TOYOTA AVENSIS 2005 Service Manual PDF

02±12
± PREPARATIONENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
09950±50013Puller C SetCHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09951±05010)Hanger 150CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09952±05010)Slide ArmCHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09953±05010)Center Bolt 100CRANKSHAFT SEAL(1CD±FTV)

± PREPARATIONENGINE MECHANICAL
02±13
AVENSIS REPAIR MANUAL (RM1018E)
(09953±05020)Center Bolt 150CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09954±05021)Claw No.2CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
CRANKSHAFT SEAL(1CD±FTV)
(09954±05031)Claw No.3TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
09950±70010Handle SetENGINE REAR OIL SEAL(1AZ±FE)
ENGINE REAR OIL SEAL(1AZ±FSE)
ENGINE REAR OIL SEAL(1CD±FTV)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
(09951±07100)Handle 100ENGINE REAR OIL SEAL(1AZ±FE)
ENGINE REAR OIL SEAL(1AZ±FSE)
ENGINE REAR OIL SEAL(1CD±FTV)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
09960±10010Variable Pin Wrench SetTIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)

02±14
± PREPARATIONENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
(09962±01000)Variable Pin Wrench Arm AssyTIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
(09963±01000)Pin 10TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
09992±00025Cylinder Compression Check Gauge
SetENGINE(1CD±FTV)
(09992±00121)No. 4 AttachmentENGINE(1CD±FTV)
(09992±00211)Gauge AssyENGINE(1CD±FTV)
09992±00242Turbocharger Pressure GaugeVALVE CLEARANCE(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
09992±00500Compression Gauge AttachmentENGINE(1AZ±FE)
ENGINE(1AZ±FSE)
ENGINE(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)

± PREPARATIONENGINE MECHANICAL
02±15
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09011±12301Socket Wrench 30 mmENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
09017±38120Deep Socket Wrench 12 mmPARTIAL ENGINE ASSY(1CD±FTV)
09040±00011Hexagon Wrench SetPARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
(09043±20050)Socket Hexagon Wrench 5PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
(09043±20100)Socket Hexagon Wrench 10PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09043±50100Bi±hexagon Wrench 10 mmCYLINDER HEAD GASKET(1AZ±FE)
CYLINDER HEAD
GASKET(1AZ±FSE)
09090±04020Engine Sling DevicePARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09216±00021Belt Tension GaugeENGINE(1CD±FTV)
DRIVE BELT(1CD±FTV)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
(09857±00031)Spark Plug Gap GaugeENGINE(1AZ±FE)
ENGINE(1AZ±FSE)
ENGINE(1ZZ±FE/3ZZ±FE)
Equipment
Hexagon wrench (6mm)
Feeler gauge
CO/HC meter
Compression gauge
Dial indicator
Dial indicator or dial indicator with magnetic base
Micro meter
Radiator cap tester
Straight edge
Tachometer
Torque wrench

02±16
± PREPARATIONENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Vernier calipers
Tire pressure gauge
Alignment tester
Toe±in gauge
OBD II scan tool
Deep socket wrench 24 mm
Slide calipers
Sand paper (#400)
Wooden block
Chain block
Spark plug cleaner
Angle gauge
Universal engine lifter
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)VALVE CLEARANCE(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
VALVE CLEARANCE(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
VALVE CLEARANCE(1CD±FTV)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
VA LV E
CLEARANCE(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CAMSHAFT(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
08833±00070ºAdhesive 1324,º
THREE BOND 1324 or equivalentPARTIAL ENGINE ASSY(1AZ±FE)
ENGINE REAR OIL SEAL(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
ENGINE REAR OIL SEAL(1AZ±FSE)
ENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)

022KR±01
± PREPARATIONINTAKE
02±7
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE
PREPARATION
SST
09992±00242Turbocharger Pressure GaugeTURBO CHARGER SYSTEM
(1CD±FTV)
Recomended Tools
09082±00040TOYOTA Electrical TesterTURBO CHARGER SYSTEM
(1CD±FTV)
(09083±00150)Test Lead SetTURBO CHARGER SYSTEM
(1CD±FTV)
Equipment
Vacuum gauge
Voltmeter
Ohmmeter
Service wire harness
Torque wrench
Slide calipers
Radiator cap testor
Vernier calipers
Hand±held vacuum pump
Wooden block

022J6±01
02±4
± PREPARATIONFUEL
AVENSIS REPAIR MANUAL (RM1018E)
FUEL
PREPARATION
SST
09023±12700Union Nut Wrench 17mmINJECTOR ASSY(1CD±FTV)
INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
COMMON RAIL ASSY(1CD±FTV)
09213±54015Crankshaft Pulley Holding ToolINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(90105±08076)BoltINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09228±64030Fuel Filter WrenchFUEL FILTER ASSY(1CD±FTV)
09268±21010Fuel Hose PullerFUEL INJECTOR ASSY(1AZ±FE)
FUEL PRESSURE PULSATION
DAMPER ASSY(1AZ±FE)
FUEL INJECTOR ASSY
(1ZZ±FE/3ZZ±FE)
09268±41047Injection Measuring Tool SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09268±41110)AdaptorFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09268±41300)ClampFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(95336±08070)HoseFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09280±00010Union Bolt,inspectionINJECTOR ASSY(1CD±FTV)
09330±00021Companion Flange Holding ToolINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09617±24011)Steering Rack WrenchFUEL PUMP ASSY(1AZ±FSE)

± PREPARATIONFUEL
02±5
AVENSIS REPAIR MANUAL (RM1018E)
09808±14010Fuel Sender Gauge Tool AssyFUEL TANK ASSY(DIESEL)
FUEL PUMP ASSY(GASOLINE)
FUEL TANK ASSY(GASOLINE)
09842±30080Wire ºHº EFI InspectionFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09950±50013Puller C SetINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09951±05010)Hanger 150INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09952±05010)Slide ArmINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09953±05020)Center Bolt 150INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09954±05021)Claw No.2INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09954±05031)Claw No.3INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09962±01000)Variable Pin Wrench Arm AssyINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09963±01000)Pin 10INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09992±00242Turbocharger Pressure GaugeINJECTOR ASSY(1CD±FTV)
Recomended Tools
09042±00020Torx Socket T40FUEL INJECTOR ASSY(1AZ±FSE)

02±6
± PREPARATIONFUEL
AVENSIS REPAIR MANUAL (RM1018E)
09082±00040TOYOTA Electrical TesterFUEL SYSTEM(1CD±FTV)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1AZ±FSE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09130±00150Water Pump PliersFUEL FILTER ASSY(1CD±FTV)
09216±00021Belt Tension GaugeINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
Equipment
Clip
Hexagon wrench (6 mm)
Measuring Flask
Ohmmeter
Radiator cap tester
Service Wire Harness
Stopwatch
Torque wrench
Vernier calipers
Wooden block
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)INJECTOR ASSY(1CD±FTV)
08850±00065Butyl Tape SetFUEL TANK ASSY(DIESEL)

022KP±01
02±62
± PREPARATIONEXTERIOR/INTERIOR TRIM
AVENSIS REPAIR MANUAL (RM1018E)
EXTERIOR/INTERIOR TRIM
PREPARATION
Recomended Tools
09070±20010Moulding RemoverFRONT DOOR BELT MOULDING
ASSY LH
REAR DOOR BELT MOULDING
ASSY LH
ROOF HEADLINING
ASSY(LIFTBACK MODELS)
ROOF HEADLINING ASSY(SEDAN
MODELS)
ROOF HEADLINING ASSY(WAGON
MODELS)
Equipment
Adhesive tapeTo avoid surface damage.
Clip remover
Piano wire
Protective tapeTo avoid surface damage.
Torque wrench
Wooden blockFor tying both piano wire ends