TOYOTA AVENSIS 2005 Service Repair Manual

A85744
5.0 (51, 44 in.
lbf)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2zInjection Pipe Sub−assy
* 31 (316, 23)
34 (347, 25)
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
* Use SST
Common Rail Assy
Intake Manifold
Insulator No. 1
Fuel Hose No. 4
zFuel Inlet Pipe Sub−assy
5.0 (51, 44 in.
lbf)
43 (438, 32)
* 31 (316, 23)
34 (347, 25)
27 (275, 20)
Fuel Pipe No. 3
zGasket
5.0 (51, 44 in.
lbf)
x2
5.0 (51, 44 in.
lbf)
* 22 (223, 16)
24 (240, 17)
11−66− FUELCOMMON RAIL ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)

110U9−02
A85741
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
7.0 (71, 62 in.
lbf)
N·m (kgf·cm, ft·lbf)
: Specified torque
Radiator Hose Outlet
Clip
Engine Room Cover Side
Clip
Retainer
Radiator Support
Opening Cover
8.0 (82, 71 in.
lbf)
5.5 (56, 49 in.
lbf)
V (Cooler Compressor
to Crankshaft Pulley)
Belt No. 1
Injector Driver
72 (734, 53)
52 (530, 38)52 (530, 38)
Engine Cover
Sub−assy No. 1
Engine Mounting Insulator Sub−assy RH
39 (398, 29)
Power Steering
Idle Pulley Bracket
52 (530, 38)
Clip
Engine Under Cover RH
Engine Under Cover Sub−assy No. 1
Clip
Radiator Reserve Tank Assy
6.0 (61, 53 in.
lbf)
x5
x3
Exhaust Gas Temperature
Sensor Connector
Vacuum Hose
Mass Air Flow Meter
Connector
− FUELINJECTION OR SUPPLY PUMP
ASSY (1CD−FTV)(From September, 2003)11−55
AVENSIS Supplement (RM1045E)
INJECTION OR SUPPLY PUMP ASSY (1CD−FTV)(From
September, 2003)
COMPONENTS

A85610
: Specified torqueN·m (kgf·cm, ft·lbf)
* Replace only if damagedTiming Belt No. 2 Cover
Transverse Engine
Engine Mounting Bracket
Seal Washer Timing Belt No. 1 Cover
Crankshaft Pulley Seal Washer
x5 Generator V belt
Glow Plug
Screw Grommet Timing Belt GuideTiming Belt * Gasket
x7
Glow Plug Assy * Gasket Timing Chain Cover Plate
Timing Belt
Tensioner
180 (1,835, 133)
21 (214, 16)
9.0 (92, 80 in.·lbf)
37 (375, 27)
64 (650, 47)
2.2 (22, 19 in.·lbf)
7.4 (75, 65 in.·lbf)
7.4 (75, 65 in.·lbf)
Idler Pulley
40 (408, 30)Glow Plug
No. 1 Connector
11−56− FUELINJECTION OR SUPPLY PUMP
ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)

A85742
5.0 (51, 44 in.
lbf)
* 36 (372, 27)
40 (408, 30)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2
Injection Pipe Sub−assy
zFuel Inlet Pipe Sub−assy
64 (653, 47)
Injection Pump
Drive Pulley
zO−ring Oil Level Gage Guide
: Specified torqueN·m (kgf·cm, ft·lbf)
* Use SST
18 (184, 13)
Oil Level Gage Sub−assy Injection or
Supply Pump Assy
21 (209, 15)
21 (209, 15)
Water Inlet
8.8 (90, 78 in.
lbf)
zGasket
5.0 (51, 44 in.
lbf)
Intake Manifold Insulator No. 1
Injection Pump to Fuel Filter
Fuel Hose or Pipe
Injection Pump to Fuel Pipe
Fuel Hose
Fuel Pipe No. 3
zGasket
27 (275, 20)
5.0 (51, 44 in.
lbf)
x3
zNon−reusable part
5.0 (51, 44 in.
lbf)
* 22 (223, 16)
24 (240, 17)
* 31 (316, 23)
34 (347, 25)
− FUELINJECTION OR SUPPLY PUMP
ASSY (1CD−FTV)(From September, 2003)11−57
AVENSIS Supplement (RM1045E)

1111 D−01
A93661
(a)
(a)
(b)(b)
(a)
(a)
A85630
11−46
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
NOTICE:
If an incorrect injector compensation code was registered with the ECM, it may rattle the engine as-
sembly or the engine idling may become rough. In addition, it may become a cause of engine failure
or shorten the life of the engine.
HINT:
SIn order to optimize the injector’s fuel injection characteristic, the ECM compensates the injection dura-
tion by each cylinder. The ECM stores and uses compensating data in the form of a 30−digit−alphanu-
meric value that is imprinted on the head portion of each injector as the injector compensation code.
SIf you installed a new injector, its own injector compensation code is needed to register with the ECM.
Also, if you replaced the ECM, the compensation codes of all the injectors are needed to register be-
cause the new ECM does not have the codes until they are registered.
SOnce the ECM is replaced, DTC P1601 will be present when turning the ignition switch to ON. This
is to inform you that the injector compensation codes are required to register with the ECM. In order
to clear the DTC, register the compensation codes first, then turn the ignition switch to OFF and wait
for 30 seconds or longer.
1. REMOVE VACUUM RESERVOIR SUB−ASSY
(a) Disconnect the 2 vacuum hoses and connector.
(b) Remove the 2 bolts and vacuum reservoir.
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER SUB−ASSY NO.1
(a) Remove the 5 nuts and engine cover.
4. REMOVE AIR CLEANER ASSY
(a) Disconnect the connector.
(b) Remove the air cleaner cap together with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and air cleaner case.
5. REMOVE AIR TUBE NO.1
(a) Remove the 3 bolts and nut, then separate the air tube
No. 1.
(b) Loosen the hose clamp bolts.
6. REMOVE FUEL PIPE NO.3
(a) Remove the fuel pipe insulator.

A85631
SST
A85632
A93406
SST
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−47
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, remove the fuel pipe No.
3 from the injector side.
SST 09023−12700
(c) Remove the bolt and 3 nuts, then remove the fuel pipe No.
3 and 2 gaskets.
7. REMOVE INJECTION PIPE SUB−ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023−12700
(c) Using SST, remove the injection pipe from the injector
side.
SST 09023−12700
(d) After removing the fuel pipe, to prevent dust or foreign ob-
jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
8. REMOVE INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
9. REMOVE INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
10. REMOVE INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
11. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, then remove the timing belt cover.

A09656
A79144
A85755
11−48
−
FUEL INJECTOR ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
12. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
13. REMOVE NOZZLE LEAKAGE PIPE NO.2
(a) Disconnect the 2 fuel hoses from the nozzle leakage pipe No. 2.
(b) Remove the 2 bolts and nozzle leakage pipe No. 2. 14. REMOVE CYLINDER HEAD COVER SUB −ASSY
(a) Remove the 10 bolts and cylinder head cover.
15. REMOVE NOZZLE LEAKAGE PIPE ASSY
(a) Remove the bolt and 4 hollow screws, then remove the nozzle leakage pipe and 4 gaskets.
NOTICE:
When removing the nozzle leakage pipe, place a shop rag
under the pipe to protect the cylinder head from the fuel re-
maining inside the pipe.
16. REMOVE NOZZLE HOLDER CLAMP
(a) Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.
17. REMOVE INJECTOR ASSY
HINT:
Each injector assembly has its own fuel injection characteristic. When replacing the injector assembly, store
them in the correct order so that they can be returned to the original locations when reassembling.
(a) Remove the 4 injectors from the cylinder head.
(b) Remove the O −rings and back −up rings from each injector.
(c) Remove the 4 nozzle seats from the cylinder head.
18. REGISTRATION OF INJECTOR COMPENSATION CODE (REPLACEMENT OF THE NEW INJECTORS) (See page 05 −277)
HINT:
Each injector assembly has characteristic fuel injecting behavior. When replacing the injector assembly,
store them in the correct order so that they can be returned to the original locations when reassembling.

A79187
O−ring Back−up Ring
A92435
A85760
90_
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−49
AVENSIS Supplement (RM1045E)
19. INSTALL INJECTOR ASSY
(a) Install the 4 new nozzle seats to the cylinder head.
(b) Install new back−up rings and O−rings to each injector.
(c) Apply a light coat of engine oil to the O−rings on each in-
jector.
(d) Install the injector to the cylinder head.
NOTICE:
Fit the injectors to the nozzle seat.
(e) Install the nozzle holder clamp as shown in the illustration.
Tighten the camshaft bearing cap bolt by hand to fix the
nozzle holder clamp.
NOTICE:
SPay attention to the mounting orientation of the wash-
er.
SWhen temporarily attaching the nozzle holder clamp
and mounting bolt, be careful not to orient them at an
angle.
HINT:
Apply a light coat of engine oil to the threads of the nozzle hold-
er clamp bolts.
(f) Install the injection pipe No. 1, No. 2, No. 3 and No. 4, then
tighten the nuts by hand.
(g) Install new 4 gaskets and the leakage pipe No. 1. Tighten
the 4 hollow screws by hand.
(h) Tighten the 4 nozzle holder clamp bolts.
Torque: 27 N
m (270 kgf
cm, 20 ft
lbf)
(i) Remove the 4 injection pipes.
20. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Install the nozzle leakage pipe and 4 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint of the gasket
comes within the range shown in the illustration.
(b) Apply a light coat of engine oil to the 4 hollow screws and
the bolt.

A86430
New Gasket
Hollow Screw
SST
A09663
:Seal Packing
11
−50
−
FUEL INJECTOR ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(c) Tighten the 4 hollow screws and bolt by hand.
(d) Tighten the 4 hollow screws and bolt. Torque:
16 N
m (163 kgf
cm, 12 ft
lbf) for hollow screw
20 N
m (204 kgf
cm, 15 ft
lbf) for flange bolt
NOTICE:
In any case, when the torque exceeds the upper limit, re-
place the leakage pipe hollow screw and gaskets with new
ones.
(e) Check that there are no leaks from the nozzle leakage
pipe connection.
(1) Apply a light coat of soapy water (any fluid to detect fuel leaks) to the nozzle leakage pipe connection.
(2) Using SST (a turbocharger pressure gauge), attach SST to the fuel return side of the nozzle leakage
pipe, then maintain 100 kPa (1.0 kgf/cm
2 , 14.5 psi)
of pressure for 60 seconds to check that there are
no bubbles from the pipe connection.
SST 09992 −00242
(3) After checking fuel leaks, wipe off soapy water from
the pipe connection.
21. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head. Seal packing: Part No. 08826 −00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.8 ft
lbf)
22. INSTALL NOZZLE LEAKAGE PIPE NO.2
(a) Install the nozzle leakage pipe No. 2 with the 2 bolts. Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
(b) Connect the 2 fuel hoses.
23. INSTALL NOZZLE HOLDER SEAL
(a) Install new 4 nozzle holder seals.
24. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)

A87959
SST (11.81 in.)30 cm
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−51
AVENSIS Supplement (RM1045E)
25. INSTALL INJECTION PIPE SUB−ASSY NO.1
NOTICE:
SIn case of replacing the injectors, the injection pipes
must be replaced, too.
SWhen assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or plastic bag from the injector and vinyl
tape from the common rail.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail.
SST 09023−12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec-
tor.
SST 09023−12700
Torque:
For used pipe:
36 N
m (372 kgf
cm, 27 ft
lbf) with SST
40 N
m (408 kgf
cm, 30 ft
lbf) without SST
For new pipe:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
26. INSTALL INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
27. INSTALL INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.