TOYOTA AVENSIS 2005 Service Repair Manual

14−94−
ENGINE MECHANICAL VALVE CLEARANCE (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:
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.
(e) Install the 2 upper injection pipe clamps.
26. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
27. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
28. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
29. INSTALL FUEL PIPE NO.3 (See page 14 −108)
30. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)

A93405
2to7mm
(0.0787 to
0.2756 in.)0to2mm
(0 to
0.0787 in.)
5to13mm
(0.1969 to
0.5118 in.)
Turbocharger Side:
Air Hose No. 2 Side:
A87967
Upward
90_
Clamp
Bolt
Turbocharger Side:
Air Hose No. 2 Side:
Front 90
_ Clamp Bolt
20.4_
−
ENGINE MECHANICAL VALVE CLEARANCE (1CD−FTV)(From September,
2003)14 −95
AVENSIS Supplement (RM1045E)
31. INSTALL AIR TUBE NO.1
(a) Install a new air hose No. 2 and new 2 hose clamps as
shown in the illustration.
(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)
32. INSTALL BATTERY (See page 14 −108)
33. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
34. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
35. CHECK FOR FUEL LEAKS (See page 11 −46)

A57526
Adjusting Shim Selection Chart (Intake)
New Shim Thickness mm (in.)
Shim
No.Thickness
01Shim
No.Thickness
03
05
07
09
11
13
1519
21
23
25
27 2.500(0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
29
31
33 2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950(0.1161)
3.000(0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299)
17
Intake valve clearance (Cold):
0.20 to 0.30 mm (0.008 to 0.012 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 21
shim. 14−96
− ENGINE MECHANICALVALVE CLEARANCE (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)

A57527
Adjusting Shim Selection Chart (Exhaust)
New Shim Thickness mm (in.)
Shim
No.Thickness
01Shim
No.Thickness
03
05
07
09
11
13
1519
21
23
25
27 2.500(0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
29
31
33 2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950(0.1161)
3.000(0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299)
17
Exhaust valve clearance (Cold):
0.35 to 0.45 mm (0.014 to 0.018 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.590 mm (0.0232 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No. 21
shim.
− ENGINE MECHANICALVALVE CLEARANCE (1CD−FTV)(From September,
2003)14−97
AVENSIS Supplement (RM1045E)

141ND−01
A57063
Measure Point for Belt
Deflection and Tension
Alternator
Crankshaft Compressor
P/SP/S
Alternator Crankshaft
A/C Equipped
A/C Not Equipped
−
ENGINE MECHANICAL ENGINE (1CD−FTV)(From September, 2003)
14 −87
AVENSIS Supplement (RM1045E)
ENGINE (1CD −FTV)(From September, 2003)
INSPECTION
1. INSPECT ENGINE COOLANT (See page 16 −15)
2. INSPECT ENGINE OIL (See page 17 −9)
3. INSPECT BATTERY (See Pub. No. RM1018E on page 19 −26)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB −ASSY
5. INSPECT DRIVE BELT
(a) Inspect the vane pump V −ribbed belt.
(1) Measure the belt deflection.
Pressing force: 98 N (10 kgf, 22 lbf)
New Belt
mm (in.)Used Belt mm (in.)
A/C Equipped8.0 to 10.5
(0.31 to 0.41)10.5 to 12.5
(0.41 to 0.49)
A/C Not Equipped10 to 12
(0.39 to 0.47)14 to 17
(0.55 to 0.67)
(2) Measure the belt tension.
New Belt
N (kgf, lbf)Used Belt
N (kgf, lbf)
A/C Equipped647 to 843
(66 to 86, 145 to 189)441 to 637
(45 to 65, 99 to 143)
A/C Not Equipped686 to 784
(70 to 80, 154 to 176)294 to 441
(30 to 45, 66 to 99)
NOTICE:
SCheck the drive belt deflection at the specified point.
SWhen installing a new belt, set its tension value as
specified.
SWhen inspecting the belt which has been used for
over 5 minutes, apply the specifications of ”Used
Belt.”
SWhen reinstalling the belt which has been used for
over 5 minutes, adjust its deflection and tension to
the intermediate value of each specification of ”Used
Belt.”
SThe V −ribbed belt tension and deflection should be
checked after 2 revolutions of engine cranking.
SWhen using a belt tension gauge, confirm the accura-
cy by using a master gauge first.

A61173
B A
TA C
A52006
A09593
SST
(Attachment) 14−88
− ENGINE MECHANICALENGINE (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Inspect the generator V−ribbed belt.
(1) Check that the tension indicator is within range A on
the auto tensioner scale.
If the tension indicator is not within range A, replace the belt with
a new one.
HINT:
When replacing the drive belt with a new one, the tension indi-
cator should be within range B.
6. INSPECT ENGINE IDLE SPEED
(a) Using SST, connect a tachometer test probe to terminal
9 (TAC) of the DLC3.
SST 09843−18040
(b) Check the idle speed.
Idle speed: 750 to 850 rpm
NOTICE:
SCheck the idle speed with the cooling fan OFF.
SSwitch OFF all accessories and air conditioning be-
fore connecting the test probe to the terminal.
7. INSPECT MAXIMUM SPEED
(a) Start the engine.
(b) Fully depress the accelerator pedal.
(c) Check the maximum speed.
Maximum speed: 5,100 to 5,250 rpm
8. INSPECT COMPRESSION
(a) Warm up the engine to the normal operating temperature,
then stop the engine.
(b) Remove the 4 glow plugs
(see Pub. No. RM1018E on page 19−33).
(c) Disconnect the 4 injector connectors.
(d) Inspect the cylinder compression pressure.
(1) Install SST (an attachment) to the glow plug hole.
SST 09992−00025 (09992−00121, 09992−00211)
Torque: 12 N
m (125 kgf
cm, 95 ft
lbf)

A61174
SST
Compression Gauge
− ENGINE MECHANICALENGINE (1CD−FTV)(From September, 2003)
14−89
AVENSIS Supplement (RM1045E)
(2) Connect SST (a compression gauge) to SST (the
attachment).
SST 09992−00025 (09992−00121, 09992−00211)
(3) Fully open the throttle valve, then start the engine.
(4) While cranking the engine, measure the compres-
sion pressure.
NOTICE:
SAlways use a fully−charged battery to obtain engine
speed of 250 rpm or more.
SCheck the other cylinder compression pressure in
the same way.
SThis measurement must be done as quickly as pos-
sible.
Compression pressure:
2,628 kPa (26.8 kgf/cm
2, 381 psi) or more
Minimum pressure:
2,157 kPa (22.0 kgf/cm
2, 312 psi) or more
Difference between each cylinder:
490 kPa (5.0 kgf/cm
2, 71 psi) or less
(5) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
glow plug hole, then measure the compression
pressure again.
HINT:
SIf adding oil raises the compression pressure, the piston
rings and/or cylinder bore may be worn or damaged.
SIf the compression pressure stays low, the valve may be
sticking or seating improperly, or there may be leakage
past the gasket.

141BS−02
A77421
Cut Position
A77422SST
14
−86
−
ENGINE MECHANICAL ENGINE REAR OIL SEAL (2AZ −FSE)
AVENSIS Supplement (RM1045E)
ENGINE REAR OIL SEAL (2AZ −FSE)
REPLACEMENT
1. REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40 −3)
2. REMOVE DRIVE PLATE & RING GEAR SUB −ASSY (See page 14 −23)
SST 09213 −54015 (91651 −60855), 09330 −00021
3. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the engine rear oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out the engine rear oil seal.
HINT:
After the removal, check that the crankshaft is not damaged.
If damaged, smooth the surface with 400 −grit sandpaper.
4. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new engine rear oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retain-
er edge.
SST 09223 −15030, 09950 −70010 (09951 −07100)
NOTICE:
Wipe off extra grease on the crankshaft.
5. INSTALL DRIVE PLATE & RING GEAR SUB −ASSY (See page 14 −23)
SST 09213 −54015 (91651 −60855), 09330 −00021
6. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40 −3)

141NC−01
Cut Position
A13332
A77419
SST
−
ENGINE MECHANICAL TIMING GEAR CASE OR TIMING CHAIN CASE OIL
SEAL (2AZ−FSE)14 −85
AVENSIS Supplement (RM1045E)
TIMING GEAR CASE OR TIMING CHAIN CASE OIL
SEAL (2AZ −FSE)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −45)
8. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
9. REMOVE CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05021)
10. REM O VE TI M I NG G EAR CASE O R T I M I NG CHAI NCASE OIL SEAL
(a) Using a screwdriver with tip wrapped in the tape, pry out the oil seal.
HINT:
After removal, check that the crankshaft is not damaged.
If damaged, smooth the surface with 400 −grit sandpaper.
11. I NSTALL TI M I NG G EAR CASE O R T I M I NG CHAI N CASE OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST and a hammer, tap in the oil seal until its sur- face is flush with the rear oil seal retainer edge.
SST 09223 −22010
NOTICE:
Wipe off extra grease on the crankshaft.
12. INSTALL CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021
13. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
14. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
15. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
16. CHECK FOR ENGINE OIL LEAKS

141NB−01
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
14 −79
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11 −4)
2. REMOVE FRONT WHEEL RH
3. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
4. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
5. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
7. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
8. DRAIN COOLANT (See page 16 −7)
9. DRAIN ENGINE OIL (See page 17 −6)
10. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −45)
11. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
12. SEPARATE FUEL TUBE SUB −ASSY (See page 11 −4)
13. REMOVE FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
14. REMOVE FUEL PUMP ASSY (See page 11 −24)
15. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
16. REMOVE GENERATOR ASSY (See page 19 −8)
17. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −2)
18. SEPARATE VANE PUMP ASSY (See page 14 −45)
19. REMOVE IGNITION COIL ASSY (See page 14 −45)
20. SEPARATE RETURN TUBE SUB −ASSY (See page 14 −45)
21. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14 −45)
22. REMOVE VANE PUMP OIL RESERVOIR ASSY (See page 14 −45)
23. REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14 −45)
24. SEPARATE ENGINE WIRE (See page 14 −23)
25. REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14 −45)
26. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(See page 14 −45)
27. REMOVE CYLINDER HEAD COVER SUB −ASSY (See page 14 −45)
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −45)
29. REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14 −45)
30. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14 −45)
31. REMOVE CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05021)
32. REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14 −45)
33. REMOVE CRANKSHAFT POSITION SENSOR (See page 14 −45)
34. REMOVE OIL PAN SUB −ASSY (See page 14 −45)
SST 09032 −00100
35. REMOVE V −RIBBED BELT TENSIONER ASSY (See page 14 −45)
36. REMOVE TIMING CHAIN OR BELT COVER SUB −ASSY (See page 14 −45)
37. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14 −45)
38. REMOVE CHAIN TENSIONER SLIPPER (See page 14 −45)
39. REMOVE CHAIN VIBRATION DAMPER NO.1 (See page 14 −45)
40. REMOVE TIMING CHAIN GUIDE (See page 14 −45)
41. REMOVE CHAIN SUB −ASSY (See page 14 −45)