2005 TOYOTA AVENSIS fuel

A93406
SST
A09656
A85924
14−168−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
63. 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.
64. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
65. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
66. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
67. REMOVE VACUUM PUMP ASSY (See page 14 −108)
68. REMOVE NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
69. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
70. REMOVE CYLINDER HEAD COVER SUB −ASSY
(a) Remove the 10 bolts, cylinder head cover and gasket.

A85925
A09566
1
234 5
67 89
10 11
12 13
14 15
16
1718
A61194
Pry
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −169
AVENSIS Supplement (RM1045E)
71. REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 14 −151)
72. 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. 73. REM O VE EXHAUST F UEL ADDI TI O N I NJECTO R
ASSY
(a) Using a Torx socket wrench (T40), remove the Torx screw.
NOTICE:
Be careful that the tools do not interfere with the resin part
when removing.
(b) Remove the nozzle holder clamp, addition injector and gasket.
74. REMOVE CAMSHAFT OIL SEAL RETAINER (See page 14 −151)
75. REMOVE CAMSHAFT (See page 14 −151)
76. REMOVE NO.2 CAMSHAFT (See page 14 −151)
77. REMOVE CYLINDER HEAD SUB −ASSY
(a) Using several steps, loosen the 18 cylinder head bolts
uniformly in the sequence shown in the illustration. Re-
move the 18 cylinder head bolts and plate washers.
NOTICE:
Removing the bolts in a wrong order could cause warpage
or cracks of the cylinder head.
(b) Lift the cylinder head from the dowels on the cylinder block, then place the cylinder head on wooden blocks on
a work bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
To lift the cylinder head, pry between the cylinder head and cyl-
inder block using a screwdriver.
78. REMOVE CYLINDER HEAD GASKET

14−174−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
(e) 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.
(f) Install the 2 upper injection pipe clamps.
98. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
99. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
100. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
101. INSTALL FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
102. INSTALL FUEL INLET PIPE SUB −ASSY
NOTICE:
SIn case of replacing the cylinder head gasket, 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.

A87960
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −175
AVENSIS Supplement (RM1045E)
(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:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After 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.
(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:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After 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.
103. INSTALL TURBOCHARGER SUB −ASSY (See page 13 −12)
104. INSTALL TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
105. INSTALL TURBOCHARGER STAY (See page 13 −12)
106. INSTALL MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
107. INSTALL MANIFOLD STAY NO.2 (See page 13 −12)
108. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
109. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
110. INSTALL EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
111. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
112. INSTALL EGR PIPE INSULATOR (See page 13 −12)
113. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
114. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
115. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
116. INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13 −12)
117. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
118. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
119. INSTALL HEATER BRACKET (W/ COLD AREA) (See page 13 −12)
120. INSTALL HEATER PUMP ASSY (W/ COLD AREA) (See page 13 −12)
121. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)

14−176−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
122. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
123. INSTALL TIMING BELT (See page 14 −138)
124. CHECK VALVE TIMING (See page 14 −138)
125. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
126. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
127. INSTALL TIMING BELT GUIDE (See page 14 −138)
128. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
129. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
130. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
131. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
132. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
133. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
134. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
135. INSTALL INJECTOR DRIVER (See page 14 −108 )
136. INSTALL AIR TUBE NO.1 (See page 14 −108)
137. INSTALL AIR TUBE NO.2 (See page 14 −108)
138. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
139. INSTALL BATTERY (See page 14 −108)
140. INSTALL AIR CLEANER ASSY (See page 14 −108)
141. INSTALL VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
142. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
143. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
144. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
145. ADD ENGINE COOLANT (See page 16 −19)
146. CHECK FOR FUEL LEAKS (See page 11 −46)
147. CHECK FOR ENGINE OIL LEAKS
148. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
149. CHECK FOR EXHAUST GAS LEAKS

141NK−01
SSTA61187
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −151
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. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
8. REMOVE AIR CLEANER ASSY (See page 14 −108)
9. REMOVE BATTERY
10. REMOVE VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
11. REMOVE AIR TUBE NO.1 (See page 14 −108)
12. REMOVE INJECTOR DRIVER (See page 14 −108)
13. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
14. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
15. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
16. DISCONNECT ENGINE WIRE (See page 14 −138)
17. DISCONNECT VACUUM HOSE (See page 14 −108)
18. REMOVE ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
19. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
20. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
21. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
22. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
23. REMOVE TIMING BELT GUIDE
24. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
25. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
26. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
27. REMOVE TIMING BELT (See page 14 −138)
28. REMOVE CAMSHAFT POSITION SENSOR (See page 14 −108)
29. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt. SST 09960 −10010 (09962 −01000, 09963 −01000)
(b) Remove the timing pulley.
HINT:
Using a plastic −faced hammer, tap out the pulley.
(c) Remove the set key.
30. REMOVE FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700

A93406
SST
A09656
A85924
14−152
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
31. 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.
32. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
33. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
34. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
35. REMOVE VACUUM PUMP ASSY (See page 14 −108)
36. REMOVE NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
37. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
38. REMOVE CYLINDER HEAD COVER SUB −ASSY
(a) Remove the 10 bolts, cylinder head cover and gasket.

A85934
A09668
A09650
1
3
2 4
5
9 6
87
14
10
11
15
13
12
A09619
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −153
AVENSIS Supplement (RM1045E)
39. REMOVE NOZZLE LEAKAGE PIPE ASSY
(a) Remove the 4 hollow screws and bolt.
(b) Remove the nozzle leakage pipe and 4 gaskets from the
cylinder head and injector.
40. 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.
41. REMOVE CAMSHAFT OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by pryingbetween the oil seal retainer and camshaft bearing cap.
42. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 14 bearing cap bolts uniformly in the sequence shown in the illustra-
tion.
(b) Remove the 5 bearing caps and camshaft sub −assembly.
43. REMOVE NO.2 CAMSHAFT
(a) Remove the camshaft sub −assembly and camshaft carrier.
44. REMOVE CAMSHAFT OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal.