TOYOTA AVENSIS 2005 Service Repair Manual

A87941
10 mm (0.394 in.)
22 mm
(0.866 in.)6 mm (0.236 in.)
11 m m
(0.433 in.)14 mm
(0.551 in.)
AB Rear Side: Exhaust Side:
C
B
A
C
6 mm (0.236 in.)
A87942
Rear Side: Lower Side:
A
27.5 mm
(1.083 in.)
A (M6) B (M6)28 mm
(1.102
in.)
B
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−57
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
23. INSTALL STRAIGHT PIN
(a) Using a plastic−faced hammer, tap in new straight pins.
Standard protrusion:
13 mm (0.5118 in.) for straight pin A
4.0 mm (0.1575 in.) for straight pin B
5.0 mm (0.1968 in.) for straight pin C
24. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque: 2.9 N
m (30 kgf
cm, 27 in.
lbf)

A87939
6mm
Hexagon
Wrench
A85943
A56044
A56045
A09510Groove
14−58− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
25. INSTALL CYLINDER BLOCK OIL ORIFICE
(a) Using a hexagon wrench (6 mm), install the oil orifice.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
26. INSTALL SUB−ASSY OIL NOZZLE NO.1
(a) Install the 4 oil nozzles with the 4 bolts.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
27. INSTALL CRANKSHAFT
(a) Install the bearing on the cylinder block and bearing cap.
HINT:
Each upper bearing has an oil groove and oil hole and each low-
er bearing does not.
(1) Align the bearing claw with the claw groove of the
cylinder block, then push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the
main bearing cap, then push in the 5 lower bear-
ings.
(b) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.

A09512
Groove
A56048
A09497
A56046
A87946
Front Mark
(Arrow)
Front Mark
(Protrusion)
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−59
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(c) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.
(d) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and font mark.
(e) Apply a light coat of engine oil to the threads and under-
heads of the main bearing cap bolts.
(f) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several steps.
Torque: 115 N
m (1,173 kgf
cm, 85 ft
lbf)
(g) Check that the crankshaft turns smoothly.
28. INSTALL W/PIN PISTON SUB−ASSY
(a) Install a new snap ring on one side of the piston pin hole.
(b) Gradually heat the piston up to approximately 60_C
(140_F).
(c) Coat the piston pin and piston hole of the piston with en-
gine oil.
(d) Align the front marks of the piston and connecting rod,
then push in the piston pin by hand.
(e) Install a new snap ring on the other side of the piston pin
hole.

A09508
A56047
Coil Joint
Oil Ring End
A87947
No. 1
No. 2Code Mark
Code Mark
A87948
Front Mark
(Arrow)No. 1
Compression
Ring
Oil Ring
No. 2
Compression
Ring
Coil
A09511
Front Mark
(Arrow)
Front
Push
14−60− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
29. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
30. INSTALL PISTON RING SET
(a) Install the coil by hand.
(b) Using a piston ring expander, install the oil ring.
HINT:
Align the oil ring so its end faces the opposite of the coil joint.
(c) Using a piston ring expander, install the No. 2 and No. 1
piston rings with the code mark facing upward.
Code mark:
No. 11T
No. 22T
NOTICE:
Try to keep the piston ring expansion as small as possible.
(d) Position the piston rings so that the ring ends are as illus-
trated.
31. INSTALL PISTON SUB−ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and sur-
faces of the connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly−num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.

A09514
Front Mark
(Protrusion)
A09493
90_
90_
A09490
Painted Mark
Front
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−61
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(d) Match the numbered connecting rod cap with the con-
necting rod.
(e) Install the connecting rod cap with the front mark facing
forward.
(f) Apply a light coat of engine oil to the threads and under-
heads of the connecting rod cap bolts.
(g) Install and alternately tighten the 2 cap bolts in several
steps.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
If any of the cap bolts does not meet the specified torque, re-
place the connecting rod cap bolts.
(h) Mark the front of the cap bolt with paint.
(i) Retighten the cap bolts by 90_as illustrated.
(j) Check that the painted mark is now at a 90_angle to the
front.
(k) Check that the crankshaft turns smoothly.

031H4−02
− SERVICE SPECIFICATIONSCOOLING
03−21
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x Body1919414
Fan assy w/ motor x Radiator6.06153 in.
lbf
Radiator relay block x Radiator5.05446 in.
lbf
1CD−FTV:
Part TightenedN
mkgf
cmft
lbf
Drain plug1313310
Water pump x Cylinder block3132023
Injection pipe x Common rail
With SST
Without SST
31
34316
34723
25
Injection pipe x Injector
For used pipe With SST
Without SST
For new pipe With SST
Without SST
36
40
31
34372
408
316
34727
30
23
25
Fuel inlet pipe sub−assy x Common rail assy
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe sub−assy x Injection pump
With SST
Without SST
31
34316
34723
25
Timing belt idler Sub−assy No.1 x Cylinder head3535726
Front wheel1031,05076

031H3−02
03−20
− SERVICE SPECIFICATIONSCOOLING
AVENSIS Supplement (RM1045E)
COOLING
SERVICE DATA
2AZ−FSE:
Thermostat
Valve opening temperature
Valve lift at 95_C (203_F)
80 to 84_C (176 to 183_F)
10 mm (0.394 in.) or more
Radiator cap sub−assy
Standard opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
Cooling fan
Standard amperage at 20_C (68_F)
Standard amperage (No. 2) at 20_C (68_F)
8.5 to 11.5 A
5.2 to 8.2 A
Cooling fan relay
Specified condition Between terminals 3 and 5
Cooling fan relay No. 2
Specified condition Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No. 3
Specified condition Between terminals 3 and 5
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
Below 1

10 k
or higher (Apply battery voltage terminals 1 and 2)
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
1CD−FTV:
Thermostat
Valve opening temperature
Valve lift at 95_C (203_F)
80 to 84_C (176 to 183_F)
8.5 mm (0.335 in.) or more
Radiator cap sub−assy
Standard opening pressure
Minimum opening pressure
93 to 122 kPa (0.95 to 1.25 kgf/cm2, 13.4 to 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.4 psi)

031E3−03
− SERVICE SPECIFICATIONSEXHAUST
03−19
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold converter sub−assy4344032
Exhaust pipe assy center x Exhaust pipe assy front4344032
Exhaust pipe assy tail x Exhaust pipe assy center434432
Floor panel brace front x Body3030222
1CD−FTV:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy front x Tail pipe assy4344032
Floor panel brace front x Body3030222
Air fuel ratio sensor x Exhaust pipe assy front4444933

031E2−03
03−18
− SERVICE SPECIFICATIONSEXHAUST
AVENSIS Supplement (RM1045E)
EXHAUST
SERVICE DATA
2AZ−FSE:
Compression spring (Exhaust pipe assy front x Exhaust manifold converter
sub−assy)
Free length Minimum
41.5 mm (1.634 in.)
Compression spring (Exhaust pipe assy tail x Exhaust pipe assy center)
Free length Minimum
38.5 mm (1.516 in.)
1CD−FTV:
Compression spring
Minimum length Exhaust pipe assy front x Exhaust manifold
41.5 mm (1.634 in)
Compression spring
Minimum length Exhaust pipe assy front x Tail pipe assy
38.5 mm (1.515 in)

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