2005 TOYOTA AVENSIS drain bolt

410DD±01
D30524
C80550
C67601
C67602
41±4
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the manual transmission filler plug and gasket
from the manual transmission case.
2. REMOVE DRAIN (MTM) PLUG SUB±ASSY
(a) Remove the drain plug and gasket from the manual trans-
mission case.
3. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB±ASSY
(a) Remove the bolt and speedometer driven hole cover sub±assy.
(b) Remove the O±ring from the speedometer driven hole cover sub±assy.
4. REMOVE CLUTCH RELEASE FORK SUB±ASSY
(a) Remove the clutch release fork sub±assy with clutch re-
lease bearing assy from the front transaxle case.
5. REMOVE CLUTCH RELEASE BEARING ASSY
(a) Remove the clutch release bearing clip and clutch release
bearing assy from the clutch release fork sub±assy.

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

A09449
SST
A09451
A09555
Measuring Point
16 mm (0.63 in.)
P12477
Seal Packing
A09522
Upper
Front
60

± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
27. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
28. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
29. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard outside diameter:
10.75 ± 11.00 mm (0.4232 ± 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
30. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB±ASSY
(a) Apply seal packing 2 or 3 threads.
Seal packing: Part No. 08826±00100 or equivalent
(b) Install the drain union.
Torque: 29 N
m (291 kgf
cm, 21 ft
lbf)
HINT:
After applying the specified torque, if the drain pipe of the drain
union is not at the position shown in the illustration, rotate the
drain union further clockwise and make the drain pipe face
downward.

031H2−02
03−14
− SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by−pass pipe No.1 x Cylinder block9.09280 in.
lbf
Water by−pass pipe No. 3 x Cylinder block9.09280 in.
lbf
Oil cooler pipe x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
V−ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Exhaust manifold heat insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Drive plate & ring gear x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub−assy front x Body Bolt
Nut45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133
801,356
81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356
81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No. 2 RH x Transverse engine
engine mounting insulator A
B
52
11 3530
1,15238
83
Vane pump assy x Timing chain cover3737027
Front suspension arm sub−assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub−assy x Frame8.08271 in.
lbf
Radiator reserve tank Sub−assy x Body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 5
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Engine cover No. 1 x Cylinder head cover9.09280 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90 _806
Turn 90 _58
Turn 90 _
Camshaft timing oil control valve assy x Cylinder head9.09279 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Battery carrier x Frame131319.5
Battery clamp x Body Bolt
Nut5.0
3.551
3644 in. lbf
31 in. lbf
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14 −45) Bolt A
Bolt B
Bolt C
Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1 CD −FTV:
Part TightenedN
mkgf
cmft
lbf
Air tube No. 1 hose clamp bolt6.06153 in.
lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover sub −assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub −assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020014
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5657542
Compressor mounting bracket x Cylinder block4242831
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf