2005 TOYOTA AVENSIS fuel reserve

±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±217
AVENSIS REPAIR MANUAL (RM1018E)
158.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
159.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
160.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
161.INSTALL BATTERY CARRIER
162.INSTALL AIR CLEANER ASSEMBLY WITH HOSE
Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
163.INSTALL COMPRESSOR AND MAGNETIC CLUTCH Torque: 25 N
m (255 kgf
cm,18 in.
lbf)
164.INSTALL GENERATOR ASSY (See page 19±20)
165.INSTALL FAN AND GENERATOR V BELT (See page 14±185)
166.INSTALL RADIATOR ASSY (See page 16±36)
167. INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
168. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
169. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
170. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
171. ADD ENGINE OIL
172.ADD COOLANT (See page 16±31)
173.ADD POWER STEERING FLUID (See page 51±4)
174. BLEED POWER STEERING FLUID
175. CHECK FOR ENGINE OIL LEAKS
176.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
177.CHECK FOR FUEL LEAKS (See page 11±30)
178. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
179.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
180.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±204)
181. INSPECT CO/HC
182. CHECK ABS SPEED SENSOR SIGNAL

A80059
30 (306, 22)
Radiator Reserve
Tank Sub±assy
Fuel Tube Sub±assy
Exhaust Pipe Assy center

Gasket

Gasket
Gasket
Floor Panel Brace Front Vane Pump Oil
Reservoir Assy
Accelerator Control
Cable Sub±assy
Fuel Pipe Clamp
Exhaust Pipe Assy Front
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
Return Tube
Sub±assy
43 (440, 32)
5.0 (51, 44 in.
lbf)
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
43 (440, 32)
43 (440, 32)
43 (440, 32)
43 (440, 32)
43 (440, 32)
5.0 (51, 44 in.
lbf)
14±194
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

F42620
F40019
32±20
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Install the clevis pin and clip to the brake master cylinder clevis.
(c) Connect the vacuum hose to the brake booster assy.
16. CONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, connect the brake tube to the flexible hose.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
17. INSTALL FRONT WHEEL LH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18.INSTALL HEATER ASSY (W/ COLD AREA) (See page 55±100)
19.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
20. INSTALL CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
21.INSTALL FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
22. CONNECT ENGINE ROOM RELAY BLOCK
23. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
24.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
25.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
26.BLEED BRAKE LINE (See page 32±4)
27.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
28.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
29.CHECK PEDAL FREE PLAY (See page 32±6)
30.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
31. CHECK FUEL LEAK
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
33. CHECK BRAKE FLUID LEAKAGE

110UC−02
A93407SST
A93406
SST
−
FUEL COMMON RAIL ASSY (1CD −FTV)(From September,
2003)11 −67
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DRAIN ENGINE COOLANT (See page 16 −19)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER SUB −ASSY NO.1
(a) Remove the 5 nuts and engine cover.
4. REMOVE RADIATOR RESERVE TANK SUB −ASSY (See Pub.No. RM1018E on page 16 −50)
5. REMOVE FUEL INLET PIPE SUB −ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023 −12700
(b) Using SST, remove the fuel inlet pipe from the injection
pump.
SST 09023 −12700
6. REMOVE FUEL PIPE NO.3 (See page 11 −46)
SST 09023 −12700
7. REMOVE INJECTION PIPE SUB −ASSY NO.1
(a) Remove the 2 nuts and 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, to prevent dust or foreign ob-
jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
8. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
9. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.

A87960
30 cm
(11.81 in.)
SST
11−70−
FUEL COMMON RAIL ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
21. INSTALL FUEL INLET PIPE SUB −ASSY
NOTICE:
S In case of replacing the common rail, the fuel inlet
pipe must be replaced, too.
S When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a) Temporarily install the fuel inlet pipe.
(b) Using SST, tighten the nut of the fuel inlet pipe to the com-
mon 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 to the injec- tion 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.
22. INSTALL RADIATOR RESERVE TANK SUB −ASSY (See Pub. No. RM1018E on page 16 −50)
23. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
24. ADD ENGINE COOLANT (See page 16 −19)
25. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
26. CHECK FOR FUEL LEAKS (See page 11 −46)

110UB−02
A85743
8.0 (82, 71 in.
lbf)
Engine Cover Sub−assy No. 1Radiator Support Opening Cover
N·m (kgf·cm, ft·lbf)
: Specified torque
6.0 (61, 53 in.
lbf)
Radiator Reserve
Tank Assy
Clip
Ratainer
x5
− FUELCOMMON RAIL ASSY (1CD−FTV)(From September,
2003)11−65
AVENSIS Supplement (RM1045E)
COMMON RAIL ASSY (1CD−FTV)(From September, 2003)
COMPONENTS

110U9−02
A85741
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
7.0 (71, 62 in.
lbf)
N·m (kgf·cm, ft·lbf)
: Specified torque
Radiator Hose Outlet
Clip
Engine Room Cover Side
Clip
Retainer
Radiator Support
Opening Cover
8.0 (82, 71 in.
lbf)
5.5 (56, 49 in.
lbf)
V (Cooler Compressor
to Crankshaft Pulley)
Belt No. 1
Injector Driver
72 (734, 53)
52 (530, 38)52 (530, 38)
Engine Cover
Sub−assy No. 1
Engine Mounting Insulator Sub−assy RH
39 (398, 29)
Power Steering
Idle Pulley Bracket
52 (530, 38)
Clip
Engine Under Cover RH
Engine Under Cover Sub−assy No. 1
Clip
Radiator Reserve Tank Assy
6.0 (61, 53 in.
lbf)
x5
x3
Exhaust Gas Temperature
Sensor Connector
Vacuum Hose
Mass Air Flow Meter
Connector
− FUELINJECTION OR SUPPLY PUMP
ASSY (1CD−FTV)(From September, 2003)11−55
AVENSIS Supplement (RM1045E)
INJECTION OR SUPPLY PUMP ASSY (1CD−FTV)(From
September, 2003)
COMPONENTS