TOYOTA AVENSIS 2005 Service Repair Manual

A85929
(g)
(f)
(g)
A84394
A84395
A84396
(a)
(b)
A93840
Air Hose No. 2
To
Turbocharger (b)
(b)(c)
(c)
(c) 14−11 0
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(f) Remove the bolt and engine room relay block No. 3.
(g) Disconnect the 2 connectors.
(h) Disconnect the wire harness from the fuel filter support.
(i) Disconnect the 2 exhaust gas temperature sensor con-
nectors.
27. DISCONNECT VACUUM HOSE
(a) Disconnect the 2 vacuum hoses.
28. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSY
(a) Disconnect the connector.
(b) Remove the bolt and differential pressure sensor.
29. REMOVE AIR TUBE NO.1
(a) Disconnect the vacuum hoses and connectors.
(b) Loosen the 2 hose clamps.
(c) Remove the 2 bolts and nut, then detach the air tube No.
1.

A79140
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 1
AVENSIS Supplement (RM1045E)
30. REMOVE CLUTCH ACCUMULATOR ASSY (See Pub. No. RM1018E on page 42 −22)
SST 09023 −00100
31. REMOVE CLUTCH RELEASE CYLINDER ASSY (See Pub. No. RM1018E on page 42 −17)
32. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
33. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(See Pub. No. RM1018E on page 55 −86)
HINT:
Secure the hoses off to the side instead of detaching.
34. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
35. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
36. SEPARATE RETURN TUBE SUB −ASSY
(a) Remove the 2 clamp bolts, then separate the return tube
sub−assembly.
37. SEPARATE VANE PUMP OIL RESERVOIR ASSY
38. REMOVE FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30 −6)
SST 09930 −00010
HINT:
Perform the same procedure as above on the opposite side.
39. SEPARATE TIE ROD END SUB −ASSY LH (See Pub. No. RM1018E on page 30 −6)
SST 09628 −62011
HINT:
Perform the same procedure as above on the opposite side.
40. SEPARATE FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
41. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and column hole cover silencer sheet.
42. REMOVE STEERING COLUMN HOLE COVER SUB −ASSY NO.1
43. REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See Pub. No. RM1018E on page 51 −36)
44. SEPARATE FRONT SUSPENSION ARM SUB −ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
45. SEPARATE FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.

A79184
A85928
A61177
A59793
A59792
14−11 2− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
46. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Disconnect the height control sensor connector (with dis-
charge head lamp).
(b) Set the engine lifter.
(c) Remove the 3 bolts, 3 nuts and engine mounting insulator
sub−assembly RH.
(d) Remove the through bolt and nut, then detach the engine
mounting insulator LH from the vehicle.
(e) Remove the 8 bolts and front suspension member brace
rear RH and LH.
(f) Remove the 2 bolts and 2 nuts.
(g) Carefully remove the engine together with the transaxle
from the vehicle.

A85927
Engine Hanger No. 1 Upper
Engine Hanger No. 2
Engine Hanger No. 1
A61175
A62711
A79180
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−11 3
AVENSIS Supplement (RM1045E)
(h) Install the 2 engine hangers with the 2 bolts.
Part No.:
No. 1 engine hanger upper (yellow) 12284−27020
No. 1 engine hanger upper (black) 12284−27030
No. 1 engine hanger 12281−27050
No. 2 engine hanger 12282−27060
Bolt 91642−81025
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
(i) Attach the engine sling, then hang the engine with the
chain block.
47. REMOVE POWER STEERING IDLE PULLEY
BRACKET
(a) Remove the 3 bolts and power steering idle pulley brack-
et.
48. REMOVE FRONT SUSPENSION CROSSMEMBER
SUB−ASSY
(a) Remove the through bolt and nut, then detach the engine
mounting insulator front from the engine mounting brack-
et.
(b) Remove the through bolt, then detach the engine mount-
ing insulator rear from the suspension crossmember.
(c) Separate the engine together with the transaxle from the
suspension crossmember and engine mounting member.
49. REMOVE STARTER ASSY (See Pub. No. RM1018E on page 19−24)
50. REMOVE MANUAL TRANSAXLE (See Pub. No. RM1018E on page 41−33)
51. REMOVE CLUTCH COVER ASSY (See Pub. No. RM1018E on page 42−26)
52. REMOVE CLUTCH DISC ASSY (See Pub. No. RM1018E on page 42−26)

A61186
SST
A84289
14−11 4−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
53. REMOVE FLYWHEEL SUB −ASSY
(a) Hold the crankshaft with SST. SST 09213 −54015 (09213 −70020), 09330 −00021
(b) Using a Torx socket wrench (T55), remove the 8 Torx
screws and flywheel.
54. REMOVE REAR END PLATE
(a) Remove the 2 bolts and rear end plate.
55. REMOVE DRIVE SHAFT BEARING BRACKET
56. REMOVE ENGINE MOUNTING BRACKET FR
57. REMOVE ENGINE MOUNTING BRACKET RR
58. REMOVE GLOW PLUG ASSY (See Pub. No. RM1018E on page 19 −33)
59. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
60. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
61. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
62. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
63. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
64. REMOVE TIMING BELT GUIDE
65. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
66. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
67. REMOVE TIMING BELT (See page 14 −138)
HINT:
If reusing the timing belt, draw an arrow on the belt which indicates 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.
68. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
69. REMOVE GENERATOR BRACKET NO.1
(a) Remove the 2 bolts and generator bracket.

A84290
A84291
A15985
A84397
(a)
(a)
(b)
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 5
AVENSIS Supplement (RM1045E)
70. REMOVE V −RIBBED BELT TENSIONER ASSY
(a) Remove the 3 bolts and V −ribbed belt tensioner.
71. REMOVE V −RIBBED BELT TENSIONER BRACKET
(a) Remove the bolt and V −ribbed belt tensioner bracket.
72. REMOVE OIL FILTER BRACKET SUB −ASSY
(a) Remove the bolt and 2 nuts, then remove the oil filter
bracket and gasket.
73. REMOVE TURBO INSULATOR NO.2 (See page 13 −12)
74. REMOVE TURBO INSULATOR NO.1 (See page 13 −12)
75. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
76. REMOVE EGR PIPE INSULATOR (See page 13 −12)
77. REMOVE EXHAUST GAS TEMPERATURE SENSOR
(a) Remove the 2 nuts, then detach the wire harness from the clamp.
(b) Disconnect the connector.

A85634
SST
A85623
A85914
SST
A85915
A85916
SST
14−11 6− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(c) Using SST, remove the exhaust gas temperature sensor
on up stream.
SST 09023−38400
(d) Remove the 3 nuts, then detach the wire harness from the
clamp.
(e) Disconnect the connector.
(f) Using SST, remove the exhaust gas temperature sensor
on down stream.
SST 09023−38400
78. REMOVE VACUUM TRANSMITTING PIPE SUB−ASSY
NO.1
(a) Remove the bolt.
(b) Using SST, remove the vacuum pipe.
SST 09023−38200

A85917
A85918
SST
A85624
A85625
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 7
AVENSIS Supplement (RM1045E)
79. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY
NO.2
(a) Remove the 2 bolts.
(b) Using SST, remove the vacuum pipe. SST 09023 −38200
80. REMOVE MANIFOLD STAY NO.2 (See page 13 −12)
81. REMOVE MANIFOLD STAY (See page 13 −12)
82. REMOVE MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
83. REMOVE TURBOCHARGER STAY (See page 13 −12)
84. DISCONNECT TURBO WATER HOSE NO.1 (See page 13 −12)
85. DISCONNECT TURBO WATER HOSE NO.2 (See page 13 −12)
86. REMOVE TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
87. REMOVE TURBOCHARGER SUB −ASSY (See page 13 −12)
88. DISCONNECT WATER BY −PASS HOSE NO.3
89. REMOVE EGR PIPE SUB −ASSY NO.1
(a) Remove the bolt and 4 nut, then detach the EGR pipe and
2 gaskets.

A84296
A80118
A85626
A85627
(a)(a)
(b)
(b)
(b) 14−11 8
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
90. REMOVE OIL COOLER ASSY (See Pub. No. RM1018E on page 17−32)
91. REMOVE VACUUM PUMP OIL PIPE
(a) Disconnect the 2 hoses.
(b) Remove the bolt and nut, then remove the vacuum pump
oil pipe.
92. REMOVE EXHAUST MANIFOLD
(a) Remove the 8 nuts, exhaust manifold and gasket.
93. REMOVE INTAKE AIR CONNECTOR
(a) Remove the 3 bolts, intake air connector together with the
diesel throttle body and gasket.
94. REMOVE EGR VALVE ASSY
(a) Disconnect the 2 hoses.
(b) Remove the bolt and 2 nuts, then remove the EGR valve
and gasket.

A84293
A09660
A85628
(a)
(a)(b)
(b)
A93407SST
A85630
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−11 9
AVENSIS Supplement (RM1045E)
95. REMOVE WATER OUTLET SUB−ASSY
(a) Remove the 2 bolts, water outlet and gasket.
96. REMOVE VACUUM PUMP ASSY
(a) Remove the 2 bolts, vacuum pump and 2 O−rings.
97. REMOVE NOZZLE LEAKAGE PIPE NO.2
(a) Disconnect the 2 hoses.
(b) Remove the 2 bolts, nozzle leakage pipe No. 2.
98. REMOVE FUEL INLET PIPE SUB−ASSY
(a) Using SST, remove the fuel inlet pipe from the common
rail side.
SST 09023−12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023−12700
99. REMOVE FUEL PIPE NO.3
(a) Remove the fuel pipe insulator.