2005 TOYOTA AVENSIS fuel

No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
− FUELFUEL SYSTEM (2AZ−FSE)
11−5
AVENSIS Supplement (RM1045E)
(g) Install SST (pressure gauge) and the fuel tube connector
using SST as shown in the illustration.
SST 09268−41047(95336−08070),09268−45014
(09268−41250, 09268−41200, 09268−41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (−) battery cable.
(j) Connect the hand−held tester to the DLC3.
(k) Measure the fuel pressure.
Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hose connections, fuel pump,
fuel filter and fuel pressure regulator.
(l) Disconnect the hand−held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or fuel injectors.
(q) After checking the fuel pressure, disconnect the negative
(−) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline splash.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND CHECK FOR
FUEL LEAKS
(a) When using the hand−held tester.
(1) Connect the hand−held tester to the DLC3.
(2) Turn the ignition switch ON and the hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the hand−held
tester.
(4) Perform the active test. Check that the fuel pump
operates and check for fuel leaks.

A88284Battery
A13269B12608
A91714
Hand−held Tester
11 −6
−
FUEL FUEL SYSTEM (2AZ −FSE)
AVENSIS Supplement (RM1045E)
(b) When not using the hand −held tester.
(1) Connect the positive (+) lead form the battery to ter- minal 4 of the connector, and connect the negative
(− ) lead to terminal 5.
(2) Check that the pump operates.
3. CHECK FUEL PUMP OPERATION (HIGH PRESSURE)
(a) Remove the engine cover No. 1 (see page 10 −8) .
(b) Start the engine.
(c) Using a sound scope, hear the operating sound of the pump.
If there is no sound, replace the fuel pump.
(d) Stop the engine.
(e) Reinstall the engine cover No. 1 (see page 10 −8) .
4. CHECK FUEL HIGH PRESSURE
(a) Connect the hand −held tester to the DLC3.
(b) Start the engine.
(c) Select the ACTIVE TEST mode on the hand −held tester.
(d) Perform the ACTIVE TEST check the fuel high pressure at idle to 3,000 rpm.
Fuel high pressure:
9.5 to 10.5 Mpa (97 to 107 kgf/cm
2, 1,380 to 1,520 psi)
If the pressure is not as specified, check the fuel pump, high
pressure fuel pump, fuel pressure sensor, wiring and fuel leak-
age.
(e) Stop the engine.
(f) Disconnect the hand −held tester.

100LT−01
A79186
−
ENGINE CONTROL SYSTEM ECM (From September, 2003)
10−29
AVENSIS Supplement (RM1045E)
ECM (From September, 2003)
REPLACEMENT
NOTICE:
1CD −FTV Engine Type:
S If an incorrect injector compensation code was registered with the ECM, it may rattle the engine
assembly or the engine idling may become rough. In addition, it may become a cause of engine
failure or shorten the life of the engine.
S If you replace the ECM with a new one, register all the injectors’ injector compensation codes
with the new ECM as follows:
( a) Pri or t o repl aci ng t he ECM , r ead al l t he compensat i on codes st ored i n t he exi st i ng ECM
using the hand −held tester, then write them down (see page 05 −273).
(b) After replacing the ECM, enter the written compensation codes into the ECM using the hand −
held tester (see page 05 −277).
(c) Turn the ignition switch to OFF, then wait for 30 seconds or more.
(d) Turn the ignition switch to ON, then clear DTC P1601 using the hand −held tester
(see page 05 −290).
HINT:
S In order to optimize the injector ’s fuel injection characteristic, the ECM compensates the injection dura-
tion by each cylinder. The ECM stores and uses compensating data in the form of a 30 −digit −alphanu-
meric value that is imprinted on the head portion of each injector as the injector compensation code.
S If you installed a new injector, its own injector compensation code is needed to register with the ECM.
Also, if you replaced the ECM, the compensation codes of all the injectors are needed to register be-
cause the new ECM does not have the codes until they are registered.
S Once the ECM is replaced, DTC P1601 will be present when turning the ignition switch to ON. This
is to inform you that the injector compensation codes are required to register with the ECM. In order
to clear the DTC, register the compensation codes first, then turn the ignition switch to OFF and wait
for 30 seconds or longer.
1. REMOVE GLOVE COMPARTMENT DOOR ASSY (See Pub. No. RM1018E on page 71 −11 )
2. REMOVE ECM
(a) Disconnect the 4 ECM connectors (1ZZ −FE, 3ZZ −FE,
1AZ −FE, 1CD −FTV).
(b) Disconnect t he 5 ECM connect or s ( 1AZ −FSE, 2AZ −
FSE).
(c) Disconnect the wire harness clamp.
(d) Remove the bolt and screw, then remove the ECM.
(e) Remove the 2 screws and ECM bracket No. 1 from the ECM.
(f) Remove the 2 screws and ECM bracket No. 2 from the ECM.
3. INSTALL ECM
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
4. INSTALL GLOVE COMPARTMENT DOOR ASSY (See Pub. No. RM1018E on page 71 −11 )
5. REGISTRATION OF INJECTOR COMPENSATION CODE (1CD −FTV ENGINE TYPE)
(See page 05 −277)
6. CLEAR DTC (1CD −FTV ENGINE TYPE)
(a) Turn the ignition switch to OFF, then wait for 30 seconds or longer.
(b) Turn the ignition switch to ON, then clear DTC P1601 using the hand −held tester
(see page 05 −290).

S01196S01699
30
20
10
5
3
02040 0.11
0.3
0.2 0.52
60 80 100 −20
(−4) (104) (140) (176)(32) (68) (212)
Z17274
Ohmmeter
Acceptable
Temperature_C(_F)
Resistance k

THF E2
A30331
30
20
10
5
3
2
1
0.5
0.3
0.2
0.1
−20 0
20 4060
80 100
F14741(−4) (104) (140) (176)(32) (68) (212)
A56276
Temperature_C(_F)
Resistance k

− ENGINE CONTROL SYSTEMECD SYSTEM (1CD−FTV)(From September, 2003)
10−23
AVENSIS Supplement (RM1045E)
3. INSPECT DIESEL ENGINE ENGINE COOLANT
TEMPERATURE SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
2.32 to 2.59 k
at 20_C (68_F)
0.310 to 0.326 k
at 80_C (176_F)
If the result is not as specified, replace the diesel engine engine
coolant temperature sensor.
NOTICE:
In case of checking the water temperature sensor in the wa-
ter, be careful not to allow water to go into the terminals. Af-
ter checking, wipe out the sensor.
4. INSPECT FUEL TEMPERATURE SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
2.21 to 2.69 k
at 20_C (68_F)
0.287 to 0.349 k
at 80_C (176_F)
If the result is not as specified, replace the fuel temperature sen-
sor.
5. INSPECT DIESEL TURBO INLET AIR TENPERATURE
SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
2.21 to 2.65 k
at 20_C (68_F)
If the result is not as specified, replace the diesel turbo inlet air
temperature sensor.

100LZ−01
A88269
(a)
(b)
A78436
10 _
10 _ Upper
Engine
Front
10
−16
−
ENGINE CONTROL SYSTEM KNOCK SENSOR (2AZ−FSE)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11 −1)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 10 −8)
3. REMOVE ENGINE ROOM COVER SIDE (See page 10 −8)
4. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
5. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 10 −8)
6. DRAIN ENGINE COOLANT (See page 16 −7)
7. REMOVE AIR CLEANER CAP SUB −ASSY (See page 10 −8)
8. REMOVE THROTTLE BODY ASSY (See page 10 −8)
9. REMOVE FUEL TUBE SUB −ASSY (See page 11 −24)
SST 09617 −24011
10. REMOVE FUEL HOSE (See page 11 −24)
11. REMOVE FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
12. REMOVE FUEL PUMP ASSY (See page 11 −24)
13. REMOVE CHARCOAL CANISTER ASSY (See page 11 −13)
14. REMOVE VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE) (See page 11 −13)
15. REMOVE INTAKE MANIFOLD (See page 11 −4)
16. REMOVE SURGE TANK STAY NO.1 (See page 11 −13)
17. REMOVE INTAKE MANIFOLD INSULATOR NO.2 (See page 11 −13)
18. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Remove the nut, then remove the knock sensor.
19. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the nut as shown in the il- lustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the knock sensor connector.
20. INSTALL INTAKE MANIFOLD INSULATOR NO.2
21. INSTALL SURGE TANK STAY NO.1 ( See page 11 −13)
22. INSTALL INTAKE MANIFOLD (See page 11 −13)
23. INSTALL VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE) (See page 11 −13)
24. INSTALL CHARCOAL CANISTER ASSY

−
ENGINE CONTROL SYSTEM KNOCK SENSOR (2AZ−FSE)
10 −17
AVENSIS Supplement (RM1045E)
25. INSTALL FUEL PUMP ASSY (See page 11 −24)
26. INSTALL FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
27. INSTALL FUEL HOSE
28. INSTALL FUEL TUBE SUB −ASSY (See page 11 −24)
SST 09617 −24011
29. INSTALL THROTTLE BODY ASSY (See page 10 −8)
30. INSTALL AIR CLEANER CAP SUB −ASSY (See page 10 −8)
31. CONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL) Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
32. ADD ENGINE COOLANT (See page 16 −7)
33. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)
34. CHECK FOR FUEL LEAKS (See page 11 −4)
35. CHECK FOR ENGINE OIL LEAKS
36. INSTALL ENGINE COVER SUB −ASSY NO.1 ( See page 10 −8)
37. INSTALL ENGINE ROOM COVER SIDE
38. INSTALL RADIATOR SUPPORT OPENING COVER

141NM−01
14 −166−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE RADIATOR SUPPORT OPENING COVER
6. REMOVE ENGINE ROOM COVER SIDE
7. DRAIN ENGINE COOLANT (See page 16 −19)
8. DRAIN ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
9. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
10. REMOVE VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
11. REMOVE AIR CLEANER ASSY (See page 14 −108)
12. REMOVE BATTERY
13. REMOVE AIR TUBE NO.2 (See page 14 −108)
14. REMOVE AIR TUBE NO.1 (See page 14 −108)
15. REMOVE INJECTOR DRIVER (See page 14 −108)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
17. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
18. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
19. DISCONNECT ENGINE WIRE (See page 14 −138)
20. DISCONNECT VACUUM HOSE (See page 14 −108)
21. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSY(See page 14 −108)
22. REMOVE ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
23. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
24. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
25. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
26. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
27. REMOVE TIMING BELT GUIDE
28. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
29. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
30. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
31. REMOVE TIMING BELT (See page 14 −138)
HINT:
If reusing the timing belt, draw an arrow on the timing belt which indicates the engine revolution direction
and put match marks on the pulleys and timing belt.
32. REMOVE FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
33. REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13 −12)
34. REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13 −12)
35. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
36. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
37. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13 −12)
38. DISCONNECT RADIATOR HOSE INLET
39. DISCONNECT HEATER INLET WATER HOSE
40. DISCONNECT HEATER OUTLET WATER HOSE
41. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
42. DISCONNECT OIL COOLER HOSE

A93407SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −167
AVENSIS Supplement (RM1045E)
43. REMOVE TURBO INSULATOR NO.2 (See page 13 −12)
44. REMOVE TURBO INSULATOR NO.1 (See page 13 −12)
45. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
46. REMOVE EGR PIPE INSULATOR (See page 13 −12)
47. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
48. REMOVE EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
49. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
50. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
51. REMOVE MANIFOLD STAY NO.2 (See page 13 −12)
52. REMOVE MANIFOLD STAY (See page 13 −12)
53. REMOVE MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
54. REMOVE TURBOCHARGER STAY (See page 13 −12)
55. REMOVE TURBO WATER HOSE NO.1 (See page 13 −12)
56. REMOVE TURBO WATER HOSE NO.2 (See page 13 −12)
57. SEPARATE TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
58. REMOVE TURBOCHARGER SUB −ASSY (See page 13 −12)
59. REMOVE CAMSHAFT POSITION SENSOR (See page 14 −108)
60. REMOVE CAMSHAFT TIMING PULLEY (See page 14 −151)
SST 09960 −10010 (09962 −01000, 09963 −01000)
61. 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
NOTICE:
After removing the fuel pipe, cover the common rail and in-
jector mounting holes with vinyl tape to prevent dust from
being introduced.
62. REMOVE FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700