TOYOTA AVENSIS 2005 Service Repair Manual

A09449
SST
A09451
A09555
Measuring Point
16 mm (0.63 in.)
P12477
Seal Packing
A09522
Upper
Front
60

± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
27. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
28. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
29. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard outside diameter:
10.75 ± 11.00 mm (0.4232 ± 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
30. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB±ASSY
(a) Apply seal packing 2 or 3 threads.
Seal packing: Part No. 08826±00100 or equivalent
(b) Install the drain union.
Torque: 29 N
m (291 kgf
cm, 21 ft
lbf)
HINT:
After applying the specified torque, if the drain pipe of the drain
union is not at the position shown in the illustration, rotate the
drain union further clockwise and make the drain pipe face
downward.

A09519
Hexagon
Wrench
(8mm)
A09476
Seal Width
2 ± 3 mm
A56701
Seal Width
2 ± 4 mm
Seal
PackingNew Gasket
14±10
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
31. INSTALL OIL CHECK VALVE SUB±ASSY
(a) Using hexagon wrench (8mm), install a new gasket and
the pressure valve.
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)
32. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 6 bolts. Uniformly tighten
the bolt in several passes.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
33. INSTALL OIL PUMP ASSY
(a) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Avoid applying an excessive amount to the surface.

Install a nozzle that has been cut to a 2 ± 4 mm (0.08
± 0.16 in.) opening

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install a new gasket to the oil pump.

B08024
A57099
A56702
A56703
Seal Width
4 ± 7 mm AB
B A
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±11
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Pour in 0.5 cm3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(d) Apply engine oil to the cylinder block side where it con-
tacts with the oil pump driven rotor.
(e) Install the oil pump with the 9 bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
(f) Measure the oil pump rotating torque
(1) Check that the pump rotates smoothly without ab-
normal noise.
(2) Using a torque wrench, check the pump rotating
torque.
Rotating torque: 3.0 N
m (30 kgf
cm, 26 in.
lbf) or less
34. INSTALL OIL PAN SUB±ASSY
(a) Apply seal packing to the No. 1 oil pan as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 4 ± 7 mm (0.16
± 0.28 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 19 bolts and 3 nuts.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for 10 mm head bolt and
nut
21 N
m (210 kgf
cm, 15 ft
lbf) for 12 mm head bolt
42 N
m (429 kgf
cm, 31 ft
lbf) for 14 mm head bolt

A56696
A56704
Seal Width
4 ± 7 mmBA
A
B
A56706
Front
Measuring Point
A57100
Measuring Tip
Protrusion 14±12
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
35. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (210 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
36. INSTALL OIL PAN SUB±ASSY NO.2
(a) Apply a seal packing to the oil pan as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 4 ± 7 mm (0.16
± 0.28 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 16 bolts and 3 nuts. Uniformly tight-
en the bolts and nuts in several passes.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
37. INSTALL CYLINDER HEAD SUB±ASSY
(a) Check piston protrusions for each cylinder.
(1) Find where the piston head protrudes most by slow-
ly turning the crankshaft clockwise and counter-
clockwise.
(2) Measure each cylinder at 2 places as shown in the
illustration, marking a total of 8 measurements.
(3) For the piston protrusion valve of each cylinder, use
the average of the 2 measurements of each cylin-
der.
Protrusion: 0.165 ± 0.425 mm (0.0065 ± 0.0168 in.)

A
B
C
D
E
A09570
Front
A56055
A09564
1
18 2 3
4 56
78 9 (A)
10 11
12 1314
1516 17(B)
(A) (A) (A) (A)(A) (A)
(A)
(B) (B) (B) (B)
(B) (B) (B) (B) (B)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±13
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Select a new cylinder head gasket.
HINT:
There are 5 sizes of new cylinder head gaskets, marked ºAº,
ºBº, ºCº, ºDº, or ºEº according.
New installed cylinder head gasket thickness:
A0.85 ± 0.95 mm (0.0335 ± 0.0374 in.)
B0.90 ± 1.00 mm (0.0354 ± 0.0394 in.)
C0.95 ± 1.05 mm (0.0374 ± 0.0413 in.)
D1.00 ± 1.10 mm (0.0394 ± 0.0433 in.)
E1.05 ± 1.15 mm (0.0413 ± 0.0453 in.)
(1) Select the largest piston protrusion value from the
measurements made, then select a new appropri-
ate gasket according to the table below.
Piston protrusion mm (in.)Gasket size
0.165 ± 0.220 (0.0065 ± 0.0087)Use A
0.220 ± 0.270 (0.0087 ± 0.0106)Use B
0.270 ± 0.320 (0.0106 ± 0.0126)Use C
0.320 ± 0.370 (0.0126 ± 0.0146)Use D
0.370 ± 0.425 (0.0146 ± 0.0167)Use E
(c) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(d) Place the cylinder head in position on the cylinder head
gasket.
(e) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 4 progressive steps
(steps (3), (5), (6) and (7)).
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts and plate
washers.
(2) Install the plate washer to the cylinder head bolt.
(3) Install and uniformly tighten the 18 cylinder head
bolts and plate washers in several passes in the se-
quence shown.
Torque: 45 N
m (460 kgf
cm, 33 ft
lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
(A)160 mm (6.30 in.)
(B)104 mm (4.09 in.)
If any of the cylinder head bolt does not meet the torque specifi-
cation, replace the cylinder head bolts.

90
90

90
90
90

90

A09565
Front
Painted
Mark
A09624
A09625
A09626
Alignment Mark
A09601
Seal Packing
14±14
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(4) Mark the front of the cylinder head bolt with paint.
(5) Retighten the cylinder head bolts additional 90
in
the numerical order shown.
(6) Retighten the cylinder head bolts additional 90
in
the numerical order shown.
(7) Retighten the cylinder head bolts additional 90
in
the numerical order shown.
(8) Check that the painted mark is at the intake man-
ifold side now.
38. INSTALL CAMSHAFT SUB±ASSY, NO.1
(a) Place the camshaft carrier in position on the cylinder
head.
(b) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(c) Place the intake camshaft on top of the camshaft carrier
as shown in the illustration so that the No. 3 and No. 4 of
cylinder cam lobes face downward.
39. INSTALL CAMSHAFT SUB±ASSY, NO.2
(a) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(b) Engage the exhaust camshaft gear to the intake cam-
shaft gear by matching the alignment marks on each
gear.
(c) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.
(d) Install the camshaft bearing caps.
(1) Remove any old packing (FIPG) material from the
No.5 camshaft bearing cap.
(2) Apply seal packing to the No. 5 camshaft bearing
cap as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent

A09627
A09650
6 10
1 2
3 7 89 511
412
1314
15
A09687
Upward
Cam Lobe
Clearance
A09617
Upward
Notch
Cam Lobe
Intake
Manifold
Side
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±15
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(3) Place the 5 bearing caps in their proper locations.
(4) Install and uniformly tighten the 15 bearing cap
bolts in several passes and in the sequence shown.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
40. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe of the camshaft
on the inspecting valve points 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 ± 0.30 mm (0.008 ± 0.012 in.)
Exhaust0.35 ± 0.45 mm (0.014 ± 0.018 in.)
41. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft so that the cam lobe of the cam-
shaft on the adjusting valve points upward.
(2) Position the notch of the valve lifter facing the intake
manifold side.

A62959
SST (B)SST (A)
A09615
Magnetic
Finger
A54826
SST (A)
SST (B)
A09686
14±16
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(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) on the side marked with º11º.
(4) Remove the adjusting shim with a small screwdriver
and magnetic finger.
(b) Determine the replacement adjusting shim size by follow-
ing the formula:
(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.).
(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).
SST 09248±55050 (09248±05510, 09248±05520)
(d) Recheck the valve clearance.

A57098
A09600
Seal Width
2 ± 4 mm
Seal Packing
SST
A57101
Inward
Angle Sensor
A57102
Turn
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±17
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
42. INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 7bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
43. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 2 ± 4 mm (0.08
± 0.16 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 4 bolts. Uniformly tighten
the 4 bolts in several passes.
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
44. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the timing
pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the angle sensor inward.
SST 09223±46011
45. INSTALL TIMING BELT IDLER SUB±ASSY NO.2
(a) Install the idler pulley with the bolt.
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
(b) Check that the idler pulley moves smoothly.

A57103
Plate Washer
Hexagon
Wrench
(8mm)
A62592
SST
B08252
B09792
Spring
Convex
14±18
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
46. INSTALL TIMING BELT IDLER SUB±ASSY NO.1
(a) Using an hexagon wrench (8mm), install the plate washer
and idler pulley with the idler pulley shaft.
Torque: 35 N
m (350 kgf
cm, 25 ft
lbf)
(b) Check that the pulley bracket moves smoothly.
47. INSTALL CAMSHAFT TIMING PULLEY
(a) Install the pulley set key to the key groove of the cam-
shaft.
(b) Align the pulley set key with the key groove of the timing
pulley, and slide on the timing pulley.
(c) Using SST, install the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
48. INSTALL INJECTOR ASSY
(a) Install 4 new nozzle seats to the cylinder head.
(b) Set the spring to each injector.
NOTICE:
Be sure to make the opening direction of the spring and the
direction of the injector positioning convex meet.
(c) Install a new back±up ring and O±ring to each injector.
(d) Apply a light coat of oil onto O±ring for each injector.