2005 TOYOTA AVENSIS tow

H42762
Tires
(5 or more)
SST(s)
H42763
SST(s)
H42764
Battery SST(s)
10 m (33 ft) or more
± SUPPLEMENTAL RESTRAINT SYSTEMCURTAIN SHIELD AIR BAG ASSY LH
60±45
AVENSIS REPAIR MANUAL (RM1018E)
(f) Place the tires.
CAUTION:
Do not place the deployment direction of the curtain shield
airbag assy LH facing toward the ground.
(1) Place at least 2 tires under the tire to which the cur-
tain shield airbag assy LH is tied.
(2) Place at least 2 tires over the tire to which the curtain
shield airbag assy is tied. The top tire should have
the wheel installed.
NOTICE:
Do not place the SST(s) connector under the tire because
the SST connector could be damaged.
(3) Tie the tires together with 2 wire harnesses.
CAUTION:
Make sure that the wire harness is tight. It is highly danger-
ous when looseness in the wire harness results in the tires
coming free due to the shock from the airbag deployment.
HINT:
Place the SST(s) connector and the wire harness inside tires.
Secure at least 1 m (3 ft) of slack for the wire harness.
(g) Install the SST(s).
Connect one SST(s) connector to the SST(s) connector
connected to the curtain shield airbag.
SST 09082±00700
NOTICE:
To avoid damaging the SST(s) connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST(s) wire harness inside the tire.
(h) Deploy the airbag.
(1) Connect the red clip of the SST(s) to the battery
positive (+) terminal and the black clip of the SST(s)
to the battery negative (±) terminal.
(2) Check that no one is within a 10 m (33 ft) radius of
the tire to which the curtain shield airbag assy LH is
tied.
(3) Press the activation switch of the SST(s) and
deploy the airbag.
HINT:
The airbag deploys as the LED of the SST(s) activation switch
comes on.

C81320
C81321
C81322
40±74
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL FRONT DIFFERENTIAL SIDE GEAR
[ 41331F / 4301 ]
(a) After applying ATF to the 2 front differential side gears, 2
side gear thrust washers No. 1, 2 front differential pinions
and 2 pinion thrust washers, install them to the front differ-
ential case.
HINT:
At the time of installation, set the alignment of the front differen-
tial pinions perpendicular to that of the side gear and rotate
them so that their holes will be aligned with the holes in the dif-
ferential case.
11. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
[ 41342F / 4301 ]
(a) Install the pinion shaft so as to align the lock pin holes on
the pinion shaft and differential case.
12. INSPECT BACKLASH
(a) Measure the side gear backlash while holding 1 pinion
gear toward the case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
If the backlash is out of specification, install the correct thrust
washer to the side gear.
(b) Referring to the table below, select thrust washers which
will ensure that the backlash is within for both sides.
Thrust washer thickness: mm (in.)
ThicknessThickness
0.95 (0.0374)1.10 (0.0433)
1.00 (0.0394)1.15 (0.0453)
1.05 (0.0413)1.20 (0.0472)
If the backlash is not within the specification, install a thrust
washer of a different thickness.

A09687
UpwardCam Lobe
Clearance
A87966
A81553
Upward
Notch
Cam Lobe
Intake
Manifold
Side
−
ENGINE MECHANICAL VALVE CLEARANCE (1CD−FTV)(From September,
2003)14 −91
AVENSIS Supplement (RM1045E)
12. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
13. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
14. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
15. REMOVE NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
16. REMOVE CYLINDER HEAD COVER SUB −ASSY (See page 14 −151)
17. REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11 −46)
18. REMOVE INJECTOR ASSY (See page 11 −46)
HINT:
Since each injector assembly has characteristic fuel injecting behavior, keep them in the correct order so
that they can be returned to the original locations when reassembling.
19. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe located over theinspecting valve faces upward.
(b) Using a feeler gauge, measure the clearance between
the valve lifter and camshaft.
(c) Measure the clearance at 16 places.
(d) Record the out −of −specification valve clearance mea-
surements. They will be used later to select an adjusting
shim to replace.
Valve clearance (Cold):
Intake0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust0.35 to 0.45 mm (0.014 to 0.018 in.)
20. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft so that the cam lobe located over the adjusting valve faces upward.
(2) Position the notch of the valve lifter toward the in- take manifold side.

A92433
B
B
AA
A79444A79164A80106
A
A
B
B
− INTAKETURBOCHARGER SUB−ASSY (1CD−FTV)(From
September, 2003)13−17
AVENSIS Supplement (RM1045E)
33. INSTALL TURBO WATER PIPE SUB−ASSY NO.1
(a) Install a new gasket and the turbo water pipe with the 2 nuts.
Torque: 13 N
m (135 kgf
cm, 9.8 ft
lbf)
34. INSTALL TURBOCHARGER SUB−ASSY
(a) Install a new gasket and the turbocharger with the 3 nuts.
Torque: 60 N
m (612 kgf
cm, 44 ft
lbf)
35. INSTALL TURBO OIL INLET PIPE SUB−ASSY
(a) Install a new gasket and the oil pipe with the 2 nuts.
Torque: 13 N
m (135 kgf
cm, 9.8 ft
lbf)
36. INSTALL TURBOCHARGER STAY
(a) Install the turbocharger stay, then temporarily tighten
bolts A.
(b) Temporarily tighten nuts B while pushing the cylinder
head toward the turbocharger stay.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c) Tighten bolts A.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d) Tighten nuts B.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
37. INSTALL EXHAUST MANIFOLD CONVERTER
SUB−ASSY
(a) Install the manifold stay, then temporarily tighten the cyl-
inder block side of the manifold stay.
(b) Install a new gasket and the manifold converter, then tem-
porarily tighten bolts A and bolts B while pushing the up-
per portion of the converter toward the turbocharger.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c) Tighten the 3 nuts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(d) Tighten bolts A.
Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)
(e) Tighten bolts B.
Torque: 61 N
m (622 kgf
cm, 45 ft
lbf)

A85753
13−18−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
38. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay No. 2, then temporarily tighten the bolt.
(b) Temporarily tighten the nut while pushing the manifold
stay No. 2 toward the cylinder head.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
HINT:
No clearance between the stay and cylinder head should be
confirmed.
(c) Tighten the bolt.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d) Tighten the nut. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
39. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
40. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
41. INSTALL EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
42. INSTALL EGR PIPE INSULATOR Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)
43. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
44. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)
45. INSTALL TURBO INSULATOR NO.1 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
46. INSTALL TURBO INSULATOR NO.2 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
47. INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
48. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
49. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
50. INSTALL HEATER BRACKET (W/ COLD AREA)
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
51. INSTALL HEATER PUMP ASSY (W/ COLD AREA)
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
52. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)

C86268
SST
C67417
Matchmarks
G24058
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
30−13
AVENSIS Supplement (RM1045E)
(5) Using SST, adjust the clearance of the damper
clamp.
SST 09240−00020
Clearance: 0.8 mm (0.031in.) or less
NOTICE:
When the measured value exceeds the specified value, re-
tighten the clamp.
HINT:
SInstall the damper clamp to inboard joint side.
SPerform the above procedure only when reassembling
the RH side.
37. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
(a) Wrap the outboard joint shaft assy LH spline with vinyl
tape to prevent it from being damaged.
(b) Install new parts to the outboard joint shaft assy LH in the
following order.
(1) Inboard joint boot LH clamp
(2) Inboard joint boot
(3) Inboard joint boot LH No.2 clamp
(c) Place the beveled side of the tripod axial spline toward the
outboard joint.
(d) Align the match marks.
(e) Using a brass bar and hammer, tap in the tripod joint assy
to the drive shaft assy LH.
NOTICE:
SDo not tap the roller.
SBe sure to install the tripod joint assy in the correct
direction.
(f) Pack the inboard joint shaft and boot with grease in the
boot kit.
Grease capacity:170 to190 g (6.0 to 6.7 oz.)
(g) Using a snap ring expander, install a new shaft snap ring.

A87780
1
2
3
4
5
68
79
10
A87781
A87782
Plastigage
A87783
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−59
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
9. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts in the sequence shown in the illustration.
(b) Use 2 removed main bearing cap bolts to remove the 5
main bearing caps and 5 lower bearings.
NOTICE:
Insert the bolts into one of the caps. Ease the cap out by
gently pulling up and applying force toward the front and
back side of the cylinder block, as shown in the illustration.
Take care not to damage the contact surfaces of the cap
and cylinder block.
HINT:
SKeep the lower bearing and main bearing cap together.
SArrange the main bearing caps in the correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (see step 36).
HINT:
Do not turn the crankshaft.
(i) Remove the main bearing cap (see steps (a) to (b)
above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
0.017 to 0.040 mm (0.00067 to 0.00157 in.)
Maximum oil clearance: 0.050 mm (0.002 in.)
If the oil clearance is greater than the maximum, replace the
bearings. If necessary, replace the crankshaft.

D25600
SST
C50943
C50216
C50213
Differential
Case LH
Differential
Case No.2
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−119
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950−70010 (09951−07100), 09608−10010
8. INSTALL DIFFERENTIAL CASE SUB−ASSY NO.2
(a) Coat the front differential side gear thrust washer No.1,
front differential planetary ring gear, front differential pin-
ion No.2, front differential pinion thrust washer No.2, front
differential pinion shaft holder, front differential pinion
shaft and 2 differential pinion shafts with ATF, install them
to the differential case No.2.
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
(c) Engage the front differential side gear to the above men-
tioned front differential case.
(d) Install the differential case LH to the front differential case
and measure its center.
(e) After that, remove the differential case LH.