2005 TOYOTA AVENSIS check engine

A86430
New GasketHollow
Screw
SST
A09663
:Seal Packing
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −157
AVENSIS Supplement (RM1045E)
(1) Apply a light coat of soapy water (any fluid to detect
fuel leakage) to the nozzle leakage pipe connec-
tion.
(2) Using SST (a turbocharger pressure gauge), attach SST to the fuel return side of the nozzle leakage
pipe, then maintain 100 kPa (1.0 kgf/cm
2 , 14.5 psi)
of pressure for 60 seconds to check that there are
no bubbles from the pipe connection.
SST 09992 −00242
(3) After checking fuel leaks, wipe off soapy water from the pipe connection.
56. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as illustrated. Seal packing: Part No. 08826 −00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
57. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
58. INSTALL NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
59. INSTALL VACUUM PUMP ASSY (See page 14 −108)
60. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold at room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Remove the vinyl or plastic bag from the injector and the
vinyl tape from the common rail.
(c) Temporarily install the injection pipe.

A87959
Fulcrum Length
30 cm (11.81 in.)
SST
14−158
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(d) Using SST, tighten the nut of the injection 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 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) 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.
61. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
62. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
63. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
64. INSTALL FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
65. INSTALL TIMING BELT (See page 14 −138)
66. CHECK VALVE TIMING (See page 14 −138)
67. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
68. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
69. INSTALL TIMING BELT GUIDE (See page 14 −138)

−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −159
AVENSIS Supplement (RM1045E)
70. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
71. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
72. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
73. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
74. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
75. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
76. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
77. INSTALL INJECTOR DRIVER (See page 14 −108)
78. INSTALL AIR TUBE NO.1 (See page 14 −108)
79. INSTALL VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
80. INSTALL BATTERY (See page 14 −108)
81. INSTALL AIR CLEANER ASSY (See page 14 −108)
82. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
83. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
84. CHECK FOR FUEL LEAKS (See page 11 −46)

A84302
A84303
A09605Turn
A61185
14−140
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
17. REMOVE TIMING BELT NO.1 COVER
(a) Remove the 5 bolts and 5 seal washers, then remove the
timing belt cover.
18. REMOVE TIMING BELT GUIDE
19. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 6 bolts and engine mounting bracket.
20. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, align the dot mark of the
crankshaft timing gear with the TDC mark of the oil pump
by turning the crankshaft.
(b) Check that the timing mark of the camshaft timing pulley
is aligned with the joint of the cylinder head and cylinder
head cover.

A09612
1st
2nd 5th
3rd
4th 6th 7th
A09609
Timing Mark
Timing
Mark
Timing Mark
A09589
Hexagon
Wrench
(1.27 mm)
(A)
A09623
14−142
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
24. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Remove any oil or water on each pulley, then keep them
clean.
NOTICE:
Do not use any cleaning agent.
(b) Install the timing belt in the following order:
1. Camshaft timing pulley
2. Supply pump drive pulley
3. Water pump pulley
4. Crankshaft timing pulley
5. No. 2 idler pulley
6. Oil pump pulley
7. No. 1 idler pulley
(c) Check that the timing marks are aligned as shown in the
illustration.
(d) Install the timing belt tensioner.
(1) Using a press, slowly press in the push rod with
pressure of 981 to 9,807 N (100 to 1,000 kgf, 200
to 2,205 lbf).
(2) Align the holes of the push rod and housing, then
insert hexagon wrench (1.27 mm) through the holes
to keep the setting position of the push rod.
(3) Release the press.
(4) Temporarily install the tensioner with bolt (A).
(5) Turn the tensioner clockwise, then temporarily
install the other bolt.

A61179
Hexagon
Wrench
(1.27 mm)
A09605
Dot Mark
TDC Mark
Turn
A09679
A84303
A
AAA
AB
B
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
14−143
AVENSIS Supplement (RM1045E)
(6) Alternately tighten the 2 bolts.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
(7) Remove the hexagon wrench from the tensioner.
25. CHECK VALVE TIMING
(a) Slowly turn the crankshaft by 2 complete revolutions
(720_) from the TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.
HINT:
Align the TDC mark with the dot mark.
(b) Check that each timing mark of the pulleys is aligned with
the timing marks of the engine assembly as shown in the
illustration.
If the timing marks are not aligned, remove the timing belt, then
reinstall it.
(c) Remove the crankshaft pulley bolt.
26. INSTALL TIMING CHAIN COVER PLATE
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
27. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
Torque:
37 N·m (375 kgf·cm, 27 ft·lbf) for bolt A
64 N·m (650 kgf·cm, 47 ft·lbf) for bolt B

A09596
A09603
Seal Packing
Gasket
Groove 14−144
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
28. INSTALL TIMING BELT GUIDE
(a) Install the belt guide with the cap side facing outward.
29. INSTALL TIMING BELT NO.1 COVER
(a) Check the timing belt cover gasket for cracks or deteriora-
tions, etc.
If the gasket has cracked or deteriorated, replace it by the fol-
lowing steps:
(1) Using a screwdriver and gasket scraper, remove all
the old gaskets.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Remove the backing paper from a new gasket, then
affix the gasket to the timing belt cover as shown in
the illustration.
NOTICE:
SAffix the gasket at the center of the groove.
SAt the corners, try to keep the gasket thickness uni-
form.
(4) After installing the gasket, press it down so that the
adhesive firmly sticks to the timing belt cover.
(5) If there is a gap between the ends of the gasket, use
seal packing to close the gap.
Seal packing: Part No. 08826−00080 or equivalent
(b) Install the No. 1 timing belt cover and gasket with the 5
bolts and 5 seal washers.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
(c) After installing the belt cover, check that there is no peel-
ings of the gasket.
30. INSTALL TIMING BELT NO.2 COVER
(a) Check the timing belt cover gasket for cracks or deteriora-
tions, etc.
If the gasket has cracked or deteriorated, replace it by the fol-
lowing steps:
(1) Using a screwdriver and gasket scraper, remove all
the old gasket.
(2) Thoroughly clean all components to remove all the
loose material.

A87959
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −123
AVENSIS Supplement (RM1045E)
133. INSTALL INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
134. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts. Torque: 21 N
m (209 kgf
cm, 15 ft
lbf)
135. INSTALL COMMON RAIL ASSY (See page 11 −67)
136. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
137. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
SIn case of replacing the injectors, the injection pipes
must be replaced, too.
SWhen assembling the pipes, perform the operation
with the engine cold at room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Temporarily install a new injection pipe.
(c) Using SST, tighten the nut of the injection 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 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.