TOYOTA AVENSIS 2005 Service Repair Manual

A85631
SST
A85632
A93406
SST
14−120− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, remove the fuel pipe No.
3 from the injector side.
SST 09023−12700
(c) Remove the bolt and 3 nuts, then remove the fuel pipe No.
3 and 2 gaskets.
100. 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.
(e) Remove the 2 lower injection pipe clamps from the intake
manifold.
101. REMOVE INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
102. REMOVE INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
103. REMOVE INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.

A79150
A09671
A84294
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −121
AVENSIS Supplement (RM1045E)
104. REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a) Remove the 2 bolts and intake manifold insulator.
105. REMOVE COMMON RAIL ASSY (See page 11 −67)
106. REMOVE INTAKE MANIFOLD
(a) Remove the 8 bolts and 2 nuts, then remove the intake manifold and gasket.
107. REMOVE INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
108. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, then remove the timing belt cover.
109. REMOVE OIL LEVEL GAGE GUIDE (See page 17 −11 )
110. REMOVE INJECTION PUMP STAY NO.1 (See page 11 −58)
111. REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
112. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
(a) Remove the 4 bolts and compressor mounting bracket.
113. REMOVE WATER INLET (See Pub. No. RM1018E on page 16 −50)
114. REMOVE THERMOSTAT
115. REMOVE OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, remove the union bolt,oil cooler pipe and gasket.

A84380
A84378
14−122−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
116. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and fuel pipe.
117. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
118. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor. 119. REM O VE ENG I NE CO O L ANT TEM PERAT URESENSOR
120. REPLACE PARTIAL ENGINE ASSY
121. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Torque: 20 N
m (200 kgf
cm, 14 ft
lbf)
122. INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
123. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
124. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE
Torque:
8.8 N
m (90 kgf
cm, 78 in.
lbf) for M6
21 N
m (209 kgf
cm, 15 ft
lbf) for M8
125. INSTALL OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 56 N
m (575 kgf
cm, 42 ft
lbf)
126. INSTALL THERMOSTAT (See Pub. No. RM1018E on page 16 −50)
127. INSTALL WATER INLET (See Pub. No. RM1018E on page 16 −50)
128. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
129. INSTALL INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
130. INSTALL INJECTION PUMP STAY NO.1 (See page 11 −58)
131. INSTALL OIL LEVEL GAGE GUIDE (See page 17 −11 )
132. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

A87959
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −123
AVENSIS Supplement (RM1045E)
133. INSTALL INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
134. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts. Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
135. INSTALL COMMON RAIL ASSY (See page 11 −67)
136. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
137. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
SIn case of replacing the injectors, the injection pipes
must be replaced, too.
SWhen assembling the pipes, perform the operation
with the engine cold at room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Temporarily install a new injection pipe.
(c) 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.

A85632
14−124− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(d) 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:
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.
(e) Install the 2 upper injection pipe clamps.
138. INSTALL INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
139. INSTALL INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
140. INSTALL INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
141. INSTALL FUEL PIPE NO.3
(a) Install 2 new gaskets, then temporarily install the bolt, 3
nuts and fuel pipe No. 3.

A85631
SST
A85632
A
A
BA
A87960
Fulcrum Length
30 cm (11.81 in.)
SST
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−125
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, tighten the nut of the fuel
pipe No. 3 on the injector side.
SST 09023−12700
Torque:
22 N
m (223 kgf
cm, 16 ft
lbf) with SST
23.5 N
m (240 kgf
cm, 17 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.
(c) Tighten the bolt and 3 nuts.
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt and nut A
27 N
m (275 kgf
cm, 20 ft
lbf) for nut B
(d) Install the fuel pipe insulator.
142. INSTALL FUEL INLET PIPE SUB−ASSY
NOTICE:
SIn case of replacing the cylinder head, 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.
(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:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter 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.

A79196
New O−ring
New O−ring
A79182
Collar
Groove
14−126− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(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:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter 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.
143. INSTALL NOZZLE LEAKAGE PIPE NO.2
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
144. INSTALL VACUUM PUMP ASSY
(a) Install 2 new O−rings to the vacuum pump.
(b) Align the key of the vacuum pump with the keyway of the
exhaust camshaft, then insert the vacuum pump into
place. Secure the pump with the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
145. INSTALL WATER OUTLET SUB−ASSY
(a) Install a new gasket and the water outlet with the 2 bolts.
Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
146. INSTALL EGR VALVE ASSY
(a) Install a new gasket and the EGR valve with the bolt and 2 nuts.
Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
147. INSTALL INTAKE AIR CONNECTOR
(a) Install a new gasket and the intake air connector together with the diesel throttle body with the 3 bolts.
Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
148. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket, the exhaust manifold and 8 collars
with new 8 nuts.
Torque: 47 N
m (474 kgf
cm, 34 ft
lbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. The ring groove of the collar should be outward. Re-
fer to the illustration on the left.

A85918
SST
A85916SST
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −127
AVENSIS Supplement (RM1045E)
149. INSTALL VACUUM PUMP OIL PIPE
Torque:
21 N
m (214 kgf
cm, 15 ft
lbf) for bolt
8.8 N
m (90 kgf
cm, 78 in.
lbf) for nut
150. INSTALL OIL COOLER ASSY (See Pub. No. RM1018E on page 17 −32)
151. INSTALL EGR PIPE SUB −ASSY NO.1
(a) Install 2 new gaskets and the EGR pipe with the bolt and 4 new nuts. Torque:
37 N
m (375 kgf
cm, 27 ft
lbf) for bolt
25 N
m (250 kgf
cm, 18 ft
lbf) for nut
152. INSTALL TURBOCHARGER SUB −ASSY (See page 13 −12)
153. INSTALL TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
154. INSTALL TURBOCHARGER STAY (See page 13 −12)
155. INSTALL MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
156. INSTALL MANIFOLD STAY NO.2 (See page 13 −12)
157. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY
NO.2
(a) Temporarily install the vacuum pipe.
(b) Using SST, tighten the nut of the vacuum pipe on the man- ifold converter side.
SST 09023 −38200
Torque:
27 N
m (275 kgf
cm, 20 ft
lbf) with SST
30 N
m (306 kgf
cm, 22 ft
lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Install the 2 bolts. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
158. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY
NO.1
(a) Temporarily install the vacuum pipe.
(b) Using SST, tighten the nut of the vacuum pipe on the man- ifold converter side.
SST 09023 −38200
Torque:
27 N
m (275 kgf
cm, 20 ft
lbf) with SST
30 N
m (306 kgf
cm, 22 ft
lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Install the bolt.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)

A85921
5mm
(0.20 in.)
A85914
SST
A8592215 mm (0.59 in.)
A87961
SST
14−128−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
159. INSTALL EXHAUST GAS TEMPERATURE SENSOR
(a) Temporarily install the 3 nuts and exhaust gas tempera- ture sensor on down stream as shown in the illustration.
NOTICE:
Keep 5 mm (0.20 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(b) Using SST, tighten the sensor on the manifold converter
side.
SST 09023 −38400
Torque:
27 N
m (275 kgf
cm, 20 ft
lbf) with SST
30 N
m (306 kgf
cm, 22 ft
lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Tighten the 3 nuts.
Torque: 6.4 N
m (65 kgf
cm, 57 in.
lbf)
(d) Temporarily install the 2 nuts and exhaust gas tempera- ture sensor on up stream as shown in the illustration.
NOTICE:
Keep 15 mm (0.59 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(e) Using SST, tighten the sensor on the manifold converter side.
SST 09023 −38400
Torque:
27 N
m (275 kgf
cm, 20 ft
lbf) with SST
30 N
m (306 kgf
cm, 22 ft
lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(f) Tighten the 2 nuts.
Torque: 6.4 N
m (65 kgf
cm, 57 in.
lbf)
160. INSTALL EGR PIPE INSULATOR (See page 13 −12)
161. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
162. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
163. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
164. INSTALL OIL FILTER BRACKET SUB −ASSY
(a) Install a new gasket and the oil filter bracket with the bolt and 2 nuts.
Torque: 34 N
m (347 kgf
cm, 25 ft
lbf)
165. INSTALL V −RIBBED BELT TENSIONER BRACKET
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)

A61186
SST
A57108
Adhesive
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −129
AVENSIS Supplement (RM1045E)
166. INSTALL V −RIBBED BELT TENSIONER ASSY
Torque: 31 N
m (316 kgf
cm, 23 ft
lbf)
167. INSTALL GENERATOR BRACKET NO.1 Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
168. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
169. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
170. INSTALL TIMING BELT (See page 14 −138)
171. CHECK VALVE TIMING (See page 14 −138)
172. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
173. INSTALL TIMING BELT GUIDE (See page 14 −138)
174. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
175. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
176. INSTALL IDLER PULLEY SUB −ASSY
Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
177. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
178. INSTALL GLOW PLUG ASSY (See Pub. No. RM1018E on page 19 −33)
179. INSTALL ENGINE MOUNTING BRACKET RR
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
180. INSTALL ENGINE MOUNTING BRACKET FR Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
181. INSTALL DRIVE SHAFT BEARING BRACKET Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
182. INSTALL REAR END PLATE Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
183. INSTALL FLYWHEEL SUB −ASSY
(a) Using SST, hold the crankshaft. SST 09213 −54015 (09213 −70020), 09330 −00021
(b) Clean the bolts and their bolt holes.
(c) Apply adhesive to the 2 or 3 threads of the bolt end. Adhesive: Part No. 08833 −00070, THREE BOND 1324
or equivalent