TOYOTA AVENSIS 2005 Service Repair Manual

1509X±01
A80114
(a)(a)(b)(b)
(b) 15±10
± EXHAUSTEXHAUST PIPE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and the floor panel brace front.
2. REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 bolts and 2 compression springs.
(b) Disconnect the 3 exhaust pipe supports and remove the
exhaust pipe tail.
(c) Remove the gasket from the exhaust pipe tail.

A78272
(a)(b)
(b)
(a)
A77857
A76194
Wooden
Block
Gasket
± EXHAUSTEXHAUST PIPE ASSY (1CD±FTV)
15±11
AVENSIS REPAIR MANUAL (RM1018E)
3. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs.
(b) Disconnect the 2 exhaust pipe supports and remove the
exhaust pipe front.
(c) Remove the gasket from the manifold converter.
4. INSTALL EXHAUST PIPE ASSY FRONT
(a) Using vernier calipers, measure the free length of the
compression spring.
Minimum Length: 41.5 mm (1.634 in.)
If the minimum length is less than minimum, replace the com-
pression spring.
(b) Using a plastic hammer and a wooden block, tap in a new
gasket until its surface is flush with the exhaust manifold.
NOTICE:

Tap in the gasket in the correct direction.

Do not reuse the removed gasket.

Be sure not to push in the gasket when installing the
exhaust pipe.
(c) Connect the 2 exhaust pipe supports and install the ex-
haust pipe front with the 2 compression springs and 2
bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)

A77857
A78440
New Gasket
15±12
± EXHAUSTEXHAUST PIPE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL EXHAUST PIPE ASSY TAIL
(a) Using vernier calipers, measure the free length of the
compression spring.
Minimum Length: 38.5 mm (1.515 in.)
If the minimum length is less than minimum, replace the com-
pression spring.
(b) Install a new gasket to the pipe front converter as shown
in the illustration.
(c) Connect the 3 exhaust pipe supports and install the ex-
haust pipe tail with the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
6. CHECK FOR EXHAUST GAS LEAKS
7. INSTALL FLOOR PANEL BRACE FRONT
Torque: 30 N
m (302 kgf
cm, 22 ft
lbf)

1509W±01
A79443
30 (302, 22)43 (440, 32)
Gasket
Gasket
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
43 (440, 32)
Compression Spring
Exhaust Pipe Assy Tail
± EXHAUSTEXHAUST PIPE ASSY (1CD±FTV)
15±9
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST PIPE ASSY (1CD±FTV)
COMPONENTS

1509V±01
A77867
(a)
(a)
(b)
(b)
A77868
±
EXHAUST EXHAUST PIPE ASSY(1AZ±FE/1AZ±FSE)
15±7
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
2.REMOVE EXHAUST PIPE ASSY TAIL (See page 15±2)
3. REMOVE EXHAUST PIPE ASSY CENTER
(a) Remove the 2 bolts.
(b) Remove the exhaust pipe center and the gasket from the2 exhaust pipe supports.
4. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs, and then remove the exhaust pipe front.
(b) Remove the gasket from the exhaust manifold.

A77857
A78440
New Gasket
15±8
±
EXHAUST EXHAUST PIPE ASSY(1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
5.INSTALL EXHAUST PIPE ASSY FRONT
(a)Compression spring inspection (1)Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 41.5 mm (1.634 in.)
If the free length is less than minimum, replace the compression
spring.
(b)Install a new gasket to the exhaust manifold as shown in the illustration.
(c)Install the exhaust pipe front with the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
6.INSTALL EXHAUST PIPE ASSY CENTER
(a)Install a new gasket and the exhaust pipe center to the 2 exhaust pipe s\
upports.
(b)Tighten the 2 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
7.INSTALL EXHAUST PIPE ASSY TAIL (See page 15±2)
8. CHECK FOR EXHAUST GAS LEAKS
9.INSTALL FLOOR PANEL BRACE FRONT (See page 15±2)

1509U±01
A77864
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
Exhaust Pipe GasketExhaust Pipe Assy Front
Compression SpringExhaust Pipe Assy Center
Floor Panel Brace Front

Exhaust Pipe Gasket
43 (440, 32)
43 (440, 32)

Exhaust Pipe Gasket
30 (302, 22)
43 (440, 32)Compression Spring
Exhaust Pipe Assy Tail
Exhaust Pipe Assy Center
1AZ±FE (Leaded Gasoline)
1AZ±FSE: 15±6
± EXHAUSTEXHAUST PIPE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST PIPE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS

1509T±01
A78493
A78494
(c)
(d)
A78495
A78496
15±2
±
EXHAUST EXHAUST PIPE ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR) (See page 76±32) 2. REMOVE HEATED OXYGEN SENSOR (W/O HIDSENSOR)
(a) Using a clip remover, remove the 2 clips.
(b) Open the floor carpet.
(c) Disconnect the heated oxygen sensor connector.
(d) Remove the grommet.
(e) Remove the heated oxygen sensor.
3. REMOVE HEATED OXYGEN SENSOR (W/ HID SENSOR)
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the heated oxygen sensor.

A77865
A77866
(a)(a)
(b)(b)
(b)
± EXHAUSTEXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
15±3
AVENSIS REPAIR MANUAL (RM1018E)
4. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts, and then remove the floor panel
brace front.
5. REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 bolts and 2 compression springs.
(b) Remove the exhaust pipe tail from the 3 exhaust pipe
supports.
(c) Remove the gasket from the exhaust pipe front.

A78492
(a)(a)
(b)
(b)
A77857
A78440
New Gasket
15±4
± EXHAUSTEXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs.
(b) Remove the exhaust pipe front from the 2 exhaust pipe
supports.
(c) Remove the gasket from the exhaust manifold.
7. INSTALL EXHAUST PIPE ASSY FRONT
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 41.5 mm (1.634 in.)
If the free length is less than minimum, replace the compression
spring.
(b) Install a new gasket to the exhaust manifold as shown in
the illustration.
(c) Install the exhaust pipe front to the 2 exhaust pipe sup-
ports.
(d) Tighten the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)