TOYOTA AVENSIS 2005 Service Repair Manual

A56683
Intake Side: Rear Side:
Exhaust Side:A (M8)
B (M10)C (M8) 36 mm
64 mm34 mm
A62596
14±36
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
30. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
Bolt A 8.8N
m (90 kgf
cm, 78 in.
lbf)
Bolt B 12N
m (120 kgf
cm, 9 ft
lbf)
Bolt C 8.8N
m (90 kgf
cm, 78 in.
lbf)
31. INSTALL W/HEAD TAPER SCREW PLUG NO.1
(a) Apply adhesive to the plugs end.
Adhesive: Part No. 08833 ± 00070, THREE BOND 1324 or equivalent
(b) Using a hexagon wrench (6 mm), install the 3 plugs.
Torque:25N
m (255 kgf
cm, 18 ft
lbf)
SST 99999±70037
32. INSTALL SEMICIRCULAR PLUG
(a) Apply seal packing to the semi±circular plug grooves.
Seal packing: Part No. 08826 ± 00080 or equivalent
(b) Install the semi±circular plug to the cylinder head.
33. INSTALL VALVE SPRING SEAT PLATE WASHER

A56032
A56684
A62597
SST
A62598
A62599
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±37
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
34. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil on the valve stem.
(b) Install a new oil seal on the valve guide bushing.
35. INSTALL INTAKE VALVE
(a) Install the valve, valve spring, and spring retainer.
(b) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(c) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
36. INSTALL EXHAUST VALVE
(a) Install the valve, valve spring, and spring retainer.

A56672
SST
A56685
14±38
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(c) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not to damage the valve stem tip.

140L5±01
A62604
Non±reusable part
Valve Stem Oil
O Seal or RingValve Adusting Shim
Valve Lifter
Valve Spring Retainer
Valve Spring Retainer Lock
Inner Compression Spring
Valve Spring Seat
Plate Washer

Valve Guide Bushing
Exhaust Valve
Semicircular Plug

Valve Stem Oil O Seal or Ring Valve Adusting Shim
Valve Lifter
Valve Spring RetainerValve Spring Retainer Lock
Inner Compression Spring
Valve Spring Seat Plate Washer

Valve Guide Bushing
Intake Valve
14±22
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
CYLINDER HEAD ASSY (1CD±FTV)
COMPONENTS

140L4±01
A56691
A62591
A56692
A56693
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE OIL FILLER CAP SUB±ASSY
2. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
3. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, cylinder head cover and gasket.
4. REMOVE NOZZLE LEAKAGE PIPE ASSY
(a) Using a hexagon wrench (6mm), remove 4 hollow screws.
(b) Remove the union bolt, nozzle leakage pipe and 5 gas-
kets from the cylinder head and injector.
5. REMOVE NOZZLE HOLDER CLAMP
(a) Remove the 4 bolts, 4 washers and 4 nozzle holder
clamps.

A56694
A62592
SST
A57095
Hexagon
Wrench
(8mm)
SST
A57096
14±4
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
6. REMOVE INJECTOR ASSY
(a) Remove the 4 injectors from the cylinder head.
HINT:
Arrange the injectors in correct order.
7. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
8. REMOVE TIMING BELT IDLER SUB±ASSY NO.1
(a) Using hexagon wrench (8mm), remove the idler pulley
shaft, idler pulley and plate washer.
9. REMOVE TIMING BELT IDLER SUB±ASSY NO.2
10. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the pulley cannot be removed by hand, use SST to re-
move the timing pulley.
SST 09950±50013 (09951±05010, 09952±05010,
09953±05010, 09953±05020, 09954±05021)

A57097
A57098
A09650
1 3
24
576
8
9
10 11
12
13 14
15
A09624
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
11. REMOVE CAMSHAFT OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and camshaft
bearing cap.
12. REMOVE WATER PUMP ASSY
(a) Remove the 7 bolts, water pump and gasket.
13. REMOVE CAMSHAFT SUB±ASSY, NO.2
(a) Uniformly loosen and remove the 15 bearing cap bolts in
several passes in the sequence shown.
(b) Remove the 5 bearing caps.
(c) Remove the camshaft No. 2.
14. REMOVE CAMSHAFT SUB±ASSY, NO.1
(a) Remove the camshaft from the cylinder head.
(b) Remove the camshaft carrier from the cylinder head.

A09566
2
1 3
45
67 8
9
14 15 16
17 1211 1013
18
A09563
Pry
A56695
SSTSST
B08601
A56696
14±6
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
15. REMOVE CYLINDER HEAD SUB±ASSY
(a) Uniformly loosen the 18 cylinder head bolts in several
passes in the sequence shown. Remove the 18 cylinder
head bolts and plate washers.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
16. REMOVE OIL PAN SUB±ASSY NO.2
(a) Remove the 16 bolts and 3 nuts.
(b) Insert the blade of SST between the No. 1 and No. 2 oil
pans, and cut off the applied seal and remove the No. 2
oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surfaces of the No. 1
and No. 2 oil pans.
17. REMOVE OIL STRAINER SUB±ASSY
(a) Remove the 2 bolts, 2 nuts, oil strainer and gasket.

A56697
A56698
A56699
A09518
A09519
Hexagon
Wrench
(8mm)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
18. REMOVE OIL PAN SUB±ASSY
(a) Remove the 19 bolts and 3 nuts.
(b) Using a screwdriver, remove the oil pan by prying the por-
tions between the cylinder block and No. 1 oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and No. 1 oil pan.
19. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying a screwdriver between the
oil pump and main bearing cap.
(c) Remove the gasket.
20. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
21. REMOVE OIL CHECK VALVE SUB±ASSY
(a) Using hexagon wrench (8mm), remove the pressure
valve and gasket.

A09619
SST
A09620
B07976
A56700
SST
14±8
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
22. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
23. REMOVE CAMSHAFT OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
24. INSTALL CAMSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the camshaft oil seal retainer edge.
SST 09223±46011
25. REMOVE CRANKSHAFT SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
26. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316±60011 (09316±00011, 09316±00021)