2005 TOYOTA AVENSIS check engine light

A32639
A77414
Straight
Pin
Key
Groove
A77284
A77415Bearing Cap No. 1Bearing Cap No. 3 5
312 4
± ENGINE MECHANICALCAMSHAFT (1AZ±FSE)
14±243
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove a fringe bolt of camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If reusing the camshaft timing gear, release the
straight pin lock first, and then install the gear.
17. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear 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) while lightly pushing it to-
ward the camshaft. Push further at the position where the
pin gets into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right direction).
(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 can move to the re-
tard angle side (to the right direction), and is locked at the
most retarded position.
18. INSTALL CAMSHAFT
(a) Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
(b) Install the timing chain on the camshaft timing gear, with
the painted links aligned with the timing marks on the
camshaft timing gear.
(c) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 30 N
m (301 kgf
cm, 22 ft
lbf)
Bearing cap No. 3 9.0 N
m (92 kgf
cm, 80 in.
lbf)
19. INSTALL NO.2 CAMSHAFT
(a) Put the No. 2 camshaft on the cylinder head with the
painted links of chain aligned with the timing mark on the
camshaft timing gear.

A61189
10
11
12
13 14
15 16
17
18
2
1
4
5 6
3
7 8
9
(A) (A)
(A)
(A) (A)
(A)
(A)
(B) (B) (B) (B) (B) (B) (B)
(B)
(B)
(B) (A)
A61190
90
 90

9090
 90

90
Front Paint Mark
90
A09683
TDC Mark
Dot Mark
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±337
AVENSIS REPAIR MANUAL (RM1018E)
70. INSTALL CYLINDER HEAD SUB±ASSY
HINT:

The cylinder head bolts are tightened in 4 successive
steps (steps (c), (e), (f) and (g)).

If the cylinder head bolt is broken or deformed, replace it
with a new bolt.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts and the plate washers.
(b) Install the plate washer to the cylinder head bolt.
(c) Using several steps, install and tighten the 18 cylinder head bolts uniformly in the sequence shown in the illustra-
tion.
Torque: 45 N
m (459 kgf
cm, 33 ft
lbf)
HINT:
See the table below for the bolt length.
Bolt TypeBolt Length
(A)160mm (6.30 in.)
(B)104mm (4.09 in.)
If the cylinder head bolt does not meet the torque specification,
replace the cylinder head bolt with a new bolt.
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90  in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by additional 90  in the
same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional 90 in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man- ifold side.
71. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing pulley at the position
of 90  BTDC.
NOTICE:
If the timing belt is disengaged, having the crankshaft tim-
ing pulley at wrong angle can cause the piston head and
valve head to come into contact with each other.
72.INSTALL CAMSHAFT (See page 14±318)
73.INSTALL NO.2 CAMSHAFT (See page 14±318)
74.REMOVE CAMSHAFT OIL SEAL (See page 14±318)
75.INSTALL CAMSHAFT OIL SEAL (See page 14±318) SST 09223±46011

170FV±01
A56222
A56223
± LUBRICATIONOIL FILTER SUB±ASSY (1AZ±FSE)
17±19
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FSE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or sol-
vents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter.
SST 09228±06501
4. 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
5. ADD ENGINE OIL
(a) Fill with fresh engine oil.
Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp. qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK

170FW±01
A56222
A56223
17±12
± LUBRICATIONOIL FILTER SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or sol-
vents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter.
SST 09228±06501
4. 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
5. ADD ENGINE OIL
(a) Fill with fresh engine oil.
Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp. qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK

170FS±01
A79297
A79298
SST
A79299
3/4 turn
SST 17±4
± LUBRICATIONOIL FILTER SUB±ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1ZZ±FE/3ZZ±FE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with engine oil will result in the removal of natural oils from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Wear protective clothes and gloves. Wash your skin thoroughly
with soap and water, or use water±less hand cleaner to remove any used engine oil. Do not use
gasoline, thinners, or solvents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil pan drain plug and drain engine oil.
2. REMOVE OIL FILTER SUB±ASSY
(a) Remove the screw and open the under cover.
(b) Using SST, remove the oil filter
SST 09228±06501
3. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter mounting 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 as shown in the
illustration.
SST 09228±06501

190NQ±01
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow
B00543
± STARTING & CHARGINGCHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
19±5
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
3. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.
4. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.

B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter BatteryAmmeter 19±6
± STARTING & CHARGINGCHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that it fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
5. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engine is running.
7. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine and check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an amme-
ter and voltmeter as shown in the illustration.
(1) Disconnect the wire from terminal B of the generator
and connect it to the negative (±) lead of the amme-
ter.
(2) Connect the positive (+) lead of the ammeter to ter-
minal B of the generator
(3) Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
(4) Ground the negative (±) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm, check the
reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 to 14.9 V
HINT:

If the voltmeter reading is more than standard voltage, re-
place the voltage regulator.

If the voltmeter reading is less than the standard voltage,
check the voltage regulator and generator as follows:
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights and turn the heater blower
switch to the ºHIº position.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
HINT:

If the ammeter reading is less than standard amperage, repair the generator.

If the battery is fully charged, the indication will sometimes be less than standard amperage.

170FQ±01
B14352
B14354
New O±RingNew O±Ring
B14355
17±32
±
LUBRICATION OIL COOLER ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
OIL COOLER ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2.DRAIN ENGINE OIL(See page 17±30)
3.REMOVE ENGINE UNDER COVER LH 4.REMOVE OIL COOLER ASSY
(a)Disconnect the 2 cooler hoses from the oil cooler.
(b)Remove the union bolt and the oil cooler.
(c)Remove the O±ring from the oil cooler.
(d)Remove the O±ring from the union bolt.
5.INSTALL OIL COOLER ASSY
(a)Clean the oil cooler mounting surface.
(b)Install a new O±ring to the union bolt.
(c)Install a new O±ring to the oil cooler.
(d)Apply a light coat of engine oil on the threads of the unionbolt.
(e)Align the tab of the oil cooler with the tab located on the cylinder block.
(f)Install the oil cooler with the union bolt. Torque: 45 N
m (454 kgf
cm, 33 ft
lbf)
(g)Connect the 2 cooler hoses to the oil cooler.
6.ADD ENGINE OIL(See page 17±30)
7.ADD ENGINE COOLANT(See page 16±44)
8.CHECK FOR ENGINE OIL LEAKS(See page 16±44)
9. CHECK FOR ENGINE COOLANT LEAKS