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05 avalon engine cover

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2005 TOYOTA AVALON TVIP V4 (REMOTE ENGINE STARTER) INSTALLATION MANUAL

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TOYOTA AVALON 2005 – TVIP V4 (REMOTE ENGINE STARTER) Procedure Page 2 of 33 pages Issue: C 02/02/05 Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document. This document covers such items as:- • Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Visassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Vehicle Disassembly. (a) Remove the negative battery cable. (Fig. 1-1) (1) Protect the fender before starting. (2) Do not touch the positive terminal with any tool removing the cable. (b) Remove the glove box under-dash cover. (Fig. 1-2) (c) Remove the passenger’s step cover. (Fig. 1-3) Fig. 1-1 10mm Wrench Negative Battery Cable Battery Step Cover Fig. 1-3 Nylon Panel Removal Tool Fig. 1-2 Under-Dash Cover Nylon Panel Removal Tool TOYOTA AVALON 2005 – TVIP V4 (REMOTE ENGINE STARTER) Procedure Page 3 of 33 pages Issue: C 02/02/05 (d) Remove the passenger’s cowl cover. (Fig. 1-4) (1) Remove one nut securing the cowl cover. (e) Remove one screw and one bolt from the glove box assembly. (Fig. 1-5) (f) Remove the glove box assembly. (Fig. 1-6) (1) Open the glove box door and remove three screws securing the glove box assembly. (2) Disconnect the trunk opener cancel switch from the glove box assembly if equipped. For vehicles with Smart Entry, the disassembly process ends on Step f. Go to Section 5. For vehicles without Smart Entry, continue the disassembly process. FOR VEHICLES WITHOUT SMART ENTRY SYSTEM ONLY. (Step g) NOTE: Do not perform this step if the vehicle has Smart Entry. (g) Remove the driver’s step cover. (Fig. 1-7) Screw Fig. 1-5 10mm Wrench, Phillips Screwdriver Bolt Glove Box Assembly Cowl Cover Fig. 1-4 Nut Fig. 1-6 Nylon Panel Removal Tool, Phillips Screwdriver Screws (x3) Glove Box Assembly Trunk Opener Cancel Switch Connector Fig. 1-7 Step Cover Nylon Panel Removal Tool
TOYOTA AVALON 2005 – TVIP V4 (REMOTE ENGINE STARTER) Procedure Page 4 of 33 pages Issue: C 02/02/05 FOR VEHICLES WITHOUT SMART ENTRY SYSTEM ONLY. (Steps h-l) NOTE: Do not perform this step if the vehicle has Smart Entry. (h) Remove the driver’s cowl cover. (Fig. 1-8) (1) Remove the one nut securing the cowl cover. (i) Remove the hood release cable. (Fig. 1-9) (1) Do not bend the hood release cable. (j) Open the screw cover on the lower dash cover. Insert the tip of a Nylon Panel Removal Tool in the upper slot to loosen it. (Fig. 1-9) (1) Remove one screw and one bolt securing the lower dash cover. (k) Remove the lower dash cover. (Fig. 1-10) (1) Disconnect the temperature sensor (connector and aspirator hose) from the lower dash cover if equipped. (l) Carefully remove the driver side airbag assembly. (Fig. 1-11) (1) Remove four bolts securing the driver side airbag assembly. (2) Be careful not to get cut by the sharp metal edges. (3) Do not disconnect the airbag assembly. (4) Use the empty V4 kit box to support the airbag assembly on the floor

3406E Truck Engine Installation OR Removal Of The Speed/ Timing Sensor

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1. Disconnect the speed/timing connector “P9/J9″ (2) . Inspect the connector for the following conditions. * Corrosion * Bent pins * Missing pins * Damaged sockets * Mismating * Broken wires 2. Remove the Speed/timing sensor (1) from the front gear cover. 3. Examine the plastic end of the sensor for signs of wear or contaminants such as metal filings. The plastic end of the speed/timing sensor should have no contaminants and should show no wear (greater than 0.051 mm (0.0020 inch) from the face) . 4. Use a screwdriver to carefully pry the plastic sensor end to the fully extended position (approximately 4.775 mm (0.1880 inch) beyond the metal housing of the sensor). 5. Gently push in on the plastic end of the sensor. The plastic end should be firm. The plastic end should resist movement in the retract direction. If there is no resistance replace the sensor 6. Remove the two bolts (3) and remove the cover (5) from the flywheel housing. This hole is used for engine turning. 7. Put one bolt (3) in the timing bolt location (4) . The timing bolt location is approximately 127 mm to 152 mm (5 inch to 6 inch) above the hole in the flywheel housing for engine turning. I 8. Use 9S-9082 Engine Turning Tool (6) and a 1/2 inch drive ratchet wrench to turn the engine flywheel in the direction of normal engine rotation. The normal engine rotation is in a counterclockwise direction when viewed from the flywheel end. Turn the engine flywheel until the timing bolt engages with the threaded hole in the flywheel. Note: Visually check the location of the tooth on the wheel on which the speed/timing sensor is to be positioned. The end of the sensor must be in alignment with a tooth on the wheel and not in alignment with the valley of the wheel. Note: The No. 1 piston must be at either top center of the compression stroke or at top center of the exhaust stroke. 9. Inspect the speed/timing sensor before installation. Use steps 3 through step 6 to inspect the sensor. 10. If the sensor end is not fully extended, use a screwdriver to carefully pry the plastic sensor end to the fully EXTENDED position approximately 4.775 mm (0.1880 inch) beyond the metal housing of the sensor.

3406E TRUCK ENGINE 2WS Camshaft Gear Removal And Installation Manual

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1. Verify that the timing mark on camshaft gear (1) is aligned with Timing Mark (X) on front housing (3) . 2. Remove top bolt (2) from camshaft gear (1) . Install Tooling (A) in place of the bolt. 3. Remove remaining bolts (2) and remove camshaft gear (1) . 4. NOTICE Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine. Remove Tooling (A) . 5. Installation Procedure Required Tools Tool Part Number Part Description Qty A 9U-6896 Guide Bolt 1. Align the hole in the back of camshaft gear (1) with the dowel in the adapter. Install camshaft gear (1) over Tooling (A) . Note: Camshaft timing is critical. The timing mark on the camshaft gear must be aligned with the timing mark on the front cover when the No. 1 piston is at the top center of the compression stroke. Refer to Testing and Adjusting, “Gear Group (Front) – Time”. Verify that the timing mark on camshaft gear (1) is aligned with Timing Mark (X) on front housing (3) . 3. Note: If the timing marks are not aligned, remove camshaft gear (1) and rotate the camshaft until the timing marks are aligned. Install bolts (2) . Remove Tooling (A) and install remaining bolt (2) . 4. 5. Check the backlash between the camshaft gear and the adjustable idler gear. The backlash should be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch). Refer to Testing and Adjusting, “Gear Group (Front) – Time” for the backlash adjustment procedure. 6. End By: Install the front cover. Refer to Disassembly and Assembly, “Front Cover – Install”

1997 Saturn SL2 FRONT COVER And TIMING CHAIN REMOVAL AND INSTALLATION MANUAL

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Removal 1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. Put a block of wood between cradle and engine torque strut at bottom front end of engine. See Fig. 2 . 2. Remove mount from upper front end of engine, allowing engine to rest on wood block. Remove accessory drive belt and tensioner. Remove accessory belt idler. Remove cylinder head cover. 3. Replace silicone isolators on cylinder head cover screws if deteriorated. Remove power steering pump (leave hoses attached). Remove A/C compressor (leave hoses attached). Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. 4. Remove support bracket between intake manifold and engine block. Remove front balancer/pulley using a 3-jaw puller. Disconnect exhaust pipe from exhaust manifold. Install Crankshaft Gear Retainer (SA9104E) onto end of crankshaft, with flat side toward crankshaft gear (sprocket). Crankshaft gear retainer holds crankshaft gear in place during removal of front cover. 5. Remove 4 bolts from front end of oil pan. Using RTV Cutter (SA9123E), cut RTV sealant between oil pan and front cover. Spray penetrating oil onto front cover dowel pins. Remove front cover bolts (one bolt is located above accessory drive belt pulley). Pry front cover from engine block. 6. To prevent pistons from hitting valves, turn crankshaft 90 degrees clockwise as viewed from front of engine until timing mark and keyway are aligned with split line of main bearing cap. Remove timing chain tensioner, guides and chain. While using a 7/8″ (21 mm) wrench to keep camshaft(s) from turning, remove camshaft sprocket bolt(s). Remove camshaft sprocket(s). Installation 1. To prevent pistons from hitting valves, ensure timing mark and keyway on crankshaft are aligned with split line of main bearing cap. Install camshaft sprocket(s) with the letters FRT (front) facing away from cylinder head. Use a 7/8″ (21 mm) wrench to keep camshaft(s) from turning. 2. Install and tighten camshaft sprocket bolt(s) to specification. Rotate camshaft(s) until a 3/16″ (4.8 mm) drill bit can be inserted through timing pin hole(s) and into cylinder head. See Fig. 5 or Fig. 6 . 3. Rotate crankshaft counterclockwise as viewed from front of engine until timing marks at crankshaft sprocket are aligned. Install timing chain, aligning Silver-plated chain links with timing mark(s) on camshaft sprocket(s) and bottom tooth (or teeth) of crankshaft sprocket. See Fig. 5 or Fig. 6 . 4. Install fixed chain guide. Slack part of chain should be on tensioner side of cylinder block. Chain should be tight against fixed chain guide. Install pivoting chain guide. Retract tensioner plunger, and pin ratchet

Lexus IS300 2JZ I-6 Engine TURBOCHARGER SYSTEMS INSTALLATION INSTRUCTIONS

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1. Do not drain the engine oil until specified to in step 12 2. Remove strut tower brace (if equipped) 3. Remove engine cover by unbolting the four 10mm bolts . SEE FIGURE 1 FIGURE 1 4. Remove factory air box. SEE FIGURE 2 FIGURE 2 5. Remove mass air sensor from the stock intake tube using a Philips screwdriver. SEE FIGURES 3 & 4 FIGURE 3 FIGURE 4 60153_revA Page 8 of 31 6. Install the factory mass air sensor into the new supplied intake tube (P/N 21441) and secure using the two factory Philips screws. SEE FIGURE 5 FIGURE 5 7. Unplug the three O2 sensors on the factory exhaust manifold / catalytic converters. 8. Remove three 12mm bolts at the collector where the factory manifold / catalytic converter meets the exhaust. Save both factory crush o-rings, it will be used later when re-installing the new supplied downpipe. SEE FIGURE 6 FIGURE 6 9. Remove the factory exhaust manifold and catalytic converters by unbolting eight 14mm bolts. SEE FIGURES 7 & 8 INTAKE PIPE P/N 21441 FACTOR Y MASS AIR SENSOR 60153_revA Page 9 of 31 FIGURE 7 FIGURE 8 10. Unplug and remove all three O2 sensors (two pre-cats, and one post cat) from the factory exhaust manifold / catalytic converter. Make you keep track of which sensors are pre-cats and which one is post cat. SEE FIGURE 9 & 10 FIGURE 9 FIGURE 10 11. Locate the pad on the mid-pan on the passenger side of the vehicle. Drill the mid-pan with a 9/16″ drill bit and tap the hole with the supplied 3/8″ NPT tap (P/N 30809) for the turbo oil return. NOTE: When drilling and tapping the mid-pan, use extreme caution to get minimal amount of chips into the motor. Coat both drill bit and tap with excess amount of grease to catch any chips that may enter the engine. 12. Prior to draining the engine oil, clean the threaded hole thoroughly using brake / carb cleaner for any chips or debris. Remove oil drain plug and drain oil. 13. Install new supplied 5/8″ barb x 3/8″ NPT brass fitting (P/N 30133) to the new threaded hole on the mid- pan. It is strongly recommended that you apply a small amount of liquid Teflon to the threads of the fitting. FIGURE 11 POST CAT O2 SENSOR PLUG PRE CAT O2 SENSOR 1 PLUG PRECAT O2 SENSOR 2 PLUG 60153_revA Page 10 of 31 FIGURE 11 14. Unplug the factory oil sending unit located on the driver’s side below the intake manifold, next to the oil filter. Remove sending unit using a 24mm socket. SEE FIGURE 12 FIGURE 12 15. Thread the supplied brass 1/8″ NPT to -3AN fitting (P/N 30544) to the supplied 1/8″ NPT T-fitting (P/N 30562) as shown in FIGURE 13 NOTE: It is recommended that you apply a minimal amount of liquid Teflon to the threads of the fittings. Do not use Teflon Tape. FIGURE 13 P/N 30544 P/N 30562 FACTORY OIL SENDING UNIT ENGINE BLOCK 60153_revA Page 11 of 31 16. Thread the T-fitting assembly into the original port of the factory oil sending unit with the open female port facing upward when tightened. FIGURE 14 FIGURE 14 17. Install the factory oil sending unit to the open female port as shown in FIGURE 15 FIGURE 15 18. Install one end of the supplied -3AN line (P/N 10721) to the 1/8″ NPT to -3AN fitting (P/N 30544) installed previously on the t-fitting (P/N 30562) with the factory oil sending unit. SEE FIGURE 15 INSTALLING THE TURBOCHARGER, WASTEGATE, DOWNPIPE, AND MANIFOLD 19. Install the four supplied M10x1.25 studs (P/N 30806) to the turbo flange of the new supplied exhaust manifold (P/N 21444) and install the two supplied M8x1.25 studs (P/N 30860) into the wastegate flange on the new exhaust manifold. SEE FIGURE 16