2005 TOYOTA AVENSIS timing belt

05±546
±
DIAGNOSTICS ECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E) P0380
(05±622)
Glow Plug/Heater Circuit ºAº

Open or short in glow plug circuit

Glow fuse

Glow relay

Glow plug

ECM

P0400
(05±629)Exhaust Gas Recirculation Flow
EGR valve assy

EGR passage
P0403
(05±629)Exhaust Gas Recirculation Con-
trol Circuit
EGR assage

Open or short in EGR circuit

ECM
P0488
(05±633)Exhaust Gas Recirculation
Throttle Position Control Range/
Performance
Open or short in intake shutter circuit

Open or short in fully opened switch circuit

Intake shutter

ECM

P0500
(05±640)Vehicle Speed Sensor ºAº

Open or short in speed sensor circuit

Speed sensor

Combination meter

ECM

Skid control ECU

P0504
(05±643)Brake Switch ºAº/ºBº Correlation

Short in stop lamp switch signal circuit

Stop lamp switch

ECM


P0560
(05±647)System Voltage
Open in back±up power source circuit

ECM
P0606
(05±650)ECM/PCM Processor

ECM



P0607
(05±650)Control Module Performance

ECM

P0622
(05±651)Generator Field ºFº Terminal Cir-
cuit

Open in generator circuit

Generator

Drive belt

ECM

P0627
(05±655)Fuel Pump Control Circuit / Open

Open or shot in suction control valve circuit

Suction control valve

ECM

P1229
(05±563)Fuel Pump System

Short in supply pump (suction control valve) circuit

Suction control valve

ECM

P1238
(05±658)Injector Malfunction

Injector

EDU (P0200 is set simultaneously)

Open or short in engine wire (P0200 is set simultaneously)

Connector connection (P0200 is set simultaneously)

Compression pressure

Valve clearance

Valve timing

ECM

P1251
(05±612)Turbo/Super Charger Overboost
Condition (Too High)

VRV

Open or short in VRV circuit

Turbocharger

EGR valve

Vacuum hose

ECM

P1271
(05±663)Fuel Regulator Circuit Malfunc-
tion (EDU Drive)

Open or short in pressure discharge valve circuit

Open or short in pressure discharge valve it self

EDU

ECM

P1272
(05±663)Fuel Pressure Regulator Mal-
function

Open or short in pressure discharge valve circuit (P1271 is set
simultaneously)

Pressure discharge valve

Supply pump

ECM


110UA±01
A15950
±
FUEL INJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
11±69
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.DRAIN ENGINE COOLANT(See page 16±44)
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
9.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
10.DISCONNECT RADIATOR HOSE OUTLET
(a)Disconnect the radiator hose outlet from the water inlet.
11.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.REMOVE INJECTOR DRIVER
(a)Remove the 2 nuts which are used to secure the injector driver.
(b)Disconnect the injector driver connector and the harness clamp.
(c)Remove the injector driver.
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
15.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
16.REMOVE IDLER PULLEY SUB±ASSY
(a)Remove the bolt and washer, then remove the idler pulley.
17.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
19. REMOVE TIMING BELT GUIDE
20. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 6 bolts and the engine mounting bracket.
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
23.REMOVE TIMING BELT(See page 14±307)

A79149
SST
30 cm
(11.81 in.)
11±74
±
FUEL INJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
46.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the injection pump replaced, must
replace the fuel inlet pipe, too.

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.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can 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.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
47.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
48.INSTALL TIMING BELT(See page 14±307)
49.CHECK VALVE TIMING(See page 14±307)
50.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
51. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Torque:
37 N
m (375 kgf
cm, 27 ft
lbf) for 14mm head bolt
64 N
m (650 kgf
cm, 47 ft
lbf) for 17mm head bolt

±
FUEL INJECTION OR SUPPLY PUMP ASSY (1CD±FTV)
11±75
AVENSIS REPAIR MANUAL (RM1018E)
52.INSTALL TIMING BELT GUIDE(See page 14±307)
53.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
54.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
55. INSTALL IDLER PULLEY SUB±ASSY
Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
56.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
57.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
58. INSTALL INJECTOR DRIVER Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
59. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
60.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
61. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
62.INSTALL AIR CLEANER ASSY (See page 11±60)
63. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
64.ADD ENGINE COOLANT(See page 16±44)
65.CHECK FOR ENGINE COOLANT LEAKS(See page 16±37)
66.CHECK FOR FUEL LEAKS(See page 11±60)

A61211
: Specified torqueN´m (kgf´cm, ft´lbf)
* Replace only if damagedTiming Belt No. 2 Cover
Transverse Engine
Engine Mounting Bracket
Seal Washer Timing Belt No.1 Cover
Crankshaft Pulley Seal Washer
x 5 Generator V belt
Glow Plug
Screw Grommet Timing Belt GuideTiming Belt * Gasket
x 7
Glow Plug Assy * Gasket Timing Chain Cover Plate
Timing Belt
Tensioner
180 (1,837, 133)
21 (214, 15)
9.0 (92, 80 in.´lbf)
37 (375, 27)
64 (650, 47)
2.2 (22, 19 in.´lbf)
7.4 (76, 66 in.´lbf)
7.4 (76, 66 in.´lbf)
Idler Pulley
40 (408, 30)Glow Plug
No.1 Connector
± FUELINJECTION OR SUPPLY PUMP ASSY (1CD±FTV)
11±67
AVENSIS REPAIR MANUAL (RM1018E)

110U8±01
A79143
SST
11±60
±
FUEL INJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes
which are used to optimize fuel injection for the injectors. When replacing t\
he injector assembly, a compensa-
tion code for the new injector assembly must be set to the ECM.
1.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
4.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
5.REMOVE AIR TUBE NO.1 (See page 14±270) 6. 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 plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
9. REMOVE INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, then remove the timing belt cover\
.

A79147
SST
30 cm
(11.81 in.)
11±64
±
FUEL INJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
20.INSTALL NOZZLE HOLDER SEAL
(a)Install new 4 nozzle holder seals.
21.INSTALL TIMING BELT NO.2 COVER(See page 14±307) 22. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:

In case of having the injectors replaced, must replace
the injection pipes, too.

When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and
vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)

A79442
Timing Belt No. 2 Cover
Seal Washer *
2 Gasket
Injection Pipe
Clamp No. 2

Injection
Pipe Sub±assy
13 (135, 9.7)
Cylinder Head Cover Sub±assy
Gasket

Nozzle Holder Seal

Gasket

O±ring
Fuel Injector Back±up Ring No. 1

Injection Nozzle Seat Washer
Nozzle Holder ClampNozzle Leakage
Pipe Assy
Injector Assy
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
7.4 (75, 65 in.´lbf)
*1 31 (316, 23)
34 (347, 25)

Gasket
22 (224, 16)
18 (184, 13)
27 (270, 20)
Nozzle
Leakage
Pipe No. 2
*1 Use SST
*2 Replace only if damaged
*1 31 (316, 23)
34 (347, 25)
5.0 (51, 44 in.´lbf)

Gasket
21 (214, 15)
8.8 (90, 79 in.´lbf)
± FUELINJECTOR ASSY (1CD±FTV)
11±59
AVENSIS REPAIR MANUAL (RM1018E)