TOYOTA AVENSIS 2005 Service Repair Manual

A79183
2
1
3
4
5
6
7
8
A79180
A62711
A61175
BA
A 14−130
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(d) Using a Torx socket wrench (T55), uniformly install and
tighten the 8 Torx screws in several steps in the sequence
shown in the illustration.
Torque: 71 N
m (720 kgf
cm, 52 ft
lbf)
184. INSTALL CLUTCH DISC ASSY (See Pub. No. RM1018E on page 42−26)
SST 09301−00210
185. INSTALL CLUTCH COVER ASSY (See Pub. No. RM1018E on page 42−26)
186. INSTALL MANUAL TRANSAXLE (See Pub. No. RM1018E on page 41−33)
187. INSTALL STARTER ASSY (See Pub. No. RM1018E on page 19−24)
188. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB−ASSY
(a) Attach the engine together with the transaxle to the sus-
pension crossmember and engine mounting member.
(b) Install the bolt which secures the rear engine mounting
bracket to the mounting insulator.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(c) Install the bolt which secures the front engine mounting
bracket to the mounting insulator.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
189. I N S TA L L P O W E R S T E E R I N G I D L E P U L L E Y
BRACKET
(a) Install the power steering idle pulley bracket with the 3
bolts.
Torque:
72 N
m (734 kgf
cm, 53 ft
lbf) for bolt A
39 N
m (398 kgf
cm, 29 ft
lbf) for bolt B
190. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine together with the transaxle on the engine
lifter.

A59792
A61177
A85928
A59792
AA
BB
A59793
AA
BB
BBB
B
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−131
AVENSIS Supplement (RM1045E)
(b) Temporarily install the suspension crossmember with the
2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N
m (816 kgf
cm, 59 ft
lbf)
(d) Install the engine mounting insulator RH.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
(e) Install the front suspension crossmember with the 2 bolts
and 2 nuts.
Torque:
45 N
m (459 kgf
cm, 33 ft
lbf) for bolt A
133 N
m (1,356 kgf
cm, 98 ft
lbf) for nut B
(f) Install the front suspension member brace LH and RH
with the 8 bolts.
Torque:
133 N
m (1,356 kgf
cm, 98 ft
lbf) for bolt A
80 N
m (816 kgf
cm, 59 ft
lbf) for bolt B
NOTICE:
After installing the crossmember, check that the position-
ing holes on the crossmember and vehicle are aligned.

A93403
2to7mm
(0.0787 to
0.2756 in.)0to4mm
(0 to
0.1575 in.)
Intake Shutter Side:
Air Hose No. 3 Side:
4to12mm
(0.1575 to
0.4724 in.)
14
−132
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
191. INSTALL FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
192. INSTALL 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.
193. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2
(See Pub. No. RM1018E on page 51 −36)
194. INSTALL FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
195. INSTALL TIE ROD END SUB −ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
196. INSTALL FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
197. INSTALL RETURN TUBE SUB −ASSY
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
198. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
199. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
200. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See Pub. No. RM1018E on page 55 −86)
201. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
202. INSTALL CLUTCH RELEASE CYLINDER ASSY (See Pub. No. RM1018E on page 42 −17)
203. INSTALL CLUTCH ACCUMULATOR ASSY (See Pub. No. RM1018E on page 42 −22)
SST 09023 −00100
204. INSTALL AIR TUBE NO.2
(a) Install the air hose and 2 hose clamps as shown in the il-lustration.

A93404
90_
Clamp
Bolt Intake Shutter Side:
Air Hose No. 3 Side:
FrontUpward 90_
Clamp BoltFrontRH
15.1_
A93405
2to7mm
(0.0787 to
0.2756 in.)0to2mm
(0 to
0.0787 in.) Turbocharger Side:
Air Hose No. 2 Side:
5to13mm
(0.1969 to
0.5118 in.)
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−133
AVENSIS Supplement (RM1045E)
(b) Tighten the 2 hose clamps as shown in the illustration.
Torque:
6.0 N
m (61 kgf
cm, 53 in.
lbf) for intake shutter side
5.3 N
m (54 kgf
cm, 47 in.
lbf) for air hose No. 3 side
(c) Install the bolt and air tube No. 2 assembly to the trans-
axle.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
205. CONNECT ENGINE WIRE
Torque:
8.4 N
m (85 kgf
cm, 74 in.
lbf) for wire harness
5.3 N
m (54 kgf
cm, 47 in.
lbf) for engine room relay block No. 2
206. INSTALL INJECTOR DRIVER
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
207. INSTALL AIR TUBE NO.1
(a) Install a new air hose No. 2 and new 2 hose clamps as
shown in the illustration.

A87967
Upward90_
Clamp
Bolt
Turbocharger Side:
Air Hose No. 2 Side:
Front 90
_ Clamp Bolt
20.4_
14
−134
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(b) Tighten the 2 hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
208. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
209. INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See Pub. No. RM1018E on page 16 −51)
210. INSTALL ENGINE ROOM RELAY BLOCK NO.3
Torque: 5.3 N
m (54 kgf
cm, 47 in.
lbf)
211. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
212. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
213. INSTALL BATTERY Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt
3.0 to 4.0 N
m (31 to 41 kgf
cm, 27 to 35 in.
lbf) for nut
5.4 N
m (55 kgf
cm, 48 in.
lbf) for terminal
214. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
215. BLEED CLUTCH PIPE LINE (See Pub. No. RM1018E on page 42 −12)
216. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
217. ADD MANUAL TRANSAXLE OIL (See Pub. No. RM1018E on page 41 −5)
218. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
219. ADD ENGINE COOLANT (See page 16 −19)
220. CHECK CLUTCH FLUID LEAKAGE
221. CHECK FLUID LEVEL IN RESERVOIR
222. CHECK BRAKE FLUID LEAKAGE
223. CHECK FOR ENGINE OIL LEAKS
224. CHECK FOR FUEL LEAKS (See page 11 −46)
225. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
226. CHECK FOR EXHAUST GAS LEAKS
227. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See Pub. No. RM1018E on page 26 −6)

−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −135
AVENSIS Supplement (RM1045E)
228. INSPECT ENGINE IDLE SPEED (See page 14 −87)
229. CHECK ABS SPEED SENSOR SIGNAL (See Pub. No. RM1018E on page 05 −756)

141NE−01
A93837
To
Turbocharger
Air Hose No. 2
A93406
SST
14 −90−
ENGINE MECHANICAL VALVE CLEARANCE (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
VALVE CLEARANCE (1CD −FTV)(From September, 2003)
ADJUSTMENT
NOTICE:
S Before removing the injection pipes, clean them up with a soft brush and compressed air.
S After removing the injection pipes, cover the supply pump, common rail and injector mounting
area of the cylinder head cover with vinyl tape to prevent dust from being introduced.
S After removing the cylinder head cover, protect the injector inlet with a vinyl or plastic bag to
prevent foreign objects from being introduced.
HINT:
Inspect and adjust the valve clearance after the engine becomes cold.
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE COVER SUB −ASSY NO.1
(a) Remove the 5 nuts, then remove the engine cover.
7. REMOVE BATTERY
8. REMOVE AIR TUBE NO.1
(a) Disconnect the vacuum hoses and connectors.
(b) Loosen the 2 hose clamps.
(c) Remove the 3 bolts and nut, then detach the air tube No.1.
9. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
10. REMOVE FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
11. 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.

A09687
UpwardCam Lobe
Clearance
A87966
A81553
Upward
Notch
Cam Lobe
Intake
Manifold
Side
−
ENGINE MECHANICAL VALVE CLEARANCE (1CD−FTV)(From September,
2003)14 −91
AVENSIS Supplement (RM1045E)
12. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
13. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
14. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
15. REMOVE NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
16. REMOVE CYLINDER HEAD COVER SUB −ASSY (See page 14 −151)
17. REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11 −46)
18. 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.
19. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe located over theinspecting valve faces upward.
(b) Using a feeler gauge, measure the clearance between
the valve lifter and camshaft.
(c) Measure the clearance at 16 places.
(d) Record the out −of −specification valve clearance mea-
surements. They will be used later to select an adjusting
shim to replace.
Valve clearance (Cold):
Intake0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust0.35 to 0.45 mm (0.014 to 0.018 in.)
20. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft so that the cam lobe located over the adjusting valve faces upward.
(2) Position the notch of the valve lifter toward the in- take manifold side.

SST (A)
SST (B)
A09616
A09615
Magnetic
Finger
A54826
EXAMPLE (Intake):
Measured valve clearance = 0.45 mm (0.0177 in.)
0.45 mm (0.0177 in.)−0.25 mm (0.0098 in.) = 0.20 mm (0.0078 in.)
(Measured−Specification = Excess clearance)
Used shim measurement = 2.80 mm (0.1102 in.)
0.20 mm (0.0078 in.) + 2.80 mm (0.1102 in.) = 3.00 mm (0.1181 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 3.00 mm (0.1181 in.)
Select No. 21 shim
14−92− ENGINE MECHANICALVALVE CLEARANCE (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(3) Using SST (A), press down the valve lifter, then
place SST (B) between the camshaft and valve lift-
er. Remove SST (A).
SST 09248−55050 (09248−05510, 09248−05520)
HINT:
Use SST (B) marked with ”11”.
(4) Remove the adjusting shim using a small screw-
driver and magnetic finger.
(b) Select the size of an adjusting shim to replace by following
the formula or the charts attached to the end of this sec-
tion.
(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 the specified value.
HINT:
T ........... Thickness of the removed adjusting shim
A ........... Measured valve clearance
N ........... Thickness of a 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 which is as close
to the calculated value as possible.
HINT:
The 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.).

SST (A)
SST (B)
A09686
A87959
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL VALVE CLEARANCE (1CD−FTV)(From September,
2003)14 −93
AVENSIS Supplement (RM1045E)
(c) Install the new adjusting shim.
(1) Place the new adjusting shim on the valve lifter.
(2) Using SST (A), press down the valve lifter, then re- move SST (B).
SST 09248 −55050 (09248 −05510, 09248 −05520)
(d) Recheck the valve clearance.
21. INSTALL INJECTOR ASSY (See page 11 −46)
22. INSTALL NOZZLE LEAKAGE PIPE ASSY (See page 11 −46)
SST 09992 −00242
23. INSTALL CYLINDER HEAD COVER SUB −ASSY (See page 14 −151)
24. INSTALL NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
25. 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) Temporarily install the 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.