TOYOTA AVENSIS 2005 Service Repair Manual

A09663
:Seal Packing
A87959
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −173
AVENSIS Supplement (RM1045E)
93. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as illustrated. Seal packing: Part No. 08826 −00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
94. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
95. INSTALL NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
96. INSTALL VACUUM PUMP ASSY (See page 14 −108)
97. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold at room temperature.
(a) Remove the vinyl or plastic bag from the injector and the vinyl tape from the common rail.
(b) Install the 2 lower injection pipe clamps to the intake man- ifold.
(c) Temporarily install the injection pipe.
(d) Using SST, tighten the nut of the injection pipe on the common rail side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.

14−174−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
(e) Using SST, tighten the nut of the injection pipe on the in- jector side.
SST 09023 −12700
Torque:
For used pipe:
36 N
m (372 kgf
cm, 27 ft
lbf) with SST
40 N
m (408 kgf
cm, 30 ft
lbf) without SST
For new pipe:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
(f) Install the 2 upper injection pipe clamps.
98. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
99. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
100. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
101. INSTALL FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
102. INSTALL FUEL INLET PIPE SUB −ASSY
NOTICE:
SIn case of replacing the cylinder head gasket, the fuel
inlet pipe must be replaced, too.
SWhen assembling the pipe, perform the operation
with the engine cold at room temperature.
(a) Temporarily install a new fuel inlet pipe.

A87960
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −175
AVENSIS Supplement (RM1045E)
(b) Using SST, tighten the nut of the fuel inlet pipe on the
common rail side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe on the pump side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
103. INSTALL TURBOCHARGER SUB −ASSY (See page 13 −12)
104. INSTALL TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
105. INSTALL TURBOCHARGER STAY (See page 13 −12)
106. INSTALL MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
107. INSTALL MANIFOLD STAY NO.2 (See page 13 −12)
108. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
109. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
110. INSTALL EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
111. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
112. INSTALL EGR PIPE INSULATOR (See page 13 −12)
113. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
114. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
115. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
116. INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13 −12)
117. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
118. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
119. INSTALL HEATER BRACKET (W/ COLD AREA) (See page 13 −12)
120. INSTALL HEATER PUMP ASSY (W/ COLD AREA) (See page 13 −12)
121. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)

14−176−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
122. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
123. INSTALL TIMING BELT (See page 14 −138)
124. CHECK VALVE TIMING (See page 14 −138)
125. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
126. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
127. INSTALL TIMING BELT GUIDE (See page 14 −138)
128. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
129. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
130. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
131. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
132. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
133. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
134. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
135. INSTALL INJECTOR DRIVER (See page 14 −108 )
136. INSTALL AIR TUBE NO.1 (See page 14 −108)
137. INSTALL AIR TUBE NO.2 (See page 14 −108)
138. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
139. INSTALL BATTERY (See page 14 −108)
140. INSTALL AIR CLEANER ASSY (See page 14 −108)
141. INSTALL VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
142. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
143. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
144. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
145. ADD ENGINE COOLANT (See page 16 −19)
146. CHECK FOR FUEL LEAKS (See page 11 −46)
147. CHECK FOR ENGINE OIL LEAKS
148. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
149. CHECK FOR EXHAUST GAS LEAKS

141NK−01
SSTA61187
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −151
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE RADIATOR SUPPORT OPENING COVER
6. REMOVE ENGINE ROOM COVER SIDE
7. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
8. REMOVE AIR CLEANER ASSY (See page 14 −108)
9. REMOVE BATTERY
10. REMOVE VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
11. REMOVE AIR TUBE NO.1 (See page 14 −108)
12. REMOVE INJECTOR DRIVER (See page 14 −108)
13. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
14. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
15. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
16. DISCONNECT ENGINE WIRE (See page 14 −138)
17. DISCONNECT VACUUM HOSE (See page 14 −108)
18. REMOVE ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
19. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
20. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
21. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
22. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
23. REMOVE TIMING BELT GUIDE
24. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
25. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
26. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
27. REMOVE TIMING BELT (See page 14 −138)
28. REMOVE CAMSHAFT POSITION SENSOR (See page 14 −108)
29. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt. SST 09960 −10010 (09962 −01000, 09963 −01000)
(b) Remove the timing pulley.
HINT:
Using a plastic −faced hammer, tap out the pulley.
(c) Remove the set key.
30. REMOVE FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700

A93406
SST
A09656
A85924
14−152
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
31. REMOVE INJECTION PIPE SUB −ASSY NO.1
(a) Remove the 2 upper injection pipe clamps from 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, in order to prevent dust or
foreign objects from being introduced, cover the common
rail with vinyl tape and protect the injector inlet with a vinyl
or plastic bag.
32. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
33. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
34. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
35. REMOVE VACUUM PUMP ASSY (See page 14 −108)
36. REMOVE NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
37. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
38. REMOVE CYLINDER HEAD COVER SUB −ASSY
(a) Remove the 10 bolts, cylinder head cover and gasket.

A85934
A09668
A09650
1
3
2 4
5
9 6
87
14
10
11
15
13
12
A09619
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −153
AVENSIS Supplement (RM1045E)
39. REMOVE NOZZLE LEAKAGE PIPE ASSY
(a) Remove the 4 hollow screws and bolt.
(b) Remove the nozzle leakage pipe and 4 gaskets from the
cylinder head and injector.
40. REMOVE INJECTOR ASSY (See page 11 −46)
HINT:
Since each injector assembly has characteristic fuel injecting behavior, keep them in the correct order so
that they can be returned to the original locations when reassembling.
41. REMOVE CAMSHAFT OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by pryingbetween the oil seal retainer and camshaft bearing cap.
42. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 14 bearing cap bolts uniformly in the sequence shown in the illustra-
tion.
(b) Remove the 5 bearing caps and camshaft sub −assembly.
43. REMOVE NO.2 CAMSHAFT
(a) Remove the camshaft sub −assembly and camshaft carrier.
44. REMOVE CAMSHAFT OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal.

SST
A09620
A85427
TDC Mark
Dot Mark90_
A09624
A09625
14−154
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
45. 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
(b) Apply multipurpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign object.
46. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set
the dot mark of the crankshaft timing gear at the position
of 90_BTDC.
NOTICE:
If the timing belt is disengaged, the crankshaft timing gear
placed at wrong angle can cause contact of the piston head
with the valve head.
47. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following procedures
should be carried out.
(a) Place the camshaft carrier on the cylinder head.
(b) Install the camshaft.
(c) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(d) Place the intake camshaft on the camshaft carrier so that
the No. 3 and No. 4 of the cylinder cam lobes face down-
ward as shown in the illustration.

A09626
Alignment Mark
A09601
Seal Packing
A09627
A09650
12
3
5
49
6
8
7
13
10
11
15
14 12
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −155
AVENSIS Supplement (RM1045E)
48. INSTALL NO.2 CAMSHAFT
(a) Install the No. 2 camshaft.
(b) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(c) Engage the exhaust camshaft gear and intake camshaft gear by aligning the alignment marks on each gear.
(d) Roll down the exhaust camshaft onto the bearing journals while engaging the gears with each other.
(e) 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
(3) Place the 5 bearing caps in their proper locations.
(4) Using several steps, install and tighten the 15 bear- ing cap bolts uniformly in the sequence shown in the
illustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
49. INSPECT VALVE CLEARANCE (See page 14 −90)
50. ADJUST VALVE CLEARANCE (See page 14 −90)
51. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surfaces of the oil seal re-
tainer and cylinder block.
(1) Thoroughly clean all components to remove all the loose material.
(2) Using non −residue solvent, clean both the sealing
surfaces.

A85428
Seal Width
2to4mm
(0.08 to 0.16 in.)Seal Packing
A62592
SST
A85760
90_
14
−156
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826 −00080 or equivalent
(1) Install a nozzle of which opening is cut to 2 to 4 mm
(0.08 to 0.16 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing.
(3) Immediately remove the nozzle from the tube, then reinstall the cap.
(c) Install the oil seal retainer with the 4 bolts. Tighten the 4 bolts uniformly in several steps.
Torque: 9.8 N
m (100 kgf
cm, 7.2 ft
lbf)
52. INSTALL CAMSHAFT TIMING PULLEY
(a) Install the pulley set key to the groove of the camshaft.
(b) Align the keyway of the timing pulley with the key located on the camshaft, then slide the pulley into place.
(c) Using SST, install the pulley bolt. SST 09960 −10010 (09962 −01000, 09963 −01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
53. INSTALL CAMSHAFT POSITION SENSOR (See page 14 −108)
54. INSTALL INJECTOR ASSY 55. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Remove the bolt which is tightened at the center of thecamshaft bearing cap No. 4.
(b) Install the nozzle leakage pipe and 4 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint of the gasket
comes within the ranges shown in the illustration.
(c) Apply a light coat of engine oil to the 4 hollow screws and bolt.
(d) Tighten the 4 hollow screws and bolt by hand.
(e) Tighten the 4 hollow screws and bolt. Torque:
16 N
m (163 kgf
cm, 12 ft
lbf) for hollow screw
20 N
m (204 kgf
cm, 15 ft
lbf) for flange bolt
NOTICE:
In any case, when the torque exceeds the upper limit, re-
place the leakage pipe hollow screw and gaskets with new
ones.
(f) Check that there are no leaks from the nozzle leakage pipe connection.