB
7 mm
4.5 mm
3 mm 6 mm 12 mm
B
A
A ± A B ± BA
A
A62177
Raise
Push
Hook
Pin
A62178
Push
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Apply seal packing in the shape of bead (Diameter 3.5
mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent
(c) Install the timing chain cover, with the 12 bolts and nut.
Torque:
M6 13 N
m (133 kgf
cm, 10 ft
lbf)
M8 19 N
m (194 kgf
cm, 14 ft
lbf)
NOTICE:

Remove any oil from the contact surface.

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

Do not put into engine oil within 2 hours after instal-
ling.
61. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check the O±ring is clean, and set the hook as shown in
the illustration.
(b) Apply engine oil to the chain tensioner and install it with
the 2 nuts..
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
When installing the tensioner, set the hook again if the
hook releases the plunger.