2005 TOYOTA AVENSIS fuel

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)

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)

A32664
A56213
Wooden Block
A83481
14−80
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
AVENSIS Supplement (RM1045E)
42. REMOVE BATTERY (See page 14 −45)
43. REMOVE AIR CLEANER ASSEMBLY WITH HOSE (See page 14 −23)
44. DISCONNECT RADIATOR HOSE INLET (See page 14 −23)
45. DISCONNECT UNION TO CONNECTOR TUBE HOSE (See page 14 −23)
46. DISCONNECT HEATER INLET WATER HOSE (See page 14 −23)
47. SEPARATE FUEL TUBE SUB −ASSY (See page 11 −1)
48. SEPARATE ENGINE WIRE
49. REMOVE THROTTLE BODY ASSY (See page 10 −8)
50. REMOVE CHARCOAL CANISTER ASSY
51. REMOVE INTAKE MANIFOLD (See page 11 −13)
52. REMOVE MANIFOLD CONVERTER INSULATOR NO.1 (See page 14 −23)
53. REMOVE EXHAUST MANIFOLD CONVERTER SUB −ASSY (See page 14 −23)
54. REMOVE NO.2 CAMSHAFT (See page 14 −64)
55. REMOVE CAMSHAFT (See page 14 −64)
56. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See page 14 −23)
57. REMOVE CAMSHAFT BEARING NO.2
58. SUPPORT ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the oil pan sub −assy.
(b) Set the jack under the engine assembly with transaxle,
then place a wooden block on the jack.
(c) Remove the chain block and sling devise.
59. REMOVE CYLINDER HEAD SUB −ASSY
(a) Remove the bolt, then separate the water by −pass pipe.
(b) Remove the camshaft housing plug.

A83481
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
14 −83
AVENSIS Supplement (RM1045E)
(i) Install the water by −pass pipe with a bolt.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
65. INSTALL CAMSHAFT (See page 14 −64)
66. INSTALL NO.2 CAMSHAFT (See page 14 −64)
67. INSTALL EXHAUST MANIFOLD CONVERTER SUB −ASSY (See page 14 −23)
68. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See page 14 −23)
69. INSTALL INTAKE MANIFOLD (See page 11 −13)
70. INSTALL THROTTLE BODY ASSY (See page 10 −8)
71. INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 14 −23)
72. INSTALL BATTERY
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for Bolt
3.5 N
m (36 kgf
cm, 31 in.
lbf) for Nut
73. INSTALL CHAIN VIBRATION DAMPER NO.1 (See page 14 −45)
74. INSTALL CHAIN SUB −ASSY (See page 14 −45)
75. INSTALL TIMING CHAIN GUIDE (See page 14 −45)
76. INSTALL CHAIN TENSIONER SLIPPER (See page 14 −45)
77. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14 −45)
78. INSTALL TIMING CHAIN OR BELT COVER SUB −ASSY (See page 14 −45)
79. INSTALL V −RIBBED BELT TENSIONER ASSY (See page 14 −45)
80. INSTALL OIL PAN SUB −ASSY (See page 14 −45)
81. INSTALL CRANKSHAFT POSITION SENSOR (See page 14 −45)
82. INSTALL CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021
83. INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14 −45)
84. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
85. INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14 −45)
86. INSTALL CYLINDER HEAD COVER SUB −ASSY (See page 14 −45)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB −ASSY
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
92. INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
93. INSTALL FUEL PUMP ASSY (See page 11 −24)

14−84
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
AVENSIS Supplement (RM1045E)
94. INSTALL FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
95. INSTALL FUEL TUBE SUB −ASSY (See page 11 −24)
96. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11 −24)
97. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
98. INSTALL VANE PUMP ASSY Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
99. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −2)
100. INSTALL GENERATOR ASSY (See page 19 −8)
101. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
102. ADD COOLANT (See page 16 −7)
103. ADD ENGINE OIL (See page 17 −6)
104. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS (See page 11 −4)
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
108. ADD POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
109. BLEED POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
110. CHECK POWER STEERING FULUID LEVEL IN RESERVOIR
(See Pub. No. RM1018E on page 51 −4)
111. CHECK FUNCTION OF THROTTLE BODY

A89214
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketzGasketFuel Tube Sub−assy
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy
zFuel Pump
Insulator
Fuel HoseFuel Pipe Sub−assy No. 1
zFuel Injector Back−up Ring No. 1
zFuel Injector Back−up Ring No. 2
zFuel Injector Back−up Ring No. 3
25 (255, 18)x2
zO−ring
9.0 (92, 80 in.
lbf)
30 (306, 22)
x2
33 (331, 24)
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
14−73
AVENSIS Supplement (RM1045E)

A84701
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketzGasketFuel Tube Sub−assy
Fuel Pipe
Clamp
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy
zFuel Pump
Insulator
Fuel HoseFuel Pipe Sub−assy No. 1
zFuel Injector Back−up Ring No. 1
zFuel Injector Back−up Ring No. 2
zFuel Injector Back−up Ring No. 3
25 (255, 18)x2
zO−ring
9.0 (92, 80 in.
lbf)
30 (306, 22)
x2
33 (331, 24)
− ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ−FSE)
14−19
AVENSIS Supplement (RM1045E)