TOYOTA AVENSIS 2005 Service Repair Manual

A84302
A84303
A09605Turn
A61185
14−140
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
17. REMOVE TIMING BELT NO.1 COVER
(a) Remove the 5 bolts and 5 seal washers, then remove the
timing belt cover.
18. REMOVE TIMING BELT GUIDE
19. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 6 bolts and engine mounting bracket.
20. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, align the dot mark of the
crankshaft timing gear with the TDC mark of the oil pump
by turning the crankshaft.
(b) Check that the timing mark of the camshaft timing pulley
is aligned with the joint of the cylinder head and cylinder
head cover.

A87962
A09609
A09680
SST
A09611
A09606
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
14−141
AVENSIS Supplement (RM1045E)
21. REMOVE TIMING CHAIN COVER PLATE
(a) Remove the bolt and timing chain cover plate.
22. REMOVE TIMING BELT
HINT:
If reusing the timing belt, draw an arrow on the belt which indi-
cates the engine revolution direction and put match marks on
the pulleys and belt before removing. This operation will be very
helpful when reinstalling the timing belt.
(a) Alternately loosen the 2 bolts to remove the timing belt
tensioner.
(b) Remove the timing belt.
23. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, set the pulleys of the camshaft and injection
pump so that each timing mark of the pulleys is aligned
with its timing mark on the cylinder head assembly and
water pump assembly.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Using the crankshaft pulley bolt, align the dot mark of the
crankshaft timing gear with the TDC mark of the oil pump
by turning the crankshaft.
NOTICE:
Be very careful in turning the camshaft and crankshaft.
Since the valve head and piston head are sensitive, contact
of the piston head with the valve heads may damage them.

A09612
1st
2nd 5th
3rd
4th 6th 7th
A09609
Timing Mark
Timing
Mark
Timing Mark
A09589
Hexagon
Wrench
(1.27 mm)
(A)
A09623
14−142
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
24. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Remove any oil or water on each pulley, then keep them
clean.
NOTICE:
Do not use any cleaning agent.
(b) Install the timing belt in the following order:
1. Camshaft timing pulley
2. Supply pump drive pulley
3. Water pump pulley
4. Crankshaft timing pulley
5. No. 2 idler pulley
6. Oil pump pulley
7. No. 1 idler pulley
(c) Check that the timing marks are aligned as shown in the
illustration.
(d) Install the timing belt tensioner.
(1) Using a press, slowly press in the push rod with
pressure of 981 to 9,807 N (100 to 1,000 kgf, 200
to 2,205 lbf).
(2) Align the holes of the push rod and housing, then
insert hexagon wrench (1.27 mm) through the holes
to keep the setting position of the push rod.
(3) Release the press.
(4) Temporarily install the tensioner with bolt (A).
(5) Turn the tensioner clockwise, then temporarily
install the other bolt.

A61179
Hexagon
Wrench
(1.27 mm)
A09605
Dot Mark
TDC Mark
Turn
A09679
A84303
A
AAA
AB
B
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
14−143
AVENSIS Supplement (RM1045E)
(6) Alternately tighten the 2 bolts.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
(7) Remove the hexagon wrench from the tensioner.
25. CHECK VALVE TIMING
(a) Slowly turn the crankshaft by 2 complete revolutions
(720_) from the TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.
HINT:
Align the TDC mark with the dot mark.
(b) Check that each timing mark of the pulleys is aligned with
the timing marks of the engine assembly as shown in the
illustration.
If the timing marks are not aligned, remove the timing belt, then
reinstall it.
(c) Remove the crankshaft pulley bolt.
26. INSTALL TIMING CHAIN COVER PLATE
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
27. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
Torque:
37 N·m (375 kgf·cm, 27 ft·lbf) for bolt A
64 N·m (650 kgf·cm, 47 ft·lbf) for bolt B

A09596
A09603
Seal Packing
Gasket
Groove 14−144
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
28. INSTALL TIMING BELT GUIDE
(a) Install the belt guide with the cap side facing outward.
29. INSTALL TIMING BELT NO.1 COVER
(a) Check the timing belt cover gasket for cracks or deteriora-
tions, etc.
If the gasket has cracked or deteriorated, replace it by the fol-
lowing steps:
(1) Using a screwdriver and gasket scraper, remove all
the old gaskets.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Remove the backing paper from a new gasket, then
affix the gasket to the timing belt cover as shown in
the illustration.
NOTICE:
SAffix the gasket at the center of the groove.
SAt the corners, try to keep the gasket thickness uni-
form.
(4) After installing the gasket, press it down so that the
adhesive firmly sticks to the timing belt cover.
(5) If there is a gap between the ends of the gasket, use
seal packing to close the gap.
Seal packing: Part No. 08826−00080 or equivalent
(b) Install the No. 1 timing belt cover and gasket with the 5
bolts and 5 seal washers.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
(c) After installing the belt cover, check that there is no peel-
ings of the gasket.
30. INSTALL TIMING BELT NO.2 COVER
(a) Check the timing belt cover gasket for cracks or deteriora-
tions, etc.
If the gasket has cracked or deteriorated, replace it by the fol-
lowing steps:
(1) Using a screwdriver and gasket scraper, remove all
the old gasket.
(2) Thoroughly clean all components to remove all the
loose material.

A09602
Seal
Packing
Gasket
Groove
A61186
SST
−
ENGINE MECHANICAL TIMING BELT (1CD−FTV)(From September, 2003)
14 −145
AVENSIS Supplement (RM1045E)
(3) Remove the backing paper from a new gasket, then
affix the gasket to the timing belt cover as shown in
the illustration.
NOTICE:
S Affix the gasket at the center of the groove.
S At the corners, try to keep the gasket thickness uni-
form.
(4) After installing the gasket, press it down so that the
adhesive firmly sticks to the timing belt cover.
(5) If there is a gap between the ends of the gasket, use
seal packing to close the gap.
Seal packing: Part No. 08826 −00080 or equivalent
(b) Install the No. 2 timing belt cover and gasket with the 7
bolts and 7 seal washers.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
31. INSTALL IDLER PULLEY SUB −ASSY
Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
32. INSTALL CRANKSHAFT PULLEY
(a) Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.
(b) Using SST, install the pulley bolt.
SST 09213 −54015 (09213 −70020), 09330 −00021
Torque: 180 N·m (1,835 kgf·cm, 133 ft·lbf)
HINT:
When using the bolt (91651 −60855), a plate washer (5 mm
(0.20 in.)) must be inserted between the pulley bolt and SST.
33. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
34. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
35. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
36. INSTALL INJECTOR DRIVER (See page 14 −108)
37. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
38. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

141NH−01
A85614
Clip
ClipRetainer
8.0 (82, 71 in.
lbf)
Engine Cover Sub−assy No. 1
Clip
Engine Under Cover RH
Clip
w/ A/C:
V (Cooler
Compressor to
Crankshaft
Pulley) Belt No. 1
Engine Mounting Insulator Sub−assy RH
x3
5.5 (56, 49 in.·lbf)
Injector Driver
39 (398, 29)
72 (734, 53)
52 (530, 38)
Power Steering
Idle Pulley
Bracket
52 (530, 38)
52 (530, 38)
Radiator Support Opening Cover
: Specified torqueN·m (kgf·cm, ft·lbf)Engine Wire Vacuum Hose
Engine Under Cover Sub−assy No. 1 14−136
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
TIMING BELT (1CD−FTV)(From September, 2003)
COMPONENTS

A85610
: Specified torqueN·m (kgf·cm, ft·lbf)
* Replace only if damagedTiming Belt No. 2 Cover
Seal Washer
x7
Transverse Engine
Engine Mounting Bracket
Timing Belt No. 1 Cover
Generator
V Belt
Idler Pulley
Crankshaft Pulley
x5
Seal Washer
Timing Belt Guide * Gasket
* Gasket
Timing Belt
Tensioner
Timing Chain Cover Plate
Timing Belt
Glow Plug
No. 1 Connector
Glow Plug Assy
21 (214, 15)
64 (650, 47)
7.4 (76, 66 in.·lbf)
9.0 (92, 80 in.·lbf)
2.2 (22, 19 in.·lbf)
7.4 (76, 66 in.·lbf)
180 (1,837, 133)40 (408, 30)
37 (375, 27)
Washer
Spacer
Glow Plug
Screw Grommet
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
14−137
AVENSIS Supplement (RM1045E)

141NG−01
A84393
(a)
(a)
(b)(b)
(a)
A84286
14 −108−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE FRONT WHEELS
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. DRAIN ENGINE COOLANT (See page 16 −19)
8. DRAIN ENGINE OIL (See Pub No. RM1018E on page 17 −30)
9. DRAIN MANUAL TRANSAXLE OIL
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE ENGINE COVER SUB −ASSY NO.1
(a) Remove the 5 nuts, then remove the engine cover.
11. REMOVE BATTERY
12. REMOVE AIR CLEANER ASSY
(a) Disconnect the mass air flow meter connector.
(b) Remove the air cleaner cap together with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and air cleaner case.
13. REMOVE VACUUM RESERVOIR SUB −ASSY
(a) Disconnect the 2 vacuum hoses and connector.
(b) Remove the 2 bolts and vacuum reservoir.
14. REMOVE FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
15. REMOVE RADIATOR HOSE INLET
16. REMOVE RADIATOR HOSE OUTLET
17. DISCONNECT WATER BY−PASS HOSE NO.2

A84285
A87968
Air Hose No. 3
(a)(b)
(a)
(b)
A79178
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−109
AVENSIS Supplement (RM1045E)
18. REMOVE ENGINE ROOM RELAY BLOCK NO.3
(a) Remove the 2 bolts, then remove the engine room relay
block.
19. REMOVE RADIATOR ASSY (W/ AIR CONDITIONING)
(See Pub. No. RM1018E on page 16−51)
20. DISCONNECT HEATER INLET WATER HOSE
21. DISCONNECT HEATER OUTLET WATER HOSE
22. DISCONNECT FUEL HOSE NO.2
23. REMOVE AIR TUBE NO.2
(a) Loosen the 2 hose clamps, then disconnect the air hose
No. 3.
(b) Remove the 2 bolts and air tube No. 2.
24. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, then separate the control cable assembly.
25. REMOVE INJECTOR DRIVER
(a) Remove the 2 nuts which secure the injector driver.
(b) Disconnect the injector driver connector and harness clamp.
(c) Remove the injector driver.
26. DISCONNECT ENGINE WIRE
(a) Remove the glove compartment door.
(b) Disconnect the engine wire from the ECM and junction
block.
(c) Pull out the engine wire.
(d) Disconnect the engine wire from the engine room junction
block.
(e) Remove the bolt, then disconnect the wire harness from
the body.