TOYOTA AVENSIS 2005 Service Repair Manual

A79424
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
8.8 (90, 65 in.
lbf)
8.8 (90, 6.5 in.
lbf)
8.4 (86, 74 in.
lbf)
21 (209, 15)
8.8 (90, 78 in.
lbf)
34 (347, 25)
18 (184, 13)21 (210, 15)
21 (210, 15)
42 (428, 31)
37 (377, 27)
59 (600, 43)
21 (214, 15)
45 (454, 33)

O±ring

O±ring

Gasket

O±ring

O±ring
Vacuum Pump Oil Pipe
Union Bolt
Oil Cooler AssyFuel Filter To Injection Pump
Fuel Pipe
Rear End Plate
Crankshaft Position
Sensor
Thermostat
Water Inlet
Oil Level Gage Guide Oil Filter Bracket Sub±assy
Injection or Supply Pump Assy Compressor Mounting
Bracket No. 1Generator Bracket No. 1 V±ribbed Belt
Tensioner
AssyGenerator Assy
Oil Cooler Pipe

Gasket
Turbo Oil Outlet Pipe No. 2
31 (320, 23)

Gasket
33 (331, 24)
8.8 (90, 78 in.
lbf)
47 (475, 34)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±285
AVENSIS REPAIR MANUAL (RM1018E)

141C2±01
A78277
A79143
SST
14±270
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1CD±FTV)
ADJUSTMENT
NOTICE:

Before removing the injection pipes, clean them up with a soft brush and compr\
essed air.

After removing the injection pipe, cover the supply pump, the common rail and the injector
mounting area of the cylinder head cover with vinyl tape to prevent dust from being introduce\
d.

After removing the cylinder head cover, protect the injector inlet with a vinyl or a plastic bag
to prevent foreign objects from being introduced.
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE FRONT WHEEL RH
3.REMOVE ENGINE UNDER COVER RH
4.DRAIN ENGINE COOLANT (See page 16±44)
5.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
6.REMOVE AIR TUBE NO.1
(a)Disconnect the vacuum hoses and the connectors.
(b)Loosen the hose clamps.
(c)Remove the 3 bolts and nut, and then detach the air tubeNo. 1.
7.REMOVE TIMING BELT NO.2 COVER (See page 14±307) 8. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clampsfrom 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 a
plastic bag.

A09687
UpwardCam Lobe
Clearance
A80107
A81553
Upward
Notch
Cam Lobe
Intake
Manifold
Side
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
14±271
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10.REMOVE INJECTION PIPE SUB±ASSY NO.3
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
11.REMOVE INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
12.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 11±60)
13.REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11±60)
14.REMOVE INJECTOR ASSY (See page 11±60)
HINT:
Since each injector assembly has characteristic fuel injecting behavior, store them in correct order so that
they can be returned to the original locations when re±assembling.
15. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe located over theinspecting valve faces upward.
(b) Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
(c) Measure the clearance at 16 places.
(d) Record the out±of specification valve clearance mea- surements. They will be used later to determine the re-
quired replacement adjusting shim.
Valve clearance (Cold):
Intake0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust0.35 to 0.45 mm (0.014 to 0.018 in.)
16. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.(1) Turn the crankshaft so that the cam lobe located
over the adjusting valve faces upward.
(2) Position the notch of the valve lifter toward the in- take manifold side.

SST (A)
SST (B)
A09616
A09615
Magnetic
Finger
A54826
EXAMPLE (Intake):
Measured valve clearance = 0.45 mm (0.0177 in.)
0.45 mm (0.0177 in.) ± 0.25 mm (0.0098 in.) = 0.20 mm (0.0078 in.)
(Measured ± Specification = Excess clearance)
Used shim measurement = 2.80 mm (0.1102 in.)
0.20 mm (0.0078 in.) + 2.80 mm (0.1102 in.) = 3.00 mm (0.1181 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 3.00 mm (0.1181 in.)
Select No. 21 Shim
14±272
± ENGINE MECHANICALVALVE CLEARANCE (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(3) Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248±55050 (09248±05510, 09248±05520)
HINT:
Apply SST (B) which marked º11º.
(4) Remove the adjusting shim with a small screwdriver
and a magnetic finger.
(b) Determine the replacement adjusting shim size using the
following formula or the matrix attached to the end of this
section.
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
HINT:
T ........... Thickness of removed adjusting shim
A ........... Measured valve clearance
N ........... Thickness of new adjusting shim
Intake: N = T + (A ± 0.25 mm (0.010 in.))
Exhaust: N = T + (A ± 0.40 mm (0.016 in.))
(3) Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).

SST (A)
SST (B)
A09686
A79147
Fulcrum
Length
30 cm
SST
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
14±273
AVENSIS REPAIR MANUAL (RM1018E)
(c)Install a new adjusting shim.
(1)Place a new adjusting shim on the valve lifter.
(2)Using SST (A), press down the valve lifter and re-move SST (B).
SST09248±55050 (09248±05510, 09248±05520)
(d)Recheck the valve clearance. SST09248±55050 (09248±05510, 09248±05520)
17.INSTALL INJECTOR ASSY (See page 11±60)
18.INSTALL NOZZLE LEAKAGE PIPE ASSY (See page 11±60) SST 09992±00242
19.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 11±60) 20. INSTALL INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the 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 side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.

14±274
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(d)Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e)Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
21.INSTALL INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
22.INSTALL INJECTION PIPE SUB±ASSY NO.3 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
23.INSTALL INJECTION PIPE SUB±ASSY NO.4 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
24.INSTALL TIMING BELT NO.2 COVER (See page 11±60)
25. INSTALL AIR TUBE NO.1 Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
26. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
27. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
28.ADD ENGINE COOLANT (See page 16±44)
29.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
30.CHECK FOR FUEL LEAKS (See page 11±60)

A57526
Adjusting Shim Selection Chart (Intake)
New shim thickness
Intake valve clearance (Cold):
0.20 ± 0.30 mm (0.008 ± 0.012 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.21
shim.mm (in.)
Shim
No.Thickness
01Shim
No.Thickness
03
05
07
09
11
13
1519
21
23
25
27 2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
29
31
33 2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299)
Installed shim thickness
mm (in.)
Measured clearance
mm (in.)
17
± ENGINE MECHANICALVALVE CLEARANCE (1CD±FTV)
14±275
AVENSIS REPAIR MANUAL (RM1018E)

A57527
Adjusting Shim Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.35 ± 0.45 mm (0.014 ± 0.018 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.590 mm (0.0232 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.21
shim.
Installed shim thickness
mm (in.)
Measured clearance
mm (in.)
New shim thickness mm (in.)
Shim
No.Thickness
01Shim
No.Thickness
03
05
07
09
11
13
1519
21
23
25
27 2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
29
31
33 2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299)
17
14±276
± ENGINE MECHANICALVALVE CLEARANCE (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

141C1±01
A56434
AB
A56462
A56434
AB
±
ENGINE MECHANICAL DRIVE BELT(1CD±FTV)
14±269
AVENSIS REPAIR MANUAL (RM1018E)
DRIVE BELT(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.REMOVE ENGINE UNDER COVER RH
4.REMOVE V (COOLER CO MPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a)Loosen nut A and bolt B.
(b)Remove the V±ribbed belt.
5.REMOVE GENERATOR V BELT
(a)Turn the V±ribbed belt tensioner assy clockwise slowly, and remove the V±ribbed belt.
6.ADJUS T V (COOLER CO MPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a)Install the V±ribbed belt.
(b)Tighten bolt B and adjust the drive belt tension. (See page 14±266)
(c) Tighten nut A. Torque: 38 N
m (390 kgf
cm, 28 ft
lbf)

140DD±03
A57063
Measure Point for Belt
Deflection and Tension
Alternator
Crankshaft Compressor
P/S P/S
Alternator Crankshaft
A/C equipped
A/C not equipped
A61173
B
A
14±266
±
ENGINE MECHANICAL ENGINE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1CD±FTV)
INSPECTION
1.INSPECT COOLANT (See page 16±37)
2.INSPECT ENGINE OIL (See page 17±20)
3.INSPECT BATTERY (See page 19±26)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY 5. INSPECT DRIVE BELT
(a) Inspect vane pump V belt.(1) Measure the belt deflection
Pressing force: 98 N
m (10 kgf 22 lbf)
New belt
mm (in.)Used belt mm (in.)
A/C equipped9.5 to 11.5
(0.37 to 0.45)12.5 to 15.5
(0.49 to 0.61)
A/C not equipped10 to 12
(0.39 to 0.47)14 to 17
(0.55 to 0.67)
(2) Measure the belt tension
New belt
N (kgf, lbf)Used belt
N (kgf, lbf)
A/C equipped519 to 755
(53 to 77, 117 to 170)196 to 392
(20 to 40, 44 to 88)
A/C not equipped686 to 784
(70 to 80, 154 to 176)294 to 441
(30 to 45, 66 to 99)
NOTICE:

Check the drive belt deflection at the specified point.

When installing a new belt, set its tension value as
specified.

When inspecting the belt which is used over 5 min-
utes, apply the specifications of ºUsed Belt.º

When reinstalling the belt which is used over 5 min-
utes, adjust its deflection and tension to the medium
value in each specification of ºUsed Belt.º

V±ribbed belt tension and deflection should be
checked after 2 revolutions of engine cranking.

When using a belt tension gauge, confirm the accura-
cy by using a master gauge first.
(b) Inspect generator V belt. (1) Check that the tension indicator is within range A onthe auto tensioner scale.
If the tension is not within the A range, replace the belt with a
new one.
HINT:
When replacing the drive belt with a new one, the belt tension
should be within the B range.