TOYOTA AVENSIS 2005 Service Repair Manual

A64007
Front90


Clamp
Bolt
±
INTAKE INTERCOOLER ASSY(1CD±FTV)
13±19
AVENSIS REPAIR MANUAL (RM1018E)
(c)Tighten the hose clamps as shown in the illustration.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
5.INSTALL INTERCOOLER COOLING AIR DUCT SUB±ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
6.INSTALL FRONT BUMPER COVER (See page 76±3)

1306Z±01
A79155
A80093
A79158
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
13±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
2.DRAIN ENGINE COOLANT(See page 16±44)
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
5.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
6.REMOVE AIR CLEANER ASSY
(a)Disconnect the PCV hose and the connector.
(b)Remove the air cleaner cap with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case. 7.REMOVE INTERCOOLER AIR HOSE
(a)Remove the 3 bolts and nut, separate the air tube No.1.
(b)Loosen the hose clamp bolts and remove the air hoseNo.1.
8.REMOVE FUEL FILTER ASSY(See page 11±82) 9. SEPARATE HEATER PUMP ASSY (W/ COLD AREA)
(a) Remove the nut and disconnect the connector.
(b) Separate the heater pump.

A79159
A79156
A79157
A79160
13±12
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
10.REMOVE HEATER BRACKET (W/ COLD AREA)
(a)Remove the bolt and the heater bracket.
11.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
12.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10) 13. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA)
(a) Remove the 2 nuts.
(b) Remove the 2 nuts and the exhaust pipe sub±assy.
14. REMOVE TURBO INSULATOR NO.2
(a) Remove the 4 bolts and the turbo insulator.

A79161
A79162
A79163
A79164
A79444
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
13±13
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE TURBO INSULATOR NO.1
(a) Remove the 2 bolts and nut, and then remove the turbo
insulator.
16. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.2
(a) Remove the 2 bolts and the exhaust manifold heat insula-
tor.
17. REMOVE MANIFOLD STAY NO.2
(a) Remove the bolt and nut and then remove the manifold
stay.
18. REMOVE MANIFOLD STAY
(a) Remove the 4 bolts and the manifold stay.
19. REMOVE EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a) Remove the 3 nuts, the manifold converter and the gas-
ket.

A79165
A79166
A79167
B13094
B13095
13±14
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE TURBOCHARGER STAY
(a) Remove the 2 bolts and 2 nuts, and then remove the
turbocharger stay.
21. DISCONNECT TURBO WATER HOSE NO.1
22. DISCONNECT TURBO WATER HOSE NO.2
23. SEPARATE TURBO OIL INLET PIPE SUB±ASSY
(a) Remove the 2 nuts, the turbo oil pipe and the gasket.
24. REMOVE TURBOCHARGER SUB±ASSY
(a) Remove the 3 nuts, the turbocharger and the gasket.

B13096
A79165
B
BAA
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
13±15
AVENSIS REPAIR MANUAL (RM1018E)
25. REMOVE TURBO WATER PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts, the turbo water pipe and the gasket.
26. INSTALL TURBO WATER PIPE SUB±ASSY NO.1
(a) Install a new gasket and the turbo water pipe with the 2 nuts.
Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
27. INSTALL TURBOCHARGER SUB±ASSY
(a) Install a new gasket and the turbocharger with the 3 nuts.
Torque: 53 N
m (540 kgf
cm, 39 ft
lbf)
28. INSTALL TURBO OIL INLET PIPE SUB±ASSY
(a) Install a new gasket and the oil pipe with the 2 nuts.
Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
29. INSTALL TURBOCHARGER STAY
(a) Install the turbocharger stay, and temporarily tighten bolt
A.
(b) Temporarily tighten nut B while pushing the cylinder head
toward the turbocharger stay.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c) Tighten bolt A.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d) Tighten nut B.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
30. INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a) Install the manifold stay, and temporarily tighten the cylin-
der block side of the manifold stay.


A80106
A
A
B
B
A79163
13±16
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket and the manifold converter, and tem- porarily tighten bolts A and bolts B while pushing the up-
per portion of the converter toward the turbocharger.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c)Tighten the 3 nuts. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(d)Tighten bolts A.
Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
(e)Tighten bolts B. Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
31.INSTALL MANIFOLD STAY NO.2
(a)Install the manifold stay No. 2, and temporarily tighten the bolt.
(b)Temporarily tighten the nut while pushing the manifold stay No. 2 toward the cylinder head.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
HINT:
No clearance between the stay and the cylinder head should be
confirmed.
(c)Tighten the bolt. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d)Tighten the nut. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
32.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)
33.INSTALL TURBO INSULATOR NO.1 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
34.INSTALL TURBO INSULATOR NO.2
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
35.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
36.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
37.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
38. INSTALL HEATER BRACKET (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
39. INSTALL HEATER PUMP ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
40.INSTALL FUEL FILTER ASSY(See page 11±82)

A64328
2 to 7 mm0 to 2 mm
A78274
Upward90

Clamp
Bolt
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
13±17
AVENSIS REPAIR MANUAL (RM1018E)
41.INSTALL INTERCOOLER AIR HOSE
(a)Install the air hose and hose clamps as shown in the il-
lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
42.INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
43.INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
44.INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
45.ADD ENGINE COOLANT(See page 16±44)
46. CHECK ENGINE OIL LEVEL
47.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
48. CHECK FOR ENGINE OIL LEAKS
49.CHECK FOR FUEL LEAKS(See page 11±60)
50. CHECK FOR EXHAUST GAS LEAKS

1306Y±01
A79439
8.0 (82, 71 in.
lbf)
Engine Cover No. 1Radiator Support Opening Cover
N´m (kgf´cm, ft´lbf)
: Specified torque
7.0 (71, 62 in.
lbf)
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Engine Under Cover Sub±assy No. 1
Clip
Retainer
Clip
13±8
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
TURBOCHARGER SUB±ASSY (1CD±FTV)
COMPONENTS

A79440
Union To Connector Tube Hose
Fuel Filter Assy Vacuum Reservoir Sub±assy
43 (440, 32)
43 (440, 32)

Gasket

GasketCompression Spring
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Intercooler Air Hose

Gasket
7.5 (76, 66 in.
lbf)
Exhaust Pipe Assy
30 (302, 22)
7.5 (76, 66 in.
lbf)
Heater Bracket
Heater Pump Assy25 (255, 18)
25 (255, 18)
7.5 (76, 66 in.
lbf)
18 (178, 13)
7.5 (76, 66 in.
lbf)
w/ Cold Area:
w/ Cold Area:
w/ Cold Area:
8.3 (85, 73 in.
lbf)
Air Tube No. 1
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
13±9
AVENSIS REPAIR MANUAL (RM1018E)