2005 TOYOTA AVENSIS fuel

A85631
SST
A85632
A93406
SST
14−120− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, remove the fuel pipe No.
3 from the injector side.
SST 09023−12700
(c) Remove the bolt and 3 nuts, then remove the fuel pipe No.
3 and 2 gaskets.
100. 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.
101. REMOVE INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
102. REMOVE INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
103. REMOVE INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.

A84380
A84378
14−122−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
116. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and fuel pipe.
117. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
118. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor. 119. REM O VE ENG I NE CO O L ANT TEM PERAT URESENSOR
120. REPLACE PARTIAL ENGINE ASSY
121. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Torque: 20 N
m (200 kgf
cm, 14 ft
lbf)
122. INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
123. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
124. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE
Torque:
8.8 N
m (90 kgf
cm, 78 in.
lbf) for M6
21 N
m (209 kgf
cm, 15 ft
lbf) for M8
125. INSTALL OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 56 N
m (575 kgf
cm, 42 ft
lbf)
126. INSTALL THERMOSTAT (See Pub. No. RM1018E on page 16 −50)
127. INSTALL WATER INLET (See Pub. No. RM1018E on page 16 −50)
128. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
129. INSTALL INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
130. INSTALL INJECTION PUMP STAY NO.1 (See page 11 −58)
131. INSTALL OIL LEVEL GAGE GUIDE (See page 17 −11 )
132. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

A85632
14−124− ENGINE MECHANICALPARTIAL ENGINE ASSY (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:
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.
(e) Install the 2 upper injection pipe clamps.
138. INSTALL INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
139. INSTALL INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
140. INSTALL INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
141. INSTALL FUEL PIPE NO.3
(a) Install 2 new gaskets, then temporarily install the bolt, 3
nuts and fuel pipe No. 3.

A85631
SST
A85632
A
A
BA
A87960
Fulcrum Length
30 cm (11.81 in.)
SST
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−125
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, tighten the nut of the fuel
pipe No. 3 on the injector side.
SST 09023−12700
Torque:
22 N
m (223 kgf
cm, 16 ft
lbf) with SST
23.5 N
m (240 kgf
cm, 17 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.
(c) Tighten the bolt and 3 nuts.
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt and nut A
27 N
m (275 kgf
cm, 20 ft
lbf) for nut B
(d) Install the fuel pipe insulator.
142. INSTALL FUEL INLET PIPE SUB−ASSY
NOTICE:
SIn case of replacing the cylinder head, 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.
(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:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter 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.

A79196
New O−ring
New O−ring
A79182
Collar
Groove
14−126− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(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:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter 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.
143. INSTALL NOZZLE LEAKAGE PIPE NO.2
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
144. INSTALL VACUUM PUMP ASSY
(a) Install 2 new O−rings to the vacuum pump.
(b) Align the key of the vacuum pump with the keyway of the
exhaust camshaft, then insert the vacuum pump into
place. Secure the pump with the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
145. INSTALL WATER OUTLET SUB−ASSY
(a) Install a new gasket and the water outlet with the 2 bolts.
Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
146. INSTALL EGR VALVE ASSY
(a) Install a new gasket and the EGR valve with the bolt and 2 nuts.
Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
147. INSTALL INTAKE AIR CONNECTOR
(a) Install a new gasket and the intake air connector together with the diesel throttle body with the 3 bolts.
Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
148. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket, the exhaust manifold and 8 collars
with new 8 nuts.
Torque: 47 N
m (474 kgf
cm, 34 ft
lbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. The ring groove of the collar should be outward. Re-
fer to the illustration on the left.

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)

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.