2005 TOYOTA AVENSIS manifold belt

A77332
23
145
A77350
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±213
AVENSIS REPAIR MANUAL (RM1018E)
106.INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a)Install a new gasket and the exhaust manifold converter
with the 5 nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(b)Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
107.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
108.INSTALL V±RIBBED BELT TENSIONER ASSY Torque: 60 N
m (607 kgf
cm,44 ft
lbf)
109.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
110.INSTALL FUEL INJECTOR ASSY (See page 11±42)
111.INSTALL FUEL DELIVERY PIPE SUB±ASSY (See page 11±42)
112.INSTALL NOZZLE HOLDER CLAMP (See page 11±42)
113. INSTALL SURGE TANK STAY NO.1
(a) Install the surge tank stay with insulator No. 2. Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
114. INSTALL INTAKE MANIFOLD
(a) Install a new gasket on the cylinder head.
(b) Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
115.INSTALL FUEL PUMP ASSY (See page 11±52)
116.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
117.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±49)
118.INSTALL THROTTLE BODY ASSY (See page 10±44)
119. INSTALL THROTTLE BODY BRACKET Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
120. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
(a) Apply a light coat of engine oil to the new O±ring and install it to the c\
amshaft timing oil control valve.
(b) Install the camshaft oil control valve with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)

A79423
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket

O±ring
* Use SST
Gasket
Gasket

Gasket

Gasket

Gasket3.6 to 6.9 (40 to 70, 35 to 61 in.
lbf)
5.0 (51, 44 in.
lbf)
7.4 (76, 66 in.
lbf)
* 31 (316, 23)
34 (347, 25)
43 (438, 32)
21 (214, 15)
18 (184, 13)
21 (214, 15)
21 (214, 15)
21 (214, 15)
64 (650, 47)
21 (214, 15)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2

Injection Pipe Sub±assy
* 31 (316, 23)
34 (347, 25)
Common Rail Assy
Fuel Hose No. 4
Vacuum Pump Assy
Nozzle Leakage Pipe No. 2Fuel Inlet Pipe Sub±assy
EGR Valve Assy
Water Outlet Sub±assy
Engine Coolant
Temperature Sensor
Intake Air Connector Sub±assy
Intake Manifold
Wiring Harness Clamp Bracket Injection Pump
Drive Pulley Timing Belt
No. 3 CoverSeal Washer Camshaft Position Sensor
Check Valve
8.8 (90, 78 in.
lbf)
8.8 (90, 78 in.
lbf)
21 (214, 15)
21 (214, 15)
14±284
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

141C2±01
A78277
A79143
SST
14±270
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1CD±FTV)
ADJUSTMENT
NOTICE:

Before removing the injection pipes, clean them up with a soft brush and compr\
essed air.

After removing the injection pipe, cover the supply pump, the common rail and the injector
mounting area of the cylinder head cover with vinyl tape to prevent dust from being introduce\
d.

After removing the cylinder head cover, protect the injector inlet with a vinyl or a plastic bag
to prevent foreign objects from being introduced.
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE FRONT WHEEL RH
3.REMOVE ENGINE UNDER COVER RH
4.DRAIN ENGINE COOLANT (See page 16±44)
5.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
6.REMOVE AIR TUBE NO.1
(a)Disconnect the vacuum hoses and the connectors.
(b)Loosen the hose clamps.
(c)Remove the 3 bolts and nut, and then detach the air tubeNo. 1.
7.REMOVE TIMING BELT NO.2 COVER (See page 14±307) 8. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clampsfrom 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 a
plastic bag.

A77332
23
145
A77350
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
14±261
AVENSIS REPAIR MANUAL (RM1018E)
67.INSTALL EXHAUST MANIFOLD CONVERTER
SUB±ASSY
(a)Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N
m (378 kgf
cm, 27 ft
lbf)
(b)Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
68.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N
m (122 kgf
cm,9.0 ft
lbf)
69.INSTALL INTAKE AIR CONTROL VALVE ASSY
(a)Install a new gasket and the intake air control valve.
70.INSTALL INTAKE MANIFOLD
(a)Install the 2 stud bolts. Torque: 10 N
m (97 kgf
cm,84 in.
lbf)
(b)Install the intake manifold and insulator with the 5 bolts and 2 nuts. Torque: 30 N
m (306 kgf
cm,22 ft
lbf)
71.INSTALL THROTTLE BODY ASSY (See page 10±44)
72. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
73. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
74.INSTALL CHAIN SUB±ASSY (See page 14±222)
75. INSTALL TIMING CHAIN GUIDE Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
76. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 N
m (195 kgf
cm, 15 ft
lbf)
77.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±240)
78.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±222)
79.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±222)
80.INSTALL OIL PAN SUB±ASSY (See page 14±222)
81.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
82.INSTALL CRANKSHAFT PULLEY (See page 14±222) SST 09213±54015 (91651±60855), 09330±00021
83.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±222)
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±222)

A15985
A78280
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±291
AVENSIS REPAIR MANUAL (RM1018E)
56.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
57.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
58.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
59.REMOVE TIMING BELT GUIDE
60.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
61.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
62.REMOVE TIMING BELT (See page 14±307)
HINT:
If re±use the timing belt, draw an arrow which indicates the engine rev\
olution direction on the belt and put
match marks on the pulleys and the belt before removing. This operation will \
be very helpful when re±instal-
ling the timing belt.
63.REMOVE GENERATOR ASSY
64.REMOVE GENERATOR BRACKET NO.1
(a)Remove the 2 bolts and the generator bracket.
65.REMOVE V±RIBBED BELT TENSIONER ASSY
66.REMOVE OIL FILTER BRACKET SUB±ASSY
(a)Remove the bolt and 2 nuts, and then remove the oil filter
bracket and the gasket.
67.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
68.REMOVE TURBO INSULATOR NO.1 (See page 13±11)
69.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
70.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
71.REMOVE MANIFOLD STAY (See page 13±11)
72.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
73.REMOVE TURBOCHARGER STAY (See page 13±11)
74.DISCONNECT TURBO WATER HOSE NO.1 (See page 13±11)
75.DISCONNECT TURBO WATER HOSE NO.2 (See page 13±11)
76.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
77.REMOVE TURBO OIL OUTLET PIPE NO.2 (See page 13±11)
78.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11) 79. DISCONNECT WATER BY±PASS HOSE NO.3

A79150
A61175
A09671
14±294
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
93.REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a)Remove the 2 bolts and the intake manifold insulator.
94.REMOVE COMMON RAIL ASSY (See page 11±78) 95.REMOVE POWER STEERING IDLE PULLEY
BRACKET
(a)Remove the 3 bolts and the idle pulley bracket.
96.REMOVE INTAKE MANIFOLD
(a)Remove the 2 bolts and the wiring harness clamp bracket.
(b)Remove the 8 bolts and 2 nuts, and then remove the in- take manifold and the gasket.
97.REMOVE INJECTION PUMP DRIVE PULLEY (See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
98. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, and then remove the timing belt c\
over.
99.REMOVE OIL LEVEL GAGE GUIDE (See page 17±22)
100.REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11±69)
101. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
(a) Remove the 4 bolts and the compressor mounting bracket.
102. REMOVE WATER INLET
(a) Remove the 2 bolts and the water inlet.
103. REMOVE THERMOSTAT
104. REMOVE OIL COOLER PIPE
(a) Remove the union bolt, the oil cooler pipe and the gasket.
105. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and nut, and then detach the fuel pipe.

A79173New O±Ring
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±295
AVENSIS REPAIR MANUAL (RM1018E)
106.REMOVE CRANKSHAFT POSITION SENSOR
(a)Remove the bolt and the crankshaft position sensor.
107.REMOVE CAMSHAFT POSITION SENSOR
(a)Remove the bolt and the camshaft position sensor.
108.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
109.REPLACE PARTIAL ENGINE ASSY
110.INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Torque: 20 N
m (204 kgf
cm,15 ft
lbf)
111.INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
112.INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
113.INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE Torque:
8.8 N
m (90 kgf
cm,78 ft
lbf) for M6 and Nut
21 N
m (209 kgf
cm,15 ft
lbf) for M8
114.INSTALL OIL COOLER PIPE
(a)Install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 59 N
m (600 kgf
cm,43 ft
lbf)
115.INSTALL THERMOSTAT (See page 16±50)
116.INSTALL WATER INLET (See page 16±50)
117. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
118. INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
119. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O±ring to the oil level gage guide.
(b) Apply engine oil to the O±ring.
(c) Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d) Install the oil level gage guide with the bolt. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
(e) Apply engine oil to the O±ring on the oil level gage.
(f) Install the oil level gage.
120. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
121.INSTALL INJECTION PUMP DRIVE PULLEY (See page 11±69)
SST 09960±10010 (09962±01000, 09963±01000)
122. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts\
. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(b) Install the wiring harness clamp bracket with the 2 bolts.
Torque: 3.9 to 6.9 N
m (40 to 70 kgf
cm, 35 to 61 in.
lbf)

160ME±01
A79148
SST
16±46
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
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) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)