TOYOTA AVENSIS 2005 Service Repair Manual

A86430
New GasketHollow
Screw
SST
A09663
:Seal Packing
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −157
AVENSIS Supplement (RM1045E)
(1) Apply a light coat of soapy water (any fluid to detect
fuel leakage) to the nozzle leakage pipe connec-
tion.
(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.
56. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as illustrated. 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, 9.7 ft
lbf)
57. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
58. INSTALL NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
59. INSTALL VACUUM PUMP ASSY (See page 14 −108)
60. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold at room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Remove the vinyl or plastic bag from the injector and the
vinyl tape from the common rail.
(c) Temporarily install the injection pipe.

A87959
Fulcrum Length
30 cm (11.81 in.)
SST
14−158
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(d) Using SST, tighten the nut of the injection pipe on the common rail side.
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:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After 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.
(e) Using SST, tighten the nut of the injection pipe on the in- jector side.
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:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After 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.
(f) Install the 2 upper injection pipe clamps.
61. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
62. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
63. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
64. INSTALL FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
65. INSTALL TIMING BELT (See page 14 −138)
66. CHECK VALVE TIMING (See page 14 −138)
67. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
68. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
69. INSTALL TIMING BELT GUIDE (See page 14 −138)

−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −159
AVENSIS Supplement (RM1045E)
70. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
71. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
72. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
73. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
74. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
75. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
76. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
77. INSTALL INJECTOR DRIVER (See page 14 −108)
78. INSTALL AIR TUBE NO.1 (See page 14 −108)
79. INSTALL VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
80. INSTALL BATTERY (See page 14 −108)
81. INSTALL AIR CLEANER ASSY (See page 14 −108)
82. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
83. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
84. CHECK FOR FUEL LEAKS (See page 11 −46)

141NJ−01
A85615
Engine Cover Sub−assy No. 1
Radiator Support Opening Cover
Clip
Clip
Retainer
8.0 (82, 71 in.
lbf)
w/ A/C:
V (Cooler
Compressor to
Crankshaft
Pulley) Belt No. 1
72 (734, 53)
39 (398, 29)
Power Steering
Idle Pulley
Bracket
Clip
N·m (kgf·cm, ft·lbf)
: Specified torque Engine Under
Cover RH
Engine Under
Cover Sub−assy No. 1
Clip
Engine Under Cover LH
Clip
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
7.0 (71, 62 in.
lbf)
Mass Air Flow
Meter Connector
Engine Wire Vacuum Hose
14−146
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
CAMSHAFT (1CD−FTV)(From September, 2003)
COMPONENTS

A85616
Injector Driver
5.5 (56, 49 in.·lbf)
52 (530, 38)
Engine Mounting Insulator Sub−assy RH
52 (530, 38)x3
8.3 (85, 73 in.·lbf)
Vacuum Reservoir Sub−assy
Vacuum Warning
Switch Connector
Vacuum Hose Assy
52 (530, 38)
Union to Connector
Tube Hose
Turbo Pressure
Sensor Connector
VRV Connector
25 (255, 18)
Air Tube No. 1
N·m (kgf·cm, ft·lbf)
: Specified torque
25 (255, 18)
25 (255, 18)
6.0 (61, 53 in.·lbf)
6.0 (61, 53 in.·lbf)
Battery
Battery Tray
Air Hose No. 2
5.0 (51, 44 in.
lbf)
3.0 to 4.0 (31 to 41, 27 to 35 in.
lbf)
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
14−147
AVENSIS Supplement (RM1045E)

A85610
: Specified torqueN·m (kgf·cm, ft·lbf)
* Replace only if damagedTiming Belt No. 2 Cover
Seal Washer
x7
Transverse Engine
Engine Mounting Bracket
Timing Belt No. 1 Cover
Generator
V Belt
Idler Pulley
Crankshaft Pulley
x5
Seal Washer
Timing Belt Guide * Gasket
* Gasket
Timing Belt
Tensioner
Timing Chain Cover Plate
Timing Belt
Glow Plug
Screw Grommet
Glow Plug
No. 1 Connector
Glow Plug Assy
21 (214, 15)
64 (650, 47)
7.4 (76, 66 in.·lbf)
9.0 (92, 80 in.·lbf)
2.2 (22, 19 in.·lbf)
7.4 (76, 66 in.·lbf)
180 (1,837, 133)40 (408, 30)
37 (375, 27)
Washer
Spacer
14−148
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)

A85617
23.5 (240, 17)
Fuel Pipe No. 3
5.0 (51, 44 in.·lbf)
5.0 (51, 44 in.·lbf)
5.0 (51, 44 in.·lbf)
27 (275, 20)
zNozzle Holder Seal
Cylinder Head Cover Sub−assy
Gasket
20 (204, 15)
zGasket
18 (184, 13)
27 (270, 20)
Washer
Nozzle Holder ClampInjector AssyFuel Injector
Back−up Ring No. 1 z
zO−ringzInjection Nozzle Seat
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
* Use SSTInjection Pipe Clamp No. 2
Injection Pipe Sub−assy
zGasket
zGasket
13 (135, 9.7)
* 36 (372, 27)
40 (408, 30)
* 31 (316, 23)
34 (347, 25)
Nozzle Leakage Pipe Assy
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
14−149
AVENSIS Supplement (RM1045E)

A85618
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
21 (214, 15)
Vacuum Pump Assy
zO−ring
20 (204, 15)
20 (204, 15)
Camshaft
No. 2 Camshaft
Set Key
Camshaft Timing Pulley
88 (899, 65)
Camshaft Carrier
zOil Seal
8.8 (90, 78 in.
lbf)Camshaft Oil Seal
Retainer
9.8 (100, 7.2)
Camshaft Position
Sensor
9.8 (100, 7.2)
Camshaft Bearing Cap
14−150
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)

141NI−01
A61175
A84394
A61184
14 −138
−
ENGINE MECHANICAL TIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. REMOVE ENGINE ROOM COVER SIDE
6. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
7. REMOVE INJECTOR DRIVER (See page 14 −108)
8. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
9. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
10. SEPARATE PO W ER STEERI NG I DLE PULLEY BRACKET
(a) Remove the 3 bolts and power steering idle pulley brack- et.
11. DISCONNECT ENGINE WIRE
(a) Disconnect the 2 exhaust gas temperature sensor con- nectors.
12. DISCONNECT VACUUM HOSE (See page 14 −108)
13. REMOVE ENGINE MOUNTING INSULATOR SUB−ASSY RH
(a) Place a wooden block on a jack underneath the engine.

A85928
A61182
SST (B)
SSTSST (A)
A61183SST
A84299
A85923
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
14−139
AVENSIS Supplement (RM1045E)
(b) Remove the 3 bolts and 3 nuts, then detach the engine
mounting insulator sub−assembly RH.
14. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09213−54015 (09213−70020), 09330−00021
HINT:
When using SST (A) (09213−70020), a plate washer (5 mm
(0.20 in.)) must be inserted between SST (A) and SST (B).
(b) Using SST, remove the pulley.
SST 09950−50013 (09951−05010, 09952−05010,
09953−05020, 09954−05031)
15. REMOVE IDLER PULLEY SUB−ASSY
(a) Remove the bolt and washer, then remove the pulley.
16. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, then remove the
timing belt cover.